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Workshop Repair Manual High Pressure Common Rail Diesel Engine 4 Cast Iron Cylinders Vehicle Type Engine Clio XB07 XB08 XB09 K9K 700 and 704 K9K 702 K9K 710 Kangoo KC07 KC09 K9K 700 K9K 710 77 11 298 922 "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." JULY 2001 All copyrights reserved by Renault. EDITION ANGLAISE 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
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  • Workshop Repair Manual

    High PressureCommon Rail Diesel Engine

    4 Cast Iron Cylinders

    Vehicle Type Engine

    Clio XB07XB08XB09

    K9K 700 and 704K9K 702K9K 710

    Kangoo KC07KC09

    K9K 700K9K 710

    77 11 298 922

    "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."

    JULY 2001

    All copyrights reserved by Renault.

    EDITION ANGLAISE

    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

    Cleanness & Safety 10-1Foreword 10-7Engine identification 10-8Tightening torques (in daNm or degrees) 10-10Technical specifications 10-12Standard exchange 10-31Essential special tooling 10-32Essential equipment 10-36Engine overhaul 10-37

  • ENGINECleanness & Safety 10

    10-1

    K9ALL TYPES

    110ENGINECleanness & Safety

    CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM

    Risks relating to contamination

    The system is very sensitive to contamination. The risks caused by the introduction of contamination are: damage to or destruction of the high pressure injection system, seizing or leaking of a component.

    All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) must be allowed to enter the system during dismantling or into the circuits via the fuel unions.

    The cleanliness principle must be applied from the filter to the injectors.

    WHAT ARE THE SOURCES OF CONTAMINATION?

    Contamination is caused by: metal or plastic chips, paint, fibres,

    of cardboard, brushes, paper, clothing, cloths.

    foreign bodies such as hairs, ambient air, etc.

    IMPORTANT: it is forbidden to clean the engine using a high pressure washer because of the risk of damaging connections. Also the moisture may collect in the connectors and cause electrical connection problems.

  • ENGINECleanness & Safety 10

    10-2

    K9ALL TYPES

    INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM

    Ensure that you have the plugs for the unions to be opened (bag of plugs sold by the Parts Stores - Part no.: 77 01 206 804).Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be thrown away.

    Ensure that you have the resealable plastic bags for storing removed parts. There is less risk of parts stored in this way being exposed to contamination. The bags must be used only once, and after use they must be thrown away.

    Make sure that lint-free cleaning cloths are available (cleaning cloths part number 77 11 211 707). The use of conventional cloth or paper is prohibited. These are not lint-free and may contaminate the fuel circuit of the system. Each lint-free cloth should only be used once.

    CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE CARRYING OUT ANY WORK ON THE FUEL SYSTEM

    For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.

    For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).

    Use a brush and thinners to clean the connections to be opened.

    Blow compressed air over the cleaned parts (tools, bench and parts, connections and injection system zone). Check that no bristles remain adhered.

    Wash your hands before and during the operation if necessary.

    When wearing leather protective gloves, cover these with latex gloves.

  • ENGINECleanness & Safety 10

    10-3

    K9ALL TYPES

    INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

    As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores (part number 77 01 206 804). They must not, under any circumstances, be reused .

    Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries contamination.

    All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once the plugs have been inserted.

    The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened. In fact, these items are likely to result in impurities entering the system.

    A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.

  • ENGINECleanness & Safety 10

    10-4

    K9ALL TYPES

    INSTRUCTIONS FOR FITTING THE PLUGS (part number 77 01 206 804)

  • ENGINECleanness & Safety 10

    10-5

    K9ALL TYPES

    IMPORTANT

    The engine must not run with: diesel containing more than 10% diester, petrol, even in very small amounts.

    The system can inject the diesel into the engine at a pressure of up to 1400 bars. Before carrying out any work, check that the injector rail is no longer pressurised and that the fuel temperature is not too high.

    You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system.

    Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the diesel temperature sensor and the venturi may be changed on the pump.

    For safety reasons, it is strictly forbidden to undo a high pressure pipe union when the engine is running.

    It is forbidden to remove the pressure sensor from the fuel rail because this may cause contamination problems. If the pressure sensor develops a fault, the pressure sensor, fuel rail and the five high pressure pipes must be replaced.

    It is strictly forbidden to remove any high pressure pump pulley bearing the part no. 070 575. The pulley must be replaced when the high pressure pump is replaced.

    It is forbidden to repair the wiring connecting the accelerometer and the engine speed sensor. If the wiring should fail, it has to be replaced with new wiring.

    Applying 12 volts directly to any component in the system is prohibited.

    Ultrasonic decoking and cleaning are prohibited.

    Never start the engine if the battery is not connected correctly.

    Disconnect the injection system computer when carrying out any welding work on the vehicle.

    All disconnected plastic air inlet hoses must be replaced.

  • ENGINECleanness & Safety 10

    10-6

    K9ALL TYPES

    A 16 character code called C2I (Individual Injector Corrector) is marked on the injectors. This code, specific to each injector, takes into account any manufacturing variations and specifies the flow injected by each injector.

    The code of the new injector must be programmed into the computer when injector is replaced.

    The code of the four injectors must be programmed into the computer when the computer is replaced.

    There are two possibilities:

    If it is possible to communicate with the computer: Upload the data from the computer into the diagnostic tool, change the computer, download the data from the diagnostic tool to the computer. Using the diagnostic tool, ensure that the computer has not detected faults relating to the injector codes

    and check that the instrument panel warning light is off.

    If it is not possible to communicate with the computer: Change the computer, read the data on the injectors, store the data in the computer using the diagnostic tool. Using the diagnostic tool, ensure that the computer has not detected faults relating to the injector codes

    and check that the instrument panel warning light is off.

  • ENGINEForeword 10

    10-7

    K9ALL TYPES Foreword

    USING THE MANUAL

    There are two main sections in this manual: technical specifications, overhauling the engine.

    To repair a component on the vehicle, refer to the vehicle's Workshop Repair Manual and Technical Notes.

    UNITS OF MEASUREMENT All dimensions are expressed in millimetres mm

    (unless otherwise stated). Tightening torques are expressed in decanewton-

    metres daNm (reminder: 1 daNm = 1.02 kgm). Pressures are expressed 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 %).

  • ENGINEEngine identification 10

    10-8

    K9ALL TYPES Engine identification

    Identification is by means of an engraved plate on the cylinder block which carries: A: engine type, B: engine type approval letter, D: Renault code, E: engine suffix, F: engine fabrication number, G: engine assembly plant.

  • ENGINEEngine identification 10

    10-9

    K9ALL TYPES

    Engine SuffixCompression

    ratioBore (mm)

    Stroke (mm)

    Cubic capacity (cc)

    K9K700 - 702704 - 710

    18.25/1 76 80.5 1461

  • ENGINETightening torques (in daNm or degrees) 10

    10-10

    K9ALL TYPES Tightening torques (in daNm or degrees)

    UPPER ENGINE

    * See tightening procedure.

    Description Tightening torques

    Cylinder headCamshaft bearingsCamshaft pulleyVacuum pumpCylinder head coolant outlet unitExhaust manifoldExhaust gas recirculation valvePre-heater plugsHigh pressure pumpInjector flangesHigh pressure railHigh pressure pipeCylinder head coverTurbo - manifold mountingTurbo oil return pipeTurbo oil delivery pipeTiming tension wheel Top dead centre capCylinder head suspended mounting support

    *1

    3 + 842.11

    2.62.11.52.12.82.83.81

    2.60.92.32.52

    2.1

  • ENGINETightening torques (in daNm or degrees) 10

    10-11

    K9ALL TYPES

    BOTTOM ENGINE:

    * See tightening procedure.

    Description Tightening torques

    Heat exchanger connectorOil filter unit bracketCrankshaft bearing capsCon rodsPinking sensor Oil level sensorOil pump Engine oil sumpWater pump Flywheel Clutch mechanismCrankshaft accessories pulleyWater pump inlet pipeMultifunction supportAlternatorPower steering pump Air conditioning compressor

    4.54.5

    2.7 + 47 5 2 + 45 6

    22.22.5*

    1.15 - 5.5

    0.82 + 130 15

    24

    2.12.12.1

  • ENGINESpecifications 10

    10-12

    K9ALL TYPES Specifications

    CYLINDER HEAD

    Cylinder head tightening procedure

    REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to achieve correct tightening of the bolts.

    All bolts must always be changed after removal. Do not oil the new bolts.

    Tighten all the bolts to a torque of 2.5 daN.m.

    Check that all the bolts are correctly tightened to 2.5 daN.m then tighten to an angle, bolt by bolt, of 255 10.

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

    Thickness of the cylinder head gasket

    The thickness of the cylinder head gasket is measured at (A): thickness of the gasket when tightened:

    0.78 0.3 mm.

  • ENGINESpecifications 10

    10-13

    K9ALL TYPES

    Checking piston protrusion

    Clean the piston heads in order to eliminate any traces of deposits.

    Turn the crankshaft one turn in its operating direction to bring piston no.1 close to Top Dead Centre.

    Fit tool Mot. 251-01 equipped with a gauge on its base plate Mot. 252-01, and find top dead centre of the piston.

    N.B.: All measurements must be carried out along the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston.

    WARNING: the gauge follower must not be in the valve clearance.

    Measure the piston protrusion.

    The protrusion must be: 0.192 0.093 mm.

  • ENGINESpecifications 10

    10-14

    K9ALL TYPES

    Height of the cylinder head (in mm)

    H = 127

    Gasket face bow (in mm):

    Cylinder head 0.05Cylinder block 0.03

    NO REGRINDING IS 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 664 000 .

    Valves

    Stem diameter (in mm)

    Inlet 5.977 0.008Exhaust 5.963 0.008

    Face angle

    Inlet and exhaust: 90

    Head diameter (in mm)

    Inlet 33.5 0.12Exhaust 29 0.12

    Valve length (in mm)

    Inlet 100.95 0.22Exhaust 100.75 0.22

    Max. valve lift (in mm)

    Inlet 8.015Exhaust: 8.595

    Protrusion of valves in relation to the cylinder head gasket face (in mm)

    Inlet and exhaust 0 0.07

  • ENGINESpecifications 10

    10-15

    K9ALL TYPES

    Valve seats

    Seat angle ()

    Inlet and exhaust: 89 30'

    Mating surface width (X) (in mm)

    Inlet and exhaust: 1.8

    Seat external diameter (D) (in mm)

    Inlet 34.542 0.008

    Exhaust 30.042 0.008

    Diameter of the housing in the cylinder head (in mm)

    Inlet 34.459 0.015

    Exhaust 29.97 0.015

    Valve guides

    Length (in mm)

    Inlet and exhaust: 40.5 0.15

    Guide external diameter (in mm)

    Guide internal diameter (in mm)

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

    Diameter of the housing in the cylinder head (in mm)

    Normal 11 0.0075

    The inlet and exhaust guides have valve stem seals which must be changed each time the valves are removed.

    Normal: 11 +0.062+0.044

    Inlet and exhaust

    Not machined 5.5 +0.12 0

    Machined* 6.009 0.009

  • ENGINESpecifications 10

    10-16

    K9ALL TYPES

    It is imperative to fit the valve stem seals using tool Mot. 1511-01 or other suitable equipment.

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

    Angle of the inlet and exhaust guides (in degrees)

    Inlet and exhaust: = 90

    Position of the inlet and exhaust valve guides (in mm)

    Inlet: A = 14Exhaust A = 14.2

    19675

  • ENGINESpecifications 10

    10-17

    K9ALL TYPES

    Valve springs

    The valve springs are tapered (ensure the correct direction of fitting).

    Free length (in mm) 43.31

    Length under a load of ( in mm)

    23 daN 33.8050 daN 24.80

    Joined spires (in mm): 23.40

    Wire diameter (in mm) 3.45

    Internal diameter (in mm)Bottom 18.80 0.2Top 14.10 0.2

    External diameter (in mm):Bottom 25.70 0.2Top 21 0.2

    WARNING: THIS ENGINE DOES NOT HAVE ANY VALVE SPRING LOWER WASHERS.

    Pistons

    Piston external diameter (in mm)

    34.975 0.01

    Diameter of the housing in the cylinder head (in mm)

    35.02 0.02

    Checking the valve clearance

    Place the valves of the cylinder concerned at the "end of exhaust - beginning of inlet" position and check the clearance (X).

    NOTE: dimension (Y) corresponds to the tappet thickness class (there are 25 classes at the Parts Store).

    Compare the values recorded with the values specified, then replace the tappets which are not within tolerance.

    Clearance (in mm), when the engine is cold:

    1

    3

    4

    2

    4

    2

    1

    3

    Inlet 0.20 + 0.05-0.075

    Exhaust: 0.40 + 0.05-0.075

  • ENGINESpecifications 10

    10-18

    K9ALL TYPES

    The camshaft must be removed to replace the tappets.

    Determining dimension "Y".

    Set up the following assembly using Mot. 252-01 and Mot. 856-02, then calibrate the gauge.

    Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly), then slide in the tappet to be measured.

    Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance.

    Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s) . The Parts Stores supplies 25 classes of single-piece tappets.

    Camshaft

    End play (in mm) 0.08 to 0.178

    Number of bearings 6

    Diameter of the camshaft bearings (in mm)

    Timing diagram

    Inlet opening retard * -9 Inlet closing retard 20 Exhaust opening advance 27 Exhaust closing advance ** -7

    * As the inlet opening retard is negative, the valve is opened after Top Dead Centre.

    ** As the exhaust closing advance is negative, the valve is closed before Top Dead Centre.

    on the camshaft: bearings 1, 2, 3, 4, 5 bearing 6

    24.989 0.0127.989 0.01

    on the cylinder head: bearings 1, 2, 3, 4, 5 bearing 6

    25.05 0.0128.05 0.01

  • ENGINESpecifications 10

    10-19

    K9ALL TYPES

    1 Cylinder block top dead centre fixed mark2 Flywheel top dead centre moving mark3 Flywheel bottom dead centre moving mark4 Inlet Opening Retard 5 Exhaust Closing Advance 6 Inlet Closing Retard 7 Exhaust Opening Advance 8 Direction of engine rotation (flywheel end).

    PISTONS

    Fitting the gudgeon pin in the con rod and in the piston.

    The gudgeon pin is retained by circlips.

    These engines are fitted with FEDERAL MOGUL pistons.

    Piston marking

    1 Direction of fitting of the piston towards the flywheel

    2 Height between the gudgeon pin and the top of the piston (see table below).

    3 Used by the supplier only4 Used by the supplier only5 Used by the supplier only6 Piston axis of symmetry 7 Gudgeon pin hole axis8 Offset between the hole axis (7) and the piston's axis

    of symmetry (6) is 0.3 mm

  • ENGINESpecifications 10

    10-20

    K9ALL TYPES

    Table of gudgeon pin heights

    The tolerance on the pin heights is 0.02 mm.

    * The different gudgeon pin heights are exclusively reserved for the engine assembly plant.

    The Parts Stores will only supply piston classes (height) L, M, N.

    NOTE: if the engine is fitted with a K class piston, an L

    class piston must be fitted as a replacement. if the engine is fitted with a P class piston, an N

    class piston must be fitted as a replacement,

    Measuring the piston diameter

    The piston diameter must be measured at height A = 56 mm.

    Piston diameter (in mm): 75.94 0.007

    Gudgeon pin (in mm)

    Length 59.7 - 60.3

    External diameter 24.8 - 25.2

    Internal diameter: 13.55 - 13.95

    * Mark on piston Pin height (mm)

    K 41.667

    L 41.709

    M 41.751

    N 41.793

    P 41.835

  • ENGINESpecifications 10

    10-21

    K9ALL TYPES

    Rings

    Three rings (thickness in mm):

    The rings are supplied ready adjusted.

    T = Top

    Clearance at the gap

    Compression 2 -0.01-0.03

    Sealing 2 -0.01-0.03

    Scraper 2.5 -0.01-0.03

    RingsClearance at the gap

    (in mm)

    Compression 0.2 to 0.35

    Sealing 0.7 to 0.9

    Scraper 0.25 to 0.5

  • ENGINESpecifications 10

    10-22

    K9ALL TYPES

    CON RODS

    The connecting rods are of the "DETACHABLE CAP" type.

    WARNING: The bolts must be coated with engine oil under

    the heads and on the threads when the con rods are fitted in the engine.

    The big end caps are positioned on the con rod by irregularities on the parting line.

    The occurrence of impacts or a foreign body between the body - cap mating surfaces will lead to rapid rupture of the con rod.

    Lateral big end play (in mm) 0.205 to 0.467

    Diametrical big end play (in mm) 0.035 to 0.045

    Centre distance between the big end and small end (in mm) 133.75

    Diameter of the big end (in mm) 47.619 0.009

    Diameter of the small end (in mm)(without ring) 27.25 0.010

    (with ring) 25.019 0.006

    NOTE: the con rod small end rings cannot be replaced.

    The maximum weight difference for the con rod, piston and gudgeon pin assemblies for the same engine must be 25 grams.

    WARNING: do not use a sharp point to mark the big end caps in relation to their con rod, to avoid initiating a crack in the rod.

    Use a permanent marker pen.

  • ENGINESpecifications 10

    10-23

    K9ALL TYPES

    Direction of fitting of the con rod in relation to the piston

    Point the "" (1) engraved on the top of the piston downwards and the machined flat (2) of the big end as shown on the diagram below.

    Direction for fitting the circlips on the piston

    Position the opening (3) of the spring rings opposite the removal and fitting channel (4).

    CRANKSHAFT

    Number of main journals 5

    Crankshaft lateral clearance (in mm): without wear on lateral shims: 0.045 - 0.252 with wear on the lateral shims: 0.045 - 0.852

    Crankshaft diametrical clearance (in mm): journals 0.027 - 0.054 crankpins 0.035 - 0.045

    Journal diameter (in mm):48 0.01

    Crankpin diameter (in mm):43.97 0.01

    The lateral shims are located on bearing N 3.

    NO RECTIFICATIONS ARE ALLOWED.

  • ENGINESpecifications 10

    10-24

    K9ALL TYPES

    Working out the class of crankshaft bearing shells (Original fitment)

    Marking (5) on the crankshaft

    Detail of the marking (5):

    Number of journals

    * Flywheel end.

    Table of journal diameter classes

    1* 2 3 4 5

    B B C C BClasses of journal

    diameters

    A = D1

    B = D2

    C = D3

    Journal class mark on the crankshaft

    Journal diameter (in mm)

    A = D1 47.990 to 47.996

    B = D2 47.997 to 48.003

    C = D3 48.004 to 48.010

  • ENGINESpecifications 10

    10-25

    K9ALL TYPES

    CYLINDER BLOCK

    The diameters of the bearings (6) of the cylinder block are marked by a hole on the block (7) located above the oil filter.

    Table of cylinder block bearing diameters

    NOTE: the marking zone includes: A - B gives the diameter class of bearings 1 or 2.

    Matching the crankshaft bearing shells

    * Cylinder block crankshaft bearing diameter class.

    NOTE: the parts stores will only supply class C2 (blue).

    Hole position

    (7)

    Class reference

    Cylinder block bearing diameter

    (in mm)

    A = 33 mm 1 or blue51.936 - 51.942

    exclusive

    B = 43 mm 2 or red51.942 inclusive -

    51.949

    Journal diameter class

    D1 D2 D3

    C1 C2 C3

    1 *1.949 to 1.955

    1.946 to 1.952

    1.943 to 1.949

    yellow blue black

    2 * C4 C1 C2

    1.953 to 1.959

    1.949 to 1.955

    1.946 to 1.952

    red yellow blue

    Bearing shell thickness and class

  • ENGINESpecifications 10

    10-26

    K9ALL TYPES

    BEARING SHELLS

    Crankshaft bearing shells

    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. 1493-01.

    Direction of fitting: on the cylinder block, fit grooved bearing shells on

    all the bearings,

    on the bearing caps, fit non grooved bearing shells.

  • ENGINESpecifications 10

    10-27

    K9ALL TYPES

    Con rod bearing shells

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

    NOTE: the upper and lower con rod bearing shells are not the same width.

    Bearing shell width (in mm): upper 20.625 lower 17.625

    The bearing shells are fitted using Mot. 1492 and Mot. 1492-03.

  • ENGINESpecifications 10

    10-28

    K9ALL TYPES

    PREPARING THE ENGINE TO BE SET ON THE STAND

    Before the engine is mounted on the stand Mot. 792-03, the engine's electrical harness must be removed and the engine oil drained.

    Remove: the accessories belt,

    the alternator, the air conditioning compressor or the power-

    assisted steering pump,

    the multifunction support,

  • ENGINESpecifications 10

    10-29

    K9ALL TYPES

    the coolant inlet pipe on the water pump.

    Place the rods (A), (X), (Y) of Mot. 1378 on the cylinder block so that they fit into the holes (20, 32, 33) on the plate of Mot. 792-03.

  • ENGINESpecifications 10

    10-30

    K9ALL TYPES

    CONSUMABLES

    Type Quantity Component concerned Part no.

    Cleaner - Cleaning parts 77 01 421 513

    DECAPJOINT Coat Cleaning gasket faces 77 01 405 952

    Sealing paste Bead

    Crankshaft bearing cap

    -Camshaft bearings

    Crankshaft closure plate

    Loctite FRENETANCH 1 - 2 drops Water pump bolts 77 01 394 070

    RHODORSEAL 5661 Coat Top Dead Centre pin plug 77 00 404 452

    WARNING

    PARTS TO BE REPLACED AFTER REMOVAL: All gaskets, Flywheel bolts, Crankshaft bearing bolts, Camshaft pulley bolt, Crankshaft pulley bolts, Big end cap bolts, Injector holder copper washers, High pressure injection pipes, Pipe plugs, Belts, Timing belt tension wheel, Piston base cooling jets, Turbo plastic pipes.

    FITTING THREAD INSERTS

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

    WARNING: when working on the fuel supply system, the cleanliness rules described in this document must be strictly complied with.

  • ENGINEStandard replacement 10

    10-31

    K9ALL TYPES 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 oil filter, the oil pressure switch, the water pump, the high pressure pump, the rail, the injectors the heater plugs, the dipstick, the vacuum pump, the flywheel, the clutch

    Remember to remove: all coolant pipes, the exhaust manifold, the alternator, the power-assisted steering pump, the air conditioning compressor, the multifunction support, the oil level sensor, the cylinder head coolant outlet 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.

  • ENGINEEssential special tooling 10

    10-32

    K9ALL TYPES Essential special tooling

    IllustrationMethod part

    numberParts stores

    numberDescription

    Emb. 880 00 00 088 000 Inertia extractor

    Mot. 11 00 01 072 500 Crankshaft bearing extractor

    Mot. 251-01 00 00 025 101Gauge stand used with Mot. 252-01

    Mot. 252-01 00 00 025 201Thrust plate for measuring the protrusion of cylinder liners used with Mot. 251-01.

    Mot. 445 00 00 044 500 Oil filter wrench

    Mot. 582-01 00 00 058 201 Flywheel immobilising tool.

    Mot. 588 00 00 058 800 Liner retaining strap

    Mot. 591-02 00 00 059 102Magnetic flexible shaft for angular wrench for tightening cylinder head.

    Mot. 591-04 00 00 059 104Angular wrench for tightening cylinder head, 1/2" drive with index

  • ENGINEEssential special tooling 10

    10-33

    K9ALL TYPES

    IllustrationMethod part

    numberParts stores

    numberDescription

    Mot. 792-03 00 00 079 203Engine mounting plate for Desvil stand

    Mot. 799-01 00 00 079 901Tool for locking sprockets for toothed timing belt

    Mot. 1329 00 00 132 900 Oil filter cap

    Mot. 1335 00 00 113 500Tool for removing valve stem seals

    Mot. 1378 00 00 137 800 X and Y engine pins

    Mot. 1430 00 00 143 000 Set of top dead centre pins

    Mot. 1485-01 00 00 0148 501Tool for removing the piston bottom cooling jets

    Mot. 1489 00 00 148 900 TDC setting pin

    Mot. 1492 00 00 149 200Tool for fitting con rod bearing shells

  • ENGINEEssential special tooling 10

    10-34

    K9ALL TYPES

    IllustrationMethod part

    numberParts stores

    numberDescription

    Mot. 1492-03 00 00 149 203Adaptation kit for fitting the detachable cap con rod bearing shells

    Mot. 1493-01 00 00 149 301Tool for fitting crankshaft bearing shells

    Mot. 1494 00 00 149 400Tool for removing the piston bottom jets

    Mot. 1505 00 00 150 500 Belt tension setting tool

    Mot. 1511-01 00 00 151 101 Tool for fitting valve stem seals

    Mot. 1566 00 00 156 600Spanner for fitting and removing high pressure pipes

    Mot. 1567 00 00 156 700Pliers for exhaust gas recycling pipe clips

    Mot. 1573 00 00 157 300 Cylinder head support

    Mot. 1585 00 00 158 500Tool for fitting crankshaft seals, flywheel end

  • ENGINEEssential special tooling 10

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    IllustrationMethod part

    numberParts stores

    numberDescription

    Mot. 1586 00 00 158 600Tool for fitting crankshaft seals, timing end

    Mot. 1632 00 00 163 200 Tool for fitting inlet camshaft seals

    Mot. 1638 00 00 163 800

    Tool for tensioning accessories belt for engines with a mechanical tension wheel

    Rou. 15-01 00 00 001 501Internal shaft protector 16 mm

  • ENGINEEssential equipment 10

    10-36

    K9ALL TYPES Essential equipment

    Description

    Ring for fitting pistons in the cylinder block

    Standard 22 mm long 1/2" (12.7 mm) square drive socket for removing the oil pressure checking 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" (12.7 mm) square drive 8/12 /14 female torx socket .

    Angular tightening tool from: e.g. STAHL WILLE part number 540 100 03, e.g. FACOM part number DM360, e.g. SAM part number 1 SA.

    Tool for fitting valve stem seals, e.g. FACOM part number DM6J4.

    Angled nippers

    Wrench for removing high pressure pipes, e.g. FACOM part number DM 19

    Crowfoot adapter for tightening high pressure pipe

    Articulated wrench for removing and refitting the heater plugs, e.g. FACOM part number B10R10A.

    Wrench for removing crankshaft bearings, e.g. FACOM U49 A D5

    Valve spring compressor

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES Overhauling the engine

    Removing the upper engine

    Remove: the upper timing cover by

    unclipping the two tabs (1),

    the lower timing cover by unclipping the three tabs (2) and pulling out the plastic bolt (3),

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    the cylinder head suspended mounting support,

    the TDC pin cap.

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    K9ALL TYPES

    Positioning the belt at the timing point

    Position the hole (4) of the camshaft pulley almost opposite the hole (5) of the cylinder head.

    Screw in the TDC pin Mot. 1489.

    Turn the engine clockwise (timing side) until the crankshaft touches the TDC pin Mot. 1489.

    The pin Mot. 1430 must engage in the camshaft pulley and cylinder head holes.

    Remove Mot. 1430 and Mot. 1489.

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    Fit flywheel block Mot. 582-01.

    Remove the crankshaft accessories pulley.

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    Slacken the timing belt by loosening the bolt (6) of the tension wheel, then remove the timing belt.

    Remove: the timing belt tension wheel, the inner timing cover,

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    the air filter unit, by removing the clamp (1) and the bolt (2),

    the clamp (3), the oil vapour rebreathing pipe, the turbo oil supply pipe on the cylinder head side,

    the turbo oil supply pipe on the turbo side, the nuts (4) of the turbo flange, the bolts (5) of the catalytic converter bracket, the turbo oil return pipe (6).

    Unclip the fuel return pipe from the cylinder head cover at (7), then remove the cylinder head cover.

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    Remove: the dipstick guide, the cylinder head.

    STRIPPING THE CYLINDER HEAD

    Place the cylinder head on cylinder head support Mot. 1573.

    WARNING: when undoing the high pressure pipes, it is essential to secure the intermediate union (10) of the injector.

    Pay strict attention to the rules regarding cleanliness (see start of document).

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    K9ALL TYPES

    Remove: the high pressure pipes using Mot. 1566 or a pipe

    wrench,

    fit the protective blanking plugs to the high pressure pump, the rail and the injectors.

    the high pressure pump, the rail,

    the injectors (by marking them in relation to their cylinder),

    the pre-heater plugs using an angled spanner, the ring for lifting the engine (flywheel end),

    the vacuum pump, the cylinder head coolant outlet unit,

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    K9ALL TYPES

    the ring for lifting the engine (timing end), the exhaust gas recirculation pipe, the inlet pipe, the exhaust gas recirculation valve, the exhaust manifold,

    the camshaft pulley using Mot. 799-01,

    the camshaft bearings,

    the tappets, noting their position.

    20064-2

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    K9ALL TYPES

    Compress the valve springs using the valve lifter.

    Remove: the keys, the upper cups, the springs,

    N.B.: before removing the valves and the valve stem seals, it is vital to measure position H of one of the old seals in relation to the cylinder head using Mot. 1511 -01 or other suitable equipment.

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    Fit the pushrod (1) of Mot. 1511-01 on 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 come into contact with the metal upper section of the valve stem seal.

    Fit the guide tube (2) over the pushrod until the guide tube comes into contact with the cylinder head, locking the pushrod with the knurled wheel.

    Remove the guide tube assembly plus pushrod, being careful not to loosen the knurled wheel.

    Remove: the valves, the valve guide seals using the Mot. 1335 pliers.

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    CLEANING

    It is very important not to scratch the gasket faces of any aluminium components.

    Use DECAPJOINT to dissolve any part of the seal which remains stuck to the metal surface.

    Apply the product to the part to be cleaned, wait approximately 10 minutes, then remove it using a wooden spatula.

    Wear gloves whilst carrying out this operation.

    Do not allow this product 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.

    Failure to follow this instruction could lead to the blocking of the oilways, resulting in rapid and serious damage to the engine.

    CHECKING THE GASKET FACE

    Check for mating surface bow using a ruler and a set of shims.

    Maximum bow 0.05 mm

    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

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    CHECKING THE CAMSHAFT END PLAY

    NOTE: to attach the magnetic gauge to the cylinder head, clamp Mot. 588 must be used and secured using the oil filler attachment bolt (1) of the cylinder head cover and a spacer with the following dimensions: external diameter 18 mm, diameter of bolt (1) hole 9 mm, height 15 mm.

    Refit: the camshaft, the camshaft bearings (positioning them correctly

    with bearing 1 on the flywheel end), then tighten the bolts to a torque of 1 daN.m.

    Check the end play, which must be between 0.08 and 0.178 mm.

    Remove the camshaft bearings and the camshaft.

    REBUILDING THE CYLINDER HEAD

    Fit new valves, grind them gently into their respective seats. Clean all the parts thoroughly, mark them for identification purposes, then carry out the refitting operation.

    Lubricate the inside of the valve guide.

    It is imperative to fit the valve stem seals using tool Mot. 1511-01 or other suitable equipment.

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

    Fitting new valve stem seals

    Place the valve in the cylinder head.

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    Place the barrel of tool Mot. 1511-01 over the valve stem (the internal diameter of the barrel must be identical to the diameter of the valve stem).

    Keep the valve pressed against its seat.

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

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

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    Place the guide tube plus pushrod assembly on the valve stem seal.

    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.

    Repeat these operations for all the valves.

    Fit: the springs, the upper cups,

    Compress the springs.

    Refit the keys using tweezers.

    Check the valve protrusion which should be 0 0.07 mm.

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    CHECKING AND ADJUSTING THE VALVE CLEARANCE

    Refit: the tappets, the camshaft, the camshaft bearings, tightening the bolts to a

    torque of 1 daN.m.

    Place the valves of the cylinder concerned at the "end of exhaust - beginning of inlet" position and check the clearance (X).

    NOTE: dimension (Y) corresponds to the tappet thickness class (there are 25 classes at the Parts Store).

    Compare the values recorded with the values specified, then replace the tappets which are not within tolerance.

    Clearance, when the engine is cold, in mm:

    Remove: the camshaft bearings, the camshaft, the tappet(s) not within tolerance.

    Determining dimension Y.

    Set up the following assembly using Mot. 252-01 and Mot. 856-02, then calibrate the gauge.

    1

    3

    4

    2

    4

    2

    1

    3

    Inlet 0.20 + 0.05-0.075

    Exhaust: 0.40 + 0.05-0.075

  • ENGINEOverhauling the engine 10

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    Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly), then slide in the tappet to be measured.

    Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance.

    Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s) .

    Check the valve clearance again.

    Remove: the camshaft bearings, the camshaft, the tappet(s) not within tolerance.

    Grease the underside of the tappets and the camshaft bearings.

    Degrease the gasket faces (of the cylinder head and bearings numbers 1 and 6). They should be clean, dry and free from grease (in particular, remove finger marks).

    Lay four beads (3) of Loctite 5181 with a width of 1 mm on bearings 1 and 6 of the cylinder head.

    Refit: the camshaft, the camshaft bearings (these are numbered from 1 to

    6 and bearing (1) should be positioned on the flywheel end) tightening the bolts to a torque of 1 daN.m.

    14678-1S

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    Fitting the camshaft seal

    This engine can be fitted with two different types of seal.

    Old and new seals are easily recognised.

    The old rubber seal is fitted with a spring (2) and has a "V"-shaped sealing lip (3).

    The new rubber seal has a flat sealing lip (4) and a protector (5) which also assists in fitting the seal to the engine.

  • ENGINEOverhauling the engine 10

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    Screw the shouldered rod (6) of Mot. 1632 onto the stud of the camshaft.

    Fit the old seal on the camshaft.

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

    Fit the cover (7) and the collar nut (8) of Mot. 1632.

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

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

    Remove the nut, the cover, the protector and the shouldered rod.

    Refit the camshaft pulley, tightening the new nut to a torque of 3 daN.m plus an angle of 84.

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    Refit: the vacuum pump fitted with a new seal, tightening

    the bolts to a torque of 2.1 daNm, the cylinder head coolant outlet unit fitted with a new

    seal, tightening the bolts to a torque of 1 daNm,

    the exhaust manifold fitted with new seals, tightening the bolts to a torque of 2.6 daNm in the recommended order,

    the exhaust gas recycling valve and the exhaust gas recycling pipe fitted with new clips. Tighten the mounting bolts of the valve to a torque of 2.1 daN.m, then tighten the clips of the pipe using pliers Mot. 1567,

    the inlet pipe fitted with a new seal, the ring for lifting the engine (timing end).

  • ENGINEOverhauling the engine 10

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    Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the wipes recommended for this purpose, part no. 77 11 211 707) dipped in clean solvent.

    Dry off using a different new wipe.

    Replace the compression washer with a new washer.

    Refit: the injectors (using the marks made during removal),

    tightening the mounting flanges to a torque of 2.8 daN.m,

    the pre-heater plugs, tightening them to a torque of 1.5 daNm,

    the ring for lifting the engine (flywheel end),

    the high pressure pump, tightening the bolts to a torque of 2.1 daNm,

    the high pressure rail without locking its mounting nuts.

    Method for refitting the injector pipes

    Before fitting the new high pressure pipes, lubricate the threads of the nuts with the applicator supplied with the kit of new parts.

    WARNING: all removed high pressure pipes must be systematically replaced.

  • ENGINEOverhauling the engine 10

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    Fit the rail-high pressure pump pipe:

    remove the protective plugs from the pump high pressure outlet and the rail high pressure inlet.

    insert the olive of the high pressure pipe into the taper of the pump high pressure outlet.

    insert the olive of the high pressure pipe into the taper of the rail high pressure inlet.

    put the high pressure pipe nuts in position by hand beginning with the one located on the rail side.

    Fit the injector-high pressure rail pipe:

    remove the protective plugs from the rail high pressure rail outlet and the injector high pressure inlet.

    insert the olive of the high pressure pipe into the taper of the injector high pressure inlet.

    insert the olive of the high pressure pipe into the taper of the rail high pressure outlet.

    put the high pressure pipe nuts in position by hand beginning with the one located on the injector side.

    Fit the remaining high pressure pipes as before.

    Fit the clips supplied with the new pipes onto the high pressure pipes: Insert the first half of the clip using adjustable pliers, Insert the second half of the clip using adjustable

    pliers.

    WARNING: when tightening the high pressure pipes, it is essential to secure the intermediate union (10) of the injector.

    IMPORTANT: Pay attention to the direction of fitting of the second half of the clip. The tabs located in the centre of the clip will only fit together in one position.

  • ENGINEOverhauling the engine 10

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    Tighten the rail nuts to a torque of 2.8 daNm.

    Tighten the nuts of the pump-rail high pressure pipe using the recommended tool: tighten the nut on the rail side to a torque of

    3.8 daN.m, tighten the nut on the pump side to a torque of

    3.8 daN.m,

    Tighten the nuts of the injector-rail high pressure pipes using the recommended tool: tighten the nut on the injector side to a torque of

    3.8 daN.m, tighten the nut on the rail side to a torque of

    3.8 daN.m,

    NOTE: Tighten one pipe fully before moving on to the next pipe.

    IMPORTANT: do not touch the pipes with the wrench when torque tightening.

    WARNING: the correct order and tightening torque must be used for the high pressure pipes.

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    REMOVING THE BOTTOM ENGINE

    Fit flywheel block Mot. 582-01.

    Remove: the clutch mechanism, the flywheel,

    the sump,

    the anti-emulsion plate,

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    the oil level sensor, the oil pump,

    the crankshaft closure plate, the water pump,

    the oil pump chain, the oil pump drive sprocket.

    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. Use a permanent marker pen.

    Remove the big end cap bolts and the connecting rod/piston assemblies.

    NOTE: It is essential to mark the position of the crankshaft shells, as the category may be different for each bearing.

    Remove: the crankshaft bearing caps, the crankshaft.

  • ENGINEOverhauling the engine 10

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    Remove: the oil pressure sensor, the pinking sensor, the bolt of the oil filter unit bracket.

    the heat exchanger connector.

    Replacement of the piston base cooling jets

    REMOVAL

    To remove the piston base cooling jets (1), they must be drilled with a 7 mm diameter drill. This is necessary in order to remove the spring stop (2) and the spring (3).

    NOTE: do not remove the ball (4) to prevent swarf entering the cooling circuit.

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    Remove the swarf using a brush.

    Screw: tool Mot. 1485-01 in the drilled out jets using a 6 mm

    Allen key which must slide into the tool,

    the inertia extractor Emb. 880 onto Mot. 1485-01 and remove the jet.

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    Fitting piston base cooling jets

    The jets must be fitted using tool Mot. 1494.

    Fitting the jets for cylinders 1 and 3

    Fit plate (3) of tool Mot. 1494 onto the cylinder block (as shown on the diagram below) without tightening the two bolts (1).

    Position the guide rod (2) in the plate (3) and the end of the guide rod in the hole of the jet to centre the plate (3).

    Tighten the two bolts (1).

    Remove the guide rod.

    Fit the pushrod instead and in place of the guide rod, then insert the jet into the pushrod.

    NOTE: check that the jet is correctly oriented with the end of the jet (4) directed towards the centre of the cylinder.

    With a hammer, tap the pushrod until the shoulder (5) of the pushrod comes into contact with the plate (3).

  • ENGINEOverhauling the engine 10

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    Fitting the jets for cylinders 2 and 4

    Fit plate (3) of tool Mot. 1494 onto the cylinder block (as shown on the diagram below) without tightening the two bolts (1).

    Position the guide rod (2) in the plate (3) and the end of the guide rod in the hole of the jet to centre the plate (3).

    Tighten the two bolts (1).

    Remove the guide rod.

    Position the pushrod instead and in place of the guide rod, then insert the jet into the pushrod.

    NOTE: check that the jet is correctly oriented with the end of the jet (4) directed towards the centre of the cylinder.

    With a hammer, tap the pushrod until the shoulder (5) of the pushrod comes into contact with the plate (3).

  • ENGINEOverhauling the engine 10

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    Orientation of the piston cooling jets (see diagram below).

    A: Orientation of the jets of cylinders 2 and 4B: Orientation of the jets of cylinders 1 and 3

    Clean: the cylinder block, the crankshaft by passing a wire through the

    lubrication channels.

    Method for refitting the heat exchanger

    Remove the cylinder block from engine stand Mot. 792-03.

    Replace the seal (1) of the exchanger, positioning the lip (2) of the seal behind the lugs (3) of the exchanger.

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    Proceed as follows to ensure the exchanger is correctly refitted.

    Refit the inlet pipe of the water pump, securing using the bolt (4).

    Fit the exchanger (with its coolant pipes) on the cylinder block using the connector (5) without locking the connector.

    Insert the two coolant hoses (6) onto the ends of the coolant pipe.

    Hold the exchanger by hand whilst tightening the connector (5) to a torque of 4.5 daN.m.

    Remove the water pump inlet pipe.

    Refit the cylinder block on engine stand Mot. 792-03.

  • ENGINEOverhauling the engine 10K9ALL TYPES

    Fit the oil filter support (complete with a new seal (7)), positioning the lug (8) in the hole (9) of the exchanger. Then tighten the bolt (10) fitted with new seals, to a torque of 4.5 daN.m.

    EXTRACTING THE GUDGEON PINS

    N.B.: it is imperative to mark the connecting rod to match it to its piston, because the piston height classes in the same engine may be different (see Technical Specifications section).

    To extract the gudgeon pin, remove the spring ring using a screwdriver, then release the pin.

    10-69

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    FITTING THE CON ROD BEARING SHELLS

    The bearing shells are fitted using Mot. 1492 and Mot. 1492-03.

    On the con rod body

    Slide the bearing shell support (1) of Mot. 1492-03 (positioning the engraved mark (3) "A" as shown on the diagram below) into the groove (2) of the base of Mot. 1492.

    Fit the guide (4) of Mot. 1492-03 onto the base (as shown in the diagram).

  • ENGINEOverhauling the engine 10

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    Lay the body of the con rod on the base of the tool (as shown in the diagram). Check that the lower part (5) of the small end is touching the centring pin and push the guide (7) in the direction of the arrow.

    Lay the bearing shell (with a width of 20.625 mm) (6) on the bearing shell support, then push it in the direction of the arrow (as shown on the diagram).

    Bring the shell support up against the base of the con rod body.

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

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    On the con rod cap

    Position the bearing shell support either on: the engraved mark (3) "A" if the width of the bearing

    shell is equal to 20.625 mm, the engraved mark (4) "B" if the width of the bearing

    shell is equal to 17.625 mm,

    Fit the con rod cap as shown in the diagram.

    Push the guide (in the direction of the arrow) until the con rod cap is in contact with the pins (9) on the base of the tool.

    Fit the shell (8) on the shell support, then push it in the direction of the arrow (as shown in the diagram).

  • ENGINEOverhauling the engine 10

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    K9ALL TYPES

    Bring the shell support up against the base of the con rod cap.

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

    REFITTING THE BOTTOM ENGINE

    Fitting the crankshaft bearing shells

    Direction of fitting.

    Position the grooved bearing shells on the cylinder block.

    Fit the smooth bearing shells on the bearings.

  • ENGINEOverhauling the engine 10

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    On the cylinder block

    Position tool Mot. 1493-01 on the cylinder block.

    Fit the bearing shell in Mot. 1493-01, then press at (A) until the bearing shell is touching at (B) with Mot. 1493-01.

    On the bearings

    Position Mot. 1493-01 on the bearing.

    Fit the bearing shell in Mot. 1493-01, then press at (A) until the bearing shell is touching at (B) with Mot. 1493-01.

  • ENGINEOverhauling the engine 10

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    Oil the crankshaft bearing shells.

    Refit: the crankshaft, the lateral shims on bearing no.3, putting the grooves

    on the crankshaft side, the crankshaft bearing caps on bearing cap no.1

    (these are numbered from 1 - 5 and these numbers should be positioned opposite the water pump). Then tighten the bolts to a torque of 2.7 daN.m plus an angle of 47 5.

    Check the lateral clearance of the crankshaft (in mm) which should be: without wear on lateral shims: 0.045 - 0.252 with wear on the lateral shims: 0.045 - 0.852

  • ENGINEOverhauling the engine 10

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    Fitting bearing number 1

    Degrease the gasket faces (of the cylinder block and bearing number 1). They should be clean, dry and free from grease (in particular, remove finger marks).

    Lay two beads (3) of Threebond silicon with a width of 1 mm on bearing no.1 of the cylinder block.

    Tighten the bolts of bearing cap no. 1 to a torque of 2.7 daN.m plus an angle of 47 5.

  • ENGINEOverhauling the engine 10

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    "CON RODS / PISTON" ASSEMBLY

    The pistons have a "" mark engraved on their heads indicating the flywheel side.

    Oil the gudgeon pin.

    Check that the gudgeon pins rotate correctly in the new piston and in the matching connecting rod.

    Direction of fitting of the con rod in relation to the piston

    Point the "" (1) engraved on the top of the piston downwards and the flat (2) of the big end as shown on the diagram below.

    Direction for fitting the circlips on the piston

    Position the opening (3) of the spring rings opposite the removal and fitting channel (4).

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    FITTING THE RINGS

    Rings set to their original adjustment must be free within their channels.

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

    Orientation of the rings in the piston

    Ensure the break in each ring is correctly oriented as shown in the diagram below.

    T = Top

    Oil the pistons.

    Fit the con rod/piston assemblies into the cylinder block using the ring (e.g.: FACOM 750 TB), being careful to fit them the right way round ("" towards the flywheel).

    Fit the con rods onto the oiled crankpins of the crankshaft.

    Fit the con rod caps, ensuring they are correctly matched.

    Tighten the big end cap bolts to a torque of 2 daNm, plus an angle of 45 6.

    Check that the big ends have the correct lateral clearance of 0.205 to 0.467 mm.

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    Checking piston protrusion

    Clean the piston head.

    Turn the crankshaft one turn in its operating direction to bring piston no.1 close to Top Dead Centre.

    Fit tool Mot. 252-01 on the piston.

    Fit tool Mot. 251-01 equipped with a gauge on support plate Mot. 252-01, and find top dead centre.

    N.B.: All measurements must be carried out along the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston.

    WARNING: the gauge follower must not be in the valve clearance.

    Check the piston protrusion which must be 0.192 0.093 mm.

    Refit: the pinking sensor to a torque of 2 daN.m, the oil pressure sensor to a torque of 2.2 daN.m, the oil pump sprocket and chain to a torque of

    2.5 daN.m.

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    NOTE: the gasket faces (cylinder block, crankshaft closure plate and water pump) must be clean, dry and free from grease (in particular, remove finger marks).

    The crankshaft closure plate is sealed with THREEBOND silicon. The bead (A) must be 1.5 - 2 mm wide and be applied in accordance with the diagram below.

    Refit: the crankshaft closure plate by:

    pre-tightening bolts 1 and 6 to a torque of 0.8 daN.m,

    tightening bolts 2, 3, 4 and 5 to a torque of 1.2 daN.m,

    tightening bolts 1 and 6 to a torque of 1.2 daN.m,

    the water pump fitted with a new seal. Put a drop of LOCTITE FRENETANCH on the bolts, then tighten them to a torque of 1.1 daN.m in the recommended order.

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    NOTE: the gasket faces (cylinder block and crankshaft closure plate) must be clean, dry and free from grease (in particular, remove finger marks).

    Apply: four beads (B) of THREEBOND silicon, with a

    diameter of 5 mm, two drops (C) of THREEBOND silicon, with a

    diameter of 7 mm at the intersection of the crankshaft closure plate and the cylinder block.

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    When refitting the oil sump, ensure that: the tabs (D) of the anti-emulsion plate are correctly

    positioned in the slots (E), the cylinder block and the oil sump are correctly

    aligned on the flywheel side, to prevent the clutch housing from being damaged when fitting the gearbox.

    Refit: the anti-emulsion plate, the oil sump, tightening the bolts as follows:

    pretighten the bolts in the recommended order of 1, 2, 3, 4, 5, 6, 7, 8 to a torque of 0.8 daN.m,

    tighten the bolts in the recommended order of 1, 2, 3, 4, 5, 6, 7, 8 to a torque of 1.5 daN.m,

    pretighten the bolts in the recommended order of 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 1, 2 to a torque of 0.8 daN.m,

    tighten the bolts in the recommended order of 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 1, 2 to a torque of 1.5 daN.m,

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    Fitting the crankshaft seal gaskets

    Crankshaft elastomer seal, timing side.

    Screw the threaded rod (13) of Mot. 1586 into the crankshaft.

    Position the spacer (14) of tool Mot. 1586 on the crankshaft.

    Fit the protector complete with the seal onto the spacer, taking care not to touch the seal.

    Fit the cover (15) and the nut (16) (putting the threaded part (17) of the nut on the side away from the engine) of tool Mot. 1586.

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    Tighten the nut until the cover touches the spacer. Remove the nut, the cover, the protector and the threaded rod.

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    Crankshaft elastomer seal, flywheel side.

    Fit tool Mot. 1585 on the crankshaft, securing it with bolts (18).

    Put the protector complete with the seal on tool Mot. 1585, being careful not to touch the seal.

    Fit the cover (19) and nut (20) (putting the threaded part (21) of the nut on the side away from the engine) of Mot. 1585.

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    Tighten the nut until the cover touches the cylinder block.

    Remove the nut, the cover, the protector and the threaded rod.

    Refit: the flywheel, tightening the new bolts to a torque of

    5 - 5.5 daN.m (blocking the flywheel using Mot. 582-01),

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    the clutch and mechanism, tightening the bolts to a torque of 0.8 daN.m.

    Remove flywheel block Mot. 582-01.

    REFITTING THE UPPER ENGINE

    Refitting the cylinder head

    Position the pistons at mid-stroke.

    Fit the cylinder head gasket using the centring dowels of the cylinder block.

    Tighten the cylinder head (see the section "Cylinder head specifications").

    NOTE: the gasket faces (cylinder head and cylinder head cover) must be clean, dry and free from grease (in particular, remove finger marks).

    Lay four beads (B) of THREEBOND silicon, with a diameter of 2 mm.

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    Refit: the cylinder head, tightening the bolts to a torque of

    1 daN.m in the recommended order,

    the turbo oil return pipe fitted with new seals, the turbo, tightening the nuts to a torque of

    2.6 daN.m, the catalytic converter bracket, the turbo oil supply pipe,

    Tighten: the bolts of the turbo oil return pipe to a torque of

    0.9 daN.m, the nut and the bolt of the turbo oil supply pipe to a

    torque of 2.3 daN.m.

    Refit: the oil vapour rebreathing pipe, the new turbo air ducts,

    the air filter unit.

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    Refit: the inner timing cover, the timing tension wheel.

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    Timing adjustment

    IMPORTANT: it is essential to degrease the end of the crankshaft, the bore of the crankshaft sprocket and the bearing faces of the accessories pulley to prevent any slip between the timing and the crankshaft which would risk destroying the engine.

    Ensure that the peg (7) of the tension wheel is correctly positioned in the groove (8).

    Insert pin Mot. 1430 in the camshaft and cylinder head pulley holes.

    Check that: the mark on the high pressure

    pump pulley (9) is opposite the bolt head (10),

    the crankshaft is touching the Top Dead Centre pin Mot. 1489 (the crankshaft groove (11) must be facing upwards).

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    Fit the timing belt, aligning the marks on the belt with those on the camshaft and high pressure pump sprockets (19 teeth spaces on the belt between the marks on the camshaft and pump sprockets).

    Using a 6 mm Allen key, move the movable index (1) of the tension wheel into the position shown below, by turning the key anticlockwise.

    Tighten the tension wheel bolts to a torque of 2.5 daNm.

    Refit the crankshaft accessories pulley, tightening the bolt to a torque of 2 daNm, then angle tighten to 130 15 (crankshaft touching the Top Dead Centre pin).

    Remove the Top Dead Centre pin Mot. 1489 and the camshaft pulley timing pin Mot. 1430.

    Turn the crankshaft two full turns in a clockwise direction (timing side). Just before the hole (4) of the camshaft pulley is opposite the cylinder head hole (5), screw pin Mot. 1489 into the cylinder block. Then move the crankshaft slowly and without jolting it until it is resting on the pin.

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    Check that pin Mot. 1430 is correctly inserted in the holes of the camshaft and cylinder head pulleys and that there are 19 teeth spaces between the marks on the camshaft (3) and the high pressure pump (4) sprockets.

    Remove the Top Dead Centre pin Mot. 1489 and the camshaft pulley timing pin Mot. 1430.

    Undo the tension wheel bolt by a maximum of one turn while holding it using a 6 mm Allen key, then gradually bring the movable index (1) (by turning the key clockwise) to the centre of the timing window (2) and tighten the nut to a torque of 2.5 daNm.

    Refit the cap of the Top Dead Centre pin, applying RHODORSEAL 5661 to the thread and tightening to a torque of 2 daNm.

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    Refit: the cylinder head suspended

    mounting, tightening the bolts to a torque of 2.1 daNm,

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    the lower timing cover by positioning the tab (1) into the hole (2) on the inner timing cover,

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    the upper timing cover.

    Remove the engine from the engine stand Mot. 792-03.

    Refit: the coolant pipe, tightening the

    bolt to a torque of 2.2 daN.m, the two heat exchanger pipes,

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    the multifunction support, tightening the bolts to a torque of 4 daN.m,

    the alternator, tightening the bolts to a torque of 2.1 daNm,

    the air conditioning compressor, tightening the bolts to a torque of 2.1 daN.m,

    the power-assisted steering pump or the washer which replaces the pulley (if the engine has one), tightening the bolts to a torque of 2.1 daN.m,

    the accessories belt.

    NOTE: the accessories belt has five teeth as opposed to the pulleys which have six. It is therefore essential to ensure that tooth "E" remains free when fitting the belt.

    Version with air conditioning.

    NOTE: the engine must be turned through two revolutions in order to position the belt correctly.

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    Version without air conditioning.

    The belt is tensioned using tool Mot. 1638 (with the two mounting bolts of the tensioner undone).

    The tension value is 233 5 Hz.

    A: Crankshaft: B: Power-assisted steering pumpC: AlternatorT: Tension wheel: : Tension checking point

    NOTE: the engine must be turned through two revolutions in order to position the belt correctly.

    Contents10-ENGINECleanness & SafetyForewordEngine identificationTightening torques (in daNm or degrees)SpecificationsStandard replacementEssential special toolingEssential equipmentOverhauling the engine