Renault Kerax Service Manual

					RENAULT V.I.
	20 660 - GB - 02/2004
	ENGINE - DCI 11
		RANGE	FAMILY		VARIANT
			33AA P 8X4
			33BB P 8X4
			33CC P 8X4
			33DD P 8X4
			33GG P 6X4
			33HH P 6X4
			33II P 6X4
		KERAX	33JJ P 6X4
			33KK T 6X4
			33LL T 6X4
			33MM P 6X6
			33NN T 6X6		12094
			33PP P 4X2
			33QQ T 4X2
			33RR P 4X4
			33SS T 4X4
			22AA P 4X2
			22C T 4X2
			22CC T 4X2
		PREMIUM	22EE P 6X2/4
			22HA P 6X2/4
			22JJ T 6X2 PUSHER
			22QQ P 6X2
			22RR T 6X2

The above information may change in the course of time. Only the "Consult" section of the workshop manuals repertory in standard N° 10320 serves as reference.

20 660	20.6

20.6 . . . .

20.6 . . . .

50 21 014 139

20 660	1

CONTENTS

Generalities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 → 5

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 → 3

— General features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-2 → 7

— Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1 → 7

— Dimensions and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1 → 10

Tools / Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 → 13

Stripping and mounting on stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 → 8

— Stand 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1-2 → 4

— Belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1 → 2

— Compressor (air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1 → 1

— Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-1 → 1

— Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-1 → 1

— Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6-1 → 2

— Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7-1 → 1

— Engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8-1 → 1

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 → 3

— Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-2 → 5

— Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1 → 7

— Disassembly/inspection/assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-1 → 6

Valve timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 → 14 Reciprocating gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 → 13

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-1 → 2

— Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-2 → 2

— Centrifugal oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1 → 2

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 → 3

— Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-2 → 3

— Ventilation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-1 → 3

— Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-1 → 4

Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1 → 2

— Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1-2 → 17

— Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-1 → 30

		50 21 014 139
© RENAULT V.I. 02/2004 - Imprimé en France - le 03/2004

			20 660
	2
Diagnostics aid (setting B43) . . . . . .			. . . . . . . . . .	. . . . . . . . . . . . . . . . . . .K-1	→ 17
Diagnostics aid (setting +J01). . . . . .			. . . . . . . . . .	. . . . . . . . . . . . . . . . . . . L-1	→ 23
Diagnostics aid (setting +J01) variant 14102. . . .				. . . . . . . . . . . . . . . . . . M-1	→ 23
Turbocharger . . . . . . . . . . . . . . . . . . .			. . . . . . . . . .	. . . . . . . . . . . . . . . . . . . .N-1 → 4

Jake brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .O-1 → 7

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20 660	A-1

GENERALITIES

RENAULT V.I. 02/2004

	20 660
A-2

Warnings

In this document, safety instructions are symbolized as follows:

DANGER! NON-OBSERVANCE OF THE PROCEDURE DESCRIBED OR LACK OF CARE OR ATTENTION, RISK CAUSING SERIOUS INJURY OR EVEN DEATH.

WARNING! Any different or inappropriate working method risks causing damage to the product.

NOTE! Draws attention to particular or important points of the method.

Comply without fail with the regulations in force relative to the recovery and treatment of used parts and waste.

RENAULT V.I. 02/2004

20 660

A-3

Conventional symbols

Fitting

Tighten to torque (Nm) (left-hand thread)

Tighten by indicated value

Tighten to torque (Nm) (right-hand thread)

Loosen by indicated value

Tightening torque with lubricated threaded

hardware

Dimensioning

Tightening

... Greater than or equal to ...

Equal to

Wear limit

... Less than ...

Machining limit or dimension

... Greater than ...

Maximum out-of-true

... Less than or equal to ...

Maximum parallelism error

Repair

Force to be exerted in the direction shown

Smear or coat (see "Consumables" table)

(hammer - press)

Heat or cool: Temperature in degrees

Fill to level (see "Technical Data" and

Celsius (e.g. + 80 °C)

"Consumables" table)

Weld bead

Grease or oil (see "Consumables" table)

Repair time - Heating time

Mark - Assemble according to marking

RENAULT V.I. 02/2004

20 660

A-4

Adjustment

Rotating friction torque

Turn anti-clockwise

Turn in alternate directions

Turn anti-clockwise

(the figure shows the number of turns)

Turn clockwise

Turn clockwise

(the figure shows the number of turns)

Place in contact

Move in the direction shown

Dimension to be assured (mm)

Various information

Exhaust - Outlet

Operation with a sequence

Intake - Inlet

Involves

Weight in kg (example: 275 kg)

Return to numbered operation -

Connected with numbered operation

Depending on versions or options

Withdraw - Delete

Wrong

Direction of disassembly

(the arrow shows the direction)

Correct

Direction of assembly

(the arrow shows the direction)

Injection

... to ...

Repair dimension

Inspect - Check condition of part

Part to be replaced

Danger for persons, vehicle or equipment

RENAULT V.I. 02/2004

20 660	A-5

General instructions

Practical advice

Prior to any work:

–Clean the major unit and its surrounds (See Driving Servicing Handbook, "Vehicle washing").

–Ensure the batteries are disconnected.

–Mark the pipes and wiring harnesses, if necessary.

–Protect all ports to prevent the ingress of foreign matter.

–Before disconnecting an air pipe, drop the circuit pressure.

–If liquid is splashed onto the bodywork, clean quickly with a cleaning product recommended by RENAULT TRUCKS.

Preparation prior to assembly:

Carefully clean and check all the parts.

Do not unpack a new bearing until you are ready to install it. Do not clean off the protective grease on new bearings.

Old seals and lock-plates must be discarded and new ones fitted.

Never force fit parts with copper or brass punches or drifts. Always use a specially adapted driver to prevent ingress of metal particles into the casings and bearings. Always oil parts prior to force fitting.

Always apply grease on the inside of seal ring lips.

Shrink fitted parts are to be heated with a hot air blower or in an oven. etc. Flame heating is strictly forbidden.

When using a torque multiplier, calibrate the torque wrench/multiplier unit at the required torque loading.

Fastening, locking, sealing and adhesive products:

Prior to assembly, carefully clean the product application surfaces of the parts. Old product residue is to be removed. Threaded portions are to be brushed, tapped and, if necessary, cleaned with a suitable product.

Using the product:

Always adapt the recommended product while observing the utilization conditions appearing on the pack:

–Surface finish,

–Working temperature,

–Reaction, drying, etc. time,

–Shelf life.

Observe the assembly method so as to guarantee the quality of the repair.

RENAULT V.I. 02/2004

	20 660
A-6

RENAULT V.I. 02/2004

20 660	B1-1

TECHNICAL DATA

RENAULT V.I. 02/2004

			20 660
	B1-2
General features

Identification plate 14102 (original engine)*

–1: Spare Parts Reference N°

–2: Family N°

–3: Manufacturing N°

–4: Manufacturing Date

–5: Engine type (see symbolization)

–6: Power rating

–7: Smoke

–8: Emissions

RENAULT V.I. 02/2004

			20 660
						B1-3
	a	D	Diesel
	b	C	Common Rail
	c	I	Injection
	d
	e		Capacity:
		11	11: 11 litres
	f		6: 6 litres
			4: 4 litres
	g
	h	B
	i
	j	+	+: Multi-mode (several power ratings available)
			Blank space: Single-mode (one single power rating available)
			Month of application of pollutant emissions regulation:
			A: January
	k	J	B: February
			C: March
			......
			L: December
	l		Year of application of pollutant emissions regulation:
		01	00: 2000
	m		01: 2001
			02: 2002
			......
			Post-combustion equipment (particulate filter):
	n		Blank space or 0: without
			1: with

RENAULT V.I. 02/2004

	20 660
B1-4

Identification plate (original engine)*

–1: Spare Parts Reference N°

–2: Family N°

–3: Manufacturing N°

–4: Manufacturing Date

–5: Engine type (see symbolization)

Service exchange engine

To identify service exchange engines: see Spare Parts department technical comments.

RENAULT V.I. 02/2004

				20 660
							B1-5
Symbolization
	a		D	Diesel
	b		C	Common Rail
	c		I	Injection
	d
	e			Capacity:
			11	11: 11 litres
	f			6: 6 litres
				4: 4 litres
	g
	h		B
	i
	j		+	+: Multi-mode (several power ratings available)
				Blank space: Single-mode (one single power rating available)
				Month of application of pollutant emissions regulation:
				A: January
	k		J	B: February
				C: March
				......
				L: December
	l			Year of application of pollutant emissions regulation:
			01	00: 2000
	m			01: 2001
				02: 2002
				......
				Post-combustion equipment (particulate filter):
	n			Blank space or 0: without
				1: with

RENAULT V.I. 02/2004

				20 660
	B1-6
Technical data
		Power setting index		B43 / B+J01 / C+J01 / E+J01 / F+J01 / G+J01 / H+J01 / I+J01
		Cubic capacity				11 l
		Compression ratio		17/1
		Firing order		1.5.3.6.2.4
		n°1 cylinder:				flywheel end
		Engine rotation				clockwise
		Fuel:				diesel fuel
		Supercharged:				by turbocharger with intercooler

Cooling:

Circulating coolant activated by thermostat-regulated pump.

	Beginning of opening:	83 °C
	End of opening:	90 °C
	Min. full opening dimension:	9.4 mm
Arctic cold cooling pack:
Circulating coolant activated by thermostat-regulated pump.
	Beginning of opening:	88 °C
	End of opening:	98 °C
	Min. full opening dimension:	9.4 mm

RENAULT V.I. 02/2004

			20 660
								B1-7
Lubrication
Oil pressure (dCi 11 B43)
	Engine speed		Block rail
			Temperature			Pressure
	in rpm
			in °C			in bar
	1000		85			2.9
	2100					4.8

Oil pressure (dCi 11 J+01)

Engine speed in	Filter head			Block rail
	Temperature		Pressure	Temperature		Pressure
rpm
	in °C		in bar	in °C		in bar
1000	85		2.7	85		2.5
2000			4.7			4.3
Lubrication:					forced by gear pump

Oil: specifications and operating temperatures (see Driving & Servicing handbook). Oil capacity: (see Driving & Servicing handbook).

RENAULT V.I. 02/2004

	20 660
B1-8

RENAULT V.I. 02/2004

20 660	B2-1

Tightening torques

Definitions

There are several types of tightening:

–Tightening to torque (in Nm)

–Tightening to angle (in °)

–Tightening to torque-angle (en Nm + °)

Torques given in Nm are nominal torques (average value calculated on the basis of the minimum torque and the maximum torque).

The tightening precision class defines the tolerance of this torque in percent as a function of the nominal torque applied.

Tightening precision classes:

–Class I: Special threaded hardware (tolerances ± 10% of the final torque).

–Class II: Reserved for precise tightening (tolerance ± 10% of the nominal torque).

–Class III: Reserved for normal standard tightening (tolerance ± 20% of the nominal torque).

For standard threaded hardware indicated in the table below, use tightening class III. For other torques, see the following page(s).

"FIH" type (Nylstop) locknuts must be replaced whenever removed. "DRH" type (oval) locknuts can be re-used. If locknuts (DRH, FIH or other) are re-used, make absolutely certain that the screw-thread of the bolt protrudes least two threads above the top edge of the nut.

RENAULT V.I. 02/2004

	20 660
B2-2

Standard nut and bolt tightening torques table

The tightening torque values given in the table are based on standard 01.50.4002 and apply to new nuts and bolts fitted dry and re-used nuts and bolts with oil applied to the screw-threads. If any nuts and bolts are replaced, it is absolutely essential to use nuts and bolts recommended by the RENAULT TRUCKS Spare Parts Department (coefficient of friction in compliance with standard 01.50.4002).

Tightening torque values in Nm for conventional "metric system" threaded hardware based on standard 01.50.4002 (H: normal and HE: with flange)

dia. and pitch of nuts and bolts				Quality class III
		Quality class 8.8			Quality class 10.9
6 x 1.00		7.5 ± 1.5			11 ± 2.2
7 x 1.00		15	± 3		20		± 4
8 x 1.00		20	± 4		30		± 6
8 x 1.25		20	± 4		27 ± 5.4
10 x 1.00		40	± 8		60	± 12
10 x 1.25		40	± 8		60	± 12
10 x 1.50		40	± 8		50	± 10
12 x 1.25		70 ± 14			100		± 20
12 x 1.50		65 ± 13			95	± 19
12 x 1.75		60 ±12			90	± 18
14 x 1.50		105	± 21		155		± 31
14 x 2.00		100	± 20		145		± 29
16 x 1.50		160	± 32		220		± 44
16 x 2.00		150	± 30		220		± 44
18 x 1.50		240	± 48		340		± 68
18 x 2.50		210	± 42		310		± 62
20 x 1.50		330	± 66		480		± 96
20 x 2.50		300	± 60		435		± 87
22 x 1.50		450	± 90		650	± 130
22 x 2.50		410	± 82		595	± 119
24 x 2.00		560 ± 112			820	± 164
24 x 3.00		510 ± 102			750	± 150

Standard tightening torques table for union bolts with Cu gaskets and BS rings

Nominal tightening torque values for union bolts with CU gaskets and self-centring BS rings

Nominal dia.	Tightening torque	Nominal dia.	Tightening torque
8	10 ± 2	16	40 ± 8
10	20 ± 4	18	50 ± 10
12	27 ± 5.4	22	80 ± 16
14	32 ± 6.4	24	80 ± 16

RENAULT V.I. 02/2004

20 660	B2-3

Cylinder head

Cylinder head securing bolt (see page E-2-1)

Rocker shaft securing bolt (see page E-2-4)

Cylinder head cover bolt (see page E-2-5)

Inlet manifold securing bolt(see page E-2-6)

Exhaust manifold securing bolt (see page E-2-6)

Valve yoke adjusting nut	35 ± 7 Nm
Rocker arm adjusting nut	40 ± 8 Nm
Preheat plug(s)	41 ± 8 Nm
Heat insulating screen(s) setscrew	M8 = 20 ± 4 / M10 = 60 ± 12 Nm

Reciprocating gear

Crankshaft bearing cap securing bolt (see page G-7)

Flywheel securing bolt (see page G-13)

Connecting rod cap securing nut (see page G-10)

Block stiffener securing bolt	30	± 6 Nm
Flywheel housing setscrew	M14 = 150 ± 30 / M8 = 20	± 4 Nm

Timing

Damper hub setscrew (see page F-11)

Oil sump securing bolt (see page F-13)		20	± 4 Nm
Oil sump securing nut (see page F-13)		20	± 4 Nm
Oil sump securing stud (see page F-13)		20	± 4 Nm
Fan bracket securing stud		20	± 4 Nm
Camshaft stop securing bolt	(FRENETANCH 242)	20 ± 4 Nm
Tappet retaining pin setscrew		20	± 4 Nm
Idler gear hub securing bolt	100 ± 20 Nm
Pulley to hub securing bolt		67	± 7 Nm
Damper to hub securing bolt	120 ± 12 Nm
Alternator bracket securing stud		20	± 4 Nm
Alternator bracket securing nut	60 ± 12 Nm
Alternator bracket securing bolt	cl 8.8 =	20 ± 4 Nm
Alternator bracket securing bolt	cl 10.9 =	30 ± 4 Nm

RENAULT V.I. 02/2004

				20 660
	B2-4
							60	± 12 Nm
		Air conditioning compressor bracket securing bolt
		Air compressor pinion securing nut		550 cm3 (variant 33118)			137.5 ± 27.5 Nm
		Air compressor pinion securing nut		442 cm3 (variant 33124)			270	± 20 Nm
		Hydraulic pump pinion securing nut					60	± 12 Nm
		Hydraulic pump securing stud					30		± 6 Nm
		Oil pump securing bolt					20		± 4 Nm
		High pressure pump securing nut					195	± 20 Nm
		High pressure pump securing stud					(FRENETANCH 242) 20 ± 4 Nm
		High pressure pump securing nut (tighten in diametrically opposed					60	± 12 Nm
		sequence, then retighten first nut only)
		Breather impeller setscrew					11		± 1 Nm
		Air conditioner and alternator tensioner setscrew					40		± 8 Nm
Lubrication
		Oil sump securing nut (see page F-13)					20		± 4 Nm
		Oil sump securing stud (see page F-13)					20		± 4 Nm
		Oil nozzle setscrew					20		± 4 Nm
		Oil pump securing bolt					20		± 4 Nm
		Oil aspiration tube setscrew					20		± 4 Nm
		Oil pump delivery pipe to block stiffener setscrew					20		± 4 Nm
		Oil sump drain plug					70	± 14 Nm
		Heat exchanger oil drain plug					40		± 5 Nm
		Centrifugal filter cover securing nut					30		± 3 Nm
		Centrifugal filter bracket/cover securing stud					(FRENETANCH 242) 30 ± 3 Nm
		Oil level sender					50	± 10 Nm
Jake brake
		Mechanism to rocker shaft securing bolt (see page O-3)					60 ± 6 Nm + 120 ± 6°
		Mechanism to cylinder head securing bolt					65		± 7 Nm
		Solenoid valve to mechanism					7 ± 0.7 Nm
		Slave piston adjusting nut					40 ± 4 Nm

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		20 660
							B2-5
Turbocharger
	Turbocharger to exhaust manifold securing bolt				60 ± 12 Nm
	Exhaust brake to turbocharger securing nut				(GRAISSE GRIPCOTT NF)
					20	± 4 Nm
	Exhaust brake to turbocharger securing stud				(GRAISSE GRIPCOTT NF)
					10	± 2 Nm
	Lube tube union nut				24 ± 4.8 Nm
Cooling
	Water pump securing bolt				20	± 4 Nm
	Fan bracket securing stud				20	± 4 Nm
	Fan bracket securing nut				60 ± 12 Nm
	Fan pulley securing bolt				150 ± 30 Nm
	Fan drive belt tensioner securing bolt				(FRENETANCH 242) 40 ± 8 Nm
	Heat exchanger tube coolant drain plug				40	± 5 Nm
Air compressor
	Air compressor pinion securing nut	550 cm3 (variant 33118)			137.5 ± 27.5 Nm
	Air compressor pinion securing nut	442 cm3 (variant 33124)			270 ± 20 Nm
	Air compressor securing stud 550 cm3 (variant 33118)				(FRENETANCH 242) 30 ± 6 Nm
	Air compressor securing stud 442 cm3 (variant 33124)				(FRENETANCH 242) 30 ± 6 Nm
	Air compressor securing nut 550 cm3 (variant 33118)				40 ± 8 Nm
	Air compressor securing nut 442 cm3 (variant 33124)				60 ± 8 Nm
	Air compressor securing bolt 550 cm3 (variant 33118)				(FRENETANCH 242) 20 ± 4 Nm
	Air compressor securing bolt 442 cm3 (variant 33118)				(FRENETANCH 242) 60 ± 12 Nm
	Coolant pipe union nut				25 ± 5 Nm

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				20 660
	B2-6
Sensors
		Coolant temperature sensor				18	± 5 Nm
		Speed sensor				7.5 ± 1.5 Nm
		Oil pressure sensor				(FRENETANCH 242) 18 ± 5 Nm
		Oil temperature sensor				18	± 5 Nm
		Oil level sender				50 ± 10 Nm
		Common rail pressure sensor				60	± 5 Nm
		Pressure and boost air sensor setscrew				6.5 ± 1.5 Nm
Fuel-Injection
		High pressure pipe gallery union nut (see page J-2-6)
		Cylinder head fuel delivery pipe nut (see page J-2-10)
		Injector nozzle-holder flange setscrew (see page J-2-11)
		High pressure pump securing nut				195 ± 20 Nm
		High pressure pump securing stud				(FRENETANCH 242)
						(+ Loctite Frenétanch) 20 ± 4 Nm
		High pressure pump securing nut (tighten in diametrically opposed				60 ± 12 Nm
		sequence, then retighten first nut only)
		Booster pump securing bolts				8	± 1 Nm
		(tighten in diametrically opposed sequence)
		High pressure pump speed sensor setscrew				8	± 1 Nm
		Scavenge valve				30 + 10 Nm
		Scavenge valve plug				15 + 5 Nm
		Pressure and boost air sensor setscrew				6.5 ± 1.5 Nm
		Flow limiter				85	± 5 Nm
		Pressure limiter to common rail				45	± 5 Nm
		Common rail pressure sensor				35	± 5 Nm
		ECU cooler piping setscrew				8 ± 1.5 Nm
		Injector supply wire securing nut				1 ± 0.25 Nm
		Accelerator pedal sensor setscrew				10	± 2 Nm
		Pressure sensor to rail union				45	± 5 Nm
		Fuel leak-off return pipe to pressure limiter union				30	± 3 Nm
		Fuel leak-off return union setscrew				12 ± 2.4 Nm
		Low pressure polyamide pipes securing clamp nut				15	± 3 Nm
		High pressure pump oil filler plug				35	± 5 Nm

RENAULT V.I. 02/2004

20 660
						B2-7
				28	± 2 Nm
	Polyamide pipe union nut
	Wiring harness to engine block attaching clamp screw			30	± 6 Nm
	Fuel low pressure and leak-off return pipes securing nut on clips			3.5 ± 0.7 Nm

RENAULT V.I. 02/2004

	20 660
B2-8

RENAULT V.I. 02/2004

20 660	B3-1

Dimensions and tolerances

Cylinder head

*Only for: dCi 11 B43

**With Jake brake

RENAULT V.I. 02/2004

		20 660
B3-2

RENAULT V.I. 02/2004

20 660	B3-3

Timing

Clearance value with reduced play camshaft idler pinion N° 5010 550 239.

RENAULT V.I. 02/2004

		20 660
B3-4

Engine with power setting A: dCi 11 B43.

Engine with power setting B: dCi 11 + J01.

RENAULT V.I. 02/2004

20 660	B3-5

Quick timing check (dCi 11 B43):

–Position the piston of N° 1 cylinder at end of exhaust/beginning of intake TDC (in the direction of rotation).

–Scribe a mark on the crankshaft pulley.

–Adjust the valve clearances to zero (without compressing the control springs)

–Crank the engine through one revolution while lining up the marks on the crankshaft pulley so as to arrive at "compression TDC".

–Check the valve clearances, which should be:

•Inlet: 0.80 → 1.10 mm.

•Exhaust: 1.28 → 1.58 mm.

Repeat this check twice so as to provide more accuracy when adjusting the rocker arm clearance to zero.

RENAULT V.I. 02/2004