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77 11 296 742
FEBRUARY 2001
All copyrights reserved by Renault.
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."
Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.
RENAULT 2001
Contents
Page
10
UNITS OF MEASUREMENT All dimensions are given in millimetres (mm) (unless stated otherwise). Tightening torques are expressed in decaNewton metres (daNm) Reminder: 1 daNm = 1.02 m.kg. Pressures in bar Reminder: 1 bar = 100 000 Pa.
TOLERANCES Tightening torques given without a tolerance must be accurate to within: in Degrees ( 3). in daNm ( 10 %).
10-1
10
It displays: A : the engine type B : the engine approval letter D : the Renault identification number E : the engine suffix F : the engine production number G : the engine factory number Capacity (cm 3) 999 1149
Bore (mm) 69 69
10-2
10
* See the procedure for tightening the cylinder head ** See the procedure for tightening the rocker arm rails *** See the procedure for tightening the inlet manifold.
10-3
10
10-4
10
Check that all the bolts are tightened to 2 daNm, then angle tighten (bolt by bolt) by 2306. Do not retighten the cylinder head bolts after performing this procedure.
10-5
10
Firing order: 1-3-4-2 Gasket face bow (mm): No corrections are permitted Test the cylinder head to detect possible cracks using the cylinder head test tools (a container and a kit for the particular cylinder head, plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664 000. Spark plug tightening torque 2 to 2.7 daNm 0.05
Chamber volume with valves and spark plugs: 26.775 1.01 cm3
10-6
10
89 30'
Mating surface width X (in mm) Inlet: Exhaust: 0.994 0.403 1.136 0.377
Valve length (in mm) Inlet: Exhaust: 110.54 to 110.99 112.27 to 112.72
Valve clearance settings (in mm) Inlet: Exhaust: 0.05 to 0.12 0.15 to 0.22
10-7
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The valve stem seals must be fitted using tool Mot. 1511 or the FACOM tool part number DMJ4, for example. 40.15 0.15
11
+ 0.068 + 0.05
* This dimension is measured with the guide fitted in the cylinder head.
Diameter of the guide housing in the cylinder head (in mm) Inlet and exhaust: 110.01
The inlet and exhaust guides have valve stem seals which also act as a lower bearing washer for the valve spring. The seals must be changed every time the valves are removed.
NOTE: do not lubricate the valve stem seals before fitting them.
10-8
10
Position of the inlet and exhaust valve guides (in mm) Inlet and exhaust: B = 10.3 0.15
10-9
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Unloaded length (in mm): Loaded length (in mm): 14.5 daN8 42.8 daN20 Meeting spires (in mm): Diameter of wire (in mm): Internal diameter (in mm): Upper Lower External diameter (in mm): Upper Lower
40.20
14.100.2 16.800.2
20.300.2 230.2
10-10
10
Cylinder block top dead centre fixed mark. Flywheel top dead centre mobile mark. Flywheel bottom dead centre mobile mark. Inlet opening delay. Exhaust closing advance. Inlet closing delay. Exhaust opening advance. Engine operating direction (flywheel end).
Graph showing timing with a calculated clearance of zero (cannot be checked) Inlet opening delay* Inlet closing delay Exhaust opening advance Exhaust closing advance** * ** - 10 31 25 - 8
If the inlet opening delay is negative, the valve opening can be found after top dead centre. If the exhaust closing advance is negative, the valve opening can be found before top dead centre.
10-11
10
1 2 3 4 5 6 7
Direction of fitting of piston, flywheel side Piston diameter grade (A - B) Used by the supplier only Used by the supplier only Piston symmetry axis Gudgeon pin hole axis Offset between the pin hole (6) and the piston symmetry axis (5) is 0.8 mm
10-12
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D4D engine E 10
D4F engine 9
D4D engine Position of holes T on the cylinder block CYLINDER BLOCK BARREL SIZES IMPORTANT: the diameters of the pistons and the barrels must be matched on the cylinder block. Thus, the position of the holes T, in relation to the gasket face of the cylinder block, is used to identify the original nominal dimension of the barrel and consequently the diameters of the corresponding pistons. 1 = 5 mm 2 = 9 mm Grade marking on the pistons A B Piston diameter (mm) 68.9560.006 Barrel diameter (mm) 69 0.015
68.9640.006 69.0150.015
D4F engine Position of holes T on the cylinder block 1 = 5 mm 2 = 9 mm Grade marking on the pistons A B Piston diameter (mm) 68.9760.006 Barrel diameter (mm) 69 0.015
68.9840.006 69.0150.015
10-13
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Rings set to their original adjustment must be able to move freely in their channels. Ensure the rings are fitted the correct way round with the TOP pointing upwards. Oil and the piston rings and divide into three.
Piston ring brake clearance Clearance at the break (in mm) 0.20 to 0.35 0.35 to 0.50 0.2 to 0.9
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0.21 to 0.453 0.025 to 0.064 1220.03 + 0.11 0 - 0.021 - 0.039
Length: External diameter (A): Internal diameter (B): Collar inner diameter (C) : Inner collar length (D) :
54
WARNING: do not use a sharp point to mark the bearing caps in relation to their con rods to avoid starting a crack in the rod. Use a permanent marker pen.
9.660.2 8.20.15
The gudgeon pins (E) are fitted with ring B19, centre tool C19 and fitting shaft A19 (Mot. 574-25).
The maximum weight difference for the con rod, piston and gudgeon pin assemblies for the same engine must be 11 grams.
10-15
10
The crankshaft bearing shells are fitted on the cylinder block and on the bearings using Mot. 1493-02. CRANKSHAFT Number of bearings Burnished bushings: (in mm) nominal diameter Burnished crankpins: (in mm) nominal diameter 44 0.01
0 - 0.016
40
lateral play of the crankshaft (in mm) 0.045 to 0.235 radial play of the crankshaft (in mm) 0.02 to 0.046 The crankshaft stroke is: D4D engine Crankshaft stroke (mm) 66.80.05 D4F engine 76.80.05
10-16
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The engine is fitted with bearing shells without a locator notch. The bearing shells are fitted using Mot. 1492 and Mot. 1492-04.
10-17
10
10-18
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Place the rods (G), (H), (W1) and the plate (H1) Mot. 1360-01 (including rod W1 and plate H1), on the cylinder block so that they fit into the holes (18, 8, 4) on the plate (Mot. 792-03).
NOTE: before fitting the rods to the cylinder block, you need to alter rod W1 by making a chamfer of the following dimensions: X = 10 mm Y = 15 mm
10-19
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Part no. 77 01 421 513 77 01 405 952 77 01 404 452 77 01 421 042 77 01 394 070
WARNING PARTS TO BE REPLACED AFTER REMOVAL: all the gaskets, flywheel bolts, crankshaft bearing bolts, con rod cap bolt, belts, timing gear tension wheel, cylinder head bolts
FITTING THREAD INSERTS Threaded holes on all engine component parts can be repaired by using thread inserts.
10-20
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Remember to remove: all coolant flexible hoses, the inlet and exhaust manifolds, the alternator, the air conditioning compressor, the multifunction supports, the oil level sensor, the cylinder head coolant output unit.
The used engine should be secured to the base under the same conditions as the overhauled engine: plastic plugs and covers fitted, cardboard cover over the assembly. WARNING: never place the engine on the sump (risk of destroying the oil pump strainer).
10-21
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Description
Illustration
Part number
Mot. 574-25
00 00 057 425
Gudgeon pin fitting tool (centre tool C19, shaft A19, and ring B19)
Mot. 582-01
00 00 058 201
Mot. 591-02
00 00 059 102
Mot. 591-04
00 00 059 104
Mot. 799-01
00 00 079 901
Mot. 1054
00 00 105 400
Mot. 1330
00 00 133 000
Mot. 1335
00 00 133 500
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Description
Illustration
Part number
Mot. 1354
00 00 135 400
Mot. 1355
00 00 135 500
Mot. 1360-01
00 00 136 001
Mot. 1374
00 00 137 400
Mot. 1377
00 00 137 700
Mot. 1381
00 00 138 100
El. 1382-01
00 00 138 201
Mot. 1492
00 00 149 200
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Mot. 1492-04
00 00 149 204
Mot. 1493-02
00 00 149 302
Mot. 1502
00 00 150 200
Mot. 1505
00 00 150 500
Mot. 1511
00 00 151 100
Mot. 1573
00 00 157 300
Mot. 1587
00 00 158 700
Mot. 1605
00 00 160 500
10-24
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Description
Standard 22 mm long socket 1/2" (12.7 mm squared) for removing the oil pressure gauge.
Tooling for testing the cylinder head, including: a tray and the various kits suited for each model of cylinder head (plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664000.
Angular tightening tool from: STAHLWILLE part number 540 100 03 for example, FACOM part number DM360 for example, SAM part number 1 SA for example.
FACOM tool for fitting the valve stem seals, part number DM6J4 for example.
Angled tweezers (pliers) from: SAM, part number 366.1 for example, FACOM, part number 151 for example.
10-25
10
Remove: the upper timing housing (1), the crankshaft accessories pulley (2), the intermediate timing cover (3),
10-26
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Check that the mark (7) on the camshaft pulley is on the vertical shaft of the engine. Unscrew the nut (8) on the timing gear tension wheel, then remove the timing belt.
Insert the TDC setting pin Mot. 1054, then turn the crankshaft until it is pinned.
10-27
10
Disengage the electric wiring harness from the inlet manifold. Remove: the cylinder head cover,
10-28
10
the camshaft seal gasket by screwing the puller tool Mot. 1381 into the seal gasket.
10-29
10
Remove: the lifting rings, the cylinder head coolant output unit, the camshaft adjuster,
10-30
10
the camshaft,
10-31
10
Remove: the pins, the upper cups, the springs, the valves, the valve guide seal gaskets using the Mot. 1335 pliers.
10-32
10
Tighten bolts (1) and (2) to a torque of 0.9 daNm. Pretighten bolts (3), (4), (5), (7), (8), (9), (10), (11) and (12) in the recommended order to a torque of 0.5 daNm. Unscrew bolt (3) until it is free, then tighten bolt (3) to a torque of 0.7 daNm plus an angle of 506. Repeat the process for bolts (4), (5), (6), (7), (8), (9), (10), (11) and (12).
CHECKING THE MATING SURFACE Check for mating surface bow using a ruler and a set of shims. Maximum bow 0.05 mm
CORRECTION OF THE CYLINDER HEAD IS NOT AUTHORISED Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit suited to the cylinder head, plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664000.
10-33
10
The valve stem seals must be fitted using tool Mot. 1511 or the FACOM tool, part number DMJ4.
Remove the rocker arm shafts, the camshaft bearing caps and the camshaft.
NOTE: do not lubricate the valve stem seals before fitting them.
10-34
10
Place the valve stem seal (not lubricated) over the tool barrel.
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).
Push the valve stem seal past the tool barrel, then withdraw the barrel.
10-35
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.
NOTE: the internal diameter of the pushrod must be identical to the diameter of the valve stem. Moreover, the lower part of the pushrod must be in contact with the upper section of the valve stem seal.
10-36
10
10-37
10
10-38
10
Refit: the camshaft bearing caps by tightening the bolts (1) and (2) to a torque of 0.9 daNm. Apply: two lines (3) of Rhodorseal 5661, 2 mm wide, on cylinder head bearing 5, two beads (4) of Rhodorseal 5661 on cylinder head bearing 1.
10-39
10
Refit: the engine lifting bracket, the cylinder head coolant output unit fitted with a new seal by tightening the bolts to a torque of 0.9 daNm, the camshaft adjuster using tool Mot. 1605.
10-40
10
Screw the threaded rod (3) from tool Mot. 1587 into the camshaft.
Fit the seal gasket and protector on the camshaft. Be careful not to touch the seal.
10-41
10
Remove the nut, the canister, the protector and the threaded rod. Screw the collar nut until the canister touches the cylinder head.
10-42
10
Refit: the inlet manifold fitted with a new seal by tightening the nuts to a torque of 2.5 daNm in the recommended order,
the tension wheel by positioning it correctly. Fit the tension wheel notch (5) into the cylinder wheel rib (6).
the exhaust heat shield by tightening the bolts to a torque of 1.5 daNm.
10-43
10
Bring the exhaust valve of cylinder no. 1 to the fully open position, then adjust the inlet valve clearance for cylinder no 3 and the exhaust valve clearance for cylinder no 4. Follow the same method for the other cylinders, in the order shown by the table below.
10-44
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the crankshaft seal gasket on the flywheel side by screwing puller tool Mot. 1377 into the seal gasket.
the flywheel,
10-45
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the oil pump seal gasket by screwing puller tool Mot. 1374 into the seal gasket.
Remove the seal gasket by screwing the bolt (2) of tool Mot. 1374.
10-46
10
WARNING: do not use a sharp point to mark the big end caps in relation to their con rods, to prevent starting a crack in the rod. Use a permanent marker pen.
10-47
10
Clean: the cylinder block, the oil pump, the coolant pump, the crankshaft, the seal supporting ring,
10-48
10
The con rod bearing shells are fitted using Mot. 1492 and Mot. 1492-04. On the con rod body Remove the pin (1) from Mot. 1492 (using a jaw vice), and replace it with the pin (2) from Mot. 1492-04.
10-49
10
Push the shell support in the direction of the arrow (as shown in the diagram) as far as it can go into the con rod body.
Lay the body of the con rod on the base of the tool (as shown in the diagram). Ensure that the lower part (6) of the small end of the con rod is in contact with the centring pin. Then place the shell (7) on the shell support.
Remove the con rod body support and repeat the operation for the remaining con rod bodies.
10-50
10
Push the shell support in the direction of the arrow (as shown in the diagram) as far as it can go into the con rod cap.
Push the rail (in the direction of the arrow) until the con rod cap touches the bar. Then place the shell (9) on the shell support.
Remove the con rod cap support and repeat the operation for the remaining con rod caps.
10-51
10
The gudgeon pins are tightened in the con rods and able to rotate in the pistons before they are fitted. Use tooling Mot. 574-25 (to be ordered from the Replacement Parts Store to complete Mot. 574-22). A : fitting pins with centrers (C). B : piston supporting rings, M : extraction mandrel, S : piston support base,
10-52
10
Check that the gudgeon pins rotate properly in the corresponding new pistons. Use tool Mot. 574-25 containing centre tool C19 and pin fitter A19. Place the gudgeon pin (E) on the pin fitter (A), screw the centre tool (C) until it touches, and then unscrew one quarter of a turn.
10-53
10
Follow these instructions when assembling the piston and con rod:
q
Fit ring B19 on the support and place the piston (arrow pointing downwards) on the ring, securing it with the pin.
Grease the centre tool and the gudgeon pin with engine oil. q Drive the gudgeon pin into the assembly to check that it can move freely and re-centre the piston if necessary.
q
10-54
10
Rings set to their original adjustment must be able to move freely within their channels. Ensure that the rings are fitted the correct way round as shown in the diagram.
Ensure that the gudgeon pin remains set back from the piston diameter for all the positions of the con rod in the piston .
10-55
10
Fit the grooved bearing shell in Mot. 1493-02, then press at (1) until the bearing shell is touching Mot. 1493-02 at (2).2
Fit the non-grooved bearing shell in Mot. 1493-02, then press at (3) until the bearing shell is touching Mot. 1493-02 at (4).
10-56
10
Fit the con rod caps, ensuring that they are correctly matched (use the marks made on removal).
Check the crankshaft clearance which should be between 0.045 and 0.235 mm.
10-57
10
NOTE: the crankshaft closure panel is sealed with RHODORSEAL 5661. The band (1) must be 1.3 mm wide and be applied as shown in the diagram below.
Check the lateral clearance of the big end which should be between 0.21 and 0.453 mm. Tighten the crankshaft closure panel bolts on the flywheel side to a torque of 0.9 daNm in the recommended order.
10-58
10
IMPORTANT the oil pump is driven by two studs : located on the crankshaft. Tighten the coolant pump bolts to a torque of 0.9 daNm in the recommended order. NOTE: the oil pump is sealed with RHODORSEAL 5661. The band (4) must be 1.3 mm wide and be applied as shown in the diagram below.
18646R ]
10-59
10
Fitting the crankshaft seal gaskets flywheel side, use tool Mot. 1354.
Replace the strainer fitted with a new O-ring by tightening the bolts to a torque of 0.9 daNm.
10-60
10
the flywheel by tightening the new bolts to a torque of 1.8 daNm, then turning to an angle of 1106 (blocking the flywheel with Mot. 582-01).
Refit: the sump, tightening the bolts to a torque of 1 daNm in the recommended order.
10-61
10
Refit the oil filter by tightening it to a torque of 2 daNm to prevent any leaks. NOTE: the coolant pipe is sealed with RHODORSEAL 5661. The band (3) must be 1.3 mm wide and be applied as shown in the diagram below.
Hold the filter upside down and tap it on a piece of wood to remove the filter element.
10-62
10
Replace the cylinder head cover seal. Refit the cylinder head cover, tightening the bolts to a torque of 1.2 daNm in the recommended order.
10-63
10
Replace the inlet manifold seals and the oil vapour seal. Position the inlet manifold. Place a drop of Loctite FRENETANCH on the inlet manifold bolts. Tighten the eight bolts by hand, then pretighten bolts (4) and (5) to a torque of 0.6 daNm. Loosen bolts (4) and (5) until they are completely free. Tighten the eight bolts to a torque of 1 daNm in the recommended order.
Check that the wiring harness is correctly positioned at (1) and (2) before refitting the inlet manifold.
10-64
10
Adjusting the timing Check: that the tension wheel notch (5) is correctly positioned in the cylinder wheel rib (6).
that the crankshaft timing sprocket mark (7) is facing the oil pump body mark (8).
10-65
10
Turn the tension wheel eccentric ring anti-clockwise using a 6 mm Allen key to bring the tension wheel mobile index (A) into the position shown below.
Tighten the crankshaft accessories pulley bolt fitted with its washer to a torque of 1.5 daNm, to hold the timing sprocket in place. Tighten the tension wheel nut to a torque of 2.4 daNm. Fit the timing belt by aligning the belt markings with those on the camshaft and crankshaft sprockets. Rotate the crankshaft through six revolutions in a clockwise direction (timing side). Refit the TDC pin Mot. 1054 and position the timing at setting point (check that the camshaft and crankshaft sprocket marks are correctly aligned with the fixed marks). Remove the TDC setting pin Mot. 1054.
10-66
10
Remove the accessory crankshaft pulley bolt. Refit: the lower timing cover, NOTE: it is vital that you tighten the tension wheel nut to torque to avoid any loosening which may cause damage to the engine.
10-67
10
Refit: the alternator support, tightening the bolts to a torque of 5 daN.m, the coolant pipe fitted with a new seal, the air conditioning compressor mounting, tightening the bolts to a torque of 5 daNm,
Remove the flywheel block Mot. 582-01. Remove the engine from support Mot. 792-03.
the power assisted steering pump support (for engines fitted with air conditioning and power assisted steering), tightening the bolts to a torque of 2.5 daNm, the air conditioning compressor, tightening the bolts to a torque of 5 daNm, the power assisted steering pump by tightening the bolts to a torque of 2.2 daNm, the alternator by tightening the upper bolt to a torque of 2.5 daNm and the lower bolt to a torque of 5 daNm, the accessories belts.
10-68
10
A B C D G T
Crankshaft Alternator Power assisted steering pump Air conditioning compressor Tension Wheel Point for checking belt tension
10-69
10
Air conditioning and power assisted steering belt 210 5
10-70