Page 1
Workshop repair manual
ENGINE (Diesel)
Indirect injection
Aluminium, 4 cylinders
Types Vehicles
Renault 18
852
Fuego
77 11 293 322
J8S
Renault 20
Renault 21
Renault 25
Renault 30
Safrane
Espace
Trafic
Master
Jeep
Cancels and replaces note dated JULY 1991
DECEMBER 2000
EDITION ANGLAISE
"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."
© RENAULT 2000
All copyrights reserved by Renault.
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.
Page 2
Contents
ENGINE AND PERIPHERALS
10
Page
Foreword
Diagram
Engine identification
Tightening torques (in daNm)
Lubrication circuit diagram
Specifications
Standard replacement
Special tooling required
Essential equipment
Cylinder head exploded drawing
Overhauling the engine
Removing top engine
Stripping the cylinder head
Cleaning
Checking the gasket face
Redressing the valve seats
Assessment and repair of rocker arm rails
Rebuilding the cylinder head
Cylinder block exploded drawing
Removing bottom engine
Extracting the con rod -pistons
Refitting bottom engine
Refitting and assembling con rod and pistons
Fitting the rings
Checking cylinder liner protrusion
Refitting cylinder liner - pistons - con rods
Checking piston protrusion
Refitting top engine
Tensioning procedure
Notes on fitting accessory belts
10-1
10-2
10-4
10-7
10-14
10-16
10-38
10-39
10-44
10-45
10-46
10-51
10-54
10-54
10-55
10-56
10-57
10-65
10-66
10-74
10-75
10-84
10-85
10-85
10-86
10-89
10-98
10-108
10-114
Page 3
ENGINE AND PERIPHERALS
ENGINE AND PERIPHERALS
110
Foreword
Foreword
USING THE MANUAL
There are two main sections in this manual:
– technical specifications,
– overhauling the engine.
To repair the component on the vehicle, refer to the
Workshop Repair Manual and Technical Notes for
the vehicle.
UNITS OF MEASUREMENT
– All dimensions are given in millimetres (mm)
(except where stated otherwise).
– Tightening torques are expressed in
decaNewtonmetres (daNm).
Reminder: 1 daNm = 1.02 m.kg.
– Pressures in bar
Reminder: 1 bar = 100 000 Pa.
10
TOLERANCES
Tightening torques given without a tolerance must be
accurate to within:
– in degrees (± 3˚).
– in daNm (± 10 %).
10-1
Page 4
ENGINE AND PERIPHERALS
J8S TURBO ENGINE
Diagram
Diagram
10
10-2
Page 5
ENGINE AND PERIPHERALS
J8S AND 852 ENGINES
Diagram
10
10-3
Page 6
ENGINE AND PERIPHERALS
Engine identification
Engine identification
The engine is identified by a plate riveted onto the
cylinder block.
10
It includes:
A: the engine type
B: the engine approval letter
C: the manufacturer code
D: the engine index
E: the engine fabrication number
F: the engine assembly works
10-4
Page 7
ENGINE AND PERIPHERALS
Engine identification
Engine Index Type
852
J8S
700
710
720
750
240
330
600
604
620
622
704
708
714
738
742
746
758
774
786
788
1276
1344, 2354, 1354
Pxx3
Txx3
Vxx3
J115, S115
Rxx3
X480
X48A
PxxF
TxxK
X486
B290
X488
B29W
X488
X486, X48W
TxxF
J114
X487
X48P
Compression
ratio
21/1 86 89 2068
Bore
(in mm)
Stroke
(mm)
10
Capacity
(in cm
3
)
10-5
Page 8
ENGINE AND PERIPHERALS
Engine identification
Engine Index Type
J63D, S63D
J63E
1270
B296
1344 TA, 1354TA
1346, 1356, 1366
B296
X48, 6, V, V 4x4
B546
J635, S635
J634
J633
X480
CJ
XJ
J8S
J8S
610
612
702
706
711
712
736
740
760
772
776
778
784
800
814
Compression
ratio
21.5/1 86 89 2068
21.5/1 86 89 2068
Bore
(in mm)
Stroke
(in mm)
10
Capacity
(in cm
3
)
10-6
Page 9
ENGINE AND PERIPHERALS
Tightening torques (in daNm)
Tightening torques (in daNm)
10
A 0.5 to 0,9
B 2.5 to 3
C 1.3 to 1.8
D 2
E 6 to 6.5
F 13
G 2.5
H 1.3
J 5
K 1.25
10-7
Page 10
ENGINE AND PERIPHERALS
Tightening torques (in daNm)
CYLINDER BLOCK
10
A 2
B 2
C 2.5
* Preheating shunt nut connector: 0.25 daNm
** Aluminium sump : 1.4 to 1.7 daNm
Metal sump : 1.25 daNm
10-8
Page 11
ENGINE AND PERIPHERALS
Tightening torques (in daNm)
10
A 3.2 to 3.9
B 2
C 1.3
D 1.4
* Turbo:
IHI : 4.5 daNm
Garrett : 2.6 daNm
10-9
Page 12
ENGINE AND PERIPHERALS
Tightening torques (in daNm)
10
A 5
B 5
C 2.25 to 2.75
D 5
E 13
F 2.5
G 1.3
* Turbo:
IHI : 4.5 daNm
Garrett : 2.6 daNm
10-10
Page 13
ENGINE AND PERIPHERALS
Tightening torques (in daNm)
10
A 2
B 4
C 5 to 5.5
10-11
Page 14
ENGINE AND PERIPHERALS
A 7
B 2.3
C 6.5±0.25
D 8.75 to 9.75
E 1.3
F 4 to 4.5
Tightening torques (in daNm)
10
* Spark plug M12 tighten to 2 daNm
Spark plug M10 tighten to 1.6 daNm
st
** 1
*** Seethe cylinder head tightening procedure page 10-16
model:
– coolant pipe : 0.8 to 1 daNm
– coolant rail : 2 to 2.5 daNm
nd
model:
2
– cooling jets only : 1.2 to 1.4 daNm
10-12
Page 15
ENGINE AND PERIPHERALS
Tightening torques (in daNm)
10
A 3.2 to 3.9
B 8.75 to 9.75
C 2.5 to 3
D 3
E 2.3
* Turbo:
IHI : 4.5 daNm
Garrett : 2.6 daNm
10-13
Page 16
ENGINE AND PERIPHERALS
Key:
All types
Turbo with radiator
Turbo with heat
exchanger
1 returning cooling jets
2 integrated cooling jets
3 integrated cooling jets
st
1
nd
2
fitting
fitting
Lubrication circuit diagram
Lubrication circuit diagram
10
10-14
Page 17
ENGINE AND PERIPHERALS
Lubrication circuit diagram
10
10-15
Page 18
ENGINE AND PERIPHERALS
Specifications
Specifications
CYLINDER HEAD
Tightening procedure
All the cylinder head bolts must always be
changed after removal (including the mounting
studs).
Lubricate the threads and under the bolt heads
with engine oil.
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.
J8S transverse engine
Carry out the following in the order prescribed:
10
Unscrew bolt 1 until it is completely free, and then
carry out:
st
1
retightening 2 daNm
nd
retightening (angle) according to the table:
2
Symbol
1
2
3
4
5
6
7
8
9
Angle
(in degrees)
105
60
60
80
70
60
60
105
105
Symbol
10
11
12
13
14
15
16
17
Angle
(in degrees)
60
60
80
70
60
60
90
80
st
tightening : 3 daNm
1
nd
2
tightening : 5 daNm
Wait 3 minutes settling time.
83174S2
Repeat the above operation for all the bolts.
nd
retightening (angle) according to the table:
3
Symbol
1
2
3
4
5
6
7
8
9
There is no cylinder head retightening operation.
Angle
(in degrees)
105
60
60
80
70
60
60
105
105
Symbol
10
11
12
13
14
15
16
17
Angle
(in degrees)
60
60
80
70
60
60
90
80
10-16
Page 19
ENGINE AND PERIPHERALS
J8S longitudinal engine
Carry out the following in the order prescribed:
st
tightening : 3 daNm
1
nd
tightening: 5 daNm
2
Specifications
Unscrew bolt 1 until it is completely free, and then
carry out:
st
retightening 2 daNm
1
nd
retightening (angle) according to the table:
2
Symbol
1
2
3
4
5
6
7
8
9
Angle
(in degrees)
105
60
60
70
70
60
60
105
105
Symbol
10
11
12
13
14
15
16
17
10
Angle
(in degrees)
60
60
70
70
60
60
80
80
Wait 3 minutes settling time.
83174S2
Repeat the operation for all the bolts.
nd
3
retightening (angle) according to the table:
Symbol
1
2
3
4
5
6
7
8
9
There is no cylinder head retightening operation.
Angle
(in degrees)
105
60
60
70
70
60
60
105
105
Symbol
10
11
12
13
14
15
16
17
Angle
(in degrees)
60
60
70
70
60
60
80
80
10-17
Page 20
ENGINE AND PERIPHERALS
Specifications
Thickness of the cylinder head gasket
There are several different thicknesses of cylinder
head gasket as replacements. When the 1 model (A)
gaskets have been used up, the Parts Store will only
deliver 2
st
1
On engines fitted with a 1
gasket (marked A on the drawing opposite), the label
showing the gasket thickness cannot be seen from the
outside. The thickness of the gasket must therefore be
calculated before each operation.
Cylinder head gasket thickness 1.6 mm:
– 1.6 is stamped on the gasket.
Cylinder head gasket thickness 1.7 mm:
– not stamped.
model
nd
model (B, C or D) gaskets.
st
model cylinder head
10
nd
2
model
nd
On engines fitted with a 2
gasket, the label showing the gasket thickness can be
seen from the outside. There is no need to recalculate
the gasket thickness if the operations performed have
not involved modifying the piston protrusion
dimension.
B - Cylinder head gasket thickness 1.6 mm:
marked with a hole
C - Cylinder head gasket thickness 1.7 mm:
no hole
D - Cylinder head gasket thickness 1.8 mm:
marked with two holes
model cylinder head
Cylinder head gasket thickness 1.8 mm:
– 1.8 is stamped on the gasket.
16621R
NOTE: if replacing:
– the crankshaft,
– the cylinder block,
– the con rods,
– the pistons,
it is essential to calculate the thickness of the
cylinder head gasket.
10-18
Page 21
ENGINE AND PERIPHERALS
Cylinder head cover gasket
All types except J8S 736
st
model:
1
This gasket is not symmetrical.
Cylinder side graphitised surface.
Specifications
rd
3
model:
same position as the 2
nd
model.
10
93780R
nd
2
model:
This gasket has a an area intended to prevent
confusion; it is located opposite the timing end.
93779-1R
10-19
Page 22
ENGINE AND PERIPHERALS
Height of the cylinder head (in mm)
H = 104.5 ± 0.04
NO REDRESSING IS PERMITTED
Specifications
Channel angle
Mark (X) None.
Diameter (D) of the housing in the cylinder head
– Original dimension 1
– Original dimension 2
16721R
Original dimension 2 is exclusively for works-repaired
cylinder head dimensions.
(α)
Engine type
Normally
aspirated
35˚ 31˚
(in mm)
10
Turbo
A drill
stamp
35.5
35.7
Test the cylinder head for cracks. (refer to the mating
face checking section in the Engine overhaul
section).
Maximum mating face deformation 0.05 mm
Prechamber
Assembled prechamber
This is fitted in the cylinder head.
Protrusion in relation to cylinder head:
it should be between 0.01 and 0.04 mm.
16546R
86188-1R
10-20
Page 23
ENGINE AND PERIPHERALS
Bare prechamber
Half-prechamber
Specifications
Valve seats
Seat angles (
Inlet and exhaust: 90˚
Mating surface width X (in mm)
Inlet and exhaust: 1.75 ± 0.2
External diameter D (in mm)
Inlet: 42
Exhaust: 34.6
92448-1S
10
α
)
+ 0.13
+ 0.11
+ 0.03
+ 0.01
Valves
Stem diameter (in mm)
Inlet: 7.991
Exhaust: 7.978
Setting angle
Head diameter (in mm)
Inlet:
Exhaust:
Maximum valve lift (in mm)
Inlet:
Exhaust:
Valve set back in relation to the
cylinder head mating surface
(in mm)
40.32 ± 0.12
33.32 ± 0.12
+ 0
- 0.02
+ 0
- 0.02
90˚
73928R
See the "Overhauling the engine" section for how to
redress the valve seats.
9.27
8.80
0.80 to 1.15
Valve clearance settings (in mm)
Inlet:
Exhaust:
0.20 ± 0.02
0.25 ± 0.02
10-21
Page 24
ENGINE AND PERIPHERALS
Specifications
Valve guides
Internal diameter (in mm) 8
External diameter (in mm):
– Normal
– Repair (two grooves)
The inlet and exhaust guides have valve stem seals
which must be changed every time the valves are
removed.
The valve stem seals must be fitted using tool
Mot. 1511 or with the FACOM tool, part number
DM6J4 for example.
13.10
13.35
10
Position of the inlet and exhaust valve guides
Position of guides in relation to the cylinder head
mating face (in mm):
D = 32.5
15737R1
NOTE: do not lubricate the valve stem seals before
fitting them.
Mot. 1511 consists of:
– four cores (1),
– four pushrods (2),
– one guide tube (3),
– one sleeve (4).
83172R
The diameter of the housing is smaller
(by approximately 0.1 mm) to obtain the necessary
seal.
It is vital to drill the guide after fitting.
10-22
Page 25
ENGINE AND PERIPHERALS
Specifications
Valve springs
The inlet and exhaust valve springs are identical.
Free length (in mm): 45.2
Length under a load of (in mm):
23 daNm
60 daNm
Sealing turns (in mm): 27.2
Wire diameter (in mm): 4.25
Internal diameter (in mm): 21.5
Camshaft
39.3
29.8
10
Rocker arm rail
When performing operations on faults that cause
metallic particles to become suspended in the
lubricating oil, e.g.:
– damaged con rod bearing shells or crankshaft,
– parts grating,
it is essential to replace:
– the oil filter (A) located in the rocker arm rail shaft,
– the oil filter located on the main pipe,
– the lubricating oil.
REMINDER: The rocker arm rail filter must be
replaced if an operation requires the removal of the
rocker box cover.
All types except J8S 736 and J8S 740
Longitudinal play (in mm): 0.05 to 0.15
Number of bearings 5
Timing diagram:
– Inlet opening advance
– Inlet closing retardation
– Exhaust opening advance
– Exhaust closing retardation
With a theoretical clearance to the valve stem of
0.35 mm (All types).
Engines J8S 736 and J8S 740
Longitudinal clearance (in mm) 0.05 to 0.15
Number of bearings: 5
Timing diagram:
– Inlet opening advance
– Inlet closing retardation
– Exhaust opening advance
– Exhaust closing retardation
14˚
46˚
50˚
10˚
14˚
46˚
58˚
14˚
The value of the theoretical clearance to the valve
stems is only valid following a check on the timing
diagram and has no relation to the rocker arm
clearances.
10-23
Page 26
ENGINE AND PERIPHERALS
Specifications
PISTONS
These engines are fitted with Floquet Monopole
pistons.
The gudgeon pin is free in the con rod and in the
piston.
Piston marking
10
16576R
16576-1R
16576-2R
16576-3R
10-24
Page 27
ENGINE AND PERIPHERALS
Specifications
The paint mark that indicates diameter class is also
present on the piston.
Table of gudgeon pin heights
Classes and marks on
piston
H 50.890 to 50.930
K 50.931 to 50.970
M 50.971 to 51.010
P 51.011 to 51.050
R 51.051 to 51.090
Measuring the piston diameter
10
Shaft height
(in mm)
16577R
1 Height between the gudgeon pin and the top of the
piston (see table below).
2 Modification index, for supplier's use only.
3 For supplier's use only.
4 Dater, for supplier's use only.
5 Diameter class mark, paint mark (see following
table).
Table of piston diameter classes
Piston mark Piston diameter (in mm):
Blue 85.875 to 85.890
Red 85.890 to 85.905
The diameter of the piston (86 mm diameter) should
be measured at position:
Engine type
J8S 852
normally aspirated
J8S Turbo 24
Piston measuring
point (A) (in mm)
24.35
10-25
86928-4R1
Page 28
ENGINE AND PERIPHERALS
Rings
Three rings (thickness in mm)
Normally aspirated engine
– Compression
– Sealing
– Scraper
Turbo engine
– Compression
– Sealing
– Scraper
Gudgeon pin (in mm)
– Length:
– External diameter:
– Internal diameter:
2
2
2
2.5
2.5
4
Specifications
(tapered)
(rounded)
(trapezoidal)
(trapezoidal)
(rounded)
75
28
16
10
FITTING THE RINGS
Rings set to their original adjustment must be free
within their channels.
Ensure the fitting direction is observed.
Fit the rings so that the gaps are equally spaced
around the piston.
86187R
10-26
72552R
Page 29
ENGINE AND PERIPHERALS
Specifications
CON RODS
in mm
Lateral play in the big end 0.31 to 0.57
Centre-to-centre distance between
big end and small end
Big end diameter 60
Small end diameter
without ring 30
●
with ring 28
●
The small end has a bush.
155 ± 0.035
+ 0.019
- 0.005
+ 0.021
0
+ 0.01
+ 0.003
10
Refitting and assembling con rods and pistons
Direction of fitting:
rotochamber on the injector side or the side opposite
the oil filter.
Check that the gudgeon pins rotate properly in the new
piston and the con rod.
Oil the gudgeon pin.
Ensure that the piston and con rod are fitted the right
way around (follow the arrows):
Engines 852 J8S all types except turbo
N.B.: the small end bushes cannot be replaced or redrilled.
WARNING: do not use a sharp point to mark the
bearing caps in relation to their con rods as this could
start a crack in the rods. Use an indelible marker pen.
Normally aspirated engine
The big end and the half bearing are pierced to allow
an oil jet to pass through.
Turbo engine
The con rods do not have a hole for an oil jet. The
upper and lower bearing shells are not pierced.
Turbo engine
10-27
Page 30
ENGINE AND PERIPHERALS
Specifications
Direction for fitting the circlips on the piston
Fit the circlips on the piston as shown below.
98365S
10
CRANKSHAFT
Number of bearings 5
Burnishing
normally aspirated engine with
●
turbo engine 1st fitting without
●
turbo engine 2nd fitting with
●
in mm
Longitudinal play
normally aspirated engine
●
st
1
model: 1 to 32 909
normally aspirated engine
●
nd
2
model: from 32 910
turbo engine
●
st
1
Bushing
Nominal diameter
Repair diameter
and 2
nd
models
62.88
62.63
0.07 to 0.25
0.20 to 0.30
0.20 to 0.30
- 0
- 0.019
- 0
- 0.019
Crankpin
Nominal diameter
Repair diameter
N.B.: non-burnished crankshafts fitted on turbo
engines can be redressed using the values given in
the table.
56.296
56.046
- 0.010
- 0.029
- 0.010
- 0.029
10-28
Page 31
ENGINE AND PERIPHERALS
Specifications
Burnished crankshaft
In case of correction, the burnishing must remain intact
on 140˚ in the areas indicated by the arrows.
Identification of crankshafts:
Normally aspirated engine
eight counterweights,
●
Burnished bushings and crankpins.
●
10
88007S
These zones are defined in sections (A) and (B), used
as examples.
Turbocharged engine
four counterweights,
●
Burnished or non-burnished bushings and
●
crankpins according to model.
88006S
10-29
Page 32
ENGINE AND PERIPHERALS
Specifications
RELAY SHAFT
Longitudinal play (in mm) 0.05 to 0.15
PISTON BASE COOLING RAIL
10
CLUTCH SHAFT CENTERING BEARINGS
Gearbox:
– with bearing in the clutch housing: short clutch
shaft (A).
– without bearing in the clutch housing: long clutch
shaft (B).
86609R
Never remove the mounting bolts (H) if the sump is
not removed.
16547R
If the gearbox is fitted with a long shaft (B) it is
essential to fit a bearing in the crankshaft. In cases
where the flywheel has no stop, cement the bearing
into the crankshaft using Loctite FRENBLOC.
If the gearbox is fitted with a short shaft (A) it is
essential to remove the bearing from the crankshaft.
10-30
Page 33
ENGINE AND PERIPHERALS
Specifications
CYLINDER LINER Assembling cylinder liners - cylinder block
in mm
Internal diameter 86
Diameter of the base centering (D) 93.6
Protrusion of cylinder liner without
gasket (X)
Base seal (J) O ring.
Shaft seal (F) barrel shape
0.07 to 0.13
Height (H) of the cylinder liner
Depth (K) of cylinder block
in mm
93.035
93.065
92.945
92.985
10
to
to
10-31
75615-2G 83968
Page 34
ENGINE AND PERIPHERALS
Specifications
Identification of liners
Normally aspirated engine
st
model
1
10
nd
2
model
10-32
Page 35
ENGINE AND PERIPHERALS
Turbo engine
st
model
1
Specifications
rd
model
3
10
Cylinder liner with two notches and piston fitted cooling
oil jets.
nd
model
2
Cylinder liner with no notches and tube piston cooling
oil jets.
th
model
4
Cylinder liner with four notches and integral piston
cooling oil jets.
Special Parts store cylinder liner with four notches.
May be fitted on all types of turbo engines.
10-33
Page 36
ENGINE AND PERIPHERALS
OIL PUMP
Removal
Remove:
– the oil pump cover,
– the discharge valve and its spring.
Specifications
Clearance (B)
– minimum (in mm) 0.02
– maximum (in mm) 0.10
10
Checking clearances
Clearance (A)
– minimum (in mm) 0.05
– maximum (in mm) 0.12
86303-1R
Refit:
– the oil pump cover by tightening the bolts to a torque
of 1 daNm,
– the discharge valve and its spring.
N.B.: Pour oil into the pump (to make repriming
easier).
80142R
10-34
Page 37
ENGINE AND PERIPHERALS
Specifications
PREPARING THE ENGINE TO BE SET ON THE
STAND
Before fitting the engine to support plate Mot. 792-03,
remove the engine electrical wiring harness and drain
the engine oil and the coolant by removing the drain
plug (A).
10
Turbo engine
Remove:
– the supply and oil return pipes (D),
– the strut (B),
– the turbocharger mounting bolts (C) and the
turbocharger.
16535R
10-35
Page 38
ENGINE AND PERIPHERALS
Specifications
FITTING THE ENGINE TO SUPPORT Mot. 792-03
AND THE THREE RODS A, B AND C
Engines of all types
Remove the intake and exhaust manifolds,
The rods (A), (B) and (C) are mounted on the cylinder
block so that they fit into the holes (1, 8, 17) on the
plate.
10
90749R1
SAFETY PRECAUTIONS
Turbocharger engine
After performing an operation on the engine that
involves disconnecting the oil gallery, it is essential to
reprime the turbocharger oil circuit, ensuring that the
following conditions are respected:
– connect the oil return and attach it using a new bolted
clamp,
– fill up the turbo with engine oil through the inlet
opening (A),
– run the starter motor to reprime the turbocharger oil
circuit, until the oil begins to escape from the
turbocharger inlet opening,
– reconnect the turbocharger inlet pipe,
– run the engine at idle speed so that the circulation of
oil in the turbocharger is reestablished.
SAFETY PRECAUTIONS WHEN STOPPING THE
ENGINE
Let the engine run at idle speed for 30 seconds
and then switch off the ignition.
Do not rev the engine to avoid starting the
turbocharger. If this occurs, the turbo may run by
inertia without lubrication when the ignition is switched
off and there is a risk that the turbine shaft will grate.
10-36
Page 39
ENGINE AND PERIPHERALS
Specifications
CONSUMABLES
Type Quantity Component concerned Part no.
RAVITOL S 56 - Cleaning parts 77 01 421 513
DECAPJOINT Coat Cleaning gasket faces 77 01 405 952
RHODORSEAL 5661 Coat Crankshaft bearing cap 77 01 404 452
Loctite 518 Coat Crankshaft cover, coolant pump 77 01 421 162
Loctite FRENETANCH 1 - 2 drops - 77 01 394 070
PRECAUTIONS
WASHING THE ENGINE
Do not let the alternator come into contact with water
or cleaning products.
Do not let water run into the air intake pipes.
FITTING THREAD INSERTS
Threaded holes on all engine component parts can be
repaired by using thread inserts.
PARTS TO BE REPLACED WHEN THEY HAVE
BEEN REMOVED
– All the gaskets.
– Flywheel bolts.
– Flywheel mounting bolt stops.
– Con rod bolts.
– Rocker arm rail oil filter.
– Cylinder block cap seals if they have been removed.
– Timing sprocket split pins on the crankshaft.
– Belts.
– Timing gear tensioner.
– Cylinder head bolts
10
10-37
Page 40
ENGINE AND PERIPHERALS
Standard exchange
Standard exchange
PREPARING THE USED ENGINE FOR RETURN
The engine should be cleaned and drained (oil and
water).
Leave on the used engine or include in the return box:
– the dipstick,
– the water pump,
– the cylinder head cover,
– the heater plugs,
– the timing belt tensioner,
– the timing gear cases,
– the oil filter,
– the injection pump pulley,
– the camshaft pulley,
– the relay shaft pulley,
– the crankshaft timing pulley,
– the clutch and the engine flywheel,
– the crankshaft accessories pulley,
– the injection pump,
– the injector pipes,
– the injectors,
– the vacuum pump.
10
82638-1S
Remember to remove:
– the coolant hoses,
– the water pump pulley,
– the oil pressure switch,
– the thermostat and its mounting.
The engine being returned should be attached to the
wooden base in the same way as the service
exchange engine:
– plastic plugs and covers fitted,
– cardboard cover over the assembly.
NEW EXCHANGE ENGINE
The new engine does not have:
– a clutch mechanism,
– a clutch plate,
– a flywheel.
10-38
Page 41
ENGINE AND PERIPHERALS
Essential special tooling
Essential special tooling
Illustration Tool number
Mot. 11 00 01 072 500 Crankshaft spigot bush extractor.
Mot. 251-01 00 00 025 101
Mot. 252-01 00 00 025 201
Parts Department
number
10
Description
Dial gauge support. Used with
Mot. 252-01.
Dial gauge support thrust plate. Used
with Mot. 251-01.
Mot. 382 00 00 038 200 Valve spring compressor tool.
Mot. 445 00 00 044 500 Oil filter strap wrench.
Mot. 452 00 00 045 200
Mot. 521-01 00 00 052 101 Cylinder liner clamp.
Oil pressure contact wrench
(22 mm across flats).
Mot. 582 00 00 058 200 Flywheel locking tool.
10-39
Page 42
ENGINE AND PERIPHERALS
Essential special tooling
Illustration Tool number
Mot. 591-02 00 00 059 102
Mot. 591-04 00 00 059 104
Mot. 647 00 00 064 700 Tappet adjuster.
Parts Department
number
10
Description
Magnetised flexible shaft for cylinder
head angular wrench.
Cylinder head angular wrench, 1/2"
drive with gauge.
Mot. 720 00 00 072 000 Cylinder head locating tool.
Mot. 792-03 00 00 079 203
Mot. 799-01 00 00 079 901 Timing gear wheel immobiliser
Mot. 853 00 00 085 300 Liner seal compression tool.
Engine support plate for Desvil engine
stand.
Mot. 854 00 00 085 400
10-40
Diesel injection pump sprocket locking
tool.
Page 43
ENGINE AND PERIPHERALS
Essential special tooling
Illustration Tool number
Mot. 855 00 00 085 500 Timing gear locking strap.
Mot. 856 00 00 085 600
Mot. 861 00 00 086 100 TDC setting rod.
Parts Department
number
10
Description
BOSCH diesel injection pump timing
gauge support.
Mot. 997-01 00 00 099 701 Diesel injector removal/refitting wrench.
Mot. 1054 00 00 105 400 TDC setting rod.
Mot. 1063 00 00 106 300
Mot. 1079 00 00 107 900
Socket spanner for removal/refitting
engine sump bolts.
Timing gauge kit for Roto-Diesel pumps
with rear cover access.
Mot. 1079-01 00 00 107 901
10-41
Spare checking rod and support bracket
for Mot 1079. Used with Mot. 1079-02.
Page 44
ENGINE AND PERIPHERALS
Essential special tooling
Illustration Tool number
Mot. 1079-02 00 00 107 902
Mot. 1281-01 00 00 128 101 Oil filter removing tool 96 mm diameter.
Mot. 1297 00 00 129 700
Parts Department
number
10
Description
Dial gauge for Mot. 1079-01 timing
gauge kit for Roto-Diesel pumps.
Crankshaft oil seal fitting tool (flywheel
end).
Mot. 1298 00 00 129 800
Mot. 1299 00 00 129 900 Intermediate shaft oil seal fitting tool.
Mot. 1300 00 00 130 000 Camshaft oil seal fitting tool.
Mot. 1335 00 00 133 500 Tool for removing valve stem seals.
Crankshaft oil seal fitting tool (timing
end).
Mot. 1383 00 00 138 300
10-42
17 mm diesel pump HP connection
spanner.
Page 45
ENGINE AND PERIPHERALS
Essential special tooling
Illustration Tool number
Mot. 1384 00 00 138 400 Belt tensioner adjusting tool.
Mot. 1505 00 00 150 500 Belt tension setting tool.
Parts Department
number
10
Description
Mot. 1511 00 00 151 100 Valve stem seal tool.
Mot. 1573 00 00 157 300 Cylinder head support.
10-43
Page 46
ENGINE AND PERIPHERALS
Essential equipment
Essential equipment
Description
Ring for fitting piston with rings into the liner.
Grinding kit for redressing the valve seat, for example CERGYDIS C 108
NEWAY.
Valve lifter.
10
Angular tightening tool:
– STAHLWILLE, part number 540 100 03 for example,
– FACOM, part number DM360 for example.
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 664 000
Cylinder ring pliers.
Tool for fitting the valve stem seals, FACOM part number DM 6J4 for
example.
Standard 22 mm 1/2" (12.7 mm square) drive socket for removing the oil
pressure gauge.
10-44
Page 47
ENGINE AND PERIPHERALS
Cylinder head exploded drawing
Cylinder head exploded drawing
10
10-45
Page 48
ENGINE AND PERIPHERALS
Overhauling the engine
Overhauling the engine
REMOVING THE TOP ENGINE
Remove:
– the accessories belt,
– the air conditioning compressor (if fitted),
– the power assisted steering pump,
– the alternator,
– the multifunction mounting,
– the engine lifting bracket on the flywheel end.
Fit the flywheel locking tool Mot. 582 and loosen the
accessories belt bolt.
10
Remove the TDC setting rod cap (B).
16531R
16535R1
10-46
Page 49
ENGINE AND PERIPHERALS
Adjusting the timing
Fit the TDC setting rod on Mot. 861
or Mot. 1054, then turn the engine
(clockwise from the timing end) to
bring the camshaft sprocket and
injection pump marks in line with
the valve timing cover marks (start
to pull on the rod one half-tooth
before the marks are aligned), in
order to avoid dropping into a
balance hole.
Overhauling the engine
10
10-47
Page 50
ENGINE AND PERIPHERALS
Check the timing on the camshaft
sprocket and injection pump
(marks on the valve timing cover
must be aligned with pulley marks).
Remove the timing cover.
Overhauling the engine
10
Check the marks on the crankshaft
timing sprocket (see diagram).
Make a fixed mark on the cylinder
head cover and another on the
injection pump where they are
aligned with the pulley marks.
10-48
Page 51
ENGINE AND PERIPHERALS
Remove the TDC setting rod
Mot. 861 or Mot. 1054.
Slacken and then re-tighten the
tensioner in order to remove the
timing belt.
Overhauling the engine
10
Remove:
– the fuel return pipes,
– the high pressure pipes on the
injection pump using Mot. 1383,
– the cold start coolant pipe,
– the injection pump rear
mounting bolt on the cylinder
head,
– the timing cover support,
– the rocker box cover.
10-49
Page 52
ENGINE AND PERIPHERALS
Remove the camshaft lateral shim
(pulley end).
Undo the rocker arm adjusting
bolts.
Remove the rocker arm rail.
Overhauling the engine
10
Remove the cylinder head bolts
and fastening nuts.
Insert a wooden shim and strike
the side of the cylinder head to
unstick it from the sealing face
within the clearance limit
between the cylinder head and
the studs. As the cylinder head
gasket is cemented to the cylinder
block, the cylinder head and the
cylinder liners, it is very important
not to raise the cylinder head,
which would unstick the cylinder
liners from their base and allow dirt
to penetrate.
Remove the cylinder head.
10-50
Page 53
ENGINE AND PERIPHERALS
STRIPPING THE CYLINDER
HEAD
Place the cylinder head on the
cylinder head support Mot. 1573.
Remove:
– the heater plugs and their
electrical wiring,
– the injectors and injector holders
with seals,
– the flame-shield washers
between the cylinder head and
the injector holder,
Overhauling the engine
10
– the thermostatic unit, – the camshaft pulley using Mot. 799-01 (take care
with the key),
16534S 16544R
10-51
– the gasket.
Page 54
ENGINE AND PERIPHERALS
Overhauling the engine
Remove:
– the camshaft,
– the prechambers (11) and, if necessary, gently tap
with tool B. Vi. 31-01 inserted in the injector housing.
Some prechambers may be free; be careful not to
let them fall out.
10
NOTE: before removing the valves and the valve
stem seals, it is vital that you measure position H
of one of the old seals in relation to the cylinder
head using Mot. 1511 or using a FACOM tool with
part number DM6J4.
Compress the valve springs.
83246R
15738R
Fit the pushrod from Mot. 1511 on the valve stem seal.
15738-1S
16545S
Remove the half rings, the upper and lower cups and
the springs.
10-52
Page 55
ENGINE AND PERIPHERALS
Overhauling the engine
NOTE: the internal diameter of the pushrod must
be identical to that of the valve. Moreover, the
pushrod must contact the metallic upper section
of the valve stem seal.
Fit the guide tube from above the pushrod until it
comes into contact with the cylinder head.
10
15738-3R
15738-2S
Insert sleeve (1) in the guide tube, until the sleeve
comes into contact with the pushrod.
Then secure the sleeve using the wheel (2).
Remove:
– the guide tube and sleeve, being careful not to
loosen the wheel,
– the pushrod.
Remove:
– the valves,
– the valve stem seals using pliers Mot. 1335,
– the lower cups,
10-53
16559R
Put the parts in order and mark them.
Page 56
ENGINE AND PERIPHERALS
Overhauling the engine
CLEANING
It is very important not to scratch the mating faces
of any aluminium components.
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.
Wear gloves whilst carrying out this operation.
Do not allow this agent to drip on to the paintwork.
Great care should be used in performing this
operation to avoid allowing foreign objects into the
piping taking oil under pressure to the camshafts
(piping in both the cylinder head and its cover) and
the oil return piping.
10
CHECKING THE GASKET FACE
Check for gasket face bow using a straight edge and a
set of shims.
Maximum bow 0.05 mm
No regrinding of the cylinder head is permitted.
83179S
Test the cylinder head for 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
10-54
Page 57
ENGINE AND PERIPHERALS
Overhauling the engine
REDRESSING THE VALVE SEATS
INLET
Width of mating faces X (in mm) 1.75± 0.2
Angle (α) 90˚
The mating face is corrected (1) using burr N 208 46˚.
Reduce the width of this mating face at (2) using burr
N 213 15˚ until width X is obtained.
10
EXHAUST
Width of mating faces X (in mm) 1.75± 0.2
Angle (α) 90˚
The mating face is corrected (1) using burr N 204 46˚.
Reduce the width of this mating face at (3) using burr
N 212 75˚ until width X is obtained.
N.B.: respect the mating face position of the valve on its seat.
10-55
Page 58
ENGINE AND PERIPHERALS
Overhauling the engine
ASSESSMENT AND REPAIR OF ROCKER ARM
RAILS
The filter (24) located in the rocker arm rail (17) must
be replaced in all operations on faults that cause
metallic particles to become suspended in the
lubricating oil.
In this case, the engine oil and oil filter on the main
pipe must also be replaced.
Removal
Remove the cap at the end of the rocker arm shaft and
the filter. Separate the different parts and clean them.
Put them in order.
10
They comprise:
– a greasing hole (G) for corresponding camshaft
bearings,
– an offset (F) directed towards the flywheel.
Identification of parts:
Rocker arm shaft bearings
Bearings A, B, C and D are identical.
16523-1R
Bearing (E) also comprises:
– two threaded holes (T) for attaching the shim to limit
camshaft side play,
– a threaded hole (V) for attaching the bolts to orient
the rocker arm shaft.
10-56
16523R
Page 59
ENGINE AND PERIPHERALS
Overhauling the engine
The rocker arm shaft is oriented using a full dog point
screw.
The shaft bearing greasing holes are directed towards
the camshaft (the oil passes through the rocker arm
shaft bearings).
10
Refitting
Place the bearing (E) on the shaft and fix it so that the
greasing holes point towards the bearing plate.
Then fit:
– a rocker arm,
– a spring,
– another rocker arm,
– an intermediate bearing, offset (F) pointing to the
flywheel.
Continue refitting in the same order, fit the cap with a
new oil filter and tighten to a torque of 2 daNm.
This torque has to be respected as the rocker arm
shaft is only kept rotating by the full dog point screw on
the bearing (E).
Rocker arms
The inlet and exhaust rocker arms are identical and
both have an oil way to lubricate the cams on 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.
Oil all the parts.
16526R
10-57
Page 60
ENGINE AND PERIPHERALS
Overhauling the engine
The valve stem seals must be fitted using tool
Mot. 1511 or with the FACOM tool, part
number DM6J4.
10
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).
15737R
NOTE: do not lubricate the valve stem seals before
fitting them.
Fitting new valve stem seals.
Locate the valve in the cylinder head.
15739-1S
Keep the valve pressed against its seat.
Place the valve stem seal (not lubricated) over the tool
barrel.
15739S
15739-2S
10-58
Page 61
ENGINE AND PERIPHERALS
Overhauling the engine
Push the valve stem seal past the tool barrel, then
withdraw the barrel.
10
15739-5S
Place the pushrod over the valve stem seal.
NOTE: the internal diameter of the pushrod must
be identical to the diameter of the valve stem.
Moreover, the pushrod must be in contact with the
upper section of the valve stem seal.
15739-4S
10-59
Page 62
ENGINE AND PERIPHERALS
Overhauling the engine
Place the guide tube and sleeve assembly, adjusted at
removal, over the pushrod.
10
Push the valve stem seal down by tapping the top of
the sleeve with the palm of your hand until the guide
tube touches the cylinder head.
15738-4S 15739-6S
Repeat the above sequence of operations for all the
valves.
10-60
Page 63
ENGINE AND PERIPHERALS
Overhauling the engine
Fit:
– the spring collar rings (7),
– the springs (8) (inlet and exhaust springs are
identical),
– the cups (9).
Compress the springs.
Fit the half rings (10) (inlet and exhaust valve half rings
are identical).
10
Check the amount by which the valve is retracted from
the cylinder head gasket face using tools Mot. 251-01
and Mot. 252-01.
It should be between 0.80 and 1.15 mm.
77678R5
16546-1R
It is essential to take a note of the valve retraction for
later checks on the piston-cylinder head clearance.
10-61
Page 64
ENGINE AND PERIPHERALS
Turbo engine
Mark X: a drill stamp.
Normally aspirated engine
Mark X: none.
Overhauling the engine
Fit the prechambers (11) then use tools Mot. 251-01
and Mot. 252-01 to check their protrusion.
It should be between 0.01 and 0.04 mm.
10
Engines J8S 736 and 740
Diameter (D) in mm:
– Original dimension 1 = 35.5
– Original dimension 2 = 35.7
86188-1R
16546R1
DI1074
It is essential to take a note of the diameter (D) of
the prechamber housing in the cylinder head and
to refit a chamber of the same diameter.
10-62
Page 65
ENGINE AND PERIPHERALS
Overhauling the engine
Refit the heater plugs (12) and their electrical wiring.
Place new heat flange welds (27) on a cylinder head
being re-used.
Take a note of the dimensions of the removed flameshields and replace them with new ones of the same
diameter.
Diameter (D) in mm:
– original dimension 1 = 15.5
– original dimension 2 = 17.7
Replace the injector flame-shield washers (13) making
sure that they are the right way round.
The mark (C) points towards the prechamber.
10
All engine types except J8S 736 and 740
83173R
Replace the injectors and injector holders fitted with
new copper seals and tighten the nuts to torque
(2 daNm).
Tighten both nuts equally.
Refit the thermostatic unit fitted with a new seal.
10-63
Page 66
ENGINE AND PERIPHERALS
Overhauling the engine
Engines J8S 736 and 740
Injector holders - special features
The cylinder head has been modified to accept
BOSCH "KCA" threaded injector holders.
10
92448-2R
1 Flame-shield
2 Flame-shield washer
3 Seal
Fit a new seal and a new flame-shield washer
(oriented as shown in the diagram) every time the
injector holder is refitted.
Tighten the injector holders to 7 daNm using tool
Mot. 997-01.
10-64
Page 67
ENGINE AND PERIPHERALS
Overhauling the engine
CYLINDER BLOCK EXPLODED DRAWING
10
10-65
Page 68
ENGINE AND PERIPHERALS
Overhauling the engine
REMOVING THE BOTTOM ENGINE
Fit the flywheel locking tool Mot. 582 and remove the
clutch and the flywheel.
10
Fit the cylinder liner clamp Mot. 521-01.
16558R
Remove:
– the water pump.
16531R
Unscrew the three mounting bolts on the injection
pump support to remove the unit comprising the pump,
the support and the injection pump pulley.
Remove the vacuum pump then remove the pinion
and the six pieces holding the oil pump.
16532-3S
16533S
10-66
Page 69
ENGINE AND PERIPHERALS
– the tension wheel,
Overhauling the engine
– the relay shaft cover,
– the seal using a lever,
10
16532-2S
– the relay shaft pinion, use immobiliser Mot. 855,
– the key,
16532S
– the relay shaft retainer,
– the relay shaft (2),
16532-1R
16557R
– the crankshaft timing sprocket using a two handle
extractor,
– the key.
10-67
Page 70
ENGINE AND PERIPHERALS
Remove the sump.
st
model
1
Three types of bolt marked A, B and C.
Overhauling the engine
Remove:
– the crankshaft seals,
– the oil filter using Mot. 1281-01.
Position the pistons at mid-stroke.
Disconnect the connection tube between the oil pump
and the lubricating gallery (if fitted).
10
nd
model
2
Two types of bolt marked as follows:
– 13 bolts (M7 x 100-40),
– 8 bolts (M7 x 100-52).
90571R
Remove the oil pump.
16553S
16562S
10-68
Page 71
ENGINE AND PERIPHERALS
Overhauling the engine
For engine sump with reinforcing plate
Remove:
– the oil pump strainer, bolt (A), keeping the pump
pinions,
91576R
10
– the two bolts on the oil pump body,
– the oil pump body,
– the oil level sensor,
– the plate mounting bolts (then remove all the marked
bolts).
10-69
Page 72
ENGINE AND PERIPHERALS
Overhauling the engine
Marking of the mounting bolts on the cylinder block plate and on the sump on the plate.
10
4 types of bolt marked as follows:
: 17 bolts (M7 x 100-50).
: 21 bolts (M6x100-16),
: 1 bolt (M10x150-40),
: 9 bolts (M10x150-75),
: bolt not used
10-70
Page 73
ENGINE AND PERIPHERALS
Mark the bearing caps according to
their con rods:
– n˚ 1 flywheel end,
– relay shaft end.
WARNING: do not use a sharp
point for marking as this could start
a crack in the rods. Use an
indelible marker pen.
Overhauling the engine
10
Remove the bearing caps and
shells.
10-71
Page 74
ENGINE AND PERIPHERALS
Overhauling the engine
Extract the cylinder liners and pistons (mark them).
Mark the crankshaft bearing caps according to their
housing and then remove them.
10
Remove:
– the crankshaft,
– the lateral play stops,
– the crankshaft bearing shells,
– the piston base cooling jets incorporated in the
cylinder block.
16530S
NOTE:
Extracting crankshaft bearings 1 and 5
To extract the silicone injected crankshaft bearings 1
and 5 use a locally manufactured metal tool of an
approximate thickness of 2.5 mm.
16529-1S
For engines fitted with a cooling gallery, remove the
piston base cooling gallery.
86609R
REMINDER: never remove the mounting bolts (H) if
the sump is not removed.
10-72
Page 75
ENGINE AND PERIPHERALS
Overhauling the engine
Remove the filter holder.
Replacing the bearing
NOTE: if the gearbox is fitted with a short shaft (A), it
does not need a bearing in the crankshaft.
10
Remove the bearing using tool Mot. 11.
77443R
Refitting the bearing
If the gearbox is fitted with a long shaft (B) the
crankshaft must be fitted with a bearing.
Cement the bearing with loctite FRENBLOC for
engines fitted with flywheel mounting bolts that have
no stop.
16547R
10-73
Page 76
ENGINE AND PERIPHERALS
Overhauling the engine
EXTRACTING THE CON RODS - PISTONS
Remove:
– the rings using ring pliers,
– the circlips (E) retaining the gudgeon pin,
– the gudgeon pin (F).
10
It is very important not to scratch the mating faces
of any aluminium components.
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.
Wear gloves whilst carrying out this operation.
Do not allow this agent to drip on to the paintwork.
CLEANING
Remove the threaded plugs in the lubricating pipes to
clean the cylinder block.
83342S
Your attention is drawn to the care which must be
taken when carrying out his operation to prevent
the introduction of foreign bodies into the
pressurized oil feed pipes leading to the camshafts
(pipes located both in the cylinder block and in the
cylinder head).
Failure to follow to this advice could lead to
blocking of the filter in the rocker arm rails or the
jets and thus quickly cause damage to the cams
and tappets.
10-74
Page 77
ENGINE AND PERIPHERALS
Overhauling the engine
Clean the cylinder head mounting holes, especially in
the oil outlet duct (C).
10
REFITTING THE BOTTOM ENGINE
Replace the lubrication channel plugs, tightening them
to:
8 daNm for the plugs (A),
●
2 daNm for the plugs (B) for bearing n˚ 1,
●
4 daNm for the other plugs.
●
16527R
This is necessary in order to obtain the correct
tightening of the bolts.
Also pass a wire through the crankshaft pipes.
83342R1
Check that the cylinder head mounting bolts can be
screwed easily.
Screw and unscrew the bolts several times to clear the
threads if necessary.
The cylinder head studs in the cylinder block must be
fitted with Loctite SCELBLOC.
10-75
Page 78
ENGINE AND PERIPHERALS
Overhauling the engine
When fitting the dipstick guide tube, fit the collar to butt
against the cylinder block.
If necessary, wind a cloth around the external diameter
of the tube to make fitting easier and coat it with
Loctite SCELBLOC.
Fit the various mounting studs. The water pump,
cylinder block and timing belt studs need one or two
drops of Loctite FRENETANCH, as their threads
extend into the cooling system.
10
Replace the piston base cooling jets incorporated in
the cylinder block and tighten to a torque of 1.2 to
1.4 daNm. Check that the O-ring is present.
10-76
16529-1S
Page 79
ENGINE AND PERIPHERALS
Overhauling the engine
For engines fitted with a piston base cooling rail, the oil
gallery mounting bolts (H) need a drop of Loctite
FRENETANCH. Do not add more, as too much
increases the risk of blocking the oil circulation around
the mounting bolt.
86609R
10
Engines 852 before n˚ 42 253
Check that seals (D) are present between the original
bolts (E) and the bearing bolt, oil filter side of bearings
2, 3 and 4.
If the engine does not have these seals, fit a seal (D)
and a cap (F) coated with Loctite FRENETANCH and
secure tightly using a 6 mm Allen key (200 mm long).
This is to prevent oil entering the cooling system.
86741R
10-77
Page 80
ENGINE AND PERIPHERALS
Overhauling the engine
Fitting the crankshaft bearing shells
Identification
Only grooved and pierced crankshaft bearing shells
are supplied as spares, whatever the crankshaft
lubrication configuration.
10
Grease the crankpins and bushings with engine oil.
Refit:
– the crankshaft,
– the crankshaft bearing caps except caps 1 and 5.
Tightening torque: 8.75 to 9.75 daNm
Fit the shells on to the bearings and the cylinder block
and oil them.
Fit the side shims for crankshaft n˚ 2 (grooves on the
crankshaft side).
16530S
16529S
10-78
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ENGINE AND PERIPHERALS
Overhauling the engine
Temporarily fit bearing n˚ 1 with no lateral seals in
order to fit the magnetic holder.
10
Fitting the crankshaft bearings
There are two ways to ensure that bearings 1 and 5
are properly sealed:
1 - Fit butyl rubber seals.
2 - Inject with silicone.
1 - Fitting butyl rubber seals
Position bearing caps 1 to 5.
Measure dimension (C) using a drill.
Checking end play (in mm):
852 J8S
0.07 to 0.25 (1)
0.20 to 0.30 (2)
st
(1) 1
model: n˚ 1 to 32909
nd
(2) 2
model: n˚ 32910 to ...
0.20 to 0.30
If the dimension (C) is less than or equal to 5 mm, use
a 5.1 mm thick seal.
If the dimension (C) is greater than 5 mm, use a colour
marked 5.4 mm thick seal.
Fit the lateral seals:
– seal groove pointing to the outside,
– protrusion d = 0.2 mm approximately on (A).
10-79
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ENGINE AND PERIPHERALS
Overhauling the engine
Apply a thin coating of RHODORSEAL 5661 to the
supports on bearings 1 and 5 without blocking the oil
return on the sump seals.
Screw the ∅ 12 mm centering studs (G) (span 1.50) in
to the cylinder block.
Fit the bearings.
Oil the two seals.
Use two steel shims placed either side of the bearing
cap.
Lower the whole assembly.
When the bearing is almost in place, make sure that
the side seals protrude slightly over the cylinder block
on the pressure face side.
10
Remove the shims and the studs.
Cut the side seals so that they protrude 0.5 to 0.7 mm
in relation to the sump gasket face.
80352S
Check that the crankshaft rotates freely.
2 - Injecting with silicone.
To carry out this operation you will need:
–a 50 ml syringe
–a 5 ml tube of hardener,
– a spatula for mixing,
– a user's guide.
IMPORTANT: the mixture must be injected within
approximately 5 minutes to prevent it from curing in
the syringe.
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ENGINE AND PERIPHERALS
Overhauling the engine
Thoroughly clean the cylinder block and the bearing
cap surfaces (A). Degrease using a cloth soaked in
diluted cleaning agent.
Allow to dry.
10
NOTE: New fitting (J engine)
The bearing caps have watertight grooves (C).
Following modifications to the bearing caps:
– do not coat the inner surfaces of the cylinder block,
– fit the crankshaft and timing seal(s) before injecting
the silicone.
NOTE: older engines have grooves (B) in their cylinder
blocks. Do not obstruct these oil grooves when
applying RHODORSEAL 5661.
– let the silicone run out through the watertight grooves
on the crankshaft bearing.
96597R
10-81
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ENGINE AND PERIPHERALS
Overhauling the engine
Lightly coat the inner surfaces of the cylinder block in
(B) with RHODORSEAL 5661 without obstructing the
oil grooves.
89194R
Fit the caps and tighten them to a torque of 8.75 to
9.75 daNm.
10
Insert the mixture into the syringe and inject it into the
grooves of the crankshaft bearing cap.
Mix 45 ml of RHODORSEAL 5661 (approximately half
a 100 g tube) with half the tube of hardener. Stir with
the spatula until the mixture forms a smooth, light pink
paste.
89195S
89196S
Let the paste run out slightly on either side of the
grooves of the crankshaft bearing cap, to ensure that it
has completely filled the sealing groove.
10-82
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ENGINE AND PERIPHERALS
Overhauling the engine
Use a cloth to wipe up any excess paste, both inside
and outside the cylinder block, and at (A).
10
Allow to dry for a few moments and cut the excess off
the gasket face.
89199S
89197R
Pass a thin wire through the lubricating channels to
check that they have not been blocked (this can also
be done using a compressed air gun).
89198S
10-83
Page 86
ENGINE AND PERIPHERALS
Overhauling the engine
REFITTING AND ASSEMBLING PISTON CON
RODS
Go to the cylinder liner-pistonreplacement section.
The parts in the cylinder liner-piston section are
identical to those used for this operation.
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.
Oil the gudgeon pin.
Check that the gudgeon pins rotate properly in the new
piston and the corresponding con rod.
Some con rods are pierced to allow an oil jet to pass
through; ensure that these are not blocked.
10
Turbo engine
Fit the con rod bearing shells.
Ensure that the piston and con rod are fitted the right
way round:
Normally aspirated engine
83241R1
10-84
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ENGINE AND PERIPHERALS
Overhauling the engine
FITTING THE PISTON RINGS
Rings set to their original adjustment must be free in
their channels.
Ensure the rings are fitted in the correct orientation.
10
CHECKING CYLINDER LINER PROTRUSION
This engine is fitted with cylinder liner base O-rings (J)
and cylinder liner shaft seals (F).
The seals only maintain tightness
The cylinder liner is directly supported by the cylinder
block and the cylinder liner protrusion (X) is assured
by the manufactured dimensions.
86187R
Fit the rings such that the gaps are equally spaced
around the piston.
72552R
10-85
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ENGINE AND PERIPHERALS
Overhauling the engine
Therefore, the protrusion (X) should be checked in the
following way:
– place the cylinder liner not fitted with seals, in the
cylinder block,
– check protrusion (X) using tools Mot. 251-01 and
Mot. 252-01. It should be between 0.07 and
0.13 mm.
10
NOTE: the parts supplied in the cylinder liner-piston
operation kit are identical to those used for this
operation. Mark the parts in each box from A to D to
ensure they remain identical.
Once the correct protrusion has been obtained,
reassemble groups A, B, C and D with the cylinder
liners, pistons and gudgeon pins and mark their
position in the cylinder block.
NOTE: If the protrusion is incorrect, check using a new
cylinder liner set to find out whether the cylinder block
or the cylinder liner is at fault.
REFITTING CYLINDER LINERS - PISTONS - CON
RODS
Oil the pistons.
Fit the piston-con rod assemblies into the cylinder
liners with the tool, paying attention to the direction
(the V towards the flywheel).
16528R
Position the cylinder liners so that:
– the protrusion is graduated from cylinder n˚ 1 to
cylinder n˚ 4 (or vice versa),
– the difference in protrusion between two
neighbouring cylinders is no more than 0.04 mm (in
tolerance).
The big end surfaces must be parallel with the flat
bottom of the cylinder liner.
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ENGINE AND PERIPHERALS
Overhauling the engine
Before fitting the cylinder liners-pistons-con rods
assemblies in the cylinder blocks, don't forget to
place an O-ring on each cylinder liner, making sure
that it is not twisted, as well as a shaft seal..
10
Fit the cylinder liners-pistons-con rods assemblies
in the cylinder block, making sure they are in the right
positions.
The cylinder liner flat surfaces need to be parallel.
The piston combustion cut-out should be pointing
towards the relay shaft side.
If the con rod is pierced, point the oil jet towards the
end opposite the relay shaft.
Fit the cylinder liner retaining flange Mot. 521-01 and
tighten the bolts and mounting nuts to 5 daNm.
16558R
Fit the con rods onto the oiled big end journals of the
crankshaft.
10-87
Page 90
ENGINE AND PERIPHERALS
Fit the con rod bearings caps with
their shells, observing the pairing
with the con rods.
Fit and tighten the new con rod
bearing bolts to a torque of
6.5 daNm.
Overhauling the engine
10
Check that the mobile assembly can rotate freely.
10-88
Page 91
ENGINE AND PERIPHERALS
Overhauling the engine
CHECKING PISTON PROTRUSION
Clean the piston heads.
Turn the crankshaft once clockwise at the timing end
to bring piston n˚ 1 near to top dead centre.
Place tool Mot. 252-01 on the piston.
Place tool Mot. 251-01 fitted with a gauge on the thrust
plate Mot. 252-01, the dial gauge measuring pin being
in contact with the cylinder block, and look for the TDC
of the piston (turn the crankshaft clockwise at the
timing end).
Without putting pressure on the tools or the piston,
to avoid tilting of the piston during measurement,
measure the protrusion when the piston is in position
1, then in position 2 and calculate the average of the
two measurements.
10
Example:
Protrusion in position 2: 1.09 mm.
Position 2
Example:
Protrusion in position 1: 0.83 mm.
Position 1
83814R
83815R
Calculate the average piston protrusion:
(083 + 1.09): 2 = 0.96 mm
Carry out this procedure for the other pistons (look for
the TDC by turning the crankshaft clockwise at the
timing end, do not put pressure on tools Mot. 251-01,
and Mot. 252-01 or on the piston).
ONLY CONSIDER THE DIMENSIONS OF THE
PISTON WITH THE GREATEST PROTRUSION
For a protrusion:
– less than 0.96 mm use a cylinder head gasket
1.6 mm thick, marked with 1.6 or 1 hole,
– between 0.96 and 1.04 mm, use a cylinder head
gasket 1.7 mm thick, without a stamped mark or
a hole,
– more than 1.04 mm use a cylinder head gasket
1.8 mm thick, marked with 1.8 or 2 holes.
10-89
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ENGINE AND PERIPHERALS
Overhauling the engine
Assessment and repair of the oil pump
Removing the valve
10
Checking the oil pump
Check the clearances:
Clearance A
– minimum (in mm) 0.05
– maximum (in mm) 0.12
80142R
Clearance B
– minimum (mm) 0.02
– maximum (mm) 0.10
10-90
86303-1R
Page 93
ENGINE AND PERIPHERALS
Overhauling the engine
Refitting the oil pump
Refit the oil pump control shaft, circlip on the oil pump
side.
Check for the presence of the two centring pins (A).
10
Refit the oil pump and tighten to a torque of 4 daNm.
16562S
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ENGINE AND PERIPHERALS
Overhauling the engine
Refitting the relay shaft
Refit the vacuum pump.
On APG pumps, the pinion (A) is force fitted.
10
Oil and fit the relay shaft, tightening the clamp bolts to
a torque of 1 daNm.
16548R
On the BARMAG pumps, the pinion (B) is not fixed to
the pump. Refit the relay shaft before refitting the
pinion (B).
16557S
16524R1
10-92
Page 95
ENGINE AND PERIPHERALS
Refitting the oil filter holder
Replace the O-rings (G) when refitting.
Overhauling the engine
Fitting the crankshaft seals
– flywheel side, Mot. 1297.
83334R
– timing side, Mot. 1298.
10
Fitting the relay shaft seal
Push the seal in until tool Mot. 1299 butts up against
the holder.
If the seal lip marks the crankshaft mating face, a
1.5 mm thick washer must be placed between the seal
and the tool to shift the mating face.
10-93
Page 96
ENGINE AND PERIPHERALS
Refitting the sump
Metal sump
st
model:
1
Fit a cork or rubber gasket.
Overhauling the engine
Aluminium sump
Fit a rubber gasket. The alignment of the cylinder block
and the sump must be respected (flywheel side) to
prevent the clutch housing from being damaged when
the gearbox is fitted to the engine.
10
st
nd
model:
model
nd
model
A 1
B 2
2
Only fit a rubber gasket.
DI1051R 16580S
The sump is refitted with a new gasket and tightened
to a torque of 1.4 to 1.7 daNm.
10-94
Page 97
ENGINE AND PERIPHERALS
Overhauling the engine
For engine sump with reinforcing plate
Refitting
Remove all traces of grease from the cylinder block
and the reinforcing plate with brake cleaner (for
example).
Fit two threaded rods (T) ∅ 7 length 30 mm and cut a
groove at the end of one rod with a hacksaw.
10
91510R
Put a blob of RHODORSEAL 5661 where bearing
caps 1 and 5 are joined to the cylinder block. Do not do
this if the injection was done using butyl seals.
89197R1
Position the oil pump control shaft, circlip on the oil
pump side.
10-95
Page 98
ENGINE AND PERIPHERALS
Overhauling the engine
Marking of the bolts fitting the plate to the cylinder block plate and the sump to the plate.
10
NOTE: the plate gasket is fitted dry.
Four types of bolt marked as follows:
: 17 bolts (M7 x 100-50), tightening torque: 1.2 to 1.8 daNm
: 21 bolts (M6x100-16), tightening torque: 0.7 to 1.1 daNm
: 1 bolt (M10x150-40), tightening torque: 3.2 to 4.8 daNm
: 9 bolts (M10x150-75), tightening torque: 3.2 to 4.8 daNm
: bolt not used
Fit and tighten the oil pump body (4 to 4.5 daNm).
(Ensure that the drive shaft and pinions are correctly positioned).
Remove the threaded centring rods and fit the bolts.
10-96
Page 99
ENGINE AND PERIPHERALS
Overhauling the engine
Fitting the flywheel
Use Loctite AUTOFORM to coat the flywheel bearing
face on the crankshaft
Fit the flywheel.
Place a drop of Loctite FRENETANCH on the new
bolts.
Replace the flywheel bolt stop if there is one fitted.
10
Close the stop, if there is one fitted on the flywheel.
Refit:
– the clutch, tightening it to a torque of 2 daNm.
– the timing tensioner roller,
– the coolant pump and the coolant return pipe on the
cylinder block. The water pump should be fitted with
a new seal and tightened to a torque of 1.3 daNm.
– the crankshaft timing sprocket,
– the relay shaft pinion with the key and tighten to a
torque of 5 daNm using Mot. 855,
– the water pump pulley by tightening it to a torque of
2 daNm.
73834S
Lock off the flywheel using locking tool Mot. 582 and
tighten the bolts to a torque of 6 to 6.5 daNm.
16531R
10-97
Page 100
ENGINE AND PERIPHERALS
Overhauling the engine
REFITTING THE TOP ENGINE
Position the pistons in mid-stroke and remove tool
Mot. 521-01.
Positioning the cylinder head gasket
It is necessary to use tool Mot. 720 placed in the hole
(A) on the cylinder block. Check for the presence of
the centring pin (B).
Fit the cylinder head gasket.
10
16556R
Refit the cylinder head and centre it on the studs.
Lubricate the threads on the mounting bolts and the
washers under the heads with engine oil.
All the cylinder head bolts must always be
changed after removal (including the studs).
Lubricate the threads and under the bolt heads
with engine oil.
Tightening procedure for cylinder head
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.
Consult the Technical specifications section for
information on the cylinder head tightening procedure.
10-98
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