Workshop Repair Manual

Workshop repair manual Petrol engine 4 cylinders

Engine type

Vehicle

Vehicle type

D4D 700

Clio II

XB06

D4F 702 - 704

Twingo

X06C - X06D

D4F 712

Clio II

XB0W

77 11 296 742

FEBRUARY 2001

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

EDITION ANGLAISE

All copyrights reserved by Renault.

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."

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

© RENAULT 2001

Contents Page

10 ENGINE AND PERIPHERALS Introduction Engine identification Tightening torques (in daNm or degrees) Specifications Cylinder head Camshaft Pistons Cylinder block barrel sizes Piston rings Con rods Crankshaft Bearing shells Preparing the engine to be set on the support Consumables Standard exchange Essential special tooling Essential equipment Overhauling the engine Removing the upper engine Stripping the cylinder head Cleaning Checking the mating surfaces Checking the camshaft end play Rebuilding the cylinder head Assessment and repair of rocker arm rails Removing the lower engine Extracting the gudgeon pins Fitting the con rod bearing shells Assembling the con rods - pistons Fitting the piston rings Refitting the lower engine Replacing the oil filter Refitting the upper engine Tensioning the accessories belts

10-1 10-2 10-3 10-5 10-11 10-12 10-13 10-14 10-15 10-16 10-16 10-18 10-20 10-21 10-22 10-25 10-26 10-29 10-33 10-33 10-33 10-34 10-38 10-44 10-49 10-49 10-52 10-55 10-56 10-62 10-63 10-69

ENGINE AND PERIPHERALS 110 Foreword USING THE MANUAL There are two main sections in this manual: – technical specifications, – overhauling the engine. To repair the component on the vehicle, refer to the vehicle Workshop Repair Manual and Technical Notes.

UNITS OF MEASUREMENT – All dimensions are given in millimetres (mm) (unless stated otherwise). – Tightening torques are expressed in decaNewton metres (daNm) Reminder: 1 daNm = 1.02 m.kg. – Pressures in bar Reminder: 1 bar = 100 000 Pa.

TOLERANCES Tightening torques given without a tolerance must be accurate to within: – in Degrees (± 3˚). – in daNm (± 10 %).

10-1

10

ENGINE AND PERIPHERALS Engine identification

10

The engine identification is stamped on the cylinder block.

It displays: A : the engine type B : the engine approval letter D : the Renault identification number E : the engine suffix F : the engine production number G : the engine factory number

Engine

Index

Compression ratio

Bore (mm)

Stroke (mm)

Capacity (cm 3)

D4D

700

9.8/1

69

66.8

999

D4F

702 704 712

9.8/1

69

76.8

1149

10-2

ENGINE AND PERIPHERALS Tightening torques (in daNm or degrees) UPPER ENGINE Description

Tightening torques

Cylinder head bolts

*

Coolant temperature sensor

1.5

Cylinder head coolant output unit

0.9

Rocker arm rail

**

Timing gear tension wheel

2.4

Camshaft pulley

3 plus an angle of 45˚±6˚

Spark plugs

2.4

Cylinder head cover

1.2

Lower and intermediate timing covers

1.2

Upper timing cover

3.3

Exhaust manifold

2.5

Exhaust manifold heat shield

1.5

Ignition coil

0.7

Inlet manifold

***

Air filter unit bolt

1

* See the procedure for tightening the cylinder head ** See the procedure for tightening the rocker arm rails *** See the procedure for tightening the inlet manifold.

10-3

10

ENGINE AND PERIPHERALS Tightening torques (in daNm or degrees) LOWER ENGINE Description

Tightening torques

Pinking sensor

2

Oil level sensor

3.8 2 plus an angle of 76˚ ± 6˚

Crankshaft bearing bolts

1.4 plus an angle of 39˚ ± 6˚

Con rod cap bolts Oil pump

0.9

Coolant pump

0.9

Crankshaft closure housing (flywheel side)

0.9

Strainer

0.9

Sump

1

Flywheel

1.8 plus an angle of 110˚±6˚

Clutch

2

Accessories crankshaft pulley

4 plus an angle of 70˚± 6˚

Alternator mounting

5

Air conditioning compressor mounting

5

Power steering pump mounting

2.5

Air conditioning compressor

5

Alternator Upper bolt

2.5

Lower bolt

5

Power steering pump

2.2

Oil filter

2

10-4

10

ENGINE AND PERIPHERALS Specifications CYLINDER HEAD Cylinder head tightening procedure REMINDER: in order to tighten the bolts correctly, use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes. All cylinder head bolts must always be changed after removal. Do not oil the new bolts. Tighten all the bolts to 2 daNm±0.2 daNm.

Check that all the bolts are tightened to 2 daNm, then angle tighten (bolt by bolt) by 230˚±6˚. Do not retighten the cylinder head bolts after performing this procedure.

10-5

10

ENGINE AND PERIPHERALS Specifications Thickness of the cylinder head gasket

Cylinder head height

The thickness of the cylinder head gasket is measured at (A): – thickness of the gasket when tightened: 0.49 ± 0.04 mm.

H = 99 mm

10

Firing order: 1-3-4-2 Gasket face bow (mm):

0.05

No corrections are permitted Test the cylinder head to detect possible cracks using the cylinder head test tools (a container and a kit for the particular cylinder head, plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664 000. Spark plug tightening torque

2 to 2.7 daNm

Chamber volume with valves and spark plugs: 26.775 ± 1.01 cm3

10-6

ENGINE AND PERIPHERALS Specifications Valve seats

Valves

Seat angle (∝)

Stem diameter (in mm) Inlet:

5.48

0 - 0.015

Exhaust:

5.47

0 - 0.015

Inlet and exhaust:

89˚ 30'

Mating surface width X (in mm) Inlet: Exhaust:

Mating surface angle Inlet and exhaust:

10

0.994 ± 0.403 1.136 ± 0.377

90˚ External seat diameter (D) (in mm)

Head diameter (in mm) Inlet: Exhaust:

Inlet: Exhaust:

26 ± 0.12 22.1 ± 0.12

Valve length (in mm) Inlet: Exhaust:

110.54 to 110.99 112.27 to 112.72

Max. valve lift (in mm) Inlet: Exhaust:

8.849 8.850

Valve clearance settings (in mm) Inlet: Exhaust:

0.05 to 0.12 0.15 to 0.22

10-7

27.995 to 28.005 23.995 to 24.005

ENGINE AND PERIPHERALS Specifications Valve guides

The valve stem seals must be fitted using tool Mot. 1511 or the FACOM tool part number DMJ4, for example.

Length (in mm) Inlet and exhaust:

10

40.15 ± 0.15

Guide external diameter (in mm) Inlet and exhaust:

11

+ 0.068 + 0.05

5

+ 0.075 0

5.5

+ 0.018 0

Guide internal diameter (in mm) Inlet and exhaust Non machined: Machined*:

* This dimension is measured with the guide fitted in the cylinder head.

Diameter of the guide housing in the cylinder head (in mm) Inlet and exhaust:

11±0.01

The inlet and exhaust guides have valve stem seals which also act as a lower bearing washer for the valve spring. The seals must be changed every time the valves are removed.

NOTE: do not lubricate the valve stem seals before fitting them.

10-8

ENGINE AND PERIPHERALS Specifications Angle of the inlet and exhaust guides (in degrees) Inlet: Exhaust:

A = 27 E = 21

Position of the inlet and exhaust valve guides (in mm) B = 10.3 ± 0.15

Inlet and exhaust:

10-9

10

ENGINE AND PERIPHERALS Specifications Valve springs The valve has a conical spring.

Unloaded length (in mm):

40.20

Loaded length (in mm): 14.5 daN±8 42.8 daN±20

34 25.15

Meeting spires (in mm):

23.50

Diameter of wire (in mm):

3.10±0.03

Internal diameter (in mm): Upper Lower

14.10±0.2 16.80±0.2

External diameter (in mm): Upper Lower

20.30±0.2 23±0.2

10-10

10

ENGINE AND PERIPHERALS Specifications

10

Camshaft End play (in mm):

0.08 to 0.178

Number of bearings:

5

Diameter of the cylinder head camshaft bearings (in mm) Flywheel side 1 2 25.05±0.01 3 4 28.05±0.01

5

Timing side 1 2 3 4 5 6 7 8

Diameter of the camshaft bearings (in mm) Flywheel side 1 2 24.98±0.01 3 4 27.98±0.01

5

Timing side

Graph showing timing with a calculated clearance of zero (cannot be checked) Inlet opening delay* Inlet closing delay Exhaust opening advance Exhaust closing advance**

- 10˚ 31˚ 25˚ - 8˚

*

If the inlet opening delay is negative, the valve opening can be found after top dead centre.

**

If the exhaust closing advance is negative, the valve opening can be found before top dead centre.

10-11

Cylinder block top dead centre fixed mark. Flywheel top dead centre mobile mark. Flywheel bottom dead centre mobile mark. Inlet opening delay. Exhaust closing advance. Inlet closing delay. Exhaust opening advance. Engine operating direction (flywheel end).


10

D4D engine

PISTONS Fitting the gudgeon pin in the con rod and in the piston. These engines are fitted with Mahle pistons. Piston marking D4F engine

1 2 3 4 5 6 7

10-12

Direction of fitting of Λ piston, flywheel side Piston diameter grade (A - B) Used by the supplier only Used by the supplier only Piston symmetry axis Gudgeon pin hole axis Offset between the pin hole (6) and the piston symmetry axis (5) is 0.8 mm


10

Measuring the piston diameter The piston diameter is measured at these heights (in mm).

E

D4D engine

D4F engine

10

9

Piston diameter marking in relation to cylinder block diameter

D4D engine Position of holes T on the cylinder block

Grade marking on the pistons

Piston diameter (mm)

Barrel diameter (mm)

CYLINDER BLOCK BARREL SIZES

1 = 5 mm

A

68.956±0.006

69 ±0.015

IMPORTANT: the diameters of the pistons and the barrels must be matched on the cylinder block. Thus,

2 = 9 mm

B

68.964±0.006 69.015±0.015

D4F engine

the position of the holes T, in relation to the gasket face of the cylinder block, is used to identify the original nominal dimension of the barrel and consequently the diameters of the corresponding pistons.

10-13

Position of holes T on the cylinder block

Grade marking on the pistons

Piston diameter (mm)

Barrel diameter (mm)

1 = 5 mm

A

68.976±0.006

69 ±0.015

2 = 9 mm

B

68.984±0.006 69.015±0.015


10

PISTON RINGS

Fitting the rings

Thickness of piston rings

Rings set to their original adjustment must be able to move freely in their channels.

Three rings (thickness in mm) – compression ring

1.175 to 1.19

Ensure the rings are fitted the correct way round with the TOP pointing upwards.

– sealing ring

1.475 to 1.49

Oil and the piston rings and divide into three.

– oil scraper ring which consists of three parts: ● two steel rails (1), ● a spring ring (2).

2.31 to 2.46

Piston ring brake clearance

10-14

Rings

Clearance at the break (in mm)

Compression

0.20 to 0.35

Sealing

0.35 to 0.50

Scraper

0.2 to 0.9

ENGINE AND PERIPHERALS Specifications Gudgeon pin (in mm)

10

CON RODS

The gudgeon pin is fitted with an inner collar (1).

Lateral clearance of the big end (in mm)

0.21 to 0.453

Radial clearance of the big end (in mm)

0.025 to 0.064

Centre distance between the big end and little end (in mm) Diameter of the big end (in mm) Diameter of the little end (in mm)

122±0.03 43.639 17.5

+ 0.11 0 - 0.021 - 0.039

NOTE: the small end does not have a ring.

Length: External diameter (A):

54

WARNING: do not use a sharp point to mark the bearing caps in relation to their con rods to avoid starting a crack in the rod.

0 - 0.2

17.495 to 17.499 Use a permanent marker pen.

Internal diameter (B):

10.5

+ 0.1 - 0.2

Collar inner diameter (C) :

9.66±0.2

Inner collar length (D) :

8.2±0.15

The gudgeon pins (E) are fitted with ring B19, centre tool C19 and fitting shaft A19 (Mot. 574-25).

The maximum weight difference for the con rod, piston and gudgeon pin assemblies for the same engine must be 11 grams.

10-15

ENGINE AND PERIPHERALS Specifications Direction of fitting of the con rod in relation to the piston

10

BEARING SHELLS Crankshaft bearing shells

Point the V (1) on the piston downwards and the index (2) of the con rod as shown in the diagram below.

The engine is fitted with bearing shells without a locator notch.

The crankshaft bearing shells are fitted on the cylinder block and on the bearings using Mot. 1493-02. CRANKSHAFT Number of bearings

5

Burnished bushings: (in mm) – nominal diameter

44 ±0.01

Burnished crankpins: (in mm) – nominal diameter

40

0 - 0.016

– lateral play of the crankshaft (in mm) 0.045 to 0.235 – radial play of the crankshaft (in mm) 0.02 to 0.046 The crankshaft stroke is:

Crankshaft stroke (mm)

D4D engine

D4F engine

66.8±0.05

76.8±0.05

The lateral shims are located on bearing no. 3.

10-16

ENGINE AND PERIPHERALS Specifications Direction of fitting: – on the cylinder block, fit the grooved shells on all the bearings. The shell fitted with flange stops goes on bearing 3,

10

Con rod bearing shells The engine is fitted with bearing shells without a locator notch. The bearing shells are fitted using Mot. 1492 and Mot. 1492-04.

– on the bearing caps, fit non grooved bearing shells.

10-17


10

– the alternator belt by unscrewing the two bolts (3),

PREPARING THE ENGINE TO BE SET ON THE SUPPORT Change the engine oil before fitting the engine to support Mot. 792-03. Remove: – the air conditioning compressor belt, by unscrewing the bolts (1) and turning the hexagon nut (2) clockwise,

– the air conditioning compressor and the alternator,

10-18


10

Place the rods (G), (H), (W1) and the plate (H1) Mot. 1360-01 (including rod W1 and plate H1), on the cylinder block so that they fit into the holes (18, 8, 4) on the plate (Mot. 792-03).

– the accessories multifunction supports.

NOTE: before fitting the rods to the cylinder block, you need to alter rod W1 by making a chamfer of the following dimensions: X = 10 mm Y = 15 mm

10-19


10

CONSUMABLES Type Cleaner

Quantity

Part no.

Cleaning parts

77 01 421 513

Coat

Cleaning gasket faces

77 01 405 952

Coat

Coolant pump, oil pump, crankshaft closing panel

77 01 404 452

Tube of RHODORSEAL 5661

Bead

Coolant pump, oil pump, crankshaft closing panel

77 01 421 042

Loctite FRENETANCH

1 - 2 drops

Exhaust manifold studs

77 01 394 070

DECAPJOINT RHODORSEAL 5661

-

Component concerned

WARNING PARTS TO BE REPLACED AFTER REMOVAL: – all the gaskets, – flywheel bolts, – crankshaft bearing bolts, – con rod cap bolt, – belts, – timing gear tension wheel, – cylinder head bolts

FITTING THREAD INSERTS Threaded holes on all engine component parts can be repaired by using thread inserts.

10-20

ENGINE AND PERIPHERALS Standard replacement PREPARING THE USED ENGINE FOR RETURN The engine should be cleaned and drained (oil and water). Leave on the used engine or include in the return box: – the dipstick and its guide, – the flywheel, – the clutch mechanism and plate, – the water pump, – the cylinder head cover, – the oil pressure switch, – the valve timing cover, – the oil filter.

Remember to remove: – all coolant flexible hoses, – the inlet and exhaust manifolds, – the alternator, – the air conditioning compressor, – the multifunction supports, – the oil level sensor, – the cylinder head coolant output unit.

The used engine should be secured to the base under the same conditions as the overhauled engine: – plastic plugs and covers fitted, – cardboard cover over the assembly. WARNING: never place the engine on the sump (risk of destroying the oil pump strainer).

10-21

10

ENGINE AND PERIPHERALS Essential special tooling

Illustration

10

Part number

Part Stores Number

Mot. 574-25

00 00 057 425

Gudgeon pin fitting tool (centre tool C19, shaft A19, and ring B19)

Mot. 582-01

00 00 058 201

Flywheel locking tool

Mot. 591-02

00 00 059 102

Magnetized pointer arm

Mot. 591-04

00 00 059 104

Cylinder head bolt tightening gauge (angular measuring type)

Mot. 799-01

00 00 079 901

Timing gear tension wheel immobiliser

Mot. 1054

00 00 105 400

TDC setting pin

Mot. 1330

00 00 133 000

Oil filter removing tool

Mot. 1335

00 00 133 500

Tool for removing valve stem seals

10-22

Description

ENGINE AND PERIPHERALS Essential special tooling

Illustration

10

Part number

Part Stores Number

Description

Mot. 1354

00 00 135 400

Crankshaft seal gasket fitting tool (flywheel side)

Mot. 1355

00 00 135 500

Oil pump seal gasket fitting tool

Mot. 1360-01

00 00 136 001

Additional to Mot. 792-03 containing rod W1 and plate H1

Mot. 1374

00 00 137 400

Oil pump seal gasket removal tool

Mot. 1377

00 00 137 700

Crankshaft seal gasket removal tool (flywheel side)

Mot. 1381

00 00 138 100

Camshaft seal gasket removal tool

Elé. 1382-01

00 00 138 201

Spark plug key

Mot. 1492

00 00 149 200

Tool for fitting con rod bearing shells

10-23

ENGINE AND PERIPHERALS Essential special tooling Illustration

10

Part number

Part Stores Number

Description

Mot. 1492-04

00 00 149 204

Adaptation kit for fitting the con rod bearing shells

Mot. 1493-02

00 00 149 302

Tool for fitting crankshaft bearing shells

Mot. 1502

00 00 150 200

Valve spring compressor tool

Mot. 1505

00 00 150 500

Belt tension setting tool

Mot. 1511

00 00 151 100

Tool for fitting valve stem seals

Mot. 1573

00 00 157 300

Cylinder head support

Mot. 1587

00 00 158 700

Tool for fitting inlet camshaft seals

Mot. 1605

00 00 160 500

Tool for fitting cylinder head adjuster

10-24

ENGINE AND PERIPHERALS Essential equipment

10

Description

Ring for fitting piston with ring in the cylinder block.

Standard 22 mm long socket 1/2" (12.7 mm squared) for removing the oil pressure gauge.

Tooling for testing the cylinder head, including: a tray and the various kits suited for each model of cylinder head (plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664000.

Standard 1/2" 12 female torx socket (12.7 mm squared).

Angular tightening tool from: – STAHLWILLE part number 540 100 03 for example, – FACOM part number DM360 for example, – SAM part number 1 SA for example.

FACOM tool for fitting the valve stem seals, part number DM6J4 for example.

Gun for using tube of RHODORSEAL 5661.

FACOM spark plug key, part number B.J 14 BH2.

Angled tweezers (pliers) from: – SAM, part number 366.1 for example, – FACOM, part number 151 for example.

10-25

ENGINE AND PERIPHERALS Overhauling the engine – the lower timing cover (4).

REMOVING THE UPPER ENGINE Fit the flywheel block Mot. 582-01.

Remove the flywheel block Mot. 582-01.

Remove: – the upper timing housing (1), – the crankshaft accessories pulley (2), – the intermediate timing cover (3),

10-26

10

ENGINE AND PERIPHERALS Overhauling the engine

10

Check that the mark (7) on the camshaft pulley is on the vertical shaft of the engine.

Adjusting the timing Turn the crankshaft clockwise (timing side) until it is one half-tooth from alignment with the mark (5) on the crankshaft sprocket and the fixed mark (6) on the oil pump body.

Unscrew the nut (8) on the timing gear tension wheel, then remove the timing belt.

Insert the TDC setting pin Mot. 1054, then turn the crankshaft until it is pinned.

10-27


10

Disengage the electric wiring harness from the inlet manifold.

Remove: – the ignition coil and the spark plug wires, – the four upper bolts (1) on the inlet manifold (do not pull the section of the wiring harness labelled (2) as it is held between the cylinder head cover and the manifold), – the eight lower bolts (3) on the inlet manifold.

Remove: – the cylinder head cover,

– the cylinder head bolts, – the cylinder head.

10-28


10

– the camshaft pulley, – the timing gear tension wheel,

STRIPPING THE CYLINDER HEAD Place the cylinder head on cylinder head support Mot. 1573. Remove: – the exhaust heat shield,

– the camshaft seal gasket by screwing the puller tool Mot. 1381 into the seal gasket.

– the exhaust manifold, – the fuel pipe retaining brackets (1),

10-29


10

Remove the seal gasket by screwing the bolt (1) on tool Mot. 1381.

– the rocker arm rails by removing the bolts (2).

Remove: – the lifting rings, – the cylinder head coolant output unit, – the camshaft adjuster,

Mark the camshaft bearing caps with a permanent marker pen.

10-30

ENGINE AND PERIPHERALS Overhauling the engine Remove: – the camshaft bearing caps,

– the valve springs using tool Mot. 1502.

– the camshaft,

10-31

10


10

To compress the valve springs correctly, the piston (1) of the Mot. 1502 tool must be centred on the valve stem. The spring upper retaining cup must fit into the cavity (2) of the socket (3) on tool Mot. 1502.

Remove: – the pins, – the upper cups, – the springs, – the valves, – the valve guide seal gaskets using the Mot. 1335 pliers.

10-32

ENGINE AND PERIPHERALS Overhauling the engine CLEANING

CHECKING THE CAMSHAFT END PLAY

It is very important not to scratch the mating surfaces of any aluminium components.

Refit: – the camshaft, – the camshaft bearing caps, – the rocker arm shafts.

Wear gloves whilst carrying out this operation. Use the Décapjoint product to dissolve any part of the gasket which remains attached.

Tighten bolts (1) and (2) to a torque of 0.9 daNm. Pretighten bolts (3), (4), (5), (7), (8), (9), (10), (11) and (12) in the recommended order to a torque of 0.5 daNm.

Apply the product to the parts to be cleaned; wait about ten minutes, then remove it using a wooden spatula.

Unscrew bolt (3) until it is free, then tighten bolt (3) to a torque of 0.7 daNm plus an angle of 50˚±6˚.

Do not allow this agent to drip on to the paintwork. Great care should be taken when performing this operation, to prevent foreign objects entering the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover) and the oil return pipes.

CHECKING THE MATING SURFACE Check for mating surface bow using a ruler and a set of shims. Maximum bow

10

0.05 mm

CORRECTION OF THE CYLINDER HEAD IS NOT AUTHORISED Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit suited to the cylinder head, plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664000.

10-33

Repeat the process for bolts (4), (5), (6), (7), (8), (9), (10), (11) and (12).

ENGINE AND PERIPHERALS Overhauling the engine Check the end play, which must be between 0.08 and 0.178 mm.

10

REBUILDING THE CYLINDER HEAD Lubricate the inside of the valve guide. The valve stem seals must be fitted using tool Mot. 1511 or the FACOM tool, part number DMJ4.

Remove the rocker arm shafts, the camshaft bearing caps and the camshaft.

NOTE: do not lubricate the valve stem seals before fitting them.

10-34


10

Fitting new valve stem seals

Keep the valve pressed against its seat.

Place the valve in the cylinder head.

Place the valve stem seal (not lubricated) over the tool barrel.

Place the barrel of the Mot. 1511 tool over the valve stem (the internal diameter of the barrel must be identical to the diameter of the valve stem).

Push the valve stem seal past the tool barrel, then withdraw the barrel.

10-35


10

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.

Place the pushrod (1) over the valve stem seal.

NOTE: the internal diameter of the pushrod must be identical to the diameter of the valve stem. Moreover, the lower part of the pushrod must be in contact with the upper section of the valve stem seal.

Repeat these operations for all the valves.

10-36

ENGINE AND PERIPHERALS Overhauling the engine Fit: – the springs, – the upper cups, To compress the valve springs correctly, the piston (1) of the Mot. 1502 tool must be centred on the valve stem. The spring upper retaining cup must fit into the cavity (2) of the socket (3) on tool Mot. 1502.

Refit the keys using tweezers.

10-37

10

ENGINE AND PERIPHERALS Overhauling the engine ASSESSMENT AND REPAIR OF ROCKER ARM RAILS Mark the position of the rocker arms in relation to the rails, then remove the rocker arm rails. Examine the condition of the bearing surfaces and the rocker arm bolts. Check that the cam/tappet lubricating holes are not blocked up. Replace worn parts. Refit the rocker arm rails, placing the rails in the correct position in relation to the tappets: – for the inlet rocker arm rail, put the mark (1) on the timing side, – for the exhaust rocker arm rail, put the mark (2) on the flywheel side.

10-38

10


10

Grease the camshaft bearings with engine oil. Refit the camshaft.

Refit: – the camshaft bearing caps by tightening the bolts (1) and (2) to a torque of 0.9 daNm. Apply: – two lines (3) of Rhodorseal 5661, 2 mm wide, on cylinder head bearing 5, – two beads (4) of Rhodorseal 5661 on cylinder head bearing 1.

10-39

ENGINE AND PERIPHERALS Overhauling the engine – the rocker arm rails by placing them in the correct position and tightening the bolts in the recommended order to a torque of 0.5 daNm. Then unscrew bolt (3) until it is free, then tighten bolt (3) to a torque of 0.7 daNm plus an angle of 50˚±6˚. Repeat the process for the other bolts.

10-40

10

Refit: – the engine lifting bracket, – the cylinder head coolant output unit fitted with a new seal by tightening the bolts to a torque of 0.9 daNm, – the camshaft adjuster using tool Mot. 1605.


10

Screw the threaded rod (3) from tool Mot. 1587 into the camshaft.

Fitting the camshaft seal gasket. IMPORTANT: this type of seal gasket is extremely FRAGILE. Only touch the protector part (1) when handling the gasket. It is strictly forbidden to touch the seal (2). This is to ensure that there will be no oil leaks once the gasket is fitted on the engine. Fit the seal gasket using tool Mot. 1587.

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

10-41


10

Fit the canister (4) and the collar nut (5) from Mot. 1587.

Remove the nut, the canister, the protector and the threaded rod. Screw the collar nut until the canister touches the cylinder head.

10-42


10

Refit: – the camshaft pulley by tightening the bolts to a torque of 3 daNm plus an angle of 45˚±6˚,

Refit: – the inlet manifold fitted with a new seal by tightening the nuts to a torque of 2.5 daNm in the recommended order,

– the tension wheel by positioning it correctly.

– the exhaust heat shield by tightening the bolts to a torque of 1.5 daNm.

Fit the tension wheel notch (5) into the cylinder wheel rib (6).

10-43


10

Setting the valve clearances Valve clearance setting values (in mm) – inlet – exhaust

0.05 to 0.12 0.15 to 0.22

Open exhaust valve method Bring the exhaust valve of cylinder no. 1 to the fully open position, then adjust the inlet valve clearance for cylinder no 3 and the exhaust valve clearance for cylinder no 4. Follow the same method for the other cylinders, in the order shown by the table below.

Exhaust valve to be fully opened.

Inlet valve to be adjusted.

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Exhaust valve to be adjusted.


10

– the sump,

REMOVING THE LOWER ENGINE Fit flywheel block Mot. 582-01. Remove: – the clutch,

– the crankshaft seal gasket on the flywheel side by screwing puller tool Mot. 1377 into the seal gasket.

– the flywheel,

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10

Remove the seal by screwing the bolt (1) of tool Mot. 1377.

– the oil pump seal gasket by screwing puller tool Mot. 1374 into the seal gasket.

Remove: – the crankshaft seal supporting ring,

Remove the seal gasket by screwing the bolt (2) of tool Mot. 1374.

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10

Remove: – the strainer and its seal, – the oil pump (the oil pump cannot be repaired),

– the oil pressure supply seal.

– the coolant pump,

WARNING: do not use a sharp point to mark the big end caps in relation to their con rods, to prevent starting a crack in the rod. Use a permanent marker pen.

10-47

ENGINE AND PERIPHERALS Overhauling the engine Remove: – the bearing caps and the con rod/piston assemblies.

– the crankshaft bearing shells,

– the crankshaft bearing caps,

Clean: – the cylinder block, – the oil pump, – the coolant pump, – the crankshaft, – the seal supporting ring,

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10


10

EXTRACTING THE GUDGEON PINS

FITTING THE CON ROD SHELLS

Remove the piston rings.

The con rod bearing shells are fitted using Mot. 1492 and Mot. 1492-04.

Place the piston on the V of the support, the shaft aligned with the removal hole.

On the con rod body

Drive out the gudgeon pin on the press with the extraction mandrel (E).

Remove the pin (1) from Mot. 1492 (using a jaw vice), and replace it with the pin (2) from Mot. 1492-04.

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10

Slide the shell support (3) from Mot. 1492-04 into the groove (4) on the base of Mot. 1492, then place the rail (5) from Mot. 1492-04 on the base (as shown in the diagram).

Push the shell support in the direction of the arrow (as shown in the diagram) as far as it can go into the con rod body.

Lay the body of the con rod on the base of the tool (as shown in the diagram). Ensure that the lower part (6) of the small end of the con rod is in contact with the centring pin. Then place the shell (7) on the shell support.

Remove the con rod body support and repeat the operation for the remaining con rod bodies.

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10

Push the shell support in the direction of the arrow (as shown in the diagram) as far as it can go into the con rod cap.

On the con rod cap Fit the bar (8) and the con rod cap as shown in the diagram.

Push the rail (in the direction of the arrow) until the con rod cap touches the bar. Then place the shell (9) on the shell support.

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Remove the con rod cap support and repeat the operation for the remaining con rod caps.


10

ASSEMBLING THE CON RODS - PISTONS

Fitting the gudgeon pins

Preparing the piston/gudgeon pins assembly

The gudgeon pins are tightened in the con rods and able to rotate in the pistons before they are fitted. Use tooling Mot. 574-25 (to be ordered from the Replacement Parts Store to complete Mot. 574-22).

The parts supplied in the set are identical. Mark the parts in each box from A to D to ensure they remain identical.

A : fitting pins with centrers (C).

Completely dissolve the non-stick film without scratching the parts.

B : piston supporting rings, M : extraction mandrel, S : piston support base,

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10

Preparing the con rods

Preparing the gudgeon pins

Visually inspect the condition of the con rod (piercings/ level),

Check that the gudgeon pins rotate properly in the corresponding new pistons.

Use a 1500 W heating plate.

Use tool Mot. 574-25 containing centre tool C19 and pin fitter A19.

Place the small ends on the heating plate. Place the gudgeon pin (E) on the pin fitter (A), screw the centre tool (C) until it touches, and then unscrew one quarter of a turn.

Ensure that all the small end surfaces are in contact with the plate. To test the temperature, place a solder on each small end at (a) where the fusion point is approximately 250˚ C.

Heat each small end until the test solder welds.

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10

Follow these instructions when assembling the piston and con rod:

Assembling the con rods/pistons The piston heads are stamped with an arrow pointing to the flywheel side.

●

Position the Λ (1) engraved on the piston head to point downwards and at thesame side as the boss (2) of the small end (as shown in the diagram) (or the dipstick side on the cylinder block).

Fit ring B19 on the support and place the piston (arrow pointing downwards) on the ring, securing it with the pin.

Grease the centre tool and the gudgeon pin with engine oil. ● Drive the gudgeon pin into the assembly to check that it can move freely and re-centre the piston if necessary. ●

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ENGINE AND PERIPHERALS Overhauling the engine The following operations should be performed as quickly as possible to keep heat loss at a minimum.

FITTING THE RINGS Rings set to their original adjustment must be able to move freely within their channels.

When the solder reaches welding point (becomes liquid): – – – –

10

Ensure that the rings are fitted the correct way round as shown in the diagram.

wipe off the solder, engage the centring guide in the piston, fit the con rod in the piston, quickly drive in the gudgeon pin until the guide reaches the bottom of the support base.

Ensure that the gudgeon pin remains set back from the piston diameter for all the positions of the con rod in the piston .

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ENGINE AND PERIPHERALS Overhauling the engine REFITTING THE LOWER ENGINE

Fitting the bearing shells on the bearings.

Fitting the bearing shells in the cylinder block.

Position Mot. 1493-02 on the bearing.

10

Position tool Mot. 1493-02 on the cylinder block.

Fit the non-grooved bearing shell in Mot. 1493-02, then press at (3) until the bearing shell is touching Mot. 1493-02 at (4).

Fit the grooved bearing shell in Mot. 1493-02, then press at (1) until the bearing shell is touching Mot. 1493-02 at (2).2

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10

Refit the crankshaft.

Check that the crankshaft rotates freely.

Grease the crankpins and bushings with engine oil.

Refit the con rod/piston assemblies using the fitting ring.

Fit the crankshaft bearing caps (so that the arrows (1) engraved on the bearings are pointing to the flywheel side), then tighten the bolts to a torque of 2 daNm plus an angle of 76˚±6˚.

Fit the con rod caps, ensuring that they are correctly matched (use the marks made on removal).

Check the crankshaft clearance which should be between 0.045 and 0.235 mm.

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ENGINE AND PERIPHERALS Overhauling the engine Refit the con rod caps by tightening the bolts to a torque of 1.4 daNm plus an angle of 39˚±6˚.

10

NOTE: the crankshaft closure panel is sealed with RHODORSEAL 5661. The band (1) must be 1.3 mm wide and be applied as shown in the diagram below.

Check the lateral clearance of the big end which should be between 0.21 and 0.453 mm. Tighten the crankshaft closure panel bolts on the flywheel side to a torque of 0.9 daNm in the recommended order.

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ENGINE AND PERIPHERALS Overhauling the engine NOTE: the coolant pump is sealed with RHODORSEAL 5661. The band (2) must be 1.3 mm wide and be applied as shown in the diagram below.

10

Systematically replace the oil pressure supply seal (3).

IMPORTANT: the oil pump is driven by two studs located on the crankshaft. Tighten the coolant pump bolts to a torque of 0.9 daNm in the recommended order.

NOTE: the oil pump is sealed with RHODORSEAL 5661. The band (4) must be 1.3 mm wide and be applied as shown in the diagram below.

18646R ]

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10

Tighten the oil pump bolts to a torque of 0.9 daNm in the recommended order.

– oil pump side, use tool Mot. 1355.

Fitting the crankshaft seal gaskets

Replace the strainer fitted with a new O-ring by tightening the bolts to a torque of 0.9 daNm.

– flywheel side, use tool Mot. 1354.

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10

– the flywheel by tightening the new bolts to a torque of 1.8 daNm, then turning to an angle of 110˚±6˚ (blocking the flywheel with Mot. 582-01).

NOTE: the sump must only be sealed with a special After Sales seal. Place the flat surface on the cylinder block side.

Refit: – the sump, tightening the bolts to a torque of 1 daNm in the recommended order.

– the clutch, tightening the bolts to a torque of 2 daNm.

Remove flywheel block Mot. 582-01.

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10

Replacing the oil filter The two seal gaskets (2) must be replaced when the oil filter (1) is replaced.

Refit the oil filter by tightening it to a torque of 2 daNm to prevent any leaks. NOTE: the coolant pipe is sealed with RHODORSEAL 5661. The band (3) must be 1.3 mm wide and be applied as shown in the diagram below.

Hold the filter upside down and tap it on a piece of wood to remove the filter element.

Tighten the coolant pipe bolts to a torque of 0.9 daNm.

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10

REFITTING THE UPPER ENGINE Refitting the cylinder head Position the pistons at mid-stroke. Fit the cylinder head gasket using the centring sockets of the cylinder block. Tighten the cylinder head (see the section on cylinder head specifications). Paste lines (1) of Rhodorseal 5661 around the cylinder head cover mounting bolts and on camshaft bearings 1 and 5 as shown in the diagrams below.

Replace the cylinder head cover seal. Refit the cylinder head cover, tightening the bolts to a torque of 1.2 daNm in the recommended order.

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10

Replace the inlet manifold seals and the oil vapour seal.

Refit the spark plug well seals using a socket with an external diameter of 41 mm (32 mm socket for example).

Position the inlet manifold. Place a drop of Loctite FRENETANCH on the inlet manifold bolts. Tighten the eight bolts by hand, then pretighten bolts (4) and (5) to a torque of 0.6 daNm. Loosen bolts (4) and (5) until they are completely free. Tighten the eight bolts to a torque of 1 daNm in the recommended order.

Check that the wiring harness is correctly positioned at (1) and (2) before refitting the inlet manifold.

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10

Tighten the four upper bolts in a cross on the inlet manifold to a torque of 1 daNm.

– that the TDC pin Mot. 1054 is in place,

Adjusting the timing

– that the crankshaft timing sprocket mark (7) is facing the oil pump body mark (8).

Check: – that the tension wheel notch (5) is correctly positioned in the cylinder wheel rib (6).

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10

Remove the TDC setting pin Mot. 1054.

– that the camshaft pulley mark (9) is facing the cylinder head cover mark (10).

Turn the tension wheel eccentric ring anti-clockwise using a 6 mm Allen key to bring the tension wheel mobile index (A) into the position shown below.

Tighten the crankshaft accessories pulley bolt fitted with its washer to a torque of 1.5 daNm, to hold the timing sprocket in place. Tighten the tension wheel nut to a torque of 2.4 daNm. Fit the timing belt by aligning the belt markings with those on the camshaft and crankshaft sprockets.

Rotate the crankshaft through six revolutions in a clockwise direction (timing side). Refit the TDC pin Mot. 1054 and position the timing at setting point (check that the camshaft and crankshaft sprocket marks are correctly aligned with the fixed marks). Remove the TDC setting pin Mot. 1054.

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ENGINE AND PERIPHERALS Overhauling the engine Unscrew the tension wheel nut no more than one turn with a 6 mm Allen key, then turn the mobile index (11) in a clockwise direction until it is in the middle of the timing window (12). Then tighten the timing gear tension wheel nut to a torque of 2.4 daNm.

10

Fit the flywheel block Mot. 582-01.

Remove the accessory crankshaft pulley bolt. Refit: – the lower timing cover, NOTE: it is vital that you tighten the tension wheel nut to torque to avoid any loosening which may cause damage to the engine.

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10

– the timing intermediate housing (3), tightening the bolts to a torque of 1 daNm , – the timing upper housing (1), tightening the bolts to a torque of 3.3 daNm, – the accessories crankshaft pulley (2), tightening the bolts to a torque of 4 daNm plus an angle of 70˚±6˚.

Refit: – the alternator support, tightening the bolts to a torque of 5 daN.m, – the coolant pipe fitted with a new seal, – the air conditioning compressor mounting, tightening the bolts to a torque of 5 daNm,

Remove the flywheel block Mot. 582-01.

– the power assisted steering pump support (for engines fitted with air conditioning and power assisted steering), tightening the bolts to a torque of 2.5 daNm, – the air conditioning compressor, tightening the bolts to a torque of 5 daNm, – the power assisted steering pump by tightening the bolts to a torque of 2.2 daNm, – the alternator by tightening the upper bolt to a torque of 2.5 daNm and the lower bolt to a torque of 5 daNm, – the accessories belts.

Remove the engine from support Mot. 792-03.

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ENGINE AND PERIPHERALS Overhauling the engine Tensioning the accessory belts measure the tension of the accessory belts with tool Mot. 1505. Alternator belt

Power assisted steering belt

Air conditioning and power assisted steering belt

Air conditioning belt

A B C D G T

Crankshaft Alternator Power assisted steering pump Air conditioning compressor Tension Wheel Point for checking belt tension

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Table of fitting tension values

TENSION (Hertz) Fitting tension

Alternator belt

Power assisted steering belt

Air conditioning belt

Air conditioning and power assisted steering belt

260 ± 5

210 ± 5

210 ± 5

210 ± 5

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Workshop Repair Manual

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