Page 1
RENAULT V.I.
20 660 - GB -
ENGINE - DCI 11
RANGE FAMILY VARIANT
KERAX
PREMIUM
02/2004
33AA P 8X4
33BB P 8X4
33CC P 8X4
33DD P 8X4
33GG P 6X4
33HH P 6X4
33JJ P 6X4
33KK T 6X4
33LL T 6X4
33MM P 6X6
33NN T 6X6
33PP P 4X2
33QQ T 4X2
33RR P 4X4
33SS T 4X4
22AA P 4X2
22CC T 4X2
22EE P 6X2/4
22HA P 6X2/4
22JJ T 6X2 PUSHER
22QQ P 6X2
22RR T 6X2
33II P 6X4
12094
22C T 4X2
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
Page 2
20 660
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
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
© RENAULT V.I. 02 /2004 - Imprimé en France - le 03/2004
50 21 014 139
Page 3
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
20 660
RENAULT V.I. 02/2004
Page 4
20 660
A-1
GENERALITIES
RENAULT V.I. 02/2004
Page 5
A-2
20 660
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
Page 6
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 ...
20 660
A-3
Repair
Equal to Wear limit
... Less than ... Machining limit or dimension
... Greater than ... Maximum out-of-true
... Less than or equal to ... Maximum parallelism error
Force to be exerted in the direction shown
(hammer - press)
Heat or cool: Temperature in degrees
Celsius (e.g. + 80 °C)
Weld bead Grease or oil (see "Consumables" table)
Smear or coat (see "Consumables" table)
Fill to level (see "Technical Data" and
"Consumables" table)
Repair time - Heating time Mark - Assemble according to marking
RENAULT V.I. 02/2004
Page 7
A-4
Adjustment
20 660
Rotating friction torque Turn anti-clockwise
Turn in alternate directions
Turn clockwise
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)
Turn anti-clockwise
(the figure shows the number of turns)
Turn clockwise
(the figure shows the number of turns)
Return to numbered operation Connected with numbered operation
Depending on versions or options Withdraw - Delete
Wrong
Correct
Injection ... to ...
Repair dimension Inspect - Check condition of part
Part to be replaced Danger for persons, vehicle or equipment
Direction of disassembly
(the arrow shows the direction)
Direction of assembly
(the arrow shows the direction)
RENAULT V.I. 02/2004
Page 8
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
Page 9
A-6
20 660
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Page 10
20 660
B1-1
TECHNICAL DATA
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Page 11
B1-2
20 660
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
Page 12
a D Diesel
b C Common Rail
c I Injection
d
20 660
B1-3
e
f
g
h
i
j +
k J
l
m
11
B
01
Capacity:
11: 11 litres
6: 6 litres
4: 4 litres
+: Multi-mode (several power ratings available)
Blank space: Single-mode (one single power rating available)
Month of application of pollutant emissions regulation:
A: January
B: February
C: March
......
L: December
Year of application of pollutant emissions regulation:
00: 2000
01: 2001
02: 2002
......
Post-combustion equipment (particulate filter):
n
Blank space or 0: without
1: with
RENAULT V.I. 02/2004
Page 13
B1-4
20 660
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
Page 14
Symbolization
a D Diesel
b C Common Rail
c I Injection
d
20 660
B1-5
e
f
g
h
i
j +
k J
l
m
11
B
01
Capacity:
11: 11 litres
6: 6 litres
4: 4 litres
+: Multi-mode (several power ratings available)
Blank space: Single-mode (one single power rating available)
Month of application of pollutant emissions regulation:
A: January
B: February
C: March
......
L: December
Year of application of pollutant emissions regulation:
00: 2000
01: 2001
02: 2002
......
Post-combustion equipment (particulate filter):
n
Blank space or 0: without
1: with
RENAULT V.I. 02/2004
Page 15
B1-6
20 660
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
Page 16
Lubrication
Oil pressure (dCi 11 B43)
20 660
B1-7
Engine speed
in rpm
1000 85 2.9
2100 4.8
Oil pressure (dCi 11 J+01)
Filter head Block rail
Engine speed in
rpm
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).
Temperature
in °C
Temperature
in °C
Pressure
in bar
Block rail
Pressure
in bar
Temperature
in °C
Pressure
in bar
RENAULT V.I. 02/2004
Page 17
B1-8
20 660
RENAULT V.I. 02/2004
Page 18
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
Page 19
B2-2
20 660
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)
Quality class III
dia. and pitch of nuts and bolts
Quality class 8.8 Quality class 10.9
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
10 x 1.00
10 x 1.25
10 x 1.50
12 x 1.25
12 x 1.50
12 x 1.75
14 x 1.50
14 x 2.00
16 x 1.50
16 x 2.00
18 x 1.50
18 x 2.50
20 x 1.50
20 x 2.50
22 x 1.50
22 x 2.50
24 x 2.00
24 x 3.00
7.5 ± 1.5
15 ± 3
20 ± 4
20 ± 4
40 ± 8
40 ± 8
40 ± 8
70 ± 14
65 ± 13
60 ±12
105 ± 21
100 ± 20
160 ± 32
150 ± 30
240 ± 48
210 ± 42
330 ± 66
300 ± 60
450 ± 90
410 ± 82
560 ± 112
510 ± 102
11 ± 2.2
20 ± 4
30 ± 6
27 ± 5.4
60 ± 12
60 ± 12
50 ± 10
100 ± 20
95 ± 19
90 ± 18
155 ± 31
145 ± 29
220 ± 44
220 ± 44
340 ± 68
310 ± 62
480 ± 96
435 ± 87
650 ± 130
595 ± 119
820 ± 164
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
12
14
10 ± 2
20 ± 4
27 ± 5.4
32 ± 6.4
16
18
22
24
RENAULT V.I. 02/2004
40 ± 8
50 ± 10
80 ± 16
80 ± 16
Page 20
20 660
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
B2-3
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
Page 21
B2-4
Air conditioning compressor bracket securing bolt 60 ± 12 Nm
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
20 660
High pressure pump securing nut (tighten in diametrically opposed
sequence, then retighten first nut only)
Breather impeller setscrew 11 ± 1 Nm
Air conditioner and alternator tensioner setscrew 40 ± 8 Nm
60 ± 12 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
RENAULT V.I. 02/2004
Page 22
20 660
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
B2-5
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
RENAULT V.I. 02/2004
Page 23
B2-6
20 660
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
sequence, then retighten first nut only)
Booster pump securing bolts
(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
60 ± 12 Nm
8 ± 1 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
Page 24
20 660
Polyamide pipe union nut 28 ± 2 Nm
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
B2-7
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Page 25
B2-8
20 660
RENAULT V.I. 02/2004
Page 26
Dimensions and tolerances
Cylinder head
20 660
B3-1
* Only for: dCi 11 B43
** With Jake brake
RENAULT V.I. 02/2004
Page 27
B3-2
20 660
RENAULT V.I. 02/2004
Page 28
Timing
20 660
B3-3
Clearance value with reduced play camshaft idler pinion N° 5010 550 239.
RENAULT V.I. 02/2004
Page 29
B3-4
20 660
Engine with power setting A: dCi 11 B43.
Engine with power setting B: dCi 11 + J01.
RENAULT V.I. 02/2004
Page 30
Quick timing check (dCi 11 B43):
20 660
B3-5
– 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
Page 31
B3-6
Quick timing check (dCi 11 + J01):
20 660
– 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: 1.85 →→→→ 2.85 mm.
• Exhaust: 1.80 →→→→ 2.50 mm.
Repeat this check twice so as to provide more accuracy when adjusting the rocker arm clearance
to zero.
RENAULT V.I. 02/2004
Page 32
Reciprocating gear
20 660
B3-7
∅∅∅∅ A ∅∅∅∅ BC
101.966 →→→→> 101.988 76.96 →→→→> 76.98 42.40 →→→→> 42.439
-0.25 101.716 →→→→> 101.738 76.71 →→→→> 76.73 42.90 →→→→> 42.939
-0.50 101.466 →→→→> 101.488 76.46 →→→→> 76.48
-0.75 101.216 →→→→> 101.238 76.21 →→→→> 76.23 43.40 →→→→> 43.439
-1.00 100.966 →→→→> 100.988 75.96 →→→→> 75.98
RENAULT V.I. 02/2004
Page 33
B3-8
20 660
* Only for: dCi 11 B43
RENAULT V.I. 02/2004
Page 34
20 660
B3-9
Only for: dCi 11 (variant 14102) E+J01, G+J01, I+J01, F+J01, H+J01 .
RENAULT V.I. 02/2004
Page 35
B3-10
20 660
* Only for: dCi 11 B43
** Only for: dCi 11 (variant 14102) E+J01, G+J01, I+J01, F+J01, H+J01.
RENAULT V.I. 02/2004
Page 36
20 660
C-1
TOOLS / CONSUMABLES
RENAULT V.I. 02/2004
Page 37
C-2
20 660
Generalities
RENAULT TRUCKS divide tools into three categories:
– General-purpose tools: proprietary tools.
• 50 00 26 .... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department).
• 4-figure reference number (tools classified by RENAULT TRUCKS but available from the supplier).
– Special tools: specifically created tools distributed by the RENAULT TRUCKS Spare Parts Department.
– Locally manufactured tools: these tools are classified differently according to their degree of
sophistication:
• 4-figure reference number (represented by a drawing): tools that are simple to make without need for
special qualification.
• 50 00 26 .... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department): a certain amount of skill is needed to make these tools.
Three levels (or echelons) determine their assignment:
– Level 1: tools for servicing, maintenance and minor tasks.
– Level 2: tools for major repairs.
– Level 3: tools for refurbishment.
Proprietary tools mentioned in this manual do not appear in the tools list.
These tools are identified in the standard tools manual (MO) by a 4-figure number.
RENAULT V.I. 02/2004
Page 38
General-purpose tools
20 660
LIST OF TOOLS
C-3
Illustration
RENAULT
TRUCKS Ref.
5000261000
5000269777
9732
Designation
UNIVERSAL
STAND
ANGULAR
DIAL
BOX OF
CUTTERS
Manufac-
turer
reference
CN 109 B
Manufac-
turer
code
AF
Level Qty
1
1
1
1
1
1
5000260843
PULLER
5000262351
SET OF
PUSHERS
5000260825
PISTON RING
CLAMP
5000261246
PRESSURE
GAUGE
1
1
1
1
1
1
1
1
RENAULT V.I. 02/2004
Page 39
C-4
20 660
AF
CEVMI
50 00 26 2565
15, avenue Paul Doumer
75116
PARIS
01 45 53 97 03
WRENCH
01 45 53 37 05
AB
1
FRANCE
1
AB
FACOM
6 et 8, rue Gustave Eiffel
BP 99
91423
MORANGIS CEDEX
01 64 54 45 45
01 69 09 60 93
FRANCE
RENAULT V.I. 02/2004
Page 40
Special Tools
20 660
C-5
Illustration
RENAULT
TRUCKS Ref.
5000262542
5000262322
5000261380
Designation
FITTING
SOCKET
CONTROL
Manufac-
turer
reference
Manufac-
turer
code
Level Qty
1
1
1
1
1
1
5000269838
COMPRESSING
TOOL
5000261205
PULLER
5000262549
SEAL PLATE
5000263016
HANDLE
1
1
1
1
1
1
1
1
RENAULT V.I. 02/2004
Page 41
C-6
20 660
5000262363
SET OF
PUSHERS
1
1
5000262556
GUIDE
5000261220
PUSHER
5000261281
PULLER
5000261282
PUSHER
1
1
1
1
1
1
1
1
5000262561
PUSHER
5000261230
PULLER
5000262334
FLANGE
1
1
1
1
1
1
RENAULT V.I. 02/2004
Page 42
20 660
C-7
5000262560
GUIDE
5000262562
PUSHER
5000262655
FILTER
WRENCH
5000262589
UNCLIPPER
1
1
1
1
1
1
1
1
5000262547
RETAINER
1
1
RENAULT V.I. 02/2004
Page 43
C-8
Locally manufactured tools
20 660
Illustration
RENAULT
TRUCKS Ref.
1462
2539
FL 1332
Designation
SPACER
PUSHER
PLATE
Manufac-
turer
reference
Manufac-
turer
code
Level Qty
1
1
1
1
1
1
2537
SOCKET
2548
PLATE
2513
TUBE
2648
ENDPIECE
1
1
1
1
1
1
1
1
RENAULT V.I. 02/2004
Page 44
20 660
C-9
RENAULT V.I. 02/2004
Page 45
C-10
20 660
RENAULT V.I. 02/2004
Page 46
20 660
C-11
RENAULT V.I. 02/2004
Page 47
C-12
20 660
RENAULT V.I. 02/2004
Page 48
20 660
LIST OF CONSUMABLES
Automotive reference Industrial reference
FRENETANCH 242
GRAISSE GRIPCOTT NF
S PR A Y M O LY CO TE GN P LU S
DOW CORNiNG
SCELBLOC 648
THREAD LOCKING COMPOUND 242
GRIPCOTT NF GREASE
S P R A Y M O L Y K O T E G N P L U S
DOW CORNING
RETAINING COMPOUND 648
C-13
RECTIJOINT 518
SILMATE RTV 1473
OMNIFIT 50H
GASKETING COMPOUND 518
SILMATE RTV 1473
OMNIFIT 50H SEALING COMPOUND
RENAULT V.I. 02/2004
Page 49
C-14
20 660
RENAULT V.I. 02/2004
Page 50
20 660
D1-1
STRIPPING AND MOUNTING ON STAND
RENAULT V.I. 02/2004
Page 51
D1-2
20 660
Stand 1000
Mounting
RH side
Disconnect flexible pipe (1).
Remove pipes (2).
Remove heat shield (4).
Remove the filters/heat exchanger assembly (3).
UPON ASSEMBLY OF THE BRACKET
WHICH MUST BE EQUAL TO
LH side
Disconnect wiring harness (2).
Remove setscrew (3).
Remove setscrew (1).
Tighten nuts (4).
Remove the ECU / cooler assembly (7).
Remove setscrew (6).
RH side Install tool 2542.
25
MM.
2542, IT IS
VITAL TO ENSURE THE LENGTH UNDER THE HEAD OF SCREW
(5)
RENAULT V.I. 02/2004
Page 52
LH side Install tool 2542.
20 660
D1-3
Fasten the engine to stand N°1000.
RENAULT V.I. 02/2004
Page 53
D1-4
Removal
Install O-rings (A).
20 660
UPON ASSEMBLY, IT IS VITAL TO ENSURE THE LENGTH UNDER THE HEAD OF SCREW
MM.
25
E
NSURE A TIGHT SEAL WITH A SEALING PRODUCT
For the rest of the fitting operations, proceed in the reverse sequence to removal.
Tighten to torque.
See page B-2-2
FRENETANCH 242.
(5)
WHICH MUST BE EQUAL TO
RENAULT V.I. 02/2004
Page 54
Belt tensioner
Removal
20 660
D2-1
Compress the tensioner rollers to disengage the drive belts.
Remove drive belts.
Tighten nuts (1 - 4 - 5).
Remove the tensioner rollers.
Remove setscrew (2).
Remove jockey pulley (3).
RENAULT V.I. 02/2004
Page 55
D2-2
Fitting
20 660
For fitting, proceed in the reverse sequence to removal.
Fit setscrew (5).
Ensure a tight seal with a threadlocking and sealing product FRENETANCH 242.
Tighten to torque.
See page B-2-4
RENAULT V.I. 02/2004
Page 56
20 660
Compressor (air conditioner)
Removal
Remove compressor.
Remove the bracket.
Fitting
For fitting, proceed in the reverse sequence to removal.
Tighten to torque.
See page B-2-3
Fit support.
Start bolts (1 - 2 - 3) at a torque of 6 Nm.
Tighten nut (4) to torque.
Tighten bolts (1 - 2 - 3) to torque.
See page B-2-3
D3-1
Fit the air compressor.
In the indicated sequence
Tighten to torque.
See page B-2-2
Setscrew (2) is a special screw that serves as guide. Replace it only with an identical screw.
RENAULT V.I. 02/2004
Page 57
D3-2
20 660
RENAULT V.I. 02/2004
Page 58
Alternator
Removal
Remove alternator.
Remove the bracket.
Fitting
Fit support.
Start nuts (1 - 2 - 3 - 4) at a torque of 6 Nm.
Tighten bolts (5 - 6) to torque.
Tighten nuts (1 - 2 - 3 - 4) to torque.
See page B-2-3
20 660
D4-1
RENAULT V.I. 02/2004
Page 59
D4-2
20 660
RENAULT V.I. 02/2004
Page 60
20 660
Fan control
Removal
Remove the fan control.
Fitting
For fitting, proceed in the reverse sequence to removal.
Tighten to torque.
See page B-2-5
D5-1
RENAULT V.I. 02/2004
Page 61
D5-2
20 660
RENAULT V.I. 02/2004
Page 62
20 660
Damper
Removal
Remove the damper.
Fitting
For fitting, proceed in the reverse sequence to removal.
Tighten to torque.
See page F-11
Disassembly
D6-1
Depending on the assembly.
Separate hub (2) from damper (3).
Remove pulley (1).
RENAULT V.I. 02/2004
Page 63
D6-2
20 660
Inspection
Check for the absence of:
– knock marks and bellmouthing of fixing holes;
– any cracks;
– points of impact;
– incorrect crimping on the outer part (there should be a regular
thickness of 3 mm);
– distortion on the outer part;
– convexity;
– noise when shaking the damper.
Remove the paint at 4 points on both sides and measure the
thickness of the damper.The deviation between the check points
should be less than 0.25 mm.
If any one of the above defects is noted, replace the damper.
It is essential to clean the damper prior to assembly.
Assembly
The item numbers indicated in the text refer to the drawing on page D-6-1.
Assemble hub (2) to damper (3).
Fit setscrews.
In the indicated sequence
Tighten to torque.
See page B-2-3
Assemble the pulley (1).
Fit setscrews.
Tighten to torque.
See page B-2-3
RENAULT V.I. 02/2004
Page 64
20 660
Starter
Removal
Remove the starter motor.
Fitting
For fitting, proceed in the reverse sequence to removal.
Tighten to torque.
See page B-2-2
D7-1
RENAULT V.I. 02/2004
Page 65
D7-2
20 660
RENAULT V.I. 02/2004
Page 66
20 660
Engine brackets
Removal
Remove the brackets.
Fitting
For fitting, proceed in the reverse sequence to removal.
Tighten to torque.
See page B-2-2
D8-1
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Page 67
D8-2
20 660
RENAULT V.I. 02/2004
Page 68
20 660
E1-1
CYLINDER HEAD
RENAULT V.I. 02/2004
Page 69
E1-2
Removal
Cylinder head exploded view
20 660
** With Jake brake
RENAULT V.I. 02/2004
Page 70
20 660
Removal of cylinder head
The item numbers indicated in the text refer to the drawing on page E-1-2.
Remove the cylinder head cover (8).
Remove the Jake engine-brake unit*.
See page O-3
Disconnect the wiring harness from the injectors.
Remove the wiring harness bracket.
Remove sensor (C).
Remove setscrew (A) so as to withdraw grommet (B) and the wiring
harness.
E1-3
Remove sensor (A).
Remove union (B).
Remove the clamp and clip (C).
Withdraw pipe (1).
RENAULT V.I. 02/2004
Page 71
E1-4
20 660
Remove heat shields (5 - 6) *.
Remove the angle-brackets.
Remove the turbocharger (9).
Remove exhaust manifold (7).
Tighten nuts (21).
Withdraw pipe (15).
Remove inlet manifold (24).
Remove high pressure pipe gallery (25 - 26).
Blank off the ports.
Tighten nuts (13).
Remove the rocker assembly (19).
Withdraw the push-rods.
Classify the parts in order.
RENAULT V.I. 02/2004
Page 72
Tighten nuts (17 - 18).
Remove the cylinder head.
Withdraw cylinder head gasket (22).
Immobilize the liners.
Use tool 1462.
20 660
E1-5
RENAULT V.I. 02/2004
Page 73
E1-6
20 660
RENAULT V.I. 02/2004
Page 74
20 660
Fitting
Fitting of cylinder head
The item numbers indicated in the text refer to the drawing on page E-1-2.
Withdraw tool 1462.
Check for the presence of locating dowels.
Use 2 headless screws (A) diameter: 14 mm, length: 170 mm.
Install cylinder head gasket (22).
Fit the cylinder head.
Tighten nuts (A).
E2-1
Fit setscrews (17 - 18).
In the indicated sequence
Tighten in 4 phases:
st
–1
phase: bolt dia. 20 = 200 Nm
nd
–2
phase: bolt dia. 14 (5010 295 320) = 100 Nm
nd
–2
phase: bolt dia. 14 (5010 550 554) = 120 Nm
rd
–3
phase: bolt dia. 20, loosen then retighten
one-by-one = 100 ± 10 Nm + 180° ± 6°
th
phase: bolt dia. 14 (5010 295 320), loosen then retighten
–4
one-by-one= 60 ± 6 Nm + 100° ± 6°
th
phase: bolt dia. 14 (5010 550 554), loosen then retighten
–4
one-by-one= 80 ± 6 Nm + 100° ± 6°
It is forbidden to subsequently retighten after application of this method.
RENAULT V.I. 02/2004
Page 75
E2-2
Lubrication of setbolts:
– New setbolts: These pre-lubricated bolts do not require any lubrication.
– Re-used setbolts: As early as the second fitment, lubricate the screw-thread under the head with
SPRAY MOLYCOTE GN PLUS DOW CORNiNG.
Use tool 2322 + 9777
Fitting of valve yokes
See page E-2-3
Fitting of rocker shaft
See page E-2-4
Adjustment of valve yokes
See page E-2-4
Adjustment of rocker arms
See page E-2-5
Connect up sensor (C).
Install O-ring (D).
Install grommet (B) and the wiring harness.
Fit setscrew (A).
Fit the wiring harness bracket.
Connect the wiring harness to the injectors.
Tighten to torque.
See page B-2-6
Fit the Jake engine-brake unit.
See page O-3
20 660
Fitting the cylinder head cover
See page E-2-5
Assemble the high pressure pipe lines (25 - 26).
Tighten to torque.
See page B-2-6
Install O-rings (16 - 20).
Assemble sleeve.
Fit the pipe (15).
Fit setscrews (21).
Tighten to torque.
See page B-2-2
Fitting the inlet manifold
See page E-2-6
Connect up sensor (A).
Assemble the clamp and clip (C).
Change the copper joints.
Screw the connector (B).
Tighten to torque.
See page B-2-6
RENAULT V.I. 02/2004
Page 76
Fitting the exhaust manifold
See page E-2-6
Install seal (10).
Assemble turbocharger (9).
Tighten to torque.
See page B-2-5
Assemble heat shields (5 - 6).
See page E-1-4
Proceed in the reverse sequence to removal.
Tighten to torque.
See page B-2-3
Install O-rings (2 - 4).
Assemble sleeve (3).
Fit the pipe (1).
Tighten to torque.
See page B-2-2
Fitting of valve yokes
20 660
E2-3
Apply oil.
Fit the U-bolts.
Ensure the position
Only for: dCi 11 B43
Apply oil.
Fit the U-bolts.
Ensure the position
Do not fit these yokes on other engines.
Risk of engine damage.
RENAULT V.I. 02/2004
Page 77
E2-4
20 660
Fitting of rocker shaft
Apply oil.
Put the push-rods into place.
Ensure the position
Check for the presence of locating dowels.
Remove the rocker assembly.
For engines fitted with Jake brake: provisionally use spacers (A) for
fastening the mechanisms.
In the indicated sequence
Tighten to torque:
– Rocker shaft setbolts: 40 ± 4 Nm + 90 ± 6°
– Jake brake mechanisms to rocker arm assembly setbolts: 60 ± 6 Nm + 120 ± 6°.
Lubrication of setbolts:
– New setbolts: These pre-lubricated bolts do not require any lubrication.
– Re-used setbolts: As early as the second fitment, lubricate the screw-thread under the head with
SPRAY MOLYCOTE GN PLUS DOW CORNiNG.
Adjustment of valve yokes
To be done each time before adjusting the rocker arms:
– With the cylinder at the compression stroke (valves closed),
check for the presence of clearance between the rocker arm
and the valve yoke.
– Loosen locknut (B).
– Free adjusting screw (A).
– With the rocker arm in abutment on the yoke, bring adjusting
screw (A) into contact with the valve
(without exerting any force).
– Tighten locknut (B) to torque while holding the adjusting
screw (A).
See page B-2-3
RENAULT V.I. 02/2004
Page 78
Adjustment of rocker arms
Adjustment values: engine cold:
– Exhaust: 0.70 mm.
–Inlet: 0.40 mm.
20 660
E2-5
Valves in balance
(end of exhaust, start of
induction in cylinder N°)
6
2
4
1
5
3
Use tool 1380.
Tighten the locknuts to torque.
See page B-2-3
Adjust the clearances of
the valves in cylinder N°
1
5
3
6
2
4
Fitting the cylinder head cover
The item numbers indicated in the text refer to the drawing on page E-1-2.
Install seal (14).
Fit rocker cover (8).
Fit the setbolts fitted with rubber sandwich mountings.
Tighten to torque.
– 1: preliminary tighten at 2 Nm.
– 2: tighten at 20 ± 4 Nm.
RENAULT V.I. 02/2004
Page 79
E2-6
20 660
Fitting the inlet manifold
The item numbers indicated in the text refer to the drawing on page E-1-2.
Install seals (23).
Fit intake manifold.
Fit setscrews.
In the indicated sequence
Tighten to torque.
– 1: preliminary tighten at 20 Nm.
– 2 : tighten at 60 ± 12 Nm.
Fitting the exhaust manifold (B43)
The item numbers indicated in the text refer to the drawing on page E-1-2.
Assemble rings (11).
Install seals (12).
Fit exhaust manifold (7).
Fit setscrews.
Smear the screwthreads with GRAISSE GRIPCOTT NF copper grease
In the indicated sequence
Tighten to torque.
– 1: preliminary tighten at 20 Nm.
– 2: tighten at 60 ± 12 Nm.
RENAULT V.I. 02/2004
Page 80
20 660
Fitting the exhaust manifold (+ J01)
The item numbers indicated in the text refer to the drawing on page E-1-2.
Assemble rings (11).
Install seals (12).
Fit exhaust manifold (7).
Fit setscrews.
Smear the screwthreads with GRAISSE GRIPCOTT NF copper grease
E2-7
In the indicated sequence
Tighten to torque.
– 1 : preliminary tighten at 20 Nm.
– 2 : tighten at 40 ± 8 Nm.
RENAULT V.I. 02/2004
Page 81
E2-8
20 660
RENAULT V.I. 02/2004
Page 82
Disassembly/inspection/assembly
Cylinder head detail
20 660
E3-1
** With Jake brake
RENAULT V.I. 02/2004
Page 83
E3-2
20 660
Disassembly
The item numbers indicated in the text refer to the drawing on page E-3-1.
Remove the nozzle-holders.
Take out seals.
See page J-2-10
Remove housing (17).
Take out O-ring (18).
Valves
Compress springs.
Use tool 9838.
Save valve cotters.
Withdraw cups.
Take out springs.
Withdraw cups.
Remove the valves and arrange them in order.
Take out seals (13).
Valve guides Classify the parts in order (14 - 15).
Valve seats
Weld an old valve or a washer to the seat.
Drive out valve seats (19 - 20).
Injector sleeves
Tap to ø 26 x 150 mm.
Withdraw body (12).
Use tool 1205.
Take out O-ring (11).
The injector body is to be replaced when the cylinder head is removed.
Clean after the operation.
Cleaning
If necessary
To decarbonize, take out core plugs (9 - 10 - 16).
RENAULT V.I. 02/2004
Page 84
20 660
Rocker assemblies
Remove locating dowel (1).
Remove pins (5).
Save rocker arms (2).
Withdraw pedestals (3).
Take out springs (4).
If necessary
Classify the parts in order (7 - 8).
Inspection
See page B-3-1
Check the mating surface.
Cylinder head seal
Test the cylinder head for leaks before commencing the overhaul. In
a bath of hot water (80°C), air pressure 6 bars, check for the absence
of air bubbles.
Use tool 2549.
Valves
Check the calibration of the springs.
Check the yokes and the yoke guides guide.
E3-3
Valve guides
Check the radial clearance of the valves in their guides.
Valve seats
Check the valves set-back or protrusion.
Rocker assemblies
Check the rocker arm bore.
Check the rocker shaft.
Assembly / grinding
The item numbers indicated in the text refer to the drawing on page E-3-1.
Fit core plugs (9 - 16).
Use tool 3016 + 2363 ∅∅∅∅ 25 mm.
Fit core plugs (10).
Use tool 3016 + 2363 ∅∅∅∅ 42 mm.
Use a sealing product "SCELBLOC 648".
Ensure a set-back A = 1.5 ± 0.5.
Fire grooves
After grinding the cylinder head, the fire grooves must be machined.
Ensure the dimensions.
See page B-3-2
RENAULT V.I. 02/2004
Page 85
E3-4
Injector sleeves
Apply tallow.
Install O-ring (11).
Insert the sleeve (12).
Install tool 2556.
Flange over at (A).
Use tool 1220.
Withdraw tool 1220.
Use tool 1205.
Withdraw tool 2556.
Test for leaks.
See page E-3-3
20 660
Valve guides
Apply tallow.
Press fit inlet valve guides (14).
Use tool 2539 on side A.
Use a press.
Press fit exhaust valve guides (15).
Use tool 2539 on side B.
Use a press.
After replacing the valve guides, it is essential to grind the valve seats.
As spare part, the valve guides are supplied with 7.6 mm inside diameter.
They must be re-reamed after installation in the cylinder head.
See page B-3-1
RENAULT V.I. 02/2004
Page 86
20 660
Valve seats
Shrink parts in liquid nitrogen or for 12 hours in a deep freezer.
Assemble valve seats (19 - 20).
Use tool 1332.
Use a press.
Grinding valve seats
Prior to grinding the valve seats, make sure the valve guides are in
good condition. Replace them, if necessary.
Method:
The valve guides should serve to centre the tool.
Take into consideration the valves set-back values R to determine
the amount of metal to be removed.
– Grind bearing surface P while ensuring angle A:
•Inlet = 60°
• Exhaust = 45°
E3-5
Depending on the tool used, the angles are datum located either in relation to the cylinder heat
joint face or in relation to the valve centre-line.
Use tool 9732.
Valves
Do not grind the valves.
Do not lap the valves.
Assemble seals on exhaust guides.
Use a suitable tube.
Oil the valve stems and install the valves.
Fit cups.
Fit the springs.
Tension the springs.
Use tool 9838.
Fit valve cotters.
Injector nozzle-holders
Install the nozzle-holders.
See page J-2-10
Check the injector protrusion.
See page B-3-2
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E3-6
Rocker assemblies
Fit core plugs (7 - 8).
Use a sealing product "SCELBLOC 648".
Use a suitable tube.
Apply oil.
Fit rocker arms (2).
Assemble pedestals (3).
Fit the springs (4).
Ensure the position
Fit pins (5).
Fit locating dowels (1).
Install seal (18).
Fit the casing (17).
Fit setscrews.
Tighten to torque.
See page B-2-2
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F-1
VALVE TIMING
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F-2
Exploded view
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* for trucks.
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Removal
The item numbers indicated in the text refer to the drawing on page F-2.
Tappets
Remove tappet cover (5).
Tighten nuts.
Withdraw the tappet retainers (6).
Withdraw tappets (7).
Classify the parts in order.
Damper
Remove damper.
Water pump
Remove the water pump.
Air compressor
Remove compressor.
Hydraulic pump
Remove hydraulic pump.
F-3
Oil sump
Remove the oil level sender.
Use tool 2537.
Remove oil sump (14).
Withdraw gasket (13).
Timing case
Remove breather (2).
Remove timing case (1).
Withdraw seal ring (4).
For replacement only.
Withdraw deflector (A).
Use a press.
Use tool 3016 + 2363 ∅∅∅∅ 68 mm.
High pressure pump
Remove the nut (20).
Extract pinion (23).
Remove the high-pressure pump.
See page J-2-13
Remove impeller (19).
Idler gears
Remove the circlips (21 - 26).
Remove pinions (22 - 27).
Tighten nuts.
Remove hubs (24 - 29).
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F-4
Camshaft
Take off stop (10).
Remove the camshaft assembly (9).
Crankshaft pinion
Take out O-ring (17).
Withdraw spacer (18).
Extract crankshaft pinion (25).
Remove key (11).
Oil pump
Remove pipe (16).
Remove the sensor.
Tighten nuts.
Withdraw the oil pump (15).
Front plate Remove front plate (12).
Inspection
On the camshaft, inspect:
– Coaxiality,
–Cam lift,
– Bearing surface diameter,
– Bushes.
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Check the idler gears
On the tappets, inspect:
– Diameter and housing.
Disassembly
Camshaft pinion
For replacement only.
Extract pinion (28).
Use a press.
Remove key (8).
Camshaft bearing bush
For replacement only.
Withdraw bushes.
Use tool 1281 + 1282
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Air compressor pinion
In a vice.
Use a protective device (A).
Remove the nut.
Fit nuts.
Extract pinion.
Use tool 0843.
Hydraulic pump pinion
In a vice.
Use a protective device (A).
Remove the nut.
Fit nuts.
Extract pinion.
Use tool 0843.
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F-5
Water pump
See page I-3-2
Fan hub
See page I-2-2
Assembly
Camshaft bearing bush
Fit bushes
Use tool 1281 + 1282
Line up the lubrication holes.
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F-6
Camshaft pinion
Install key (8).
Heat the part (28) to 200°C.
Minimum heating time: 60 minutes.
Assemble pinion (28).
Let cool.
Timing case
Put deflectorinto place.
Use a press.
Use tool 2351 ∅∅∅∅ 64 mm
Ensure dimension "A = 3.5 →→→→ 4.0 mm".
Air compressor pinion
Assemble pinion.
Fit the washer.
Screw up nut.
Tighten to torque.
See page B-2-5
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Hydraulic pump pinion
Assemble pinion.
Fit the washer.
Screw up nut.
Tighten to torque.
See page B-2-3
Water pump
See page B-2-5
Fan hub
See page B-2-5
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Fitting
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F-7
Front plate
Ensure a tight seal with a sealing product "RECTIJOINT 518" (A).
Fit front plate (12).
Fit clamp (30).
Fit setscrews.
Screw up without tightening.
Install hubs (24 - 29).
Fit setscrews.
Tighten to torque.
See page B-2-2
Crankshaft pinion
Install key (11).
Apply oil.
Assemble pinion (25).
Match the direction of orientation.
Fit spacer (18).
Position the crankshaft with N° 1 cylinder at TDC.
Use tool 1380.
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F-8
Oil pump
Check for the presence of locating sockets (A).
Assemble oil pump (15).
Fit setscrews.
Tighten to torque.
Check the backlash.
See page B-3-3
Apply oil.
Install O-rings.
Assemble pipe (16).
Fit setscrew.
Tighten to torque.
See page B-2-4
Idler gears
Apply oil.
Fit the pinions (22 - 27)
Ensure the marking.
See page B-3-3
Install circlips (21 - 26).
Check the side play.
Check the backlash.
See page B-3-3
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Camshaft
Apply oil.
Fit the camshaft assembly (9).
Ensure the marking.
Install stop (10).
Fit setscrews.
Use a threadlocking and sealing product "FRENETANCH 242".
Tighten to torque.
Check the backlash.
Check the side play.
See page B-3-3
High pressure pump
Install high-pressure pump.
See page J-2-13
Degrease the tapers.
Install key.
Assemble pinion (23).
Ensure the marking.
Screw up nut (20).
Tighten to torque.
Check the backlash.
See page B-3-3
Fit impeller (19).
Tighten to torque.
See page B-2-4
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F-9
Timing case
Check for the presence of locating sockets (A).
Ensure a tight seal with a sealing product "RECTIJOINT 518" (B).
Fit timing case (1).
Fit setscrews.
Tighten to torque.
See page B-2-2
The tightening sequence starts with the screws in the middle and finishes with those on the outside.
Install O-ring (3).
Fit breather (2).
Tighten to torque.
See page B-2-2
Install tool 2561.
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F-10
Install protective ring (A) to tool 2561
Match the direction of orientation.
The gasket is supplied fitted to a protective ring that is placed on the assembly tool. It is essential
to hold the gasket to the ring until it is finally installed in the case.
Do not apply grease to the lips.
Any gasket that has been removed from its ring must not be re-used.
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Fit seal ring (4).
Withdraw protective ring (A).
Withdraw tool 2561.
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Damper
Install O-ring (17).
Fit damper.
It is essential to replace the setscrews if the length under the head is more than 140 mm
Tighten to torque.
1° Preliminary tighten the bolts at 60 ± 6 Nm in the sequence shown from 1 to 5
2° Tighten the bolts at 180 ± 6 Nm in the sequence shown from 1 to 4
Lubrication of setbolts:
– New selbolts: These pre-lubricated bolts do not require any lubrication.
– Re-used setbolts: As early as the second fitment, lubricate the screw-thread under the head with
SPRAY MOLYCOTE GN PLUS DOW CORNiNG.
F-11
Tappets
Apply oil.
Put tappets (7) into place.
Ensure the position
Fit the tappet retainers (6).
Fit setscrews.
Tighten to torque.
See page B-2-3
Ensure a tight seal with a sealing product "RECTIJOINT 518" (A) + "SILMATE RTV 1473" (B).
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F-12
Fit the tappet cover (5).
Match the direction of orientation.
Fit setscrews.
Tighten to torque.
See page B-2-2
Water pump
Fit water pump-thermostat housing unit.
See page I-3-4
Air compressor
Install O-rings.
Fit the air compressor.
Fit the nuts.
Fit spacer.
Fit screw.
Ensure a tight seal with a threadlocking and sealing product FRENETANCH 242.
Tighten to torque.
See page B-2-5
Hydraulic pump
Install O-ring.
Fit the hydraulic pump.
Tighten to torque.
See page B-2-2
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Oil sump
Check the tightness of the studs.
See page B-2-3
At the intersection of the casings, provide a tight seal with adhesive tape VHB.
Install seal (13).
Fit the oil sump (14).
Install the spacers.
Fit the nuts.
In the indicated sequence
F-13
Tighten to torque.
See page B-2-3
Fit the oil level sender.
Tighten to torque.
See page B-2-4
Use tool 2537.
To find Top Dead Centre:
Use tool 1380 to turn the crankshaft.
– Turn the crankshaft (clockwise) to bring the valves of N° 1
cylinder into balance (end of exhaust / commencement of
admission).
– Place a locally manufactured pointer (a)
– Turn the crankshaft (clockwise) through 3/4 of a revolution.
– Insert a shim (c) with parallel faces (thickness: 7 mm) between
the inlet valve yoke of N° 1 and the rocker arm.
– Turn the crankshaft slowly (clockwise) to bring the piston into
contact with the valve.
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