workshop service manual for proton savvy or renault
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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
"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."
FEBRUARY 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.
Introduction 10-1Engine identification 10-2Tightening torques (in daNm or degrees) 10-3Specifications
Cylinder head 10-5 Camshaft 10-11Pistons 10-12Cylinder block barrel sizes 10-13Piston rings 10-14Con rods 10-15Crankshaft 10-16Bearing shells 10-16Preparing the engine to be set on the support 10-18Consumables 10-20
Standard exchange 10-21Essential special tooling 10-22Essential equipment 10-25Overhauling the engine
Removing the upper engine 10-26Stripping the cylinder head 10-29Cleaning 10-33Checking the mating surfaces 10-33Checking the camshaft end play 10-33Rebuilding the cylinder head 10-34Assessment and repair of rocker arm rails 10-38 Removing the lower engine 10-44Extracting the gudgeon pins 10-49Fitting the con rod bearing shells 10-49Assembling the con rods - pistons 10-52Fitting the piston rings 10-55Refitting the lower engine 10-56Replacing the oil filter 10-62Refitting the upper engine 10-63Tensioning the accessories belts 10-69
ENGINE AND PERIPHERALSForeword 10110ENGINE AND PERIPHERALSForeword
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 barReminder: 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
ENGINE AND PERIPHERALSEngine identification 10
10-2
Engine identification
The engine identification is stamped on the cylinder block.
It displays:A : the engine typeB : the engine approval letterD : the Renault identification numberE : the engine suffixF : the engine production number G : the engine factory number
Engine IndexCompression
ratioBore (mm)
Stroke (mm)
Capacity (cm3)
D4D 700 9.8/1 69 66.8 999
D4F702 704 712
9.8/1 69 76.8 1149
ENGINE AND PERIPHERALSTightening torques (in daNm or degrees) 10
10-3
Tightening torques (in daNm or degrees)
UPPER ENGINE
* 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.
Description Tightening torques
Cylinder head bolts
Coolant temperature sensor
Cylinder head coolant output unit
Rocker arm rail
Timing gear tension wheel
Camshaft pulley
Spark plugs
Cylinder head cover
Lower and intermediate timing covers
Upper timing cover
Exhaust manifold
Exhaust manifold heat shield
Ignition coil
Inlet manifold
Air filter unit bolt
*
1.5
0.9
**
2.4
3 plus an angle of 45˚±6˚
2.4
1.2
1.2
3.3
2.5
1.5
0.7
***
1
ENGINE AND PERIPHERALSTightening torques (in daNm or degrees) 10
10-4
LOWER ENGINE
Description Tightening torques
Pinking sensor
Oil level sensor
Crankshaft bearing bolts
Con rod cap bolts
Oil pump
Coolant pump
Crankshaft closure housing (flywheel side)
Strainer
Sump
Flywheel
Clutch
Accessories crankshaft pulley
Alternator mounting
Air conditioning compressor mounting
Power steering pump mounting
Air conditioning compressor
Alternator
Upper bolt
Lower bolt
Power steering pump
Oil filter
2
3.8
2 plus an angle of 76˚ ± 6˚
1.4 plus an angle of 39˚ ± 6˚
0.9
0.9
0.9
0.9
1
1.8 plus an angle of 110˚±6˚
2
4 plus an angle of 70˚± 6˚
5
5
2.5
5
2.5
5
2.2
2
ENGINE AND PERIPHERALSSpecifications 10
10-5
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.
ENGINE AND PERIPHERALSSpecifications 10
10-6
Thickness of the cylinder head gasket
The thickness of the cylinder head gasket is measured at (A):– thickness of the gasket when tightened:
0.49 ± 0.04 mm.
Firing order:1 - 3 - 4 - 2
Cylinder head height
H = 99 mm
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
ENGINE AND PERIPHERALSSpecifications 10
10-7
Valves
Mating surface angle
Inlet and exhaust: 90˚
Head diameter (in mm)
Inlet: 26 ± 0.12Exhaust: 22.1 ± 0.12
Valve length (in mm)
Inlet: 110.54 to 110.99Exhaust: 112.27 to 112.72
Max. valve lift (in mm)
Inlet: 8.849Exhaust: 8.850
Valve clearance settings (in mm)
Inlet: 0.05 to 0.12Exhaust: 0.15 to 0.22
Valve seats
Seat angle (∝ )
Inlet and exhaust: 89˚ 30'
Mating surface width X (in mm)
Inlet: 0.994 ± 0.403Exhaust: 1.136 ± 0.377
External seat diameter (D) (in mm)
Inlet: 27.995 to 28.005Exhaust: 23.995 to 24.005
Stem diameter (in mm)
Inlet: 5.48 0- 0.015
Exhaust: 5.47 0- 0.015
ENGINE AND PERIPHERALSSpecifications 10
10-8
Valve guides
Length (in mm)
Inlet and exhaust: 40.15 ± 0.15
Guide external diameter (in mm)
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.
The valve stem seals must be fitted using tool Mot. 1511 or the FACOM tool part number DMJ4, for example.
NOTE: do not lubricate the valve stem seals before fitting them.
Inlet and exhaust: 11 + 0.068+ 0.05
Guide internal diameter (in mm)
Inlet and exhaust
Non machined: 5 + 0.075 0
Machined*: 5.5+ 0.018 0
* This dimension is measured with the guide fitted inthe cylinder head.
ENGINE AND PERIPHERALSSpecifications 10
10-9
Angle of the inlet and exhaust guides (in degrees)
Inlet: A = 27Exhaust: E = 21
Position of the inlet and exhaust valve guides (in mm)
Inlet and exhaust: B = 10.3 ± 0.15
ENGINE AND PERIPHERALSSpecifications 10
10-10
Valve springs
The valve has a conical spring.
Unloaded length (in mm): 40.20
Loaded length (in mm):14.5 daN±8 3442.8 daN±20 25.15
Meeting spires (in mm): 23.50
Diameter of wire (in mm): 3.10±0.03
Internal diameter (in mm):Upper 14.10±0.2 Lower 16.80±0.2
External diameter (in mm) :Upper 20.30±0.2 Lower 23±0.2
ENGINE AND PERIPHERALSSpecifications 10
10-11
Camshaft
End play (in mm): 0.08 to 0.178
Number of bearings: 5
Diameter of the cylinder head camshaft bearings (in mm)
Diameter of the camshaft bearings (in mm)
Graph showing timing with a calculated clearance of zero (cannot be checked)
1 Cylinder block top dead centre fixed mark.2 Flywheel top dead centre mobile mark.3 Flywheel bottom dead centre mobile mark.4 Inlet opening delay.5 Exhaust closing advance.6 Inlet closing delay.7 Exhaust opening advance.8 Engine operating direction (flywheel end).
Flywheel side
1
25.05±0.012
3
4
5 28.05±0.01
Timing side
Flywheel side
1
24.98±0.012
3
4
5 27.98±0.01
Timing side
* 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.
ENGINE AND PERIPHERALSSpecifications 10
10-12
PISTONS
Fitting the gudgeon pin in the con rod and in the piston.
These engines are fitted with Mahle pistons.
Piston marking
D4F engine
D4D engine
1 Direction of fitting of Λ piston, flywheel side2 Piston diameter grade (A - B)3 Used by the supplier only4 Used by the supplier only5 Piston symmetry axis6 Gudgeon pin hole axis7 Offset between the pin hole (6) and the piston
symmetry axis (5) is 0.8 mm
ENGINE AND PERIPHERALSSpecifications 10
10-13
Measuring the piston diameter
The piston diameter is measured at these heights (in mm).
CYLINDER BLOCK BARREL SIZES
IMPORTANT: the diameters of the pistons and the barrels must be matched on the cylinder block. Thus,
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.
Piston diameter marking in relation to cylinder block diameter
D4D engine
D4F engine
D4D engine D4F engine
E 10 9
Position of holes T on the cylinder
block
Grade mark-ing on
the pis-tons
Piston diameter
(mm)
Barrel diameter
(mm)
1 = 5 mm A 68.956±0.006 69 ±0.015
2 = 9 mm B 68.964±0.006 69.015±0.015
Position of holes T on the cylinder
block
Grade mark-ing on
the pis-tons
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
ENGINE AND PERIPHERALSSpecifications 10
10-14
PISTON RINGS
Thickness of piston rings
Three rings (thickness in mm)
– compression ring 1.175 to 1.19
– sealing ring 1.475 to 1.49
– oil scraper ring 2.31 to 2.46 which consists of three parts:● two steel rails (1),● a spring ring (2).
Fitting the rings
Rings set to their original adjustment must be able to move freely in their channels.
Ensure the rings are fitted the correct way round with the TOP pointing upwards.
Oil and the piston rings and divide into three.
Piston ring brake clearance
RingsClearance 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 PERIPHERALSSpecifications 10
10-15
Gudgeon pin (in mm)
The gudgeon pin is fitted with an inner collar (1).
The gudgeon pins (E) are fitted with ring B19, centre tool C19 and fitting shaft A19 (Mot. 574-25).
NOTE: the small end does not have a ring.
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.
The maximum weight difference for the con rod, piston and gudgeon pin assemblies for the same engine must be 11 grams.
Length: 54 0- 0.2
External diameter (A): 17.495 to 17.499
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
CON RODS
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) 122±0.03
Diameter of the big end (in mm) 43.639+ 0.11 0
Diameter of the little end (in mm) 17.5- 0.021- 0.039
ENGINE AND PERIPHERALSSpecifications 10
10-16
Direction of fitting of the con rod in relation to the piston
Point the V (1) on the piston downwards and the index (2) of the con rod as shown in the diagram below.
The crankshaft stroke is:
The lateral shims are located on bearing no. 3.
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. 1493-02.
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
D4D engine D4F engine
Crankshaft stroke (mm)
66.8±0.05 76.8±0.05
ENGINE AND PERIPHERALSSpecifications 10
10-17
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,
– on the bearing caps, fit non grooved bearing shells.
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.
ENGINE AND PERIPHERALSSpecifications 10
10-18
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 alternator belt by unscrewing the two bolts (3),
– the air conditioning compressor and the alternator,
ENGINE AND PERIPHERALSSpecifications 10
10-19
– 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 mmY = 15 mm
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).
ENGINE AND PERIPHERALSSpecifications 10
10-20
CONSUMABLES
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.
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).
ENGINE AND PERIPHERALSEssential special tooling 10Essential special tooling
Illustration Part numberPart Stores
NumberDescription
Mot. 574-25 00 00 057 425Gudgeon pin fitting tool (centre tool C19, shaft A19, and ring B19)
Mot. 1605 00 00 160 500 Tool for fitting cylinder head adjuster
ENGINE AND PERIPHERALSEssential equipment 10
10-25
Essential equipment
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-26
Overhauling the engine
REMOVING THE UPPER ENGINE
Fit the flywheel block Mot. 582-01.
Remove:– the upper timing housing (1),– the crankshaft accessories pulley (2),– the intermediate timing cover (3),
– the lower timing cover (4).
Remove the flywheel block Mot. 582-01.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-27
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.
Insert the TDC setting pin Mot. 1054, then turn the crankshaft until it is pinned.
Check that the mark (7) on the camshaft pulley is on the vertical shaft of the engine.
Unscrew the nut (8) on the timing gear tension wheel, then remove the timing belt.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-28
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.
Disengage the electric wiring harness from the inlet manifold.
Remove:– the cylinder head cover,
– the cylinder head bolts,– the cylinder head.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-29
STRIPPING THE CYLINDER HEAD
Place the cylinder head on cylinder head support Mot. 1573.
Remove:– the exhaust heat shield,
– the exhaust manifold,– the fuel pipe retaining brackets (1),
– the camshaft pulley,– the timing gear tension wheel,
– the camshaft seal gasket by screwing the puller tool Mot. 1381 into the seal gasket.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-30
Remove the seal gasket by screwing the bolt (1) on tool Mot. 1381.
Remove:– the lifting rings,– the cylinder head coolant output unit,– the camshaft adjuster,
– the rocker arm rails by removing the bolts (2).
Mark the camshaft bearing caps with a permanent marker pen.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-31
Remove:– the camshaft bearing caps,
– the camshaft,
– the valve springs using tool Mot. 1502.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-32
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-33
CLEANING
It is very important not to scratch the mating surfaces of any aluminium components.
Wear gloves whilst carrying out this operation.
Use the Décapjoint product to dissolve any part of the gasket which remains attached.
Apply the product to the parts to be cleaned; wait about ten minutes, then remove it using a wooden spatula.
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 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.
CHECKING THE CAMSHAFT END PLAY
Refit:– the camshaft,– the camshaft bearing caps,– the rocker arm shafts.
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.
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 bolts (4), (5), (6), (7), (8), (9), (10), (11) and (12).
ENGINE AND PERIPHERALSOverhauling the engine 10
10-34
Check the end play, which must be between 0.08 and 0.178 mm.
Remove the rocker arm shafts, the camshaft bearing caps and the camshaft.
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.
NOTE: do not lubricate the valve stem seals before fitting them.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-35
Fitting new valve stem seals
Place the valve in the cylinder head.
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).
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-36
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.
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-37
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-38
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-39
Grease the camshaft bearings with engine oil.
Refit the camshaft.
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.
Refit:– the camshaft bearing caps by tightening the bolts (1)
and (2) to a torque of 0.9 daNm.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-40
– 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.
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-41
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.
Screw the threaded rod (3) from tool Mot. 1587 into the camshaft.
Fit the seal gasket and protector on the camshaft. Be careful not to touch the seal.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-42
Fit the canister (4) and the collar nut (5) from Mot. 1587.
Screw the collar nut until the canister touches the cylinder head.
Remove the nut, the canister, the protector and the threaded rod.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-43
Refit:– the camshaft pulley by tightening the bolts to a torque
of 3 daNm plus an angle of 45˚±6˚,
– the tension wheel by positioning it correctly.
Fit the tension wheel notch (5) into the cylinder wheel rib (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 exhaust heat shield by tightening the bolts to a torque of 1.5 daNm.
ENGINE AND PERIPHERALSOverhauling the engine 10
Setting the valve clearances
Valve clearance setting values (in mm)
– inlet 0.05 to 0.12– exhaust 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. Exhaust valve to be adjusted.
10-44
ENGINE AND PERIPHERALSOverhauling the engine 10
10-45
REMOVING THE LOWER ENGINE
Fit flywheel block Mot. 582-01.
Remove:– the clutch,
– the flywheel,
– the sump,
– the crankshaft seal gasket on the flywheel side by screwing puller tool Mot. 1377 into the seal gasket.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-46
Remove the seal by screwing the bolt (1) of tool Mot. 1377.
Remove:– the crankshaft seal supporting ring,
– the oil pump seal gasket by screwing puller tool Mot. 1374 into the seal gasket.
Remove the seal gasket by screwing the bolt (2) of tool Mot. 1374.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-47
Remove:– the strainer and its seal,– the oil pump (the oil pump cannot be repaired),
– the coolant pump,
– the oil pressure supply seal.
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.
ENGINE AND PERIPHERALSOverhauling the engine 10
10-48
Remove:– the bearing caps and the con rod/piston assemblies.
– the crankshaft bearing caps,
– the crankshaft bearing shells,
Clean:– the cylinder block,– the oil pump,– the coolant pump,– the crankshaft,– the seal supporting ring,
ENGINE AND PERIPHERALSOverhauling the engine 10
10-49
EXTRACTING THE GUDGEON PINS
Remove the piston rings.
Place the piston on the V of the support, the shaft aligned with the removal hole.
Drive out the gudgeon pin on the press with the extraction mandrel (E).
FITTING THE CON ROD SHELLS
The con rod bearing shells are fitted using Mot. 1492 and Mot. 1492-04.
On the con rod body
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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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).
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.
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.
Remove the con rod body support and repeat the operation for the remaining con rod bodies.
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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.
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.
Remove the con rod cap support and repeat the operation for the remaining con rod caps.
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ASSEMBLING THE CON RODS - PISTONS
Preparing the piston/gudgeon pins assembly
The parts supplied in the set are identical.
Mark the parts in each box from A to D to ensure they remain identical.
Completely dissolve the non-stick film without scratching the parts.
Fitting the gudgeon pins
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).
A : fitting pins with centrers (C).
B : piston supporting rings,
M : extraction mandrel,
S : piston support base,
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Preparing the con rods
Visually inspect the condition of the con rod (piercings/level),
Use a 1500 W heating plate.
Place the small ends on the heating plate.
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.
Preparing the gudgeon pins
Check that the gudgeon pins rotate properly in the corresponding new pistons.
Use tool Mot. 574-25 containing centre tool C19 and pin fitter A19.
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.
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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).
Follow these instructions when assembling the piston and con rod:
● 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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The following operations should be performed as quickly as possible to keep heat loss at a minimum.
When the solder reaches welding point (becomes liquid):
– 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 .
FITTING THE RINGS
Rings set to their original adjustment must be able to move freely within their channels.
Ensure that the rings are fitted the correct way round as shown in the diagram.
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REFITTING THE LOWER ENGINE
Fitting the bearing shells in the cylinder block.
Position tool Mot. 1493-02 on the cylinder block.
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
Fitting the bearing shells on the bearings.
Position Mot. 1493-02 on the bearing.
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).
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Refit the crankshaft.
Grease the crankpins and bushings with engine oil.
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˚.
Check the crankshaft clearance which should be between 0.045 and 0.235 mm.
Check that the crankshaft rotates freely.
Refit the con rod/piston assemblies using the fitting ring.
Fit the con rod caps, ensuring that they are correctly matched (use the marks made on removal).
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Refit the con rod caps by tightening the bolts to a torque of 1.4 daNm plus an angle of 39˚±6˚.
Check the lateral clearance of the big end which should be between 0.21 and 0.453 mm.
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.
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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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.
Tighten the coolant pump bolts to a torque of 0.9 daNm in the recommended order.
Systematically replace the oil pressure supply seal (3).
IMPORTANT: the oil pump is driven by two studs located on the crankshaft.
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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Tighten the oil pump bolts to a torque of 0.9 daNm in the recommended order.
Fitting the crankshaft seal gaskets
– flywheel side, use tool Mot. 1354.
– oil pump side, use tool Mot. 1355.
Replace the strainer fitted with a new O-ring by tightening the bolts to a torque of 0.9 daNm.
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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 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).
– the clutch, tightening the bolts to a torque of 2 daNm.
Remove flywheel block Mot. 582-01.
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Replacing the oil filter
The two seal gaskets (2) must be replaced when the oil filter (1) is replaced.
Hold the filter upside down and tap it on a piece of wood to remove the filter element.
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.
Tighten the coolant pipe bolts to a torque of 0.9 daNm.
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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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Refit the spark plug well seals using a socket with an external diameter of 41 mm (32 mm socket for example).
Check that the wiring harness is correctly positioned at (1) and (2) before refitting the inlet manifold.
Replace the inlet manifold seals and the oil vapour seal.
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.
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Tighten the four upper bolts in a cross on the inlet manifold to a torque of 1 daNm.
Adjusting the timing
Check:– that the tension wheel notch (5) is correctly
positioned in the cylinder wheel rib (6).
– that the TDC pin Mot. 1054 is in place,
– that the crankshaft timing sprocket mark (7) is facing the oil pump body mark (8).
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– that the camshaft pulley mark (9) is facing the cylinder head cover mark (10).
Tighten the crankshaft accessories pulley bolt fitted with its washer to a torque of 1.5 daNm, to hold the timing sprocket in place.
Fit the timing belt by aligning the belt markings with those on the camshaft and crankshaft sprockets.
Remove the TDC setting pin Mot. 1054.
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 tension wheel nut to a torque of 2.4 daNm.
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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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.
NOTE: it is vital that you tighten the tension wheel nut to torque to avoid any loosening which may cause damage to the engine.
Fit the flywheel block Mot. 582-01.
Remove the accessory crankshaft pulley bolt.
Refit:– the lower timing cover,
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– 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˚.
Remove the flywheel block Mot. 582-01.
Remove the engine from support Mot. 792-03.
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,
– 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.
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Tensioning the accessory belts
measure the tension of the accessory belts with tool Mot. 1505.
Alternator belt
Air conditioning and power assisted steering belt
Power assisted steering belt
Air conditioning belt
ABCDGT
CrankshaftAlternatorPower assisted steering pumpAir conditioning compressorTensionWheelPoint for checking belt tension