NT 6004A

Technical Note6004A X06, and D4D or D4F - X35, and D4F - X44, and D4F - X65, and D4D or D4F - X76, and D4D or D4F, and RENAULT - X77, and D4F - X85, and D4F - X90, and D4D or D4F D4 engine Engine workshop repair manual

Edition 5

77 11 328 182

JULY 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."

Edition Anglaise

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

© Renault s.a.s 2008

D4 engine

D4 engineContentsPage

Contents Page

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY

10A

Engine: Precautions for repair

10A-1

Engine: Specifications

10A-3

Engine: Standard replacement

10A-5

Engine: New replacement

10A-7

Engine: Repair

10A-9

Engine support equipment: Use

10A-14

Rocker cover: Removal Refitting

10A-17

Camshaft: Removal Refitting

10A-44

Camshaft: Check

10A-95

Cylinder head: Removal Refitting

10A-99

Valve: Remo va val - Refitting

10A-121

Valve: Check

10A-132

Cylinder head:Stripping Restor ing

10A-137

Cylinder he head: C Clleaning

10A-141

Cylinder head: Check

10A-143

Piston - Con rod: Removal Refitting

10A-148

Piston - Con rod: Check

10A-160

Crankshaft: Removal Refitting

10A-166

Cr ankshaft: Check

10A-172

Cylinder block: Removal Refitting

10A-177

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder block: Cleaning

10A-182

Cylinder block: Check

10A-183

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Precautions for repair

10A

X65 – X76 – X90 – X35 – X06 – X44 – X77 – X85

I - SAFETY WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).

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.

b - Special tooling - ease of use

The procedures and fault finding procedures recommended and described in this manual have been designed by automotive industry repair professionals.

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.

a - General recommendations Observe basic principles of vehicle repair.

The equipment we have approved has undergone careful research and testing, and must be used and maintained with care.

The quality of repair depends first and foremost on the care exercised by the person in carrying it out.

c - Safety

To ensure good repair: - use recommended recommended professional professional products and original original parts, - observe the the tightening tightening torques, torques, - observe the recommenda recommendations tions for parts that should always be replaced after removal, refitting or replacement operations, - clean and degrease degrease the sections sections to be bonded, to ensure they bond correctly.

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. Working safely: - use suitable tools which are are in good condition (use (use of « multi-purpose» tools, such as adjustable pliers, etc., should be avoided wherever possible), - use supports and adopt adopt a correct posture when performing heavy work or raising loads,

WARNING For proper sealing, joint faces must be clean, dry and free from grease (avoid finger marks).

- check that the working working area is clean and tidy during the operation, - use personal protection (gloves, goggles, goggles, work shoes, masks, skin protection, etc.),

WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.

- always follow the safety instructions associated with with the operation to be performed, - do not smoke when when working on on vehicles,

The design quality of the vehicles demands that nothing be left to chance during repair. Consequently, parts or components must be refitted in their original positions (for example: heat shields, wiring routing, pipe routing). Use professional products and apply them with care. For example, do not apply too much sealant to joint faces, in order to avoid plugging engine oil or coolant pipes.

- do not use harmful harmful products in unventilated unventilated rooms, rooms, - do not ingest any chemicals (brake (brake fluid, coolant, etc.). Respecting the environment: environment: - sort waste according according to its particular qualities, qualities, - do not burn discarded discarded products products (tyres, etc.).

10A-1

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Precautions for repair X65 – X76 – X90 – X35 – X06 – X44 – X77 – X85 d - Conclusion 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 in 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. 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 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 are single-use bags: after use they must be discarded.

10A-2

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Specifications

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

I - ENGINE IDENTIFICATION

Details of markings

The engine identification is located on the cylinder block under the inlet manifold.

19858

The markings include: - (1) : the engine type - (2) : the engine approval letter - (3) : the engine suffix - (4) : the factory where the engine was fitted 18636

- (5) : the engine production number

II - ENGINE SPECIFICATIONS TABLE

Engine

Suffix

Cubic city(cc)

capa-

Bore (mm)

Stroke (mm)

Compression ratio

69

66.8

9.8/1

700 706 712 D4D

720

999

752 a 760 a

10A-3

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Specifications

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

Engine

Suffix

Cubic city(cc)

capa-

Bore (mm)

Stroke (mm)

Compression ratio

702 706 708 712 714 716

9.8/1

722 728 D4F

730

1149

69

76.8

732 740 742 a

10.6/1

764 772

9.8/1 774 a 780

9.6/1 784

a: Engine running on an ethanol/petrol mixture

10A-4

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Standard replacement

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

STANDARD ENGINE REPLACEMENT X44, and D4F, and 780 – X77, and D4F, and 784 – X85, and D4F, and 784

1 - Preparing the old engine to be returned to the engine renovation factory a

Clean the engine.

a

Drain:

a

Leave the oil - coolant heat exchanger on the old engine or include it in the return box.

- the engine oil (see Engine oil: Draining - Refilling) , - the coolant (see Cooling circuit: Draining - Refilling) . a

Secure the old engine to the stand and in the same conditions as the standard replacement engine:

3 - Parts to be removed from the old engine and fitted on the new engine a

Parts to be removed from the old engine and fitted on the new engine: - all cooling system hoses,

- fit the plastic plug welds and covers,

- the oil pressure sensor,

- fit the cardboard cover over the whole assembly.

- the pinking sensor,

2 - Parts to leave on the old engine or to include in the return box: a

- the coolant temperature sensor, - the inlet manifold,

Leave on the used engine or include in the return box:

- the exhaust manifold,

- the dipstick,

- the coolant inlet hose,

- the oil filter,

- the coolant outlet unit,

- the oil pump housing,

- the alternator,

- the oil level sensor,

- the multifunction support.

- the rocker cover, X06, and AIR CONDITIONING – X35, and AIR CONDITIONING – X44, and AIR CONDITIONING – X65, and AIR CONDITIONING – X76, and AIR CONDITIONING – X77, and AIR CONDITIONING – X85, and AIR CONDITIONING – X90, and AIR CONDITIONING

- the coolant pump, - the injector rail, - the injectors, - the spark plugs, - the timing belt,

a

Remove the air conditioning compressor from the old engine and refit it on the new engine.

- the crankshaft sprocket, - the tensioning roller, - the camshaft sprocket, X90, and POWER-ASSISTED STEERING – X35, and POWER-ASSISTED STEERING – X65, and POWER-ASSISTED STEERING – X76, and POWER-ASSISTED STEERING

- the timing cover, - the crankshaft accessories pulley, - the lifting rings, - the cylinder head suspended mounting,

a

- the clutch plate and pressure plate, - the flywheel.

10A-5

Remove the power-assisted steering pump from the old engine and refit it on the new engine.

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Standard replacement X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

X44, and D4F, and 780 – X77, and D4F, and 784 – X85, and D4F, and 784 a

Parts to be removed from the old engine and fitted on the new engine: - the catalytic pre-converter, - the catalytic pre-converter stays, - the turbocharger, - the turbocharger strut.

X85, and D4F, and 764 a

Remove the camshaft dephaser solenoid valve from the old engine and refit it on the new engine.

4 - Parts always to be replaced a

Always replace: - the coolant outlet unit seal on the cylinder head, - the intake distributor seal, - the exhaust manifold gasket, - the accessories belt, - the accessories belt tensioning roller, - the accessories belt tensioning roller bolt, - the cooling circuit hoses if they are damaged.


Always replace: - the oil-coolant heat exchanger seals, - the turbocharger nuts, - the turbocharger seal, - the turbocharger oil pipes, - the turbocharger cooling pipes if replacing the turbocharger.

a

Refit the parts removed from the old engine on the new engine.

10A-6

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: New replacement

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

NEW REPLACEMENT ENGINE X44, and D4F, and 780 – X77, and D4F, and 784 – X85, and D4F, and 784

1 - Preparing the old engine to be returned to the engine renovation factory a

Clean the engine.

a

Drain:

a

- the engine oil (see Engine oil: Draining - Refilling) , - the coolant (see Cooling circuit: Draining - Refilling) . a

Leave the oil - coolant heat exchanger on the old engine or include it in the return box.

3 - Parts to be removed from the old engine and fitted on the new engine a

Secure the old engine to the stand and in the same conditions as the standard replacement engine:

Parts to be removed from the old engine and fitted on the new engine: - all cooling system hoses, - the oil pressure sensor,

- fit the plastic plug welds and covers,


- fit the cardboard cover over the whole assembly.

- the coolant temperature sensor, - the inlet manifold,

2 - Parts to leave on the old engine or to include in the return box: a

- the exhaust manifold,

Leave on the used engine or include in the return box:

- the coolant inlet hose,

- the dipstick,

- the alternator,

- the oil filter,

- the multifunction support,

- the oil pump housing,

- the clutch plate and pressure plate,

- the coolant outlet unit,

- the flywheel.

- the oil level sensor, - the rocker cover,

X06, and AIR CONDITIONING – X35, and AIR CONDITIONING – X44, and AIR CONDITIONING – X65, and AIR CONDITIONING – X76, and AIR CONDITIONING – X77, and AIR CONDITIONING – X85, and AIR CONDITIONING – X90, and AIR CONDITIONING

- the coolant pump, - the injector rail, - the injectors, - the spark plugs,

a

Remove the air conditioning compressor from the old engine and refit it on the new engine.

- the timing belt, - the crankshaft sprocket, - the tensioning roller, X90, and POWER-ASSISTED STEERING – X65, and POWER-ASSISTED STEERING – X35, and POWER-ASSISTED STEERING – X76, and POWER-ASSISTED STEERING

- the camshaft sprocket, - the timing cover, - the crankshaft accessories pulley,

a

- the lifting rings, - the cylinder head suspended mounting.

10A-7

Remove the power-assisted steering pump from the old engine and refit it on the new engine.

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: New replacement X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90


Parts to be removed from the old engine and fitted on the new engine: - the catalytic pre-converter, - the catalytic pre-converter stays, - the turbocharger, - the turbocharger strut.


Remove the camshaft dephaser solenoid valve from the old engine and refit it on the new engine.

4 - Parts always to be replaced a

Always replace: - the coolant outlet unit seal on the cylinder head, - the intake distributor seal, - the exhaust manifold gasket, - the accessories belt, - the accessories belt tensioning roller, - the accessories belt tensioning roller bolt, - the cooling circuit hoses if they are damaged.


Always replace: - the oil-coolant heat exchanger seals, - the turbocharger nuts, - the turbocharger seal, - the turbocharger oil pipes, - the turbocharger cooling pipes if replacing the turbocharger.

a

Refit the parts removed from the old engine on the new engine.

10A-8

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

Essential special tooling Mot. 582-01

Flywheel locking tool.

REMOVAL I - ENGINE REPAIR PREPARATION OPERATION a

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 10A , Engine and cylinder block assembly, Engine: Precautions for repair, page 10A-1) .

WARNING

110428

It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump may also damage the engine by: - blocking the strainer,

a

Fit the flywheel locking tool (Mot. 582-01) (1 ) onto the cylinder block.

a

Remove: - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) ,

- raising the oil level above maximum, with a risk of engine racing. a

Remove the engine - gearbox assembly (see Engine/gearbox assembly: Removal - Refitting ) .

a

Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

a

Remove the accessories belt (see Accessories belt: Removal - Refitting) .

- the clutch disc and pressure plate (see Mechanism / Disk: Removal - Refitting) (20A, Clutch), - the flywheel (see Flywheel: Removal - Refitting ) , - the flywheel locking tool (Mot. 582-01) . a

Place the engine on the component support (see 10A , Engine and cylinder block assembly , Engine support equipment: Use , page 10A-14) .

a

Drain the engine (see Engine oil: Draining - Refilling) .

II - UPPER ENGINE REMOVAL OPERATION a

Remove: - the timing belt (see Timing belt: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) .


Remove: - the catalytic pre-converter (see Catalytic pre-converter: Removal - Refitting ) ,

10A-9


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - the turbocharger (see Turbocharger: Removal Refitting) .

a

- the camshaft (see 10A , Engine and cylinder block assembly, Camshaft: Removal - Refitting , page 10A-44 ) , - the valves (see 10A , Engine and cylinder block assembly , Valve: Removal - Refitting , page 10A121) .

Remove: - the inlet manifold (see Inlet manifold: Removal Refitting) ,

III - UPPER ENGINE REPAIR OPERATION

- the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) ,

a

Clean the cylinder head (see 10A , Engine and cylinder block assembly , Cylinder head: Cleaning, page 10A-141 ) .

- the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) ,

a

Check: - the cylinder head (see Cylinder head: Check) , - the camshaft (see Camshaft: Check ) ,

- the exhaust manifold (see Exhaust manifold: Removal - Refitting) ,

- the valves and the valve springs (see Valve: Check) .

- the throttle valve (see Throttle valve: Removal Refitting) .

Note: X85, and D4F, and 764

Replace the parts whose values are outside the permitted tolerance values.

IV - LOWER ENGINE REMOVAL OPERATION a

Remove the alternator (see Alternator: Removal Refitting) .

X06, and AIR CONDITIONING – X35, and AIR CONDITIONING – X44, and AIR CONDITIONING – X65, and AIR CONDITIONING – X76, and AIR CONDITIONING – X77, and AIR CONDITIONING – X85, and AIR CONDITIONING – X90, and AIR CONDITIONING a

Remove the air conditioning compressor (see Compressor: Removal - Refitting ) (62A, Air conditioning).

116990 a

Remove the camshaft dephaser solenoid valve (2) .

a

Remove:

X35, and POWER-ASSISTED STEERING – X65, and POWER-ASSISTED STEERING – X76, and POWER-ASSISTED STEERING – X90, and POWER-ASSISTED STEERING a

- the coolant outlet unit (see Plenum chamber: Removal - Refitting) , - the spark plugs (see Spark plugs: Removal - Refitting) ,

10A-10

Remove the power-assisted steering pump (see Power assisted steering pump: Removal - Refitting ) (36B, Power-assisted steering).


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

Remove:

a

Check: - the cylinder block (see 10A, Engine and cylinder block assembly , Cylinder block: Check, page 10A-183 ) ,

- the multifunction support (see Multifunction support: Removal - Refitting ) , - the water pump inlet pipe (see Water pump inlet pipe: Removal - Refitting ) ,

- the piston - con rod assemblies (see Piston - Con rod: Check) ,


- the crankshaft (see Crankshaft: Check ) .

- the oil level sensor (see Oil level sensor: Removal - Refitting) ,

Note:

- the sump (see Sump: Removal - Refitting) ,

Replace the parts whose values are outside the permitted tolerance values.

- the gearbox side crankshaft seal (see Crankshaft seal at gearbox end : Removal - Refitting ) , - the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) ,

REFITTING I - REFITTING PREPARATION OPERATION

- the oil filter (see Oil filter: Removal - Refitting) .

a

- all seals,


Parts always to be replaced:

- the cooling circuit hoses if they are damaged,

Remove the oil-coolant heat exchanger (see Ex changer: Removal - Refitting ) .

- the accessories and timing belts, - the timing and accessories tensioners and rollers, - the crankshaft accessories pulley bolt, - the camshaft sprocket bolt,

a

Remove:

- the exhaust manifold nuts,

- the oil pump (see Oil pump: Removal - Refitting ) ,

- the exhaust manifold studs (if removed), - the oil filter,

- the coolant pump (see Water pump: Removal Refitting) ,

- the flywheel bolts, - the con rod cap bolts,

- the "piston - con rod" assembly of every cylinder (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting , page 10A148) , - the crankshaft (see 10A , Engine and cylinder block assembly, Crankshaft: Removal - Refitting , page 10A-166 ) ,

- the crankshaft bearing cap bolts, - the "piston - gudgeon pin" assembly of every cylinder. a

- the cylinder block (see 10A, Engine and cylinder block assembly, Cylinder block: Removal - Refitting, page 10A-177) .

V - LOWER ENGINE REPAIR OPERATION a

Clean the cylinder block (see 10A, Engine and cylinder block assembly, Cylinder block: Cleaning, page 10A-182 ) .

10A-11

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

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

II - LOWER ENGINE REFITTING OPERATION a

a

- the multifunction support (see Multifunction support: Removal - Refitting ) .

Refit the cylinder block (see 10A, Engine and cylinder block assembly, Cylinder block: Removal Refitting, page 10A-177 ) . When replacing the cylinder block, crankshaft or crankshaft bearing shells, always determine the thickness class for each bearing shell that will be fitted on each crankshaft bearing, to ensure that gudgeon pin clearance is within tolerances (see 10A, Engine and cylinder block assembly , Crankshaft: Check, page 10A-172) .


Refit the power-assisted steering pump (see Power assisted steering pump: Removal - Refitting ) (36B, Power-assisted steering).

Note: Any clearances of the crankshaft journal outside the tolerances can cause engine damage. a

Refit: - the crankshaft (see 10A , Engine and cylinder block assembly, Crankshaft: Removal - Refitting , page 10A-166 ) , - the "piston - con rod" assembly of every cylinder (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting , page 10A148) , - the coolant pump (see Water pump: Removal Refitting) ,


Refit the air conditioning compressor (see Compressor: Removal - Refitting ) (62A, Air conditioning).

a

Refit the alternator (see Alternator: Removal - Refitting) .

- the oil pump (see Oil pump: Removal - Refitting ) .

III - UPPER ENGINE REFITTING OPERATION X44, and D4F, and 780 – X77, and D4F, and 784 – X85, and D4F, and 784 a

a

Refit the oil-coolant heat exchanger (see Exchanger: Removal - Refitting) .

Refit the valves (see 10 A , Engine and cylinder block assembly , Valve: Removal - Refitting, page 10A-121 ) . Note:

a

When replacing valves, always replace with new valves with the same part number as the old ones to avoid any damage to the "valve - seat" assembly.

Refit: - the oil filter (see Oil filter: Removal - Refitting) , - the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) ,

a

Refit the camshaft (see 10A, Engine and cylinder block assembly , Camshaft: Removal - Refitting, page 10A-44 ) ,

a

Check:

- the gearbox side crankshaft seal (see Crankshaft seal at gearbox end : Removal - Refitting ) , - the sump (see Sump: Removal - Refitting) , - the oil level sensor (see Oil level sensor: Removal - Refitting) , - the pinking sensor, - the water pump inlet pipe (see Water pump inlet pipe: Removal - Refitting ) ,

10A-12

- the camshaft (see 10 A , Engine and cylinder block assembly , Camshaft: Check, page 10A95) , - the cylinder head (see 10A , Engine and cylinder block assembly , Cylinder head: Check , page 10A-143 ) ,


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - the valves (see 10A , Engine and cylinder block assembly , Valve: Check, page 10A-132) . a

a

- the flywheel (see Flywheel: Removal - Refitting) .

Refit:

- the clutch disc and pressure plate (see Mechanism / Disk: Removal - Refitting) (20A, Clutch),

- the spark plugs (see Spark plugs: Removal - Refitting) ,

- the flywheel locking tool (Mot. 582-01) on the cylinder block,

- the coolant outlet unit (see Plenum chamber: Removal - Refitting) . X85, and D4F, and 764 a

a

Refit the camshaft dephaser solenoid valve.

- the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) . a

Remove the flywheel locking tool (Mot. 582-01) from the cylinder block.

a

Refit the accessories belt (see Accessories belt: Removal - Refitting) .

a

Top up the engine oil (see Engine oil: Draining Refilling ) .

a

Connect the manual gearbox to the engine (see Manual gearbox: Removal - Refitting ) (21A, Manual gearbox).

a

Refit the engine - gearbox assembly (see Engine/ gearbox assembly: Removal - Refitting ) .

Refit: - the throttle valve (see Throttle valve: Removal Refitting) , - the exhaust manifold (see Exhaust manifold: Removal - Refitting) , - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) , - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) , - the intake distributor (see Inlet manifold: Removal - Refitting) .


Refit: - the turbocharger (see Turbocharger: Removal Refitting) , - the catalytic pre-converter (see Catalytic pre-converter: Removal - Refitting ) .

a

Refit: - the ignition coil (see Coils Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) .

IV - FINAL OPERATION a

Refit:

Remove the engine from the component support (see 10A , Engine and cylinder block assembly , Engine support equipment: Use , page 10A-14 ) .

10A-13

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine support equipment: Use

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

1 - First fitting

Essential special tooling Mot. 1723

Engine support for DESVIL engine support stand.

Mot. 582-01


Essential equipment workshop hoist

Tightening torques m securing bolt

120 N.m

I - PREPARING TO INSTALL THE ENGINE ON THE COMPONENT SUPPORT a

IMPORTANT

111975

To work on the engine in complete safety, it is essential to use a component support.

WARNING It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump may also damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. a


a

Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox). 111974 a

Fit the pins (1 ) mounting them on the cylinder block so that they fit in holes 5, 6, 9 and 14 of the plate (2) of tool (Mot. 1723).

2 - Second fitting a

10A-14

Remove the accessories belt (see Accessories belt: Removal - Refitting ) .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

110428

121403

a


a

Remove:

- the engine stand support studs on the cylinder block,

- the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting) ,

- the retaining struts (4) on the component support studs.


a

Fit:

- the flywheel (see Flywheel: Removal - Refitting ) ,

II - FITTING THE ENGINE ON THE COMPONENT SUPPORT

- the flywheel locking tool (Mot. 582-01) .

a

Lift the engine using the workshop hoist and the load positioner .

121404 a

10A-15

Secure the engine on the component support.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - the clutch disc and pressure plate (see Mechanism / Disk: Removal - Refitting) (20A, Clutch), - the flywheel locking tool (Mot. 582-01) on the cylinder block, - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the accessories belt (see Accessories belt: Removal - Refitting) . a

Remove the locking tool (Mot. 582-01) of the cylinder block flywheel (if it was used).

a

Connect the manual gearbox to the engine (see Manual gearbox: Removal - Refitting ) (21A, Manual gearbox).

a


116799 a

Torque tighten the securing bolt (120 N.m) (5) to prevent the engine from rotating.

a

Set the blocks to ensure that the component stand does not move.

a

Remove the load positioner.

III - OPERATION FOR REMOVING THE ENGINE FROM THE COMPONENT SUPPORT a

Position the « engine - support studs - engine stand plate » assembly or the « engine - support studs retaining bars » assembly on the component stand using the workshop hoist and the load positioner.

a

Remove the engine stand plate nuts or the retaining bars on the component stand.

a

Separate the « engine - support studs - engine stand plate » assembly or the « engine - support studs retaining bar » assembly from the component stand using the workshop hoist and the load positioner.

IV - FINAL OPERATION a

Remove: - the support stud nuts on the stand plate or the retaining bar nuts, - the stand plate or the retaining bars, - the pins of the tool (Mot. 1723).

a

Refit (if they were removed): - the flywheel (see Flywheel: Removal - Refitting ) ,

10A-16

ENGINE AND CYLINDER BLOCK ASSEMBLY Rocker cover: Removal - Refitting

10A

X76, and D4F, and 712

Tightening torques m rocker cover mounting bolts

1 daNm

REMOVAL a

Disconnect the battery, starting with the negative terminal.

a

Remove the inlet manifold (see 12A, Fuel mixture, Inlet manifold).

18441

21066 a

Remove: - the ignition coils, - the rocker cover bolts, - the rocker cover by shifting it towards the battery, - the spark plug well seals.

REFITTING a

Always replace all of the sealing rings. 18442 a

Apply RHODORSEAL 5661 (or equivalent) on camshaft bearings (1 ) and (2) , as well as the four rocker cover rear mounting holes.

a

Refit the rocker cover bolts.

a

Finger tighten the bolts.

10A-17


10A


18640 a

Tighten to torque and in order the rocker cover mounting bolts (1 daNm).

18637 a

Refit new spark plug well seals using a socket of diameter 42 mm ; for example a 32 mm socket.

a

Proceed in the reverse order to removal

a

Refit the inlet manifold (see 12A, Fuel mixture, Inlet manifold).

WARNING Connect the battery, starting with the positive terminal. carry out the necessary programming ( (see 80A, Battery) ).

10A-18


10A


Tightening torques m rocker cover bolts ignition coil mounting bolts

10 Nm 7 Nm

REMOVAL a

Disconnect the battery, starting with the negative terminal.

a

Remove the inlet manifold (see 12B, Fuel mixture, Inlet manifold).

107892 a

Remove: - ignition coil bolts (1) , - the ignition coil.

107908 a

Disconnect the connector for the ignition coil.

108904 a

Remove: - the rocker cover mounting bolts, - the rocker cover.

REFITTING a

Always replace: - the rocker cover gasket, - the plug well seals.

10A-19


10A


108904 a

Tighten to torque and in order the rocker cover bolts (10 Nm) .

a

Torque tighten the ignition coil mounting bolts (7 Nm) Nm ).

18441

18442 a

a

Apply RHODORSEAL 5661 to the camshaft bearings and the rear mounting holes on the rocker cover. Refit the rocker cover.

18637 a

Refit the new spark plug well seals ( 2 ) using a 42 mm diameter socket, for example, a 32 socket.

a

Proceed in the reverse order to removal

a

Connect the battery, starting with the positive terminal.

WARNING Carry out the necessary programming (see 80A, Battery: Removal - refitting).

10A-20


10A

X85, and D4F, and 740 or 742 or 764

REFITTING Tightening torques m rocker cover mounting bolts

I - REFITTING PREPARATION OPERATION 10 N.m

a

Clean the gasket faces with DECAPJOINT to dissolve off any part of the gasket still attached.

REMOVAL

WARNING do not allow solvent to drip on the paintwork.

I - REMOVAL PREPARATION OPERATION

Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries.

a

Disconnect the battery (see Battery : Removal Refitting) (MR 392, 80A, Battery).

a

Remove: - the air filter box box (see Air filter unit: Removal - Refitting) , - the intake distributor distributor (see Inlet manifold: Removal - Refitting) .

a

Remove the ignition coil (see Coils Removal - Refitting) .

a

Unclip the rocker cover electric wiring harnesses.

II - OPERATION FOR REMOVAL OF PART CONCERNED

110422 a

Remove: - the rocker cover mounting bolts, bolts, - the rocker rocker cover, cover, - the rocker cover gasket.

10A-21

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

WARNING Be sure to replace all seals that have been removed.


10A

X85, and D4F, and 740 or 742 or 764

II - REFITTING OPERATION FOR PART CONCERNED

110422 18441

a

Torque tighten in order the rocker cover mounting bolts (10 N.m) .

III - FINAL OPERATION. a

Clip the electric wiring harnesses onto the rocker cover.

a

Refit: - the ignition ignition coil coil (see Coils Removal - Refitting) , - the intake intake distributor distributor (see (see Inlet manifold: Removal - Refitting ) , - the air filter box box (see Air filter unit: Removal - Refitting) .

a

20005 a

Apply a bead (1) bead (1) of SILICONE ADHESIVE SEALANT 77 11 227 484 to camshaft bearings 1 and 5, and around the rear rocker cover mounting bolts.

a

Fit the rocker cover with a new gasket.

10A-22

Connect the battery (see Battery: Removal - Refitting ) (MR 392, 80A, Battery).


10A

X65

Tightening torques m rocker cover mounting bolts

10 N.m

REMOVAL I - REMOVAL PREPARATION OPERATION a

Remove the inlet manifold (see Inlet manifold: Removal - Refitting) .

II - ROCKER COVER REMOVAL OPERATION

18441

21066 a

Remove: - the ignition coils, - the fourteen rocker cover bolts, - the rocker cover by shifting it towards the battery, - the spark plug well seals.

REFITTING 18442

I - REFITTING PREPARATION OPERATION a

a

Replace the seal with a new one.

Apply RHODORSEAL 5661 : - to the camshaft bearings, - to the four rear mounting holes of the rocker cover.

II - ROCKER COVER REFITTING OPERATION a

Refit the fourteen rocker cover bolts.

a

Finger tighten the fourteen bolts.

10A-23

ENGINE AND CYLINDER BLOCK ASSEMBLY Rocker cover: Removal - Refitting X65

18640 a

Tighten to torque and in order the rocker cover mounting bolts (10 N.m) .

III - FINAL OPERATION

18637 a

Refit the new spark plug well seals using a 42 mm diameter socket; for example a 32 mm socket.

10A-24

10A


10A

X44

PARTS AND INGREDIENTS FOR THE REPAIRWORK a

- the rocker cover gasket.

REFITTING

Part always to be replaced : - rocker cover seal.

a

Consumables (see 04A, Parts and consumables for repair):

I - REFITTING PREPARATIONS OPERATION a

- super joint cleaner for joint faces

Clean the gasket faces using the SUPER JOINT CLEANER FOR JOINT FACES product to dissolve off the part of the seal still stuck on.

- silicone adhesive sealant.

WARNING Do not allow this product to drip onto the paintwork.


Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting).

a

Remove: - the air filter box (see Air filter unit: Removal - Refitting) , - the intake distributor (see Inlet manifold: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) .

a



110422 a

Remove: - the rocker cover bolts, - the rocker cover,

10A-25

Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil galleries, which would quickly result in irreparable engine damage.


10A

X44


110422 18441

a

Tighten the rocker cover bolts in order.


Refit: - the ignition coil (see Coils Removal - Refitting) , - the intake distributor (see Inlet manifold: Removal - Refitting ) , - the air filter box (see Air filter unit: Removal - Refitting) .

a

Clip on the rocker cover electric wiring harnesses.

a

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

20005 a

Apply a bead ( 1) of ADHESIVE SILICONE SEALANT to camshaft bearings 1 and 5, and around the rocker cover rear bolts.

a


10A-26


10A


Tightening torques m 5 Nm

rocker cover bolts (initial torque) rocker cover bolts

12.5 Nm

heat shield bolts

8 Nm


Parts always to be replaced with new ones 121813

- rocker cover gasket a

Consumables (see 04A, Parts and consumables for repair): - SUPER CLEANER FOR JOINT FACES

a

Remove the bolt (1 ) from the intercooler air inlet pipe on the intake distributor.

a

Remove the intercooler air inlet pipe clip ( 2 ) on the turbocharger.

- SILICONE ADHESIVE SEALANT. Note:

REMOVAL

Removing the heat-resistance protector clip ( 3 ) requires the heat-resistance protector to be replaced.

I - REMOVAL PREPARATION OPERATION a

a

Remove the scoop under the scuttle panel grille (see MR 386 Bodywork, 56A, Exterior equipment, Scoop under scuttle panel grille: Removal - Refitting).

a

Move the intercooler inlet air pipe to one side.

a

Disconnect the oil vapour rebreathing circuit union ( 4) .


10A-27


10A

X77, and D4F, and 784 - the rocker cover seal.

REFITTING I - REFITTING PREPARATIONS OPERATION a

Clean the joint faces with SUPER CLEANING AGENT FOR JOINT FACES to dissolve any seal still adhering.

WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage.

120957 a

Unpick the wiring harness from the upstream oxygen sensor at (5) .

a

Remove:

a

- the bolts (6 ) from the heat shield, - the heat shield, - the filler neck bolt (7 ) , - the filler neck, - the ignition coil (see Coils Removal - Refitting) .


121026 a


10A-28

Replace the rocker cover seal.


10A



121026 a

Refit: - the rocker cover fitted with a new seal, - the rocker cover bolts

a

Pretighten to torque and in order the rocker cover bolts (initial torque) (5 Nm) .

a

Torque tighten in order the rocker cover bolts (12.5 Nm).

18441 a

Apply a bead (1) of MASTIXO around the 4 rocker cover bolts (inner bolts on the exhaust side) and on camshaft bearing N˚5.

III - FINAL OPERATION.

a

WARNING

a

Connect the oil vapour rebreathing circuit union.

Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).

a

Refit: - the ignition coil (see Coils Removal - Refitting) , - the filler neck,

Fit the new rocker cover seal, starting with bearing N˚5, then gradually insert the seal studs as the rocker cover fits into the groove.

- the filler neck bolt, - the heat shield, - the heat shield bolts. a

Torque tighten the heat shield bolts (8 Nm) .

a

Clip the upstream oxygen sensor wiring harness into place.

a

Refit the turbocharger outlet air pipe.

a

Clip the turbocharger air outlet pipe onto the turbocharger.

a

Connect the turbocharger air outlet pipe to the intercooler air inlet pipe.

a

Tighten the turbocharger air outlet pipe clip on the intercooler air inlet pipe.

a

Refit the turbocharger air outlet pipe bolt on the intake distributor.

a

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

10A-29

ENGINE AND CYLINDER BLOCK ASSEMBLY Rocker cover: Removal - Refitting X77, and D4F, and 784 a

Refit the scoop under the scuttle panel grille (see MR 386 Bodywork, 56A, Exterior equipment, Scoop under scuttle panel grille: Removal - Refitting).

10A-30

10A


10A


Tightening torques m rocker cover bolts (initial torque) rocker cover bolts heat shield bolts

5 Nm 13 Nm 8 Nm



a

Remove the front engine cover

120957 a

Unpick the wiring harness from the upstream oxygen sensor at (5 ) .

a

Remove: - the bolts (6 ) from the heat shield, - the heat shield, - the filler neck bolt (7) , - the filler neck, - the ignition coil (see Coils Removal - Refitting) .

121813 a

Remove the bolt (1) from the intercooler air inlet pipe on the intake distributor.

a

Remove the intercooler air inlet pipe clip ( 2) on the turbocharger.


Note: If the clip (3) is removed from the heat resistant protector, the latter must be replaced. a

Move the intercooler inlet air pipe to one side.

a

Disconnect the oil vapour rebreathing circuit union (4) .

121026 a


10A-31


10A





Clean the joint faces using SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork ) (MR 392, 04B, Consumables - Products) to dissolve the part of the seal which is still attached.

WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. a

Replace the rocker cover seal.

18441 a

Apply beads (1 ) of MASTIXO (see Vehicle: Parts and ingredients for the repairwork ) (MR 392, 04B, Consumables - Products) around the 4 rocker cover bolts (lower bolts, exhaust side) and on camshaft bearing no.5.

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.). a

10A-32

Fit the new rocker cover seal, starting with bearing No. 5, then gradually insert the seal studs as the rocker cover fits into the groove.

ENGINE AND CYLINDER BLOCK ASSEMBLY Rocker cover: Removal - Refitting X85, and D4F, and 784

121026 a

Refit: - the rocker cover fitted with a new seal, - the rocker cover bolts.

a


a

Torque tighten in order the rocker cover bolts (13 Nm).


Remove: - the ignition coil (see Coils Removal - Refitting) , - the filler neck, - the filler neck bolt, - the heat shield, - the heat shield bolts.

a


a

Connect the oil vapour rebreathing circuit union.

a


a

Refit the intercooler air inlet pipe.

a

Clip the intercooler air inlet pipe onto the turbocharger.

a

Refit the intercooler air inlet pipe bolt on the intake distributor.

a

Refit the engine cover.

a

Connect the battery (see Battery : Removal - Refitting) (MR 392, 80A, Battery).

10A-33

10A


Tightening torques m rocker cover bolts (initial torque) rocker cover bolts heat shield bolts

5 Nm 13 Nm 8 Nm



a

Remove: - the air filter box (see Air filter unit: Removal - Refitting) , - the air filter box strut bolt, - the air filter box strut.

10A-34

10A


10A


Note: If the clip ( 5) is removed from the heat resistant protector, the latter must be replaced. a

Disconnect the turbocharger air outlet pipe from the turbocharger.

a

Move aside the turbocharger air outlet pipe.

122834

120957 a

Unclip the wiring harness from the upstream oxygen sensor ( 7) .

a

Remove: - the bolts (6 ) from the heat shield, - the heat shield, - the filler neck bolt (8) , - the filler neck, - the ignition coil (see Coils Removal - Refitting) .

122673 a

Note: If the turbocharger outlet air pipe tightening clip (1 ) is removed, the rubber flexible pipe ( 2) and the tightening clip (1) must be replaced. Remove the turbocharger outlet air pipe bolt ( 3) on the throttle valve. a

Move the turbocharger outlet air pipe clip on the turbocharger to one side, following the direction shown by the arrow (4) .

10A-35


10A


II - REMOVAL OPERATION FOR PART CONCERNED

121026 a

Remove: - the rocker cover bolts,

122828 a

- the rocker cover,

Disconnect the oil vapour rebreathing circuit unions (9) . - on the intake distributor,


REFITTING

- on the air filter box outlet air pipe, - on the rocker cover.

I - REFITTING PREPARATIONS OPERATION

a

Remove the oil vapour rebreathing circuit.

a

a

Disconnect the fuel vapour rebreathing circuit unions (10) . - on the air filter box outlet air pipe,

Clean the joint faces with SUPER CLEANER FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork) (MR 411, 04B, Consumables - Products) to dissolve any part of the joint still remaining.

- on the intake distributor. a

Move the fuel vapour rebreathing pipes to one side.

a

Disconnect the vacuum pipe from the brake servo (11) .

a

Move the brake servo vacuum pipe to one side.

WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. a

10A-36

The rocker cover seal must be systematically replaced.


10A



121026 a

Refit: - the rocker cover fitted with a new seal, - the rocker cover bolts.

18441 a

Apply beads (1) of MASTIXO (see Vehicle: Parts and ingredients for the repairwork ) (MR 411, 04B, Consumables - Products) around the rocker cover rear bolts (lower bolts, exhaust side) and on camshaft bearing no.5.


a


a

Torque tighten in order the rocker cover bolts (13 Nm).

III - FINAL OPERATION a

Fit the brake servo vacuum pipe.

a

Connect the brake servo vacuum pipe.

a

Fit the fuel vapour rebreathing pipes.

a

Connect the fuel vapour rebreathing circuit unions: - on the intake distributor, - on the air filter box outlet air pipe.

a

Fit the new rocker cover seal, starting with bearing No. 5, then gradually insert the seal studs as the rocker cover fits into the groove.

a

Fit the oil vapour rebreathing circuit.

a

Connect the oil vapour rebreathing circuit unions: - on the rocker cover, - on the air filter box outlet air pipe, - on the intake distributor.

a

Refit: - the ignition coil (see Coils Removal - Refitting) , - the filler neck, - the filler neck bolt, - the heat shield, - the heat shield bolts.

a


a


10A-37


122666 a

Position the turbocharger air outlet pipe.

a

Push the turbocharger outlet air pipe clip, following the direction shown by the arrow ( 10) .

a

Connect the turbocharger air outlet pipe onto the turbocharger.

a

Refit: - the turbocharger outlet air pipe bolt on the throttle valve, - the air filter box mounting, - the air filter box support bolt, - the air filter box (see Air filter unit: Removal - Refitting) .

a


10A-38

10A


10A

X90, and D4D

REFITTING Tightening torques m rocker cover bolts

I - REFITTING PREPARATIONS OPERATION 10 Nm

a

IMPORTANT

REMOVAL

Wear watertight (nitrile) gloves for the operation.


IMPORTANT Wear goggles with side protectors for this operation.

Remove: - the air filter box (see Air filter unit: Removal - Refitting) , - the intake distributor (see Inlet manifold: Removal - Refitting) ,


- the ignition coil (see Coils Removal - Refitting) . a

Unclip the wiring from the rocker cover.

Clean the cylinder head carefully to avoid any foreign bodies entering the oil return and supply pipes.


Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. Clean the joint faces with SUPER CLEANER FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork) (MR 388, 04B, Consumables - Products) to remove any part of the seal still remaining. a

110422 a

Remove: - the rocker cover bolts (1) , - the rocker cover, - the seal from the rocker cover.

10A-39

The rocker cover seal must always be replaced.


10A

X90, and D4D


110422 18441

a

Tighten to torque and in order the rocker cover bolts (10 Nm) .


Clip the wiring onto the rocker cover.

a

Refit: - the ignition coil (see Coils Removal - Refitting) , - the intake distributor (see Inlet manifold: Removal - Refitting ) , - the air filter box (see Air filter unit: Removal - Refitting) .

20005 a

Apply a beading of (2) SILICONE ADHESIVE SEALANT (see Vehicle: Parts and ingredients for the repairwork ) (MR 388, 04B, Consumables - Products) to the camshaft bearings 1 and 5, as well as around the rear rocker cover bolts.

a


10A-40


10A

X35


Tightening torques m rocker cover bolts

10 N.m


Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).

a

Remove: - the air filter unit (see Air filter unit: Removal - Refitting) , - the inlet manifold (see Inlet manifold: Removal Refitting) , - the ignition coil (see Coils Removal - Refitting) .

110422 a

Remove: - the rocker cover bolts, - the rocker cover, - the rocker cover seal.

REFITTING I - REFITTING PREPARATION OPERATION a

Always replace the rocker cover seal.

a

Use SUPER CLEANER FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to clean: - the rocker cover joint face if it is to be re-used,

113044 a

Disconnect the oil vapour rebreathing pipe (1) from the rocker cover.

a

Unclip from the rocker cover: - the engine wiring (2) , - the fuel supply pipe.

10A-41

- the cylinder head joint face.


10A

X35 a

Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to degrease:


- the rocker cover joint face if it is to be re-used, - the cylinder head joint face.


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

18441

20005 a

Apply a bead of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to camshaft bearings 1 and 5, as well as around the rear bolts of the rocker cover to ensure that the rocker cover is sealed.

a

Refit: - a new seal on the rocker cover, - the rocker cover.

10A-42

ENGINE AND CYLINDER BLOCK ASSEMBLY Rocker cover: Removal - Refitting X35

110422 a

Tighten to torque and in order the rocker cover bolts (10 N.m) .


Connect the oil vapour rebreathing pipe onto the rocker cover.

a

Clip on the rocker cover: - the engine wiring, - the fuel supply pipe.

a

Refit: - the ignition coil (see Coils Removal - Refitting) , - the inlet manifold (see Inlet manifold: Removal Refitting) , - the air filter unit (see Air filter unit: Removal - Refitting) .

a

Connect the battery (see Battery : Removal - Refitting) (80A, Battery).

10A-43

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Removal - Refitting

10A

X85, and D4F, and 740 or 742 or 764 - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17) .


Timing gear wheel immobiliser.

Mot. 1381

Camshaft oil seal removal tool, 30 x 42 x 7.

Mot. 1605

For fitting cylinder head cap.

Mot. 1587

Tool for fitting PTFE camshaft seal.

Tightening torques m mounting bolts of camshaft bearing cap no. 5

9 N.m

camshaft bearing cap mounting bolt

7 N.m + 50˚ ± 6˚

camshaft pulley mounting bolt

30 N.m + 45˚ ± 6 18722 a

REMOVAL

Remove: - the camshaft pulley mounting bolt using the (Mot. 799-01) ,


- the camshaft pulley.

a

Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).

a


a

Remove: - the air filter unit (see Air filter unit: Removal - Refitting) , - the intake distributor (see Inlet manifold: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) , - the front bumper (see Front bumper: Removal Refitting) (MR 393, 55A, Exterior protection), - the accessories belt (see Accessories belt: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting) , - the right-hand suspended mounting support (see Right-hand suspended engine mounting: Removal - Refitting) ,

18722-1 a

- the timing belt (see Timing belt: Removal - Refitting ) ,

10A-44

Position the (Mot. 1381) (2) .


10A

X85, and D4F, and 740 or 742 or 764


18722-2 a

Tighten the bolt (3) of the (Mot. 1381).

a

Remove the lip seal.

18724 a

Remove: - the camshaft mounting bolts, - the camshafts.

18723 a

Remove the camshaft seal cap. 18724-1 a

10A-45

Mark the camshaft bearing caps with an indelible marker pen.


10A

X85, and D4F, and 740 or 742 or 764

REFITTING I - REFITTING PREPARATION OPERATION

18724-2 a

Remove: - the mounting bolts (4) from camshaft bearing cap no. 5, 19595

- the camshaft bearing caps.

19594

18724-3 a

Remove the camshaft.

a

Apply: - two beads (5) of RHODORSEAL 5661 with a width of 2 mm on cylinder head bearing no. 5, - two drops (6 ) of RHODORSEAL 5661 to cylinder head bearing no. 1.

a

10A-46

Apply a blob of oil to the camshaft bearings.


10A

X85, and D4F, and 740 or 742 or 764

II - REFITTING OPERATION FOR PART CONCERNED a

Refit: - the camshaft, - the camshaft bearing caps.

18724-2 a

Torque tighten the mounting bolts of camshaft bearing cap no. 5 (9 N.m).

18945 a

- the marks (7 ) on the flywheel end.

Refit the camshafts, positioning: - the rails in relation to the tappets,

10A-47


10A

X85, and D4F, and 740 or 742 or 764

III - FINAL REFITTING

18724 20058

Pretighten in order and to torque the mounting bolts of the camshaft bearing caps (5 N.m).

a

Ensure that the seal bearing surfaces are clean.

a

Loosen the mounting bolt (1) .

a

a

Torque and angle tighten the camshaft bearing cap mounting bolt (7 N.m + 50˚ ± 6˚).

Refit the seal cap to the end of the camshaft using the (Mot. 1605).

a

Repeat these two operations for each bolt from (2) to (10) .

a

18687 a

10A-48

Fit the lip seal.


10A

X85, and D4F, and 740 or 742 or 764

19592 a

Screw the threaded rod of the (Mot. 1587) into the camshaft.

19592-2 a

19592-1 a

Fit the seal gasket and protector on the camshaft. Be careful not to touch the seal.

10A-49

Fit the cover (8 ) and the collar nut (9) of the (Mot. 1587) .


10A

X85, and D4F, and 740 or 742 or 764

19592-3

19592-5 a

Remove: - the nut from the, - the cover from the, - the seal protector, - the threaded rod of the.

19592-4 a

Screw on the collar nut until the cover touches the cylinder head.

18722 a

The camshaft pulley mounting bolt must always be replaced.

a

Refit the camshaft pulley.

a

Torque tighten the camshaft pulley mounting bolt (30 N.m + 45˚ ± 6) using the (Mot. 799-01) .

10A-50

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Removal - Refitting X85, and D4F, and 740 or 742 or 764 a

Refit: - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) , - the timing belt (see Timing belt: Removal - Refitting ) , - the right-hand suspended mounting support (see Right-hand suspended engine mounting: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the front bumper (see Front bumper: Removal Refitting) (MR 393, 55A, Exterior protection), - the ignition coil (see Coils Removal - Refitting) , - the intake distributor (see Inlet manifold: Removal - Refitting) , - the air filter box (see Air filter unit: Removal - Refitting) .

a


10A-51

10A


10A

X44 a

Essential special tooling

Remove: - the scuttle panel grille (see MR 412 Bodywork, 56A, Exterior equipment, Scuttle panel grille: Removal-Refitting),

Mot. 799-01


Mot. 1381


- the scoop under the scuttle panel grille (see MR 412 Bodywork, 56A, Exterior equipment, Scoop under scuttle panel grille: Removal-Refitting),

Mot. 1605

For fitting cylinder head cap.

Mot. 1587


- the front right-hand wheel (see 35A, Wheels and tyres, Wheel: Removal-Refitting), - the accessories belt (see Accessories belt: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) ,

Tightening torques m camshaft bearing cap no.5 bolts

5 Nm

- the timing belt (see Timing belt: Removal - Refitting) ,

camshaft bearing cap bolts (initial torque)

5 Nm

- the air filter box (see Air filter unit: Removal - Refitting) ,

camshaft bearing cap bolt

7 Nm + 50˚ ± 6

- the intake distributor (see Inlet manifold: Removal - Refitting ) ,

30 Nm + 45˚ ± 6

- the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17 ) .

camshaft pulley bolt


Parts always to be replaced: - rocker cover seal, - camshaft lip seal, - sealing cap in the end of the camshaft.

a

Consumables (see 04A, Consumables - Products, Vehicle: Parts and consumables for the repair ): - SUPER CLEANER FOR JOINT FACES - MASTIXO.


Position the vehicle on a two-post lift (see 02A, Lifting Equipment, Vehicle: Towing and lifting ).

a


10A-52


10A

X44

II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - Removing the camshaft sprocket

18722-2

18722 a

a

Tighten the bolt of the (Mot. 1381).

a

Remove the lip seal.

2 - Removing the camshaft

Remove: - the camshaft pulley bolt (1) using the (Mot. 79901) , - the camshaft sprocket.

18723 a

18722-1 a

Position the (Mot. 1381).

10A-53

Remove the camshaft sealing cap ( 2 ) .


10A

X44

18724 a

Remove:

18724-2 a

Remove:

- the camshaft bolts (3) ,

- the bolts (4 ) from camshaft bearing cap no. 5,

- the camshafts.

- the camshaft bearing caps.

18724-1 a

Mark the camshaft caps using an indelible pencil.

18724-3 a



10A-54

Clean the gasket face using SUPER CLEANER FOR JOINT FACES.


10A

X44

II - REFITTING OPERATION FOR PART CONCERNED 1 - Refitting the camshaft a

Position the pistons at mid-stroke to prevent any contact with the valves when tightening the camshaft bearings.

a

Refit: - the camshaft, - the camshaft caps.

19595

18724-2 a

19594 a

Apply: - two beads of MASTIXO, 2 mm wide, to the bearing no.5 end of the cylinder head, - two spots of MASTIXO, 2 mm wide, to the bearing no.1 end of the cylinder head.

a

Apply a drop of oil to the camshaft bearings.

10A-55

Torque tighten the camshaft bearing cap no.5 bolts (5 Nm).


10A

X44

18945 a

Refit the camshafts, positioning: - the rails in relation to the tappets, - the marks on the flywheel end.

10A-56


10A

X44

18724 a

Pre-tighten to torque and in order the camshaft bearing cap bolts (initial torque) (5 Nm) .

a

Repeat the following operation for each camshaft bearing cap bolt, following the correct tightening order:

20058 a

Refit the seal cap to the end of the camshaft using the (Mot. 1605).

- loosen the bolts, - torque and angle tighten the camshaft bearing cap bolt (7 Nm + 50˚ ± 6).

2 - Fitting the camshaft sealing cap a

Check that the camshaft support surfaces are clean.

18687 a

Fit the lip seal.

3 - Fitting the camshaft lip seal a

10A-57

Check that the camshaft support surfaces are clean.


10A

X44

19592 a

Screw the threaded rod of the (Mot. 1587) into the camshaft.

19592-2 a

19592-1 a

Fit the protector with the new seal on the camshaft, taking care not to touch the seal.

10A-58

Fit the cover and the collar nut of the (Mot. 1587).


10A

X44

19592-3

19592-5 a

Remove: - the nut from the (Mot. 1587), - the cover from the (Mot. 1587), - the seal protector, - the threaded rod of the (Mot. 1587).

4 - Refitting the camshaft pulley a

Refit: - the camshaft pulley, - the camshaft pulley bolt.

a

Torque and angle tighten the camshaft pulley bolt (30 Nm + 45˚ ± 6) using the (Mot. 799-01) .

III - FINAL OPERATION. 19592-4 a

a

Screw on the collar nut until the cover touches the cylinder head.

Refit: - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17 ) , - the intake distributor (see Inlet manifold: Removal - Refitting ) , - the air filter box (see Air filter unit: Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) ,

10A-59

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Removal - Refitting X44 - the accessories accessories belt (see Accessories belt: Removal - Refitting) , - the front right-hand wheel (see 35A, Wheels and tyres, Wheel: Removal-Refitting Removal-Refitting ), - the scoop under the scuttle panel grille (see MR 412, Bodywork, 56A, Exterior equipment, Scoop under scuttle panel grille: Removal-Refitting), - the scuttle panel panel grille (see MR 412, Bodywork, 56A, Exterior equipment, Scuttle panel grille: Removal - Refitting). a

Connect the battery (see 80A, Battery, Battery: Removal - Refitting).

10A-60

10A


10A



Lower engine support.

Mot. 799-01


Mot. 1381


Mot. 1587


Tightening torques m

121813

bolts on camshaft bearing No.5

9 Nm

a

Remove the bolt ( 1 ) from the intercooler air inlet pipe on the intake distributor.


7 Nm + 50˚ ± 6˚

a

Remove the intercooler inlet pipe clip ( 2) from the turbocharger.


30 Nm + 45˚ ± 6˚

heat shield bolts

Note: If the thermal protection clip (3) is removed, the intercooler air inlet pipe must also be replaced.

8 Nm

REMOVAL

a

Move the intercooler inlet air pipe to t o one side.

a

Disconnect the oil vapour rebreathing circuit union ( 4) .


Position the vehicle on a two-post lift (see Vehicle: Towing and lifting ) (MR 392, 02A, Lifting equipment).

a


a

Remove the front engine cover.

10A-61


10A


Remove: - the right-hand suspended suspended engine engine mounting (see Right-hand suspended engine mounting: Removal - Refitting) , - the timing timing belt belt (see Timing belt: Removal - Refitting) , - the rocker rocker cover cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17) .

120957 a

Disconnect the upstream oxygen sensor connector.

a

Unpick the wiring harness from the upstream oxygen sensor at (5) .

a

Remove: - the bolts bolts (6 ) from the heat shield, - the he heat at shield, shield, - the filler neck neck bolt (7 ) ,

18722

- the filler filler neck,

a

- the ignition coil (see Coils Removal - Refitting) , - the front bumper bumper (see Front bumper: Removal Refitting) (MR 393, 55A, Exterior protection), - the accessories accessories belt (see Accessories belt: Removal - Refitting) .

109745 a

Set up engine support tool (Mot. 1672).

10A-62

Remove: - the camshaft camshaft pulley pulley bolt (8) using the (Mot. 79901) , - the camshaft camshaft pulley. pulley.


10A



18722-1 a

Position the (Mot. 1381). 18724 a

Remove: - the camshaft bolts, - the camshafts.

18722-2 a

Remove the seal by tightening the bolt ( 9) on the (Mot. 1381).

18724-1 a

10A-63

Mark the camshaft bearing caps with a permanent marker pen.


10A




18724-2 a

Remove the camshaft bearing caps.

18724-3 a



Always replace: - the camshaft seal, - the camshaft pulley bolt.

10A-64


10A





19595

18724-3 a

19594 a

Apply: - two beads (10) of MASTIXO (see Vehicle: Parts and ingredients for the repairwork ) (MR 392, 04B, Consumables - Products) with a width of 2 mm to bearing No.5 on the cylinder head, - two drops (11) of MASTIXO to bearing No.1 on the cylinder head.

10A-65

Refit the camshaft.

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Removal - Refitting X85, and D4F, and 784

18724-2 a

Refit the camshaft bearing caps.

a

Torque tighten the bolts on camshaft bearing No.5 (9 Nm).

10A-66

10A


10A


Inlet camshaft

18945 a

Refit the inlet camshaft by positioning: - the rails in relation relation to the tappets, - the marking marking (12 ) on the timing end.

10A-67


10A


Exhaust camshaft

18944 a

Refit the exhaust camshaft by positioning: - the rails in relation relation to the tappets, - the marking marking (13 ) on the flywheel end.

10A-68


10A



18724 a

Tighten to torque and in order the camshaft bearing cap bolts (5 Nm).

a

Completely loosen bolt (1) .

a

Torque and angle tighten the camshaft bearing cap bolt (7 Nm + 50˚ ± 6˚).

a

18687 a

Prepare the camshaft seal with its protector. Note: This type of seal is extremely fragile. Only touch the protective part (1 4) when handling the gasket. It is strictly forbidden to touch the seal (15) ; this is to prevent any oil leaks once the oil seal is fitted to the engine.

Carry out the previous operations for each bolt from (2) to (10) .

a

10A-69

Fit the seal using the (Mot. 1587).


10A


19592 a

Fit the threaded rod (16) of the (Mot. 1587) into the camshaft.

19592-2 a

19592-1 a


10A-70

Fit the cover (17) and the collar nut ( 18) of the (Mot. 1587) .


10A


19592-3

19592-5 a

Remove: - the nut (18) , - the cover (17) , - the guard (14) , - the threaded rod (16) .

19592-4 a

Tighten the collar nut until the cover comes into contact with the cylinder head.

18722 a

Refit: - the camshaft pulley, - the new camshaft pulley bolt (19) .

a

10A-71

Torque and angle tighten the camshaft pulley bolt (30 Nm + 45˚ ± 6˚) using the (Mot. 799-01).

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Removal - Refitting X85, and D4F, and 784 a

Refit: - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) , - the timing belt (see Timing belt: Removal - Refitting ) , - the right-hand suspended engine mounting (see Right-hand suspended engine mounting: Removal - Refitting) .

a

Remove the engine support tool (Mot. 1672).

a

Refit: - the accessories belt (see Accessories belt: Removal - Refitting) , - the front bumper (see Front bumper: Removal Refitting) (MR 393, 55A, Exterior protection), - the ignition coil (see Coils Removal - Refitting) , - the filler neck, - the filler neck bolt, - the heat shield, - the heat shield bolts.

a


a


a

Connect: - upstream oxygen sensor connector, - the oil vapour rebreathing circuit union.

a


a


a

Refit: - the intercooler air inlet pipe bolt on the intake distributor, - the engine cover.

a


10A-72

10A


10A




Mot. 1381


Mot. 1587


Tightening torques m bolts for camshaft bearing cap no.5

5 Nm


7 Nm + 50˚ ± 6˚


30 Nm + 45˚ ± 6˚

18722 a

Remove: - the camshaft pulley bolt (1) using the (Mot. 79901) ,

REMOVAL

- the camshaft pulley.



a


a

Remove: - the front right-hand wheel (see Wheel: Removal Refitting) (MR 411, 35A, Wheels and tyres),* - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting ) (MR 412, 55A, Exterior protection), - the air filter box (see Air filter unit: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) . - the accessories belt (see Accessories belt: Removal - Refitting) , - the right-hand suspended engine mounting (see Right-hand suspended engine mounting: Removal - Refitting) ,

18722-1 a

- the timing belt (see Timing belt: Removal - Refitting ) , - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) .

10A-73

Position the (Mot. 1381).


10A


18722-2 a

Remove the seal by tightening the bolt ( 2) on the (Mot. 1381).

18724-1 a



18724-2 a

18724 a

Remove: - the camshaft bolts, - the camshafts.

10A-74



18724-3 a




a



10A-75

10A


10A





19595

18724-3 a

19594 a

Apply: - two beads (3 ) of MASTIXO (see Vehicle: Parts and ingredients for the repairwork ) (MR 411, 04B, Consumables - Products) with a width of 2 mm to bearing No.5 on the cylinder head, - two drops (4) of MASTIXO to bearing No.1 on the cylinder head.

10A-76

Refit the camshaft.


18724-2 a


a

Torque tighten the bolts for camshaft bearing cap no.5 (5 Nm) (5 ) .

10A-77

10A


10A


Inlet camshaft

18945 a

Refit the inlet camshaft by positioning: - the rails in relation to the tappets, - the marking (6) on the timing end.

10A-78


10A


Exhaust camshaft

18944 a

Refit the exhaust camshaft by positioning: - the rails in relation to the tappets, - the marking (7) on the flywheel end.

10A-79


10A



18724 a

Tighten to torque and in order the camshaft bearing cap bolts (5 Nm).

a

Completely loosen bolt (1) .

a


a

18687 a

Prepare the camshaft seal with its protector. Note: This type of seal is extremely fragile. Only touch the protective part (8) when handling the gasket. It is strictly forbidden to touch the seal (9 ) ; this is to prevent any oil leaks once the oil seal is fitted to the engine.

Carry out the previous operations for each bolt from (2) to (10) .

a

10A-80

Fit the seal using the (Mot. 1587).


10A


19592 a

Fit the threaded rod (10) of the (Mot. 1587) into the camshaft.

19592-2 a

19592-1 a


10A-81

Fit the cover (11) and the collar nut ( 12) of the (Mot. 1587) .


10A


19592-3

19592-5 a

Remove: - the nut, - the cap, - the guard, - the threaded rod.

19592-4 a

Tighten the collar nut until the cover comes into contact with the cylinder head.

18722 a

Refit: - the camshaft pulley, - the new camshaft pulley bolt (13) .

a

10A-82


ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Removal - Refitting X44, and D4F, and 780 a

Refit: - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) , - the timing belt (see Timing belt: Removal - Refitting ) , - the right-hand suspended engine mounting (see Right-hand suspended engine mounting: Removal - Refitting) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) , - the air filter box (see Air filter unit: Removal - Refitting) . - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting ) (MR 412, 55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal Refitting) (MR 411, 35A, Wheels and tyres).

a


10A-83

10A


10A

X90, and D4D



Tightening torques m bolts for camshaft bearing cap no.5

5 Nm

camshaft bearing cap bolts

5 Nm


7 Nm + 50˚ ± 6˚


30 Nm + 45˚ ± 6˚ 18722

REMOVAL

a

- the camshaft pulley bolt (1) using the (Mot. 79901) ,


a

a

Remove:

- the camshaft pulley,

Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 388, 02A, Lifting equipment). Disconnect the battery (see Battery : Removal Refitting) (MR 388, 80A, Battery). Remove:

- the camshaft seal (see Camshaft seal at timing end: Removal - Refitting) .


- the front right-hand wheel (see Wheel: Removal Refitting) (MR 388, 35A, Wheels and tyres), - the air filter box (see Air filter unit: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the right-hand suspended engine mounting (see Right-hand suspended engine mounting: Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) , - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) .

18724 a

10A-84

Remove: - the camshaft bolts,


10A

X90, and D4D - the camshafts.

18724-3 18724-1 a


a




a



18724-2 a

Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage.


10A-85


10A

X90, and D4D - two drops of (3 ) MASTIXO to bearing No.1 on the cylinder head. a



19595

18724-3 a

Refit the camshaft.

19594 a


Apply:

18724-2

- two beads (2 ) of MASTIXO (see Vehicle: Parts and ingredients for the repairwork ) (MR 388, 04B, Consumables - Products) with a width of 2 mm to bearing No.5 on the cylinder head,

a


a

Torque tighten the bolts for camshaft bearing cap no.5 (5 Nm).

10A-86


10A

X90, and D4D

Inlet camshaft

18945 a

Refit the inlet camshaft by positioning: - the rails in relation to the tappets, - the marking (4) on the timing end.

10A-87


10A

X90, and D4D

Exhaust camshaft

18944 a

Refit the exhaust camshaft by positioning: - the rails in relation to the tappets, - the marking (5) on the flywheel end.

10A-88


10A

X90, and D4D

18724

18722

a

Pre-tighten to torque and in order the camshaft bearing cap bolts (5 Nm) .

a

Completely undo the bolt (1).

- the camshaft pulley,

a


- the new camshaft pulley bolt.

a

Repeat these two operations for each bolt from (2) to (10).

a

a


a

Refit:


Refit:

- the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17 ) ,

Refit the camshaft seal (see Camshaft seal at timing end: Removal - Refitting ) .

- the timing belt (see Timing belt: Removal - Refitting) , - the right-hand suspended engine mounting (see Right-hand suspended engine mounting: Removal - Refitting) , - the accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) , - the air filter box (see Air filter unit: Removal - Refitting) , - the front right-hand wheel (see Wheel: Removal Refitting) (MR 388, 35A, Wheels and tyres). a

10A-89

Connect the battery (see Battery : Removal - Refitting ) (MR 388, 80A, Battery).


10A

X35 - the air filter unit (see Air filter unit: Removal - Refitting) ,

Essential equipment


indelible pencil

- the inlet manifold (see Inlet manifold: Removal Refitting) ,


- the ignition coil (see Coils Removal - Refitting) , bolts of camshaft bearing cap no.5

9 N.m

camshaft bearing cap bolts (initial torque)

5 N.m

camshaft bearing cap bolts

7 N.m + 50˚ ± 6˚

- the camshaft seal on the timing end (see Camshaft seal at timing end: Removal - Refitting) , - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17 ) .

II - OPERATION FOR REMOVAL OF PART CONCERNED IMPORTANT Wear protective gloves during the operation.


Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

a

Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).

a

Remove: - the engine undertray bolts, - the engine undertray.

IMPORTANT Wear leaktight gloves (Nitrile type) for this operation.

18724 a

Remove: - the camshaft bolts (1) ,

a

Drain the cooling system (see Cooling circuit: Draining - Refilling) .

a

Remove: - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the accessories belt (see Accessories belt: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting) ,

10A-90

- the camshafts.


10A

X35

18724-1 a

Mark the camshaft caps using a indelible pencil.

18724-3 a



Use SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to clean the cylinder head joint face on the side of bearing no. 5.

a

Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to degrease the cylinder head joint face on the side of bearing no.5.

WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. 18724-2 a

Remove:

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

- the bolts (2 ) from camshaft bearing cap no. 5, - the camshaft bearing caps.

10A-91


10A

X35

19595 a

Apply a bead of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) on the side of bearing no.5 of the cylinder head.

a

Apply a drop of oil to the camshaft bearings.

18724-2 a


Position the pistons at mid-stroke to prevent any contact with the valves when tightening the camshaft bearings.

a

Refit: - the camshaft, - the camshaft caps.

10A-92

Torque tighten the bolts of camshaft bearing cap no.5 (9 N.m) .


10A

X35

18945 a

Refit the camshafts, positioning: - the rails in relation to the tappets, - the marks on the flywheel end.

10A-93


10A

X35 - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres). a

Connect the battery (see Battery: Removal - Refitting ) (80A, Battery).

a

Perform the following operations: - fill the cooling system (see Cooling circuit: Draining - Refilling) , - bleed the cooling circuit (see Cooling circuit: Draining - Refilling) , - check the power-assisted steering fluid level in the power-assisted fluid reservoir, - bleed the power-assisted steering circuit (see Power-assisted steering circuit: Bleeding ) (36B, Power-assisted steering).

18724 a

Pre-tighten to torque and in order the camshaft bearing cap bolts (initial torque) (5 N.m) .

a

Loosen the camshaft bearing cap bolts.

a

Torque and angle tighten in order the camshaft bearing cap bolts (7 N.m + 50˚ ± 6˚).


Refit: - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) , - the camshaft seal on the timing end (see Camshaft seal at timing end: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) , - the inlet manifold (see Inlet manifold: Removal Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) , - the air filter unit (see Air filter unit: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the engine undertray, - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),

10A-94

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

II - CHECKING THE CAMSHAFT Essential equipment 1 - Checking the camshaft radial play

compressed air nozzle

Remove any oil that may be on the camshaft bearings and the camshaft bearing caps.

radial play measuring wire external micrometer dial gauge support dial gauge


IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 1 0 A , Engine and cylinder block assembly , Engine: Precautions for repair , page 10A-1) .

WARNING

114814

Cut some pieces of radial play measuring wire (1) the width of the camshaft journal mating face.

It is str ictly forbidden to apply any pressure to the engine oil sump. Damage to the sump may also damage the engine by:

Place each piece of wire in line with the camshaft on the camshaft journal mating faces.

- blocking the strainer, - raising the oil level above maximum, with a risk of engine racing.

Note: Do not allow the camshaft to rotate during the operation in order to avoid distorting the measurement.

Drain the cooling system (see Cooling circuit: Draining - Refilling ) . Remove:

Refit:

- the camshaft (see 10A , Engine and cylinder block assembly , Cylinder head:Stripping - Restoring , page 10A-137) .

- the camshaft,

Before any checks:

- the rocker shafts,

- clean the camshaft with SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) and dry using a compressed air nozzle,

- the rocker shaft bolts.

- the camshaft bearing caps,

- check that the camshaft is not scratched and does not show signs of impact or abnormal wear (replace the camshaft if necessary).

10A-95


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 Checking the camshaft journal diameters

102772

Place the camshaft on two slightly oiled v-blocks.

Note:

19597

Torque tighten the rocker shaft bolts (9 N.m) (1) and (2) .

Camshaft bearing No.1 is located on the flywheel end.

Pretighten to torque the bolts of the rocker shaft (3 N.m) (3) to (12) .

Use a external micrometer to measure the outer diameter of every camshaft journal which must be between the following values:

Undo the bolt (3) on the rocker shaft to release it. Torque tighten the rocker shaft bolt (5 N.m) (3) .

Number of bearings

Repeat the operation on bolts (4) to (12) . Remove: - the rocker shaft bolts,

Diameter of camshaft journals on the camshaft

No. 1

- the rocker shafts,

No. 2

- the camshaft bearing caps,

24.98 ± 0.01mm No. 3

- the camshaft. Measure the flattening of the radial play measuring wire, which must be between 0.05 and 0.09 mm , using the gauge (2) printed on the measuring wire packaging paper. Clean any traces of measuring wire off the camshaft and the camshaft bearing caps.

10A-96

No. 4 No. 5

27.98 ± 0.01mm


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

2 - Checking the concentricity of the camshaft journals

3 - Checking the height of the cam lobes

103149 103148

Place the camshaft on two slightly oiled v-blocks (3 ) . Fit: - the dial gauge support (4 ) , - the dial gauge (5 ) . Fit the sensor of the dial gauge against the centre of the camshaft journal mating face. Set the dial gauge to zero. Rotate the camshaft while avoiding the lubrication holes to check the journal concentricity, which must be less than 0.05 mm. 102771

Place the camshaft bearings no. 2 and 4 on two slightly oiled v-blocks. Use a external micrometer to measure the height of the cams which must be:

10A-97

Cam height

Inlet

Exhaust

All D4 engines except D4F 764

38.586 mm

38.794 mm

D4F 764

38.598 mm

38.425 mm


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

4 - Checking the camshaft longitudinal play Refit: - the camshaft, - the camshaft bearing caps, - the rocker shafts, - the rocker shaft bolts.

18726

Position the dial gauge sensor against the end of the camshaft. Move the camshaft towards the dial gauge until it hits a stop. Calibrate the dial gauge to zero. 19597

Torque tighten the rocker shaft bolts (9 N.m) (1) and ( 2) . Pretighten to torque the bolts of the rocker shaft (3 N.m) (3 ) to (12) .

Move the camshaft towards the side opposite the dial gauge until it hits the other stop. Use a dial gauge to measure the longitudinal clearance of the camshaft which must be between 0.08and0.178 mm .

Undo the bolt ( 3) on the rocker shaft to release it.


Torque tighten the rocker shaft bolt (5 N.m) (3 ) .

Refit:

Repeat the operation on bolts ( 4) to (12) .

- the camshaft (see 10A , Engine and cylinder block assembly , Cylinder head:Stripping - Restoring , page 10A-137) , Fill and bleed the cooling system (see Cooling circuit: Draining - Refilling) .

10A-98

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head: Removal - Refitting

10A

X85, and D4F, and 740 or 742 or 764

Essential equipment cylinder head testing tool

Tightening torques m cylinder head mounting bolts

230˚ ± 6



a


a

Remove the engine undertray.

a


a

Remove:

110422 a

Remove the rocker cover (see 10A, Engine and cylinder block assembly , Rocker cover: Removal Refitting, page 10A-17) .

- the front right-hand wheel (see Wheel: Removal Refitting) (MR 392, 35A, Wheels and tyres), - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting ) (MR 393, 55A, Exterior protection), - the accessories belt (see Accessories belt: Removal - Refitting) , - the accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the timing belt (see Timing belt: Removal - Refitting ) , - the air filter box (see Air filter unit: Removal - Refitting) ,

109722 a

Disconnect the upstream oxygen sensor connector (1) .

a

Remove the mounting (2 ) from the upstream oxygen sensor connector.

- the intake distributor (see Inlet manifold: Removal - Refitting) . a

Remove the ignition coil (see Coils Removal - Refitting) .

a


10A-99


10A

X85, and D4F, and 740 or 742 or 764


109725 a

Disconnect the coolant temperature sensor connector (3) .

a

Remove the cooling hoses (4) from the thermostat unit.

18641 a

Remove: - the cylinder head mounting bolts, - the cylinder head, - the cylinder head gasket.

108817 a

Remove: - the exhaust bracket mounting bolts (5) , - the strut bolt (6) .

10A-100


10A

X85, and D4F, and 740 or 742 or 764

REFITTING

a


1 - Cleaning the cylinder head a

Refer to the (see Cylinder head: Dismantling ) (Technical Note 6004, 10A Engine and peripherals) for the procedure for stripping down the cylinder head and for the valve clearance adjustment procedure (see Valves: Adjusting) .

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.

Clean the cylinder head.

IMPORTANT - Do not scratch the aluminium sealing surfaces. - Wear goggles.

WARNING Be sure to replace all seals that have been removed.

- Wear gloves during the operation. - Clean the joint faces with DECAPJOINT. - To dissolve any gasket which remains adhered, apply product to the surface to be cleaned, wait for approximately ten minutes then remove residues with a wooden spatula.



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

a

Fit the cylinder head with a new gasket.

Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage.

WARNING The cylinder head bolts must be replaced each time they are removed and should not be oiled before being fitted.

2 - Checking the gasket face a

With a ruler and set of feeler gauges, check for gasket face bow. 18641

The maximum deformation is 0.05 mm.

a

- pre-tighten to torque and in order the cylinder head mounting bolts (20 N.m) ,

WARNING No regrinding of the cylinder head is permitted. a

Tightening the cylinder head:

Test the cylinder head for any cracks using the cylinder head testing tool (see Garage Equipment Catalogue).

10A-101

- check that all of the cylinder head mounting bolts are correctly tightened to 20 N.m, - angle tighten, in order the cylinder head mounting bolts (230˚ ± 6).

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head: Removal - Refitting X85, and D4F, and 740 or 742 or 764


Refit the upstream oxygen sensor connector attachment

a

Connect: - the upstream oxygen sensor connector, - the coolant temperature sensor connector,

a

Refit: - the cooling hoses to the thermostat unit. - the exhaust clamp mounting bolts, - the strut bolt. - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) .

a

Clip the electric wiring harnesses onto the rocker cover.

a

Refit: - the ignition coil (see Coils Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) , - the accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting ) (MR 393, 55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal Refitting) (MR 392, 35A, Wheels and tyres), - the engine undertray, - the intake distributor (see Inlet manifold: Removal - Refitting) , - the air filter box (see Air filter unit: Removal - Refitting) .

a

Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).

a

Fill the cooling system (see Cooling circuit: Draining - Refilling) .

a

Bleed the cooling circuit (see Cooling circuit: Bleeding) .

10A-102

10A


10A

X77, and J77, and D4F, and 784


Long nose pliers for hose clips.


Tightening torques m 20 Nm

cylinder head bolts (initial torque) cylinder head bolts

230˚ ± 6


a

109807

Position the vehicle on a two-post lift (see 02A, Lifting Equipment, Vehicle: Towing and lifting ).

a

Remove: - the deflector bolts (1 ) ,

Remove:

- the air deflector (2 ) ,

- the scoop under the scuttle panel grille (see MR 386 Bodywork, 56A, Exterior equipment, Scoop under scuttle panel grille: Removal - Refitting ),

- the air deflector (3 ) .

- the front bumper (see MR 386 Bodywork, 55A, Exterior protection, Front bumper: RemovalRefitting), - the battery (see 80A, Battery, Battery: Removal Refitting), - the battery tray (see 80A, Battery, Battery: Removal - Refitting). a


109808 a

Undo the clips ( 4) : - on the intercooler air inlet pipe, - on the intercooler air outlet pipe.

10A-103


10A

X77, and J77, and D4F, and 784 - the engine undertray, - the accessories belt (see Accessories belt: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the timing belt (see Timing belt: Removal - Refitting) , - the catalytic pre-converter (see Catalytic pre-converter: Removal - Refitting ) , - the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting ) , - the ignition coil (see Coils Removal - Refitting) . 121762

121813 a

Remove: - the air pipe (5) from the air filter box inlet, - the bolt (6 ) from the intercooler air inlet pipe on the intake distributor.

a


121773 a

Move the clips (9 ) on the turbocharger cooling hoses to one side, using the (Mot. 1448).

a

Disconnect the turbocharger cooling hoses.

Note: If the clip (8) is removed from the heat resistant protector, the latter must be replaced. a

Remove the intercooler air inlet pipe.

a

Remove: - the scoop under the scuttle panel grille (see MR 386 Bodywork, 56A, Exterior equipment, Scoop under scuttle panel grille: Removal - Refitting ), - the front right-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting), - the front right-hand wheel arch liner (see 55A, Exterior protection, Wheel arch liner: RemovalRefitting),

10A-104


10A


121755

121763

a

Disconnect the intake distributor vacuum hose (10) .

a

Remove the clip from the expansion bottle.

a

Undo the clips (11) on the compressor discharge valve air pipe.

a

Remove the expansion bottle.

a

Remove:

a

Remove the compressor discharge valve air pipe.

- the intercooler air outlet pipe bolts (14) , - the intercooler outlet air pipe.

121761 a

Disconnect: - the connector (12) from the air temperature sensor, - the air pressure sensor connector (13) .

10A-105


10A


121727 a

Disconnect: - the fuel vapour recirculation pipe (15) from the air filter box air outlet pipe, - the oil vapour rebreathing pipe (17 ) on the air filter box air outlet pipe.

a

121769 a

Undo:

- the brake servo non-return valve pipe (19) ,

- the turbocharging pressure relief valve control pipe clips (16) ,

- the fuel vapour recirculation pipe (20) on the intake distributor,

- the air filter box air outlet pipe clips (18) . a

a

Disconnect:

- the oil vapour rebreathing pipe ( 21) on the intake distributor,

Disconnect: - the turbocharging pressure relief valve control pipes,

- the oil vapour rebreathing pipe ( 22) on the rocker cover,

- the air filter box outlet air pipe.

- the fuel vapour recirculation pipe (23) on the solenoid valve.

Remove the air filter box air outlet pipe. a

Remove: - the fuel vapour recirculation hose, - the petrol vapour rebreather pipe.

10A-106


10A


121765 a

121723

Disconnect:

a

- the injector rail - injector wiring harness connector ( 24) ,

Move aside the clips ( 27) on the cooling hoses using the (Mot. 1448).

a

Disconnect the cooling hoses.

- the air inlet pressure connector (25) ,

a

Remove the rocker cover (see 10A, Engine and cylinder block assembly , Rocker cover: Removal Refitting, page 10A-17) .

- the upstream oxygen sensor connector (26) , - the petrol vapour recirculation solenoid valve connector, - the coolant temperature sensor connector,


IMPORTANT Wear latex gloves during the operation. a

Disconnect the petrol supply union on the injector rail - injector.

a

Cap the apertures.

WARNING To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the union. a

18641 a

Move the wiring harness away from the engine.

Remove: - the cylinder head bolts,

10A-107


10A

X77, and J77, and D4F, and 784 - the cylinder head,

1 - Checking the gasket face

- the cylinder head gasket.

a

REFITTING

the maximum deformation is 0.05 mm.


With a ruler and set of feeler gauges, check for gasket face bow.

WARNING No regrinding of the cylinder head is permitted.

Clean the cylinder head using SUPER CLEANING AGENT FOR JOINT FACES. a

Test the cylinder head to detect any cracks using the cylinder head testing tool .

a

Refer to Technical Note 6004 for the cylinder head stripping procedure and for the valve clearance ad justment procedure (see Technical Note 6004,10A, Engine and peripherals, Valves: Adjustment ).




IMPORTANT Wear latex gloves during the operation.

2 - If replacing the cylinder head WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage.

a

Rebuild the cylinder head (see Technical Note 6004A, 10A, Engine and peripherals, Rebuilding the cylinder head ).


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

WARNING The cylinder head bolts must be replaced each time they are removed and should not be oiled before being fitted. a

Replace: - the cylinder head bolts, - the cylinder head gasket.

19598 a

10A-108

Fit the new cylinder head gasket onto the cylinder block, positioning the marking (1 ) on the oil filter side.


10A

X77, and J77, and D4F, and 784 - the air inlet pressure connector. - the injector rail - injector wiring harness connector. a

Refit: - the petrol vapour rebreather pipe, - the oil vapour recirculation pipe.

a

Connect: - the fuel vapour recirculation pipe on the solenoid valve. - the oil vapour rebreathing pipe on the rocker cover, - the oil vapour rebreathing pipe from the intake distributor, - the fuel vapour recirculation pipe onto the intake distributor, - the brake servo non-return valve pipe,

18641 a

a

Refit the air filter box air outlet pipe.

a

Connect:

Refit:

- the air filter box air outlet pipe,

- the cylinder head,

- the turbocharging pressure relief valve control pipes.

- the new cylinder head bolts. a

Pretighten to torque and in order the cylinder head bolts (initial torque) (20 Nm) .

a

Check that all the cylinder head bolts are tightened to the correct torque of 20 Nm.

a

Angle tighten in order the cylinder head bolts (230˚ ± 6).

a

- the clips on the air filter box outlet air pipe, - the turbocharging pressure relief valve control pipe clips. a

Refit the rocker cover (see 10A, Engine and cylinder block assembly , Rocker cover: Removal Refitting, page 10A-17 ) .

a

Connect the cooling hoses.

a

Refit:

Connect: - the oil vapour rebreathing pipe to the air filter unit air outlet pipe.


Tighten:

- the fuel vapour recirculation pipe to the air filter box air outlet pipe, a

Refit: - the intercooler outlet air pipe, - the intercooler air outlet pipe bolts.

- the cooling radiator hose clips using the (Mot. 1448) , - the engine wiring harness.

a

Position the expansion bottle.

a

Refit the clip to the expansion bottle.

a

Connect:

a

Remove the blanking plugs.

- air pressure sensor connector,

a

Connect:

- the air temperature sensor connector.

- the petrol inlet union on the injector rail - injectors. - the coolant temperature sensor connector, - the petrol vapour recirculation solenoid valve connector,

a

Refit the compressor discharge valve air pipe.

a

Tighten the compressor discharge valve pipe clips.

a

Connect:

- the upstream oxygen sensor connector,

- the vacuum hose on the intake distributor, - the turbocharger cooling hoses.

10A-109

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head: Removal - Refitting X77, and J77, and D4F, and 784 a

Refit: - the turbocharger cooling hose clips using the (Mot. 1448) , - the ignition coil (see Coils Removal - Refitting) , - the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting ) , - the catalytic pre-converter (see Catalytic pre-converter: Removal - Refitting ) , - the timing belt (see Timing belt: Removal - Refitting ) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the engine undertray, - the front right-hand wheel arch liner (see 55A, Exterior protection, Wheel arch liner: RemovalRefitting), - the front right-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting).

a


a


a

Refit: - the intercooler air inlet pipe bolt on the intake distributor, - the air filter unit air inlet pipe.

a

Tighten the clips: - on the intercooler air inlet pipe, - on the intercooler air outlet pipe.

a

Refit: - the air deflectors, - the deflector bolts, - the battery tray (see 80A, Battery, Battery: Removal - Refitting), - the battery (see 80A, Battery, Battery: Removal Refitting), - the front bumper (see MR 386 Bodywork, 55A, Exterior protection, Front bumper: RemovalRefitting), - the scoop under the scuttle panel grille (see MR 386 Bodywork, 56A, Exterior equipment, Scoop under scuttle panel grille: Removal - Refitting ).

a

Fill and bleed the cooling system (see Cooling circuit: Draining - Refilling) .

10A-110

10A


10A



Long nose pliers for hose clips.


Tightening torques m cylinder head bolts (initial torque) cylinder head bolts

20 Nm 230˚± 6

REMOVAL 109808



a

Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).

a

Remove:

a

Undo the intercooler air inlet pipe clip ( 2) .

a

Disconnect the intercooler air inlet pipe from the intercooler.

- the engine undertray, - the engine cover, - the front bumper (see Front bumper: Removal Refitting) (MR 393, 55A, Exterior protection). a


112029 a

Remove the air deflector ( 1) .

10A-111


10A

X85, and D4F, and 784 - the accessories belt (see Accessories belt: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the catalytic converter (see Catalytic converter: Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting) , - the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting ) , - the ignition coil (see Coils Removal - Refitting) . 121762

121727 a

121813 a

a

Disconnect: - the fuel vapour recirculation pipe (7) from the air filter box air outlet pipe,

Remove: - the air pipe (3) from the air filter box inlet,

- the oil vapour rebreathing pipe ( 9) from the air filter unit air outlet pipe,

- the bolt (4 ) from the intercooler air inlet pipe on the intake distributor.

- the turbocharging pressure relief valve ( 8) from the air filter unit air outlet pipe.


a

Undo the air filter unit air outlet pipe clips ( 10) .

a

Disconnect:

Note:

- the turbocharging pressure relief valve control pipes,

If the clip (6) is removed from the heat resistant protector, the latter must be replaced.

- the air filter box outlet air pipe.

a

Remove the intercooler air inlet pipe.

a

Remove:

a

- the front right-hand wheel (see Wheel: Removal Refitting) (MR 392, 35A, Wheels and tyres), - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting ) (MR 393, 55A, Exterior protection), - the engine undertray,

10A-112

Remove the air filter box air outlet pipe.


10A


121773 a

a

Move the clips (11) on the turbocharger cooling hoses to one side, using the (Mot. 1448).

121761 a

Disconnect: - the connector (14) from the air temperature sensor,

Disconnect the turbocharger cooling hoses.

- the air pressure sensor connector (15) .

121755 a

Disconnect the intake distributor vacuum hose (12) .

a

Undo the clips (13) on the compressor discharge valve air pipe.

a

Remove the compressor discharge valve air pipe.

121763 a

Remove the intercooler air outlet pipe bolts ( 16) .

a

Move the intercooler air outlet pipe towards the front of the vehicle.

10A-113


10A


121769 a

Disconnect:

121765 a

- the brake servo non-return valve pipe (17) ,

- the injector rail - injector wiring harness connector (22 ) ,

- the petrol vapour rebreathing pipe (18) from the intake distributor,

- the air inlet pressure connector (23) ,

- the oil vapour rebreathing pipe ( 19) on the intake distributor,

- the upstream oxygen sensor connector (24) , - the fuel vapour rebreather solenoid valve connector,

- the oil vapour rebreathing pipe (20) on the rocker cover,

- the coolant temperature sensor connector,

- the petrol vapour rebreathing pipe (21) from the petrol vapour rebreathing solenoid valve. a

Disconnect:

IMPORTANT

Remove: - the oil vapour rebreathing pipe,

During this operation, be sure to:

- the fuel vapour rebreathing pipe.

- refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the union.


WARNING To avoid any corrosion or damage, protect the areas on which fuel is likely to run. a

Disconnect the petrol supply union on the injector rail - injector.

a

Plug the openings.

a

Move the wiring harness away from the engine.

10A-114


10A

X85, and D4F, and 784 - the cylinder head, - the cylinder head gasket.


Clean the cylinder head with SUPER CLEANER FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork ) (MR 392, 04B, Consumables - Products).

WARNING Do not scratch the aluminium joint faces: any surface damage to the joint faces may cause leaks.


121723 a

Remove the clips (25) from the cooling hoses using the (Mot. 1448).

a

Disconnect the cooling hoses.

a

Remove the rocker cover (see 10A, Engine and cylinder block assembly, Rocker cover: Removal Refitting, page 10A-17 ) .


WARNING II - OPERATION FOR REMOVAL OF PART CONCERNED

Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage.

Note: The cylinder head bolts must be replaced each time they are removed and should not be oiled before being fitted. a

Always replace: - the cylinder head bolts, - the cylinder head gasket.

18641 a


10A-115


10A


1 - Checking the gasket face a

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


Test the cylinder head for any cracks using the cylinder head testing tool (see Garage Equipment Catalogue).

a

Strip the cylinder head (see Cylinder head: Dismantling) (Technical Note 6004A, 10A, Engine and peripherals).

2 - If replacing the cylinder head a

Rebuild the cylinder head (see Cylinder head: Refitting ) (Technical Note 6004A, 10A, Engine and peripherals).

18641 a


Refit: - the cylinder head, - the new cylinder head bolts.

a

Pretighten to torque and in order the cylinder head bolts (initial torque) (20 Nm) .

a

Check that all the cylinder head bolts are tightened to 20 Nm .

a

Angle tighten, in order the cylinder head bolts (230˚± 6).


19598 a

Fit the new cylinder head gasket onto the cylinder block, positioning the marking (1) on the oil filter side.

a

Refit the rocker cover (see 10A, Engine and cylinder block assembly , Rocker cover: Removal Refitting, page 10A-17) .

a

Connect the cooling hoses.

a

Refit: - the cooling radiator hose clips using the (Mot. 1448) , - the engine wiring harness.

a

Remove the blanking plugs.

a

Connect: - the petrol inlet union on the injector rail - injectors. - the coolant temperature sensor connector, - the fuel vapour rebreather solenoid valve connector, - upstream oxygen sensor connector,

10A-116


10A

X85, and D4F, and 784 - the air inlet pressure connector.

a

- the injector rail - injector wiring harness connector. a

a

- the turbocharger cooling hose clips using the (Mot. 1448) ,

Refit: - the petrol vapour rebreather pipe,

- the ignition coil (see Coils Removal - Refitting) ,

- the oil vapour rebreathing pipe.

- the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting ) ,

Connect:


- the petrol vapour rebreathing pipe to the solenoid valve,

- the catalytic converter (see Catalytic converter: Removal - Refitting) ,

- the oil vapour rebreathing pipe on the rocker cover, - the oil vapour rebreather pipe from the inlet manifold,

- the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) ,

- the fuel vapour rebreathing pipe onto the inlet manifold,

- the accessories belt (see Accessories belt: Removal - Refitting) ,

- the brake servo non-return valve pipe. a

Refit the air filter box air outlet pipe.

a

Connect:

a

- the engine undertray,

- the air filter box outlet air pipe,

- the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting ) (MR 393, 55A, Exterior protection),

- the turbocharging pressure relief valve control pipes.

- the front right-hand wheel (see Wheel: Removal Refitting) (MR 392, 35A, Wheels and tyres).

Tighten:

a


- the clips on the air filter box outlet air pipe,

a


a

Refit:

- the turbocharging pressure relief valve control pipe clips. a

Connect:

- the intercooler air inlet pipe bolt on the intake distributor,

- the oil vapour rebreathing pipe to the air filter unit air outlet pipe. - the petrol vapour rebreathing pipe to the air filter unit air outlet pipe. a

- the air filter unit air inlet pipe. a

Connect the intercooler air inlet pipe to the intercooler.

a

Tighten the intercooler inlet pipe clip.

a

Refit:

Refit: - the intercooler outlet air pipe, - the intercooler air outlet pipe bolts.

a

Refit:

- the air deflector,

Connect:

- the front bumper (see Front bumper: Removal Refitting) (MR 393, 55A, Exterior protection),

- air pressure sensor connector, - the air temperature sensor connector.

- the engine cover,

a

Refit the compressor discharge valve air pipe.

a

Tighten the compressor discharge valve pipe clips.

a

Connect: - the vacuum hose on the intake distributor,

- the engine undertray. a

Connect the battery (see Battery: Removal - Refitting ) (MR 392, 80A, Battery).

a


- the turbocharger cooling hoses.

10A-117


10A

X35 - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17) ,

Tightening torques m 20 N.m

- the catalytic converter (see Catalytic converter: Removal - Refitting) ,

230˚ ± 6˚

- the coolant outlet unit (see Plenum chamber: Removal - Refitting) .

cylinder head bolts (initial torque) cylinder head bolts


IMPORTANT Wear protective gloves during the operation.


Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

a

Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).

a

Remove: - the engine undertray bolts, - the engine undertray.

IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. a

a


18641 a


Remove:

- the cylinder head,

- the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the accessories belt (see Accessories belt: Removal - Refitting) ,

- the cylinder head gasket.


- the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting) , - the air filter unit (see Air filter unit: Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) , - the inlet manifold (see Inlet manifold: Removal Refitting) , - the ignition coil (see Coils Removal - Refitting) ,

10A-118

parts always to be replaced: Cylinder head bolts (10,02,01,14). parts always to be replaced: Cylinder head gasket (10,02,01,04) .


10A

X35

CLEANING THE CYLINDER HEAD

a

a

The maximum deformation is 0.05 mm.




WARNING To ensure proper sealing, the gask et surfaces must be clean, dry and not greasy (avoid any finger marks).


Strip the cylinder head (see Cylinder head: Dismantling) (Technical Note 6004A, 10A, Engine and peripherals).

a

Test the cylinder head for possible cracks using the cylinder head test kit (see Garage Equipment Catalogue).

a

Rebuild the cylinder head (see Rebuilding the cylinder head) (Technical Note 6004A, 10A, Engine and peripherals).

a

Position the pistons at mid-stroke.

a

Check that the centring dowel is present on the cylinder block.

a

Refit a new cylinder head gasket.



a

Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. a

Use SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to clean: - the cylinder head gasket face if being reused, - the cylinder block gasket face.

a

Check for gasket face deformation using a ruler and a set of shims.

Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products) to degrease: - the cylinder head gasket face if being reused, - the cylinder block gasket face.

10A-119

Refit: - the cylinder head, - new cylinder head bolts.


WARNING Do not oil the new bolts. Be sure to oil bolts being reused.


10A

X35 - the air filter unit (see Air filter unit: Removal - Refitting) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the accessories belt (see Accessories belt: Removal - Refitting) , - the engine undertray, - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres). a

Connect the battery (see Battery: Removal - Refitting ) (80A, Battery).

a

Perform the following operations: - fill the cooling system (see Cooling circuit: Draining - Refilling) ,

18641 a

Pretighten to torque and in order the cylinder head bolts (initial torque) (20 N.m).

a

Undo the cylinder head bolts.

a

Pretighten to torque and in order the cylinder head bolts (initial torque)20 N.m .

a

Check that all of the new cylinder head bolts are tightened to the correct torque (20 N.m).

a

Angle tighten in order the cylinder head bolts (230˚ ± 6˚). Note: Do not retighten the cylinder head bolts after applying this procedure.


Refit: - the coolant outlet unit (see Plenum chamber: Removal - Refitting) , - the catalytic converter (see Catalytic converter: Removal - Refitting) , - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) , - the ignition coil (see Coils Removal - Refitting) , - the inlet manifold (see Inlet manifold: Removal Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) ,

10A-120

- bleed the cooling circuit (see Cooling circuit: Draining - Refilling) , - check the level of power-assisted steering fluid in the power-assisted steering fluid reservoir, - bleed the power-assisted steering circuit (see Power-assisted steering circuit: Bleeding ) (36B, Power-assisted steering).

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90


Cylinder head support

Mot. 1502

Valve lifting tool for removing valves.

Mot. 1759

Tool for fitting valve stem seals

Mot. 1335

Pliers for removing valve stem seals.

Mot. 1511

Tool for fitting valve stem seals

REMOVAL I - REMOVAL PREPARATION OPERATION 18724-4

a

IMPORTANT To avoid all risk of o f damage to the systems, sy stems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 1 0A , Engine and cylinder block assembly, Engine: Precautions for repair, page 10A-1) .

a

Mount the cylinder head on the cylinder head support (Mot. 1573).

II - VALVE REMOVAL OPERATION a

Mark the valve in relation to the cylinder head.

WARNING It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump may also damage the engine by: - blocking the strainer, strainer, - raising the oil level above above maximum, with a risk of engine racing. a

a

Drain the cooling system (see Cooling circuit: Draining - Refilling) . Remove the cylinder head (see 10A , Engine and cylinder block assembly , Cylinder head: Removal - Refitting, page 10A-99)

16088 a

X44, and D4F, and 780 – X77, and D4F, and 784 – X85, and D4F, D4F, and 784 a

Remove the exhaust manifold (see Exhaust manifold: Removal - Refitting ) .

10A-121

Note: The valve springs are compressed using the tool (Mot. 1502).


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

16087

18725-2 a

To compress the valve springs correctly, it is essential that the piston ( 2) of the tool (Mot. 1502) is centred on the valve stem ( 4) . The upper cup of the valve spring should enter the housing (1 ) of the socket (3) on the tool (Mot. 1502) .

18725-1

113567 a

Remove: - the cotters cotters using using a (5) , - the valve spring upper upper cups, - the valve valve springs springs,, - the valv valves. es.

10A-122


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

Valve stem seal without lower spring retaining washer

110683 a

Note: There are two types of vaIve stem seal: - the valve stem seal with a lower spring retaining washer (6) , - the valve stem seal without a lower spring retaining washer (7 ) .

15738 a

Note: Before removing the valve stem seals, it is essential to mark the dimension (H) of the old seals on the inlet side then on the exhaust side (the fitting dimension of the seals may differ between the inlet and exhaust ends). a

10A-123

Fit a valve then compare the dimension ( H) of an old seal with the valve spring lower retaining washer using the tool (Mot. 1759) or .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

15738-1 a

Fit the pushrod ( 8) of (Mot. 1759) on to the valve stem seal.

Note: The internal diameter of the pushrod must be identical to that of the valve. In addition, the bottom of the pushrod must cover the metal upper section of the valve stem seal.

15738-3 a

Insert the sleeve ( 10) into the guide tube, until it comes into contact with the pushrod.

a

Lock the sleeve using tumblewheel (11 ) .

a

Remove the "guide tube/sleeve" assembly, being careful not to loosen the tumblewheel.

116002 15738-2 a

a

Fit the guide tube (9) above the pushrod until the guide tube comes into contact with the cylinder head.

10A-124

Remove: - the valves, - the valve stem seals using the (Mot. 1335) (12) .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90


Always replace the valve stem seals.

a

Clean, using SURFACE CLEANER (see Engine: Parts and consumables for the repair work ) : - the valves, - the valve springs, - the valve spring cups, 15737

- the valve cotters, - the valve stem guides.

WARNING Ensure the correct position of the valve face on its seat.


18077 a

110683 a

Note: There are two types of vaIve stem seal: - the valve stem seal fitted with the lower spring retaining washer (6) , - the valve stem seal without a lower spring retaining washer (7 ) . a

Apply engine oil to the inside of the valve guide.

10A-125

It is essential to fit the valve stem seals using the tool (Mot. 1511) or using the .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

1 - Valve stem seal with lower spring retaining washer

15771-1 15771 a

a

Note:

Refit the valve in the cylinder head.

The interior diameter of the protector must be the same as that of the valve stem. a

Fit the tool protector (Mot. 1511) on the valve stem.

WARNING Do not grease the valve stem seals.

10A-126


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

15771-2

15771-4

a

Keep the valve pressed against its seat.

a

Fit the valve stem seal onto the seal protector.

Note:

a

Push on the valve stem seal until it exceeds the seal protector.

The internal diameter of the pushrod must be identical to the diameter of the valve stem.

a

Also, the base of the pushrod must press against the part of the valve stem seal that acts as the lower thrust washer for the valve spring. a

15771-3 a

Remove the seal protector.

10A-127

Fit the pushrod ( 8 ) over the valve stem seal.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

2 - Valve stem seal without lower spring retaining washer

15771-5 a

Push home the valve stem seal by gently striking the top of the pushrod with the palm of the hand, until the valve stem seal makes contact with the cylinder head.

15739 a

15770 a

Repeat these operations for all the valves.

a

Refit: - the valve springs, - the valve spring upper cups.

10A-128

Refit the valve in the cylinder head.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

15739-1 a

Keep the valve pressed against its seat.

Note:

a

Fit the valve stem seal onto the seal protector.

The interior diameter of the protector must be the same as that of the valve stem.

a

Push on the valve stem seal until it exceeds the seal guard.

a

a

15739-2

Fit the tool protector (Mot. 1759) on the valve stem.

WARNING Do not grease the valve stem seals.

15739-3 a

10A-129

Remove the seal protector.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

16087 a

To correctly compress the valve springs, the piston ( 2) of the (Mot. 1502) must be centred on the valve stem. The upper cup of the spring should enter the housing ( 1) of the socket (3 ) on the (Mot. 1502).

15739-4 a

Place the « guide-tube - sleeve » assembly onto the valve stem seal.

a

Push the valve stem seal down by tapping the top of the sleeve with the palm of your hand until the guide tube touches the cylinder head.

a

Repeat these operations for all the valves.

a

Refit: - the valve springs, - the valve spring upper cups.

10A-130


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90


Refit the exhaust manifold (see Exhaust manifold: Removal - Refitting) .

a

Refit the cylinder head (see 10A, Engine and cylinder block assembly , Cylinder head: Removal Refitting, page 10A-99)

a

Fill and bleed the cooling circuit (see Cooling circuit: Draining - Refilling ) .

18725-1

18725 a

Compress the valve springs using the tool (Mot. 1502).

a

Refit the collets using a .


Remove the cylinder head from the cylinder head support (Mot. 1573).

10A-131

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - check that the parts are not scratched and do not show signs of impact or abnormal wear (replace the part if necessary),


TDC setting pin.

- check that the valve slides freely in the valve guide.

Essential equipment II - CHECKING OPERATION FOR PART CONCERNED

compressed air nozzle external micrometer

1 - Valve identification

dial gauge support dial gauge internal micrometer set of feeler gauges angular wrench

I - PREPARATION OPERATION FOR CHECK


10030

Note: When replacing valves, always replace with new valves having the same part number (1 ) as the old ones to avoid damaging the valve - seat assembly.

WARNING 2 - Checking the valve size

It is str ictly forbidden to apply any pressure to the engine oil sump. Damage to the sump may also damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. Remove: - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99 ) , - the valves (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting , page 10A-121 ) .

102778

Before any checks:

Measure using a external micrometer :

- clean the parts to be checked with SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) and dry them using a compressed air nozzle,

- the diameter (D1) of the valve stem. - the valve length (L) , - the valve head diameter (D2) .

10A-132


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

Inlet valve

Exhaust valve

5.48 mm + 0/ -0.015

5.47 mm +0/ -0.015

Stem diameter (D1) for D4F 780, 784

5.48 mm +0/ -0.015

5.464 ± 0.007

Diameter ( D2) of the head

26 ± 0.12 mm

22.1 ± 0.12mm

Total length (L) for D4D 700, 706, 712, 720, 752, 760

110.77 ± 0.23 mm

112.50 ± 0.23 mm

110.77 ± 0.23 mm

112.52 ± 0.22 mm

Stem diameter (D1) for D4D 700, 706, 712, 720, 752, 760 D4F 702, 706, 708, 712, 714, 716, 722, 728, 730, 732, 740, 742, 764, 772, 774

D4F 702, 706, 708, 712, 714, 716, 722, 728, 730, 732, 740, 742, 764, 772, 774 Total length (L) for D4F 780, 784 Mating face angle (A)

90˚

3 - Clearance check between the valve and the valve guide The clearance check between the valve and the valve guide can be carried out in two different ways.

Calculate the actual clearance between the valve and the valve guide by dividing the value measured on the dial gauge by two.

102782 102777

Position the valve head at a distance (H) of 25 mm from the valve seat. Fit: - the dial gauge support,

Or measure: - the internal diameter (2) of the valve guide using a internal micrometer ,

- the dial gauge on the mounting.

- using a external micrometer the diameter (3) of the valve stem.

Position the dial gauge feeler against the valve head at a 90˚ angle in relation to the camshaft axis.

Calculate the actual clearance = internal diameter of the valve guide (2 ) - the diameter of the valve stem (3) .

Push the valve head towards the dial gauge.

The clearance between the valve and the valve guide must be between:

Calibrate the dial gauge to zero. Push the valve head towards the side opposite the dial gauge.

- 0.020 and 0.053 mm for the inlet valve,

Note the value displayed on the dial gauge.

- 0.030 and 0.063 mm for the exhaust valve.

10A-133


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

4 - Maximum valve lift

- the exterior diameter of the valve springs.

Maximum valve lift must be: - Inlet: 8.849 mm, - Exhaust: 8.850 mm.

III - CHECKING THE VALVE SPRING 1 - Valve spring identification

104720

104720

The inlet and exhaust valve springs are identical.

Free length (L1)

42.9 ± 1 mm

Length, coils touching

25.67 mm maximum

Wire diameter (d) (mm)

3 ±0.02 mm

Internal diameter (D4)

14.1 ±0.02 mm

External diameter (D3)

20.60 mm maximum

3 - Checking valve spring wear

2 - Valve spring dimensional check Compress a valve spring using a spring compressor. Remove the half-bushings from the valve using a or a magnet. Slowly unscrew the spring compressor. Remove: - the spring compressor, - the upper cup of the spring, - the valve spring, taking care to note its position, - the washers at the bottom of the valve spring seatings. Repeat the operation for all the valve springs. Measure the length of the springs without loading. With a micrometer or sliding calliper, measure: - the diameter of the valve spring wires, - the interior diameter of the valve springs,

102776

10A-134


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 Use a dynamometer to check the wear of the valve spring by measuring the length ( X1) which must be:

Load (N)

Length (X1) load (mm)

156±11 N

36

420±21 N

27.15

5 - Adjusting valve clearances

under

Remove the valve spring from the tool for checking valve spring loading.

4 - Checking valve spring perpendicularity

18499

Check that the crankshaft is at its setting point using the (Mot. 1054).

102774

On the BODY JIG BENCH place: - the valve spring (4) , - the BRACKET (5 ) . Using a set of feeler gauges , check the perpendicularity ( X2) which must be less than 1.4 mm.

110423

Fit the angular wrench on the crankshaft accessories pulley bolt.

10A-135


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - adjust the exhaust valve clearance (E2) and (E 4) between 0.20 and 0.27 mm .

a - Camshaft without groove

Setting 4: - set the angular wrench to 0˚, - turn the crankshaft 240˚ in a clockwise direction (timing end), - adjust the inlet valve clearance (A 2) and ( A4) between 0.10 and 0.17 mm . b - Camshaft with groove This camshaft is identified by a groove between the cams (A2) and (E2). Repeat the adjustment procedure for the valves indicated above, with the following ad justment values: - inlet valve clearance: 0.25 to 0.32 mm , - exhaust valve clearance: 0.35 to 0.42 mm .

IV - FINAL OPERATION 18641

Refit: (A1)

Cylinder inlet 1

(A2)

Cylinder inlet 2

(A3)

Cylinder inlet 3

(A4)

Cylinder inlet 4

(E1 )

Cylinder exhaust 1

(E2 )

Cylinder exhaust 2

(E3 )

Cylinder exhaust 3

(E4 )

Cylinder exhaust 4

- the valves (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting, page 10A-121 ) , - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99 ) .

Setting 1: - set the angular wrench to 0˚, - turn the crankshaft 20˚ in a clockwise direction (timing end), - adjust the exhaust valve clearance (E1) and (E 3 ) between 0.20 and 0.27 mm . Setting 2: - set the angular wrench to 0˚, - turn the crankshaft 240˚ in a clockwise direction (timing end), - adjust the inlet valve clearance (A 1) and ( A3) between 0.10 and 0.17 mm . Setting 3: - set the angular wrench to 0˚, - turn the crankshaft 120˚ in a clockwise direction (timing end),

10A-136

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head:Stripping - Restoring

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

Essential special tooling

Remove:

Mot. 1573

Cylinder head support

- the accessories belt(s) (see Accessories belt: Removal - Refitting) ,

Mot. 799-01


- the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the timing belt (see Timing belt: Removal - Refitting) ,



lifting eye bolts

22 N.m

camshaft dephaser solenoid valve mounting bolts

10 N.m

- the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting, page 10A-17 ) , - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) . Mount the cylinder head on the cylinder head support (Mot. 1573).

STRIPPING

a

I - PREPARATION OPERATION FOR STRIPPING THE CYLINDER HEAD

II - STRIPPING DOWN THE CYLINDER HEAD

a



Remove: - the turbocharger (see Turbocharger: Removal Refitting) , - the throttle valve (see Throttle valve: Removal Refitting) , - the intake distributor (see Inlet manifold: Removal - Refitting ) .

WARNING It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by:

a

- blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. a


X06 – X35 – X44 – X65 – X76 – X77, and D4F, and 740 or 742 or 764 – X85, and D4F, and 740 or 742 or 764 – X90 a

Remove the air filter unit (see Air filter unit: Removal - Refitting) .

10A-137

Remove the exhaust manifold (see Exhaust manifold: Removal - Refitting )


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

X76, and D4F, and 764 – X85, and D4F, and 764

18722 a

116990 a

Remove: - the bolt (2 ) from the camshaft sprocket using the (Mot. 799-01) ,

Remove: - the bolts (1 ) from the camshaft dephaser solenoid valve mounting,

- the camshaft sprocket, - the timing tensioning roller nut,

- the camshaft dephaser solenoid valve mounting.

- the timing tensioning roller (3) , - the camshaft lip seal on the timing end (see Camshaft seal at timing end: Removal - Refitting) .

18723 a

Remove: - the lifting eye bolts (4) ,

10A-138


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - the camshaft (see 10A , Engine and cylinder block assembly, Camshaft: Removal - Refitting , page 10A-44 ) .

- the lifting eye, - the coolant outlet unit (see Plenum chamber: Removal - Refitting) ,

- the spark plugs (see Spark plugs: Removal - Refitting) ,

- the sealing cap (5) from the camshaft (if fitted), - the spark plugs (see Spark plugs: Removal - Refitting) .

- the sealing cap of the camshaft (if fitted), - the coolant outlet unit (see Plenum chamber: Removal - Refitting) , - the lifting eye, - the lifting eye bolts. a

Torque tighten the lifting eye bolts (22 N.m).

a

Refit: - the camshaft lip seal on the timing end (see Camshaft seal at timing end: Removal - Refitting) , - the timing tensioning roller, - the timing tensioning roller nut. - the camshaft sprocket, - the new camshaft sprocket bolt. Note: To refit the camshaft sprocket with camshaft dephaser (see Camshaft dephaser: Removal Refitting) .

18724 a

Remove:

a

- the camshaft (see 10A , Engine and cylinder block assembly, Camshaft: Removal - Refitting , page 10A-44 ) , - the valves (see 10A , Engine and cylinder block assembly , Valve: Removal - Refitting , page 10A121) .

- the camshaft dephaser solenoid valve mounting, - the bolts on the camshaft dephaser solenoid valve support. a

Torque tighten the camshaft dephaser solenoid valve mounting bolts (10 N.m) .

a

Refit:

REASSEMBLING

- the exhaust manifold (see Exhaust manifold: Removal - Refitting) .

I - PREPARATION OPERATION FOR REBUILDING THE CYLINDER HEAD a

Clean the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Cleaning, page 10A-141 ) .


II - OPERATION FOR REFITTING THE CYLINDER HEAD a

Refit:

Refit: - the inlet manifold (see Inlet manifold: Removal Refitting) , - the throttle valve (see Throttle valve: Removal Refitting) ,

Refit: - the valves (see 10A , Engine and cylinder block assembly , Valve: Removal - Refitting , page 10A121) ,

10A-139

- the turbocharger (see Turbocharger: Removal Refitting) .

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head:Stripping - Restoring X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90


Remove the cylinder head from the cylinder head support (Mot. 1573).

a

Refit: - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) , - the rocker cover (see 10A , Engine and cylinder block assembly, Rocker cover: Removal - Refitting , page 10A-17) , - the ignition coil (see Coils Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) , - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) , - the accessories belt(s) (see Accessories belt: Removal - Refitting) .

X06 – X35 – X44 – X65 – X76 – X77, and D4F, and 740 or 742 or 764 – X85, and D4F, and 740 or 742 or 764 – X90 a

Refit the air filter unit (see Air filter unit: Removal Refitting) .

a


10A-140

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head: Cleaning

10A

X65 – X35 – X76 – X90 – X06 – X44 – X77 – X85

I - CLEANING PREPARATION OPERATION a




113553

WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to avoid any foreign bodies entering the oil return and supply pipes. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. a


a

Place the engine on the component support (see 10A, Engine and cylinder block assembly , Engine support equipment: Use , page 10A-14) .

a

Remove the cylinder head (see 10A , Engine and cylinder block assembly , Cylinder head: Removal - Refitting, page 10A-99) .

a

Strip the cylinder head (see 10A, Engine and cylinder block assembly , Cylinder head:Stripping Restoring, page 10A-137) .

113592 a

II - CLEANING THE CYLINDER HEAD a

Clean the joint face of the cylinder head using SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork) .

a

Remove the residue using a wooden spatula

a

Finish cleaning the parts using a GREY ABRASIVE PAD, part number 77 01 405 943 .

10A-141

Wash the cylinder head using a cleaning fountain or a heated cleaning bath.

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head: Cleaning X65 – X35 – X76 – X90 – X06 – X44 – X77 – X85


Rebuild the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head:Stripping Restoring, page 10A-137) .

a

Refit the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Removal Refitting, page 10A-99 ) .

a


a


10A-142

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head: Check

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

II - CHECKING THE CYLINDER HEAD Essential equipment 1 - Cylinder head gasket

sliding calliper marking gauge cylinder head rule set of feeler gauges cylinder head testing tool internal micrometer external micrometer

I - PREPARATION OPERATION FOR CHECK 19598


Measure the thickness of the cylinder head seal at (1) which must be between 0.49 ± 0.04 mm.

2 - Checking the height of the cylinder head

WARNING It is str ictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. Remove the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal Refitting, page 10A-99) . Strip down the cylinder head, if required by the check (see 10A, Engine and cylinder block assembly, Cylinder head:Stripping - Restoring, page 10A-137 ) . Before any checks: - clean the cylinder head (see 10A, Engine and cylinder block assembly , Cylinder head: Cleaning , page 10A-141) , - check that the cylinder head does not have any scratches, any trace of impact or abnormal wear (if necessary replace the part).

18708

Measure the height ( H) of the cylinder head using a sliding calliper or a marking gauge. The height (H) of the cylinder head must be 99 mm.

3 - Position of the cylinders Cylinder No.1 is on the flywheel end. The injection order is 1-3-4-2.

10A-143

± 0.05


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

4 - Checking the flatness of the cylinder head Gasket face

Maximum tion (mm)

of the cylinder head

0.05

of the cylinder block

0.03

deforma-

WARNING No regrinding of the cylinder head is permitted.

114879

10011

Check the flatness of the gasket surfaces using a cylinder head rule and a "dial gauge support - dial gauge" assembly and a cylinder head rule and a set of feeler gauges . The maximum deformation of the cylinder head gasket face is: 0.05 mm. The maximum deformation of the cylinder block gasket face is: 0.03mm.

10A-144


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

5 - Testing the cylinder head

110415

6 - Check the camshaft bearing diameters Note: Always replace the coolant temperature sensor by a bolt at (2 ) . Check the cylinder head to detect any possible cracks using the cylinder head testing tool , see Cylinder head test tank: Use ) (Technical Note 6026, 11A, Top and front of engine) before carrying out the cylinder head testing. Check the cylinder head using the cylinder head testing tool to detect any cracks (see Cylinder head test tank: Use) (Technical Note 6026, 11A, Top and front of engine).

110416

Use a internal micrometer to measure the diameter (X1) of each cylinder head bearing which should be:

10A-145


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

7 - Checking the internal diameter of the valve guide Number of bearings

Cylinder head bearing diameter

No. 1 No. 2

25.05 ± 0.01mm No. 3 No. 4 No. 5

28.05 ± 0.01mm

129306

Use a external micrometer and a internal micrometer to measure the valve guide.

Inlet guide

Exhaust guide

40.5 ±0.15 mm

40.5±0.15 mm

Guide length for D4F 764

45± 0.15 mm

45±0.15 mm

Guide length for D4F 780, 784

45± 0.15 mm

50±0.15 mm

Outer diameter of the valve guide D4D 700, 706, 712, 720, 752, 760

11.06 ± 0.1 mm

11.06 ± 0.1 mm

11.03 ± 0.005 mm

11.03 ± 0.005 mm

Guide length for D4D 700, 706, 712, 720, 752, 760 D4F 702, 706, 708, 712, 714, 716, 722, 728, 730, 732, 740, 742, 772, 774

D4F 702, 706, 708, 712, 714, 716, 722, 728, 730, 732, 740, 742, 772, 774 Outer diameter of the valve guide D4F 764, 780, 784

5.04 ± 0.03 mm

Internal diameter of valve guide Diameter of valve guide housing in the cylinder head Position L of the valve guide

11 ± 0.01 mm 11.3 mm

10A-146

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder head: Check X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

8 - Identifying the valve seats

138864

Inlet valve seat

Exhaust valve seat

1 ± 0.3 mm

1.2 ± 0.3 mm

Width of mating face X for D4F 780, 784

1 ± 0.3 mm

1.2 ± 0.3 mm

External diameter of the valve seat

29.3 mm

25.2 mm

Width of mating face X for D4D 700, 706, 712, 720, 752, 760 D4F 702, 706, 708, 712, 714, 716, 722, 728, 730, 732, 740, 742, 764, 772, 774

III - FINAL OPERATION Rebuild the cylinder head (if necessary) (see 10A, Engine and cylinder block assembly, Cylinder head:Stripping - Restoring, page 10A-137 ) . Refit the cylinder head (see 10A, Engine and cylinder block assembly , Cylinder head: Removal - Refitting , page 10A-99) .

10A-147

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Piston - Con rod: Removal - Refitting

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90



Mot. 574-22

Tooling for replacing gudgeon pins

Mot. 1492

Tool for fitting main bearing shells.

Mot. 1492-04

Tool for fitting main bearing shells.

Mot. 574-25

Shaft A19, ring B19 and shim C19 for positioning gudgeon pin.

a

Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting ) .

a

Remove the accessories belt(s) (see Accessories belt: Removal - Refitting ) .

Essential equipment clip pliers compressed air nozzle piston mounting ring

Tightening torques m 110428

con rod cap bolts

14 N.m + 39˚ ± 6˚

REMOVAL I - REMOVAL PREPARATION OPERATION

a

Fit the flywheel locking tool (Mot. 582-01) onto the cylinder block.

a

Remove the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) .

a

Remove:

a


IMPORTANT To avoid any risk of damaging the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out the repair (see Precautions for repair ).

- the flywheel (see Flywheel: Removal - Refitting ) , - the flywheel locking tool (Mot. 582-01) . a


a


a

Remove:

WARNING It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer,

a

- raising the oil level above maximum, with a risk of engine racing.


Remove the "engine - gearbox" assembly (see Engine/gearbox assembly: Removal - Refitting) .

- the alternator (see Alternator: Removal - Refitting) .

10A-148


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90


II - PISTON - CON ROD ASSEMBLIES REMOVAL OPERATION 1 - Piston - con rod assembly removal operation

Remove the air conditioning compressor (see Compressor: Removal - Refitting ) (62A, Air conditioning).


Remove the power-assisted steering pump (see Power assisted steering pump: Removal - Refitting) (36B, Power-assisted steering).

a

Remove:

18648-2

- the multifunction support(s) (see Multifunction support: Removal - Refitting ) ,

a

WARNING Do not use a sharp point or engraving tool to mark the bearing caps con rods to avoid starting a crack in the rod.

- the ignition coil (see Coils Removal - Refitting) , - the inlet manifold (see Inlet manifold: Removal Refitting) , - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) ,

Use an indelible marker pen. a

- the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) , - the crankshaft seal on the gearbox side (see Crankshaft seal at gearbox end : Removal - Refitting) , - the sump (see Sump: Removal - Refitting) , - the oil pump (see Oil pump: Removal - Refitting ) .

10A-149

Mark the con rod bodies and caps in relation to the cylinders using a permanent marker pen (cylinder 1 flywheel end).


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

Operation only to be carried out when replacing or checking the piston or con rod (see 10A , Engine and cylinder block assembly, Piston - Con rod: Check, page 10A-160) .

18648 a

IMPORTANT Wear protective gloves during the operation.

121023 a

Remove the piston rings using a clip pliers.

Remove: - the con rod cap bolts,

3 - Operation for separating the con rods and pistons

- the marked con rod cap,

a

- the con rod cap bearing shell while marking its position in relation to the con rod cap. a

Remove: - the « con rod - piston » assembly via the cylinder head side of the cylinder block, - the con rod body bearing.

a

Mark the bearing shell in relation to the con rod body using an indelible marker pen.

a

Repeat the above operations on the other cylinders.

2 - Piston ring removal operation a

Note: Take care not to damage the piston when removing the rings. Do not open the rings too much as they risk becoming damaged. If reusing, mark the piston rings in relation to the piston.

10A-150

Operation only to be carried out when replacing or checking the piston or con rod (see 10A , Engine and cylinder block assembly, Piston - Con rod: Check, page 10A-160) .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

X44, and D4F, and 780 – X77, and D4F, and 784 – X85, and D4F, and 784

X06 – X35 – X44, and D4F, and 740 or 772 – X65 – X76 – X77, and D4F, and 740 or 742 or 764 – X85, and D4F, and 740 or 742 or 764 – X90

121226 a

Remove the locking spring rings using a screwdriver.

110433 a

Place the piston on the base plate (1) of the kit (Mot. 574-22) .

a

Align the gudgeon pin with the base clearance hole.

a

Remove the gudgeon pin using the press and the extraction mandrel (2) .

a

Repeat the above operations for the other pistons.


10A-151

parts always to be replaced: Con rod cover bolt (10,03,02,10).


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

Note: Do not knock or lean against the cap mating faces and the con rod body to prevent damaging the con rod.

IMPORTANT Wear goggles with side protectors for this operation. a

Clean the "piston con rod" assemblies with SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) .

a

Dry the "piston con rod" assemblies using a compressed air nozzle.

1 - Con rod bearing shells fitting operation 19944 a

Remove the pin (3 ) from the (Mot. 1492) (using a vice with jaws).

a

Replace the pin (3) with the pin (4) of tool (Mot. 1492-04) .

15198 a

The con rods are fitted with bearing shells without a foolproofing device.

a

The con rod bearing shells are fitted using tools (Mot. 1492) and (Mot. 1492-04) . 16352 a

Slide the bearing shell support ( 5) of (Mot. 1492-04) into the base plate groove (6 ) of (Mot. 1492).

a

Position the rail (7) of the (Mot. 1492-04) onto the base plate.

10A-152


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

19945

19947 a

a

Fit the con rod body on the base.

a

Check that the lower part (8) of the small end is in contact with the centring pin.

a

Position the bearing shell (9) on the bearing shell support.

Fit the bar ( 10) and the conrod cap.

19948 a

Push the rail (in the direction of the arrow) until the conrod cap touches the bar.

a

Position the bearing shell (11) on the bearing shell support.

19946 a

Push the bearing shell support (in the direction of the arrow) until it is fully inserted in the body of the connecting rod.

a

Remove the con rod body support and then repeat the operation for the other con rods.

10A-153


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

X44, and D4F, and 780 – X77, and D4F, and 784 – X85, and D4F, and 784

19949 a

Push on the bearing shell support (in the direction of the arrow) until it is fully in the big end cap. 121226

2 - Piston and con rod assembly operation a

a

If the piston is replaced, it is essential to check the pairing between the category of piston and that of the cylinder block barrel (see 10A, Engine and cylinder block assembly, Cylinder block: Removal - Refitting, page 10A-177) . If a piston is reused, check that the piston/con rod marks made by the operator during disassembly match.

a

Visually inspect: - the condition of the con rods (torsion and squaring),

Refit the locking spring rings with a screwdriver, making sure that they are positioned correctly (in the same position as before removal) into the piston necks.

X06 – X35 – X44, and D4F, and 740 or 772 – X65 – X76 – X77, and D4F, and 740 or 742 or 764 – X85, and D4F, and 740 or 742 or 764 – X90 a

- the cleanliness of the bearing surfaces between the con rod body and cap.

10A-154

Note: The gudgeon pins are tight in the con rods and are able to rotate in the pistons.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a - Preparing the con rods

103310 a

On each small end, place (as a temperature indicator) a piece of self-flux tin solder at ( 16) with a melting point of approximately 250˚.

a

Heat the small end until the self-flux solder melts.

b - Preparing the gudgeon pins 110433 a

Use the kit components (Mot. 574-22) and (Mot. 574-25) :

a

Check that the gudgeon pins slide freely into the corresponding new pistons.

- base (12) , - the mounting ring B19 ( 13) , - the fitting shaft A19 (14) , - the centring device C19 (15) . - a 1500 W heating plate. a

Put the small ends on the heating plate.

a

Ensure that the whole small end surface is in contact with the plate.

103309 a

Use fitting shaft A19 (17) and the centring device C19 (18) from kit (Mot. 574-22) .

a

Fit the gudgeon pin (19) onto the fitting shaft (17) .

a

Screw in the centring device (18) until the assembly locks.

a

Loosen the fitting shaft (17) by a quarter of a turn.

10A-155


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 c - Direction of fitting for pistons in relation to con rods

19596 a

Secure the piston using pin (22) .

a

Check that the gudgeon pin hole is aligned with the hole of ring B19 (the arrow on the piston facing downwards).

- the arrow (20) on the piston crown facing down,

a

- the con rod boss (21 ) (as shown in the diagram or next to the dipstick on the cylinder block).

Lubricate the centring device and gudgeon pin with engine oil.

a

Drive the gudgeon pin into the assembly to check that it can slide freely. If not, re-centre the piston.

a

Carry out the following operations quickly to prevent heat loss.

18709 a

Position:

d - Assembly of the piston and con rod

IMPORTANT Wear heat protective gloves during the operation.

18710 a

Place the ring B19 onto the base plate.

10A-156


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

18711 a

When the solder reaches welding point (becomes liquid): - wipe off the solder, - insert the locator into the piston, - insert the con rod (correctly positioned) in the piston,

a

18715-1

- quickly drive in the gudgeon pin until the locator reaches the end of the support base.

a

Observe the gap and direction of fitting for each piston ring.

Check that the gudgeon pin is withdrawn in relation to the piston skirt.

a

Refit the piston rings using a clip pliers .

3 - Piston ring refitting operation a

Operation only to be carried out when replacing or checking the piston rings (see 10A, Engine and cylinder block assembly , Piston - Con rod: Check, page 10A-160 ) .

a

Rings set to their original settings must be free within their channels.

a

Respect the piston ring fitting direction, with TOP at the top.

72552 a

10A-157

Close the rings slightly.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

II - PISTON - CON ROD ASSEMBLIES REFITTING OPERATION a

Lubricate with engine oil: - the cylinder block barrels, - the brake shoes, - the piston skirts, - the crankshaft crankpins.

18648-2 a

Refit the con rod caps corresponding to the con rod bodies.

98965 a

Refit the "con rod-piston" assemblies using the piston mounting ring first making sure that: - the piston matches the cylinder block barrel (No.1 at flywheel end), - the piston marking is in the correct place, with the arrow pointing towards the flywheel.

a

Mount the conrod heads on the crankshaft crankpins.

18648 a

Torque and angle tighten the con rod cap bolts (14 N.m + 39˚ ± 6˚).


Refit: - the oil pump (see Oil pump: Removal - Refitting ) , - the sump (see Sump: Removal - Refitting) ,

10A-158


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - the (Mot. 582-01) .

- the crankshaft seal on the gearbox side (see Crankshaft seal at gearbox end : Removal - Refitting) , - the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) , - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) , - the inlet manifold (see Inlet manifold: Removal Refitting) , - the ignition coil (see Coils Removal - Refitting) , - the multifunction support(s) (see Multifunction support: Removal - Refitting ) .

- the clutch disc and pressure plate (see Mechanism / Disk: Removal - Refitting) (20A, Clutch). a

Refit the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) .

a

Position the (Mot. 582-01) on the cylinder block.

a

Refit the accessories belt(s) (see Accessories belt: Removal - Refitting) .

a

Couple the manual gearbox to the engine (see Manual gearbox: Removal - Refitting ) .

a

Refit the "engine - gearbox" assembly (see Engine/ gearbox assembly: Removal - Refitting ) .


Refit the power-assisted steering pump (see Power assisted steering pump: Removal - Refitting ) (36B, Power-assisted steering).


Refit the air conditioning compressor (see Compressor: Removal - Refitting ) (62A, Air conditioning).

a

Refit: - the alternator (see Alternator: Removal - Refitting ) , - the timing belt (see Timing belt: Removal - Refitting ) .

a

Top up the engine with oil (see Engine oil: Draining - Refilling) .

a


a

Refit: - the flywheel (see Flywheel: Removal - Refitting ) ,

10A-159

ENGINE AND CYLINDER BLOCK ASSEMBLY Piston - Con rod: Check

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 Before any checks:

Essential equipment

- clean the parts with SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork ) and dry them using a compressed air nozzle,

compressed air nozzle external micrometer

- check that the parts do not have any scratches, any trace of impact or abnormal wear (if necessary replace the parts).

set of feeler gauges internal micrometer

II - PISTON

radial play measuring wire

1 - Piston identification I - PREPARATION OPERATION FOR CHECK a - Piston markings


X06, and D4D – X65, and D4D – X76, and D4D – X90, and D4D

WARNING It is str ictly forbidden to apply any pressure to the engine oil sump. Damage to the sump may also damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. Remove the engine - gearbox assembly (see Engine/ gearbox assembly: Removal - Refitting ) . Place the engine on the component support (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-14 ) .

18940

(1 )

Direction of fitting of the piston, arrow towards the flywheel.

Remove the con rod - piston assemblies (see 10A, Engine and cylinder block assembly, Piston - Con rod: Removal - Refitting , page 10A-148 ) .

(2 )

Piston category (A - B)

(3 )

Used by the supplier only

(4 )


Separate the con rod from the piston, if required by the check (see 10A , Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148 ) .

(5 )

Piston axis of symmetry

(6 )

Gudgeon pin hole axis

(7 )

Offset between gudgeon pin hole and piston axis of symmetry is X=0.8 mm

Remove the segments, if required by the check (see 10A , Engine and cylinder block assembly, Piston Con rod: Removal - Refitting, page 10A-148) .

10A-160


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

Model 2 X06, and D4F – X35 – X44 – X65, and D4F – X76, and D4F – X77 – X85 – X90, and D4F

Model 1

110754

18940

(1 )

Direction of fitting of the piston, arrow towards the flywheel.

(2 )

Piston category (A - B)

(3 )


(4 )


(5 )

Piston axis of symmetry

(6 )

Gudgeon pin hole axis

(7 )

Offset between gudgeon pin hole and piston axis of symmetry is X=0.8 mm

b - Piston diameter categories

Engine

Class A

Class B

D4D

68.965 ± 0.006 mm

68.969± 0.006 mm

D4F engines except D4F 780-784

68.976 ± 0.006 mm

68.989 ± 0.006 mm

D4F 780-784

68.956 ± 0.006 mm

68.969 ± 0.006 mm

10A-161


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

2 - Piston check

Use a external micrometer to measure the diameter (D) of the gudgeon pin.

a - Checking the piston diameter Engine

Diameter (D) of the gudgeon pin

All D4 engines except D4F 780-784

17.495 to 17.499 mm

D4F 780-784

17.446 to 17.450 mm

c - Checking clearances between the piston rings and grooves

16234

Use a external micrometer to measure the piston diameter at (X1) 102795

Engine

X1 (mm)

Measure the clearance between the piston grooves and piston rings using a set of shims (7) :

D4D

10 mm

- (A): Set of shims incorrectly positioned,

D4F

9 mm

- (B): Set of shims correctly positioned.

b - Gudgeon pin check

Piston rings

Play between the piston rings and the piston grooves (mm)

Compression ring

0.20 to 0. 35

Sealing ring

0.35 to 0.50

Scraper ring

0.25 to 0.75

If the clearance value is outside the permitted tolerance values, replace the piston-gudgeon pin assembly or the piston rings.

12962

Check that the gudgeon pin slides freely in the piston before checking it.

10A-162


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 d - Checking play at the ring section Note: Each con rod has its own con rod cap. They cannot be swapped or reversed. Nevertheless, it is necessary to mark them to facilitate reinstallation.

2 - Difference in weight of the « con rod - piston pin » assembly The maximum difference in weight between the « assembled con rod - piston - pin » assemblies is 11 g 102793

Place the segment (8 ) to check in the cylinder. Push the ring to the centre of the cylinder using the piston (9 ) . Measure the ring end clearance using a set of feeler gauges (10) :

3 - Centre-to-centre distance between the big end and the small end Centre-to-centre distance between the big end and the small end is 122 ± 0.035 mm.

4 - Checking the con rod a - Checking the diameter of the big end

Piston rings

Ring end clearance (mm)

Compression ring

0.20 to 0. 35

Sealing ring

0.35 to 0.50

Scraper ring

0.20 to 0.90

Fit: - the big end caps, - the bolts and the nuts of the big end caps. 102797

Torque tighten the big end cap nuts (14 N.m + 39˚ ± 6˚).

III - CON ROD

Use a internal micrometer to measure the big end diameter of each con rod not fitted with its bearing shell. The diameter of the big end must be between 43.639 and 43.65 mm.

1 - Precautions when marking con rods

WARNING Do not use a sharp point or engraving tool to mark the bearing caps con rods to avoid starting a crack in the rod. Use an indelible marker pen.

10A-163


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 b - Checking the diameter of the con rod small end Note: Do not rotate the con rod or crankshaft during the following steps. Refit the con rod - piston assembly (see 10A , Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148 ) . Remove the con rod - piston assembly (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148) .

102800

Use a internal micrometer to measure the diameter of the small end of each con rod. The diameter of the small end must be between 17.463 and 17.465 mm.

5 - Checking the diametric clearance of the big ends Wipe any oil from the crankshaft crankpins and from the bearing shells of the con rod caps and body.

102807

Measure the flattening of the wire which must be between 0.025 and 0.064 mm using the gauge printed on the wrapping paper ( 12) of the wire. Clean off of any remaining parts of the measuring wire on the crankshaft and bearing shells.

6 - Checking the lateral play of the con rod Refit the con rod - piston assembly (see 10A , Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148 ) . Set the « con rod - piston » assembly of the current cylinder at bottom dead centre.

127838

Cut pieces of radial play measuring wire. Insert the wire (11) into the axis of the crankshaft crankpins (avoiding the bearing lubrication holes).

10A-164

ENGINE AND CYLINDER BLOCK ASSEMBLY Piston - Con rod: Check X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

16253

Fit: - a magnetic holder on the sump joint face of the cylinder block, - a dial gauge on the magnetic holder, in contact with the machined flat surface of the big end cap. Without using excessive force, manually move the con rod from one stop to the other. Note the maximum and minimum values of con rod longitudinal displacement to determine the play between the con rod and the crankshaft. The lateral play of the big end must be between 0.210 and 0.453 mm. Repeat the operation with each big end cap.

IV - FINAL OPERATION Refit the piston rings (if removed) (see 10A , Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148) . Assemble the con rod and the piston (if separated) (see 10A , Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting , page 10A-148 ) . Refit the con rod - piston assemblies (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148) . Remove the engine from the component support (see 10A , Engine and cylinder block assembly, Engine support equipment: Use, page 10A-14 ) . Refit the engine - gearbox assembly (see Engine/ gearbox assembly: Removal - Refitting ) .

10A-165

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft: Removal - Refitting

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90



Mot. 1493-02

Crankshaft bearing tool.

Essential equipment compressed air nozzle

Tightening torques m crankshaft bearing cap bolts

20 N.m + 76˚ ± 6˚

crankshaft closure panel bolts on the flywheel end

9 N.m

REMOVAL

110428 a

Fit the flywheel locking tool (Mot. 582-01) onto the cylinder block.

a

Remove the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) .

a

Remove:



- the clutch disc and pressure plate (see Mechanism / Disk: Removal - Refitting) (20A, Clutch), - the flywheel (see Flywheel: Removal - Refitting ) , - the flywheel locking tool (Mot. 582-01) .

WARNING

a

It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by:


a


a

Remove:

- blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. a

Remove the "engine - gearbox" assembly (see Engine/gearbox assembly: Removal - Refitting) .

a

Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting ) .

a

Remove the accessories belt(s) (see Accessories belt: Removal - Refitting) .

- the timing belt (see Timing belt: Removal - Refitting) , - the ignition coil (see Coils Removal - Refitting) . X06 – X35 – X44, and D4F, and 772 – X65 – X76 – X77, and D4F, and 740 or 742 or 764 – X85, and D4F, and 740 or 742 or 764 – X90 a

10A-166

Remove the intake distributor (see Inlet manifold: Removal - Refitting) .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

II - CRANKSHAFT REMOVAL OPERATION

Remove: - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) , - the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) .

18648 a

18644-2 a

WARNING Do not use a sharp point or engraving tool to mark the bearing caps con rods to avoid starting a crack in the rod.

Remove: - the sump (see Sump: Removal - Refitting) , - the crankshaft closure panel bolts (1 ) ,

Use an indelible marker pen.

- the crankshaft closure panel (2 ) . a

Check that the markings made in the factory on the crankshaft bearing caps are legible (bearing 1 on the flywheel end).

a

Remove: - the crankshaft seal on the gearbox side (see Crankshaft seal at gearbox end : Removal - Refitting) ,

Mark - the crankshaft bearing caps using a permanent marker pen, if necessary, - the direction of fitting of the crankshaft bearing caps.

- the oil pump (see Oil pump: Removal - Refitting ) , - the "con rod - piston" assemblies from each cylinder (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148 ) .

Note: Always mark the position of each crankshaft bearing shell using an indelible marker pen, in relation to the crankshaft bearing number. a

Remove: - the crankshaft bearing cap bolts, - the crankshaft bearing caps, - the crankshaft, - the crankshaft bearing shells, - the crankshaft thrust washers.

10A-167


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

REFITTING

main within the tolerances, before refitting the crankshaft (see 10A , Engine and cylinder block assembly, Crankshaft: Check , page 10A-172) .


Note:

parts always to be replaced: crankshaft bearing bolt (10,03,03,12)

WARNING To ensure proper sealing, the sealing surfaces of the cylinder block and bearing cap number 1 must be clean, dry and free from grease (no finger marks).

Any clearances of the crankshaft journal outside the tolerances can cause engine damage.

II - CRANKSHAFT REFITTING OPERATION 1 - Determining crankshaft bearing shells a

For determining crankshaft bearing shells (see 10A, Engine and cylinder block assembly , Crankshaft: Check , page 10A-172 ) .

1 - Cleaning parts 2 - Direction of fitting for crankshaft bearing shells

a

Note: Avoid any impact or use for support on: -the mating faces of the seal and bearing of the crankshaft or cylinder block, -the mating faces of the crankshaft bearing caps. a

Clean with SURFACE CLEANER (see Vehicle: Parts and consumables for repair ) : - the crankshaft, - the crankshaft bearing caps, - the mating faces of the crankshaft journal bearing shells on the cylinder block, - the mating faces of the crankshaft bearing caps on the cylinder block.

18649 a

IMPORTANT Wear goggles with side protectors for this operation. a

Dry the parts using a compressed air nozzle.

2 - Preparation for refitting if replacing the crankshaft a

When replacing the crankshaft or crankshaft bearing shells, always identify the thickness class for each bearing shell that will be refitted on each crankshaft bearing, to ensure that the journal clearances re-

10A-168

Fit the grooved bearing shells on all the bearings on the cylinder block. The thrust washers are integrated into the bearing shell of bearing No.3 .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

18649-1 a

On the bearing caps, fit the non-grooved bearing shells on all the bearings.

19943 a

Place the grooved bearing shell in the (Mot. 149302) .

a

Press at (6) until the bearing shell comes into contact with the tab (7) .

3 - Fitting the bearing shells on the cylinder block

4 - Fitting the bearing shells onto the bearing caps

19942 a

Fit the tool (Mot. 1493-02) on the cylinder block. 19940 a

10A-169

Fit the (Mot. 1493-02) on the bearing cap.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

Check that the crankshaft turns freely, with no hard point.


Refit: - the con rod - piston assemblies from each cylinder (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting , page 10A148) , - the oil pump (see Oil pump: Removal - Refitting ) , - the crankshaft seal on the gearbox side (see Crankshaft seal at gearbox end : Removal - Refitting) .

WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).

19941 a

Place the bearing shell into the (Mot. 1493-02) .

a

Press at (8) until the bearing shell comes into contact with the tab (9) .

a

Oil the crankshaft bearing shells (only the surface that is in contact with the crankshaft).


18648-1 a

Refit: - the crankshaft, - the crankshaft bearing caps, placing No.1 and the arrows on the flywheel end.

a

18716 a

Torque and angle tighten in order the crankshaft bearing cap bolts (20 N.m + 76˚ ± 6˚).

10A-170

Apply at (3 ) a bead of MASTIXO with a width of 1.3 mm on the crankshaft closure panel on the flywheel end.


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

Remove the engine from the component support (see 10A , Engine and cylinder block assembly , Engine support equipment: Use, page 10A-14) .

a

Refit: - the flywheel (see Flywheel: Removal - Refitting ) , - the flywheel locking tool (Mot. 582-01) , - the clutch disc and pressure plate (see Mechanism / Disk: Removal - Refitting) (20A, Clutch).

18644-2 a

a

Refit the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting ) .

a

Remove the (Mot. 582-01) on the cylinder block.

a

Refit the accessories belt(s) (see Accessories belt: Removal - Refitting) .

a

Couple the manual gearbox to the engine (see Manual gearbox: Removal - Refitting ) .

a

Refit the "engine - gearbox" assembly (see Engine/ gearbox assembly: Removal - Refitting ) .

Refit: - the crankshaft closure panel, - the crankshaft closure panel bolts.

a

Tighten to torque and in order the crankshaft closure panel bolts on the flywheel end (9 N.m) .

a

Refit: - the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) , - the sump (see Sump: Removal - Refitting) , - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) .

X06 – X35 – X44, and D4F, and 772 – X65 – X76 – X77, and D4F, and 740 or 742 or 764 – X85, and D4F, and 740 or 742 or 764 – X90 a


a

Refit: - the ignition coil (see Coils Removal - Refitting) , - the timing belt (see Timing belt: Removal - Refitting ) .

a

Top up the engine (see Engine oil: Draining - Refilling) .

10A-171

ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft: Check

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - check that the crankshaft does not have any scratches, any trace of impact or abnormal wear (if necessary replace the crankshaft).


Crankshaft bearing tool.

II - CRANKSHAFT CHECK

Essential equipment compressed air nozzle

1 - Checking the diameter of the crankshaft journals

external micrometer radial play measuring wire dial gauge support dial gauge

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 1 0 A , Engine and cylinder block assembly , Engine: Precautions for repair , page 10A-1) ).

102805

Use a external micrometer to measure the diameter of the crankshaft journals (X1) which must be 44 ± 0.01 mm.

WARNING 2 - Checking the diameter of the crankshaft crankpins

It is str ictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing.

I - PREPARATION OPERATION FOR CHECK Remove the « engine and gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) . Separate the gearbox from the engine (see Manual gearbox: Removal - Refitting ) . Place the engine on the component support (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-14 ) . Remove the crankshaft (see 10A , Engine and cylinder block assembly , Crankshaft: Removal - Refitting , page 10A-166) .

102806

Use a external micrometer to measure the crankpin diameter (X2) which must be 39.985 to 40 mm.

Before any checks: - clean the crankshaft with SURFACE CLEANER (see Vehicle: Parts and consumables for repair ) and dry using a compressed air nozzle,

10A-172


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

3 - Crankshaft bearing shells

110773 15197

The engine is fitted with bearing shells without foolproofing devices. The bearing shells are engraved with a letter corresponding to their colour. (B = Blue, J = Yellow, M = Brown, R = Red, V = Green). The bearing shells are fitted using tool (Mot. 1493-02).

Holes ( 2) and (3) correspond to classes A and B respectively of the upper bearing shells and are positioned at ( X2) = 5 mm from the vertical axis of the crankshaft. There cannot be only a single hole (A or B) corresponding to the single class of upper bearing shells. Holes ( 4) or (5) are only used in the factory and are positioned at (X3) = 12 mm from the vertical axis of the crankshaft.

Definition of an upper bearing shell Hole (2)

Hole (3)

Class type

Class A

Class B

Diameter of oil sump bearing

47.61 to 47.62

47.62 to 47.63

Marking and thickness of upper bearing shell

"B" blue

"V" green

1.79 inclusive to 1.80

1.80 to 1.81

Definition of a lower bearing shell Crankshaft bushing diameter measurement

A = 44.00 to 44.010

B = 44.00 to 44.010

C = 43.990 to 44.00

Marking and thickness of lower bearing shell

"M" brown

"J" yellow

"R" red

1.790 to 1.800

1.800 to 1.805

1.805 to 1.810

10A-173


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

Combinations Oil sump bearing diameter

Class A

Class B

Upper bearing shell marking

"B" blue

"V" green

Crankshaft journal diameter

A

B

C

A

B

C

Lower bearing shell marking

"M" brown

"J" yellow

"R" red

"M" brown

"J" yellow

"R" red

Combinations

1

2

3

4

5

6

A clearance of 0.020 to 0.050 mm taking into account an expansion of 0.015 mm.

4 - Checking the crankshaft diameter clearance Refit the crankshaft bearing shells using tool (Mot. 1493-02) (see 10A , Engine and cylinder block assembly , Crankshaft: Removal - Refitting, page 10A166) .

102807

Position the pieces of wire (6) in line with the axis of the crankshaft journal.

103281

Note: Never turn the crankshaft during the operation. Remove any oil that may be on the crankshaft journals and on the cylinder block bearings. Refit without lubricating: - the crankshaft bearing shells, - the crankshaft.

10A-174


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

18648-1

103281

Refit without lubricating:

Refit:

- the crankshaft bearing caps, placing No.1 on the flywheel end,

- the thrust washers,

- the crankshaft cap bolts. Pretighten to torque and in order the crankshaft bearing cap bolts 20N.m.

- the crankshaft. Oil the bearing journals with engine oil.

Angle tighten and in order the crankshaft bearing cap bolts76˚ ± 6˚. Remove: - the crankshaft bearing caps, - the crankshaft. Measure the flattening of the radial play measuring wire using the gauge printed on the wire wrapping paper (7) which must be between 0.020 and 0.045 mm. Clean any traces of radial play measuring wire on the crankshaft and on the bearing shells using SUPER CLEANING AGENT FOR JOINT FACES.

5 - Checking the crankshaft lateral clearance Oil the crankshaft bearings (only the surface that comes into contact with the crankshaft). 18648-1

Refit: - the crankshaft bearing caps, placing No.1 on the flywheel end, - the crankshaft cap bolts. Pretighten to torque and in order the crankshaft bearing cap bolts 20 N.m.

10A-175


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 Angle tighten and in order the crankshaft bearing cap bolts76˚ ± 6˚. Check that the crankshaft turns freely, with no hard point.

Remove the engine from the component support (see 10A , Engine and cylinder block assembly, Engine support equipment: Use , page 10A-14 ) Couple the gearbox to the engine (see Manual gearbox: Removal - Refitting ) Refit the « engine and gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting ) .

18713

Fit: - the dial gauge support, - the dial gauge. Position the feeler of the dial gauge on the flywheel face of the crankshaft. Support the crankshaft on the thrust washer by pushing the crankshaft in the axis towards the timing end. Set the dial gauge to zero. Support the crankshaft on the other thrust washer by pushing the crankshaft in the axis towards the flywheel end. Check the lateral play of the crankshaft which must be a maximum of 0.275 mm without wear on the thrust washers. Remove: - the crankshaft bearing caps, - the crankshaft, - the thrust washers.

III - FINAL OPERATION Refit the crankshaft (see 10A , Engine and cylinder block assembly, Crankshaft: Removal - Refitting , page 10A-166 ) .

10A-176

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder block: Removal - Refitting

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90



Essential equipment workshop hoist

Tightening torques m oil level sensor or blanking cover cap

30N.m

pinking sensor

20N.m

crankshaft closure panel bolts on the flywheel end

9 N.m

110428


a


a

Remove: - the clutch disc and pressure plate (see Mechanism / Disk: Removal - Refitting) (20A, Clutch), - the flywheel (see Flywheel: Removal - Refitting ) , - the flywheel locking tool (Mot. 582-01) .

a


a


a

Remove:

WARNING It is str ictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer,


- raising the oil level above maximum, with a risk of engine racing.

- the alternator (see Alternator: Removal - Refitting) .


Remove the « engine and gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting ) ,

a

Disconnect the gearbox from the engine (see Manual gearbox: Removal - Refitting) ,

a

Remove the accessories belt(s) (see Accessories belt: Removal - Refitting) ,


10A-177

Remove the air conditioning compressor (see Compressor: Removal - Refitting ) .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90


Remove the power assisted steering pump (see Power assisted steering pump: Removal - Refitting) .

a

Remove: - the multifunction support(s) (see Multifunction support: Removal - Refitting ) , - the ignition coil (see Coils Removal - Refitting) .



18644-2 a

Remove: - the crankshaft closure panel bolts (2 ) , - the crankshaft closure panel ,

a

Remove:

- the oil pump (see Oil pump: Removal - Refitting ) ,

- the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) ,

- the coolant pump (see Water pump: Removal Refitting) ,

- the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) , - the crankshaft seal on the gearbox side (see Crankshaft seal at gearbox end : Removal - Refitting) , - the sump (see Sump: Removal - Refitting) .

10A-178

- the « piston - con rod » assemblies of every cylinder (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148 ) , - the crankshaft (see 10 A, Engine and cylinder block assembly, Crankshaft: Removal - Refitting, page 10A-166) .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

II - CYLINDER BLOCK REMOVAL OPERATION

a

Clean the cylinder block (see 10A, Engine and cylinder block assembly , Cylinder block: Cleaning, page 10A-182 ) .

a

Refit the cylinder block on the component support using a workshop hoist (see 10A, Engine and cylinder block assembly, Engine support equipment: Use , page 10A-14) .

II - OPERATION FOR REFITTING PART CONCERNED a

Refit: - the oil level sensor or blanking cover cap (depending on the equipment). - pinking sensor, - the water pump inlet pipe (see Water pump inlet pipe: Removal - Refitting ) .

a

110426 a

- the oil level sensor or blanking cover cap (30N.m) ,

Remove:

- the pinking sensor (20N.m).

- the water pump inlet pipe (see Water pump inlet pipe: Removal - Refitting ) , - pinking sensor ( 3) ,


- the oil level sensor or blanking cover cap (depending on the equipment) (4) .

a


When replacing the cylinder block, always identify the crankshaft bearing shell thickness category to refit on each crankshaft bearing to guarantee any journal clearances remain within the tolerances, before refitting the crankshaft (see 10A , Engine and cylinder block assembly , Crankshaft: Check, page 10A-172 ) .

Note:

WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).

Any clearances exceeding the tolerances of the crankshaft journals can cause engine damage. a


Torque tighten:

Remove the cylinder block from the component support using a (see 10A , Engine and cylinder block assembly , Engine support equipment: Use , page 10A-14 ) workshop hoist .

10A-179

Refit: - the crankshaft (see 10 A , Engine and cylinder block assembly, Crankshaft: Removal - Refitting, page 10A-166 ) . - the « piston - con rod » assemblies of every cylinder (see 10A, Engine and cylinder block assembly , Piston - Con rod: Removal - Refitting, page 10A-148 ) , - the coolant pump (see Water pump: Removal Refitting) , - the oil pump (see Oil pump: Removal - Refitting ) .


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 a

Tighten to torque and in order the crankshaft closure panel bolts on the flywheel end (9 N.m) .

a

Refit: - the sump (see Sump: Removal - Refitting) , - the crankshaft seal on the gearbox side (see Crankshaft seal at gearbox end : Removal - Refitting) , - the crankshaft seal on the timing side (see Crankshaft seal at timing end Removal - Refitting ) , - the cylinder head (see 10A , Engine and cylinder block assembly, Cylinder head: Removal - Refitting, page 10A-99) .



a

Refit:

18716 a

a

Use SUPER CLEANING AGENT FOR JOINT FACES (see Engine: Parts and consumables for the repair work ) to clean the surface between the crankshaft closure panel on the flywheel end and the cylinder block.


Apply at (5) a beading of MASTIXO with a width of 1.3 mm on the crankshaft closure panel on the flywheel end.

- the multifunction support(s) (see Multifunction support: Removal - Refitting ) . X35, and POWER-ASSISTED STEERING – X65, and POWER-ASSISTED STEERING – X76, and POWER-ASSISTED STEERING – X90, and POWER-ASSISTED STEERING a

Refit the power assisted steering pump (see Power assisted steering pump: Removal - Refitting) .


Refit the air conditioning compressor (see Compressor: Removal - Refitting ) .

a

Refit:

18644-2 a

Refit: - the crankshaft closure panel,

- the alternator (see Alternator: Removal - Refitting) ,

- the crankshaft closure panel bolts.

10A-180

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder block: Removal - Refitting X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - the timing belt (see Timing belt: Removal - Refitting ) , a


a

Refit: - the flywheel (see Flywheel: Removal - Refitting ) , - the flywheel locking tool (Mot. 582-01) , - the clutch plate and pressure plate (see Mechanism / Disk: Removal - Refitting) ,

a

Remove the flywheel locking tool (Mot. 582-01).

a

Refit the accessories belt(s) (see Accessories belt: Removal - Refitting) ,

a

Top up the engine oil (see Engine oil: Draining Refilling) ,

a

Couple the gearbox to the engine (see Manual gearbox: Removal - Refitting ) ,

a

Refit the « engine and gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) .

10A-181

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder block: Cleaning

10A

X65 – X76 – X90 – X35 – X06 – X44 – X77 – X85

I - CLEANING PREPARATION OPERATION a



IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. 113592

WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to avoid any foreign bodies entering the oil return and supply pipes. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. a


a

Place the engine on the component support (see 10A, Engine and cylinder block assembly , Engine support equipment: Use , page 10A-14) .

a

Remove the cylinder block (see 10A, Engine and cylinder block assembly , Cylinder block: Removal - Refitting, page 10A-177) .

113553 a

Wash the cylinder block using a cleaning fountain or a heated cleaning bath.

II - CLEANING THE ENGINE PERIPHERALS III - FINAL OPERATION. a

Clean the gasket surfaces of the cylinder block with SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and ingredients for the repairwork) .

a

Remove the residue using a wooden spatula

a

Finish cleaning the parts using a GREY ABRASIVE PAD, part number 77 01 405 943 .

a

Refit the cylinder block (see 10A , Engine and cylinder block assembly , Cylinder block: Removal Refitting, page 10A-177 ) .

a


10A-182

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder block: Check

10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90 - Check that the cylinder block does not have any scratches, any trace of impact or abnormal wear on the cylinders, the gasket faces and the mating faces of the crankshaft bearing shell (if necessary, replace the cylinder block).

Essential equipment cylinder head rule set of feeler gauges

II - CHECKING THE CYLINDER BLOCK

internal micrometer

Identification of the cylinder block IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see Upper engine: Precautions for repair ) .

a - 1-Identification of the diameter of the cylinder block barrels

WARNING It is str ictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing.

I - PREPARATION OPERATION FOR CHECK Remove the « engine and gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) . Place the engine on the component support (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-14 ) . Remove the cylinder block (see 10A , Engine and cylinder block assembly, Cylinder block: Removal Refitting, page 10A-177 ) .

12120

The position of holes ( T) in relation to the cylinder block joint face is used to identify the original nominal dimension of the barrel and consequently the diameters of the corresponding pistons.

Before any checks: - clean the cylinder block (see 10A, Engine and cylinder block assembly , Cylinder block: Cleaning, page 10A-182) ,

Engine

b - 2-Table of cylinder block barrel diameter categories

Position of the holes (T)

Class marking

Piston diameter

Barrel diameter

1 = 5 mm

A

68.96 0.005 mm

±

69 to 69.015 mm

2 = 9 mm

B

68.97 0.005 mm

±

69.015 69.030

D4D

10A-183

to


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

Engine

Position of the holes (T)

Class marking

Piston diameter

Barrel diameter

D4F 702, 706, 708, 712, 714, 716, 722, 728, 730, 732, 740, 742, 764, 772, 774

1 = 5 mm

A

68.98 0.005mm

±

69 to 69.015 mm

2 = 9 mm

B

68.99 0.005 mm

±

69.015 to 69.030 mm

1 = 5 mm

A

68.96 0.005 mm

±

69 to 69.015 mm

2 = 9 mm

B

68.97 0.005 mm

±

69.015 to 69.030 mm

D4F 780-784

c - Identifying the diameter of the cylinder block bearings

d - Table of categories of bearing diameters on the cylinder block

110773

Hole (3)

Hole (4)

Class type

Class A

Class B

Diameter of the cylinder block bearing

47.61 to 47.62

47.62 to 47.63

10A-184


10A

X06 – X35 – X44 – X65 – X76 – X77 – X85 – X90

III - CHECKING THE CYLINDER BLOCK JOINT FACE

2 - Checking the diameter of the crankshaft bearings on the cylinder block

1 - Checking the cylinder block joint face

18648-1

114884

Refit the No. 1 crankshaft bearing caps by putting the cap on the flywheel end. Torque and angle tighten the crankshaft bearing cap bolts(20 N.m + 76˚ ± 6˚).

117919

Check using a ruler and a « dial gauge - dial gauge support » assembly or a cylinder head rule and a set of feeler gauges the flatness of the gasket face of the cylinder block. Use a cylinder head ruler and set of shims to check the gasket face bow. The maximum deformation of the cylinder block gasket face is 0.03 mm.

10021

Note:

Use a internal micrometer to measure the interior diameter (X1) of the crankshaft bearings on the cylinder block which must be between 47.61 and 47.63 mm.

No regrinding of the cylinder block is authorised.

Remove the crankshaft bearing caps.

10A-185

NT 6004A

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