Workshop Repair Manual: Engine Fitted On The: - Megane: DA03 F5R 740 EA03
Workshop Repair Manual: Engine Fitted On The: - Megane: DA03 F5R 740 EA03
Workshop Repair Manual: Engine Fitted On The: - Megane: DA03 F5R 740 EA03
4 cylinders - F5R
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
© RENAULT 1999
Contents
Pages
- Foreword 10-4
- Specifications 10-8
The petrol direct injection system is very sensitive to pollution. The risks caused by the introduction of pollution are:
– damage to or destruction of the high pressure injection system,
– seizing or incorrect sealing of a component,
– destruction of the engine (by continuously injecting into the cylinder).
All after-sales operations must be performed under very good cleanliness conditions. This means that no impurities
(particle of several microns in size) must enter the high pressure injection system whilst dismantling or the circuits
through the fuel connectors.
The cleanliness principle must be applied from the filter to the injectors.
WARNING: cleaning the engine with a high pressure jet may damage the connections. In addition, moisture may
collect in the connectors and create electrical connection problems.
Water may also build up in the injector and plug wells which open out directly into the cylinder.
10-1
ENGINE AND PERIPHERALS
Cleanliness / Safety 10
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY REPAIRS ON THE INJECTION SYSTEM
● Ensure that you have the blanks for the connectors which are to be opened (bags of blanks sold from the Parts
Stores). Blanks are to be used once only. They must be disposed of after use. It is not sufficient to clean them in
order to reuse them.
● Ensure that you have the resealable plastic bags for storing removed parts. Stored parts will therefore be less
subject to the risk of impurities. Bags are to be used once only and should be disposed of after use.
● Ensure that you have lint free cleaning cloths (supplied by SODICAM). The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint free and may pollute the fuel circuit of the system. Each lint
free cloth should only be used once.
● For each operation, use new thinner (used thinner contains impurities). Pour it into a clean container.
● For each operation, use a clean brush which is in good condition (the brush must not lose its hairs).
● Using a brush and thinner, clean the parts to be dismantled, the tools which are to be used and the part of the bench
used.
● When wearing protective gloves, cover leather gloves with latex gloves (available from SODICAM).
● As soon as the circuit is open, all openings must be blanked to prevent pollution from penetrating the circuit. The
blanks to be used are available from the Parts Stores. They must not be reused under any circumstances.
● Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries pollution.
● All components of the injection system must, after having been blanked, be stored in a hermetically sealed plastic
bag.
● After opening the circuit, the use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden. These
items may effectively allow impurities to enter the system.
● When replacing a component with a new one, do not remove it from its packaging until it is to be fitted to the vehicle.
● When cleaning a gasket face, use lint free absorbent paper. Start from the centre of the part and progressively
clean towards the outside so as to move the impurities outwards.
10-2
ENGINE AND PERIPHERALS
Cleanliness / Safety 10
10-3
ENGINE AND PERIPHERALS
Foreword 10
USING THE MANUAL
– technical specifications,
UNITS OF MEASUREMENT
– Pressures in bar
Reminder: 1 bar = 100 000 Pa.
TOLERANCES
– in Degrees (± 3˚).
– in daN.m (± 10 %).
10-4
ENGINE AND PERIPHERALS
Engine identification 10
ENGINE IDENTIFICATION It contains:
The engine is identified by a plate riveted onto the A: the engine type
cylinder block. B: the engine approval letter
C: the Renault identification
D: the engine suffix
E: the engine assembly factory
F: the engine fabrication number
10-5
ENGINE AND PERIPHERALS
Tightening torques (in daN.m or in degrees) 10
Top of engine:
10-6
ENGINE AND PERIPHERALS
Tightening torques (in daN.m or in degrees) 10
Engine peripherals:
- M8 bolts 2.5
Timing tensioning roller nut 2.8
Water pump inlet pipe bolts 3.6
Pinking sensor 2
Multifunction support bolts 4.4
10-7
ENGINE AND PERIPHERALS
Specifications 10
CYLINDER HEAD
The bolts can be reused if the length under the head does not exceed 137.7 mm (otherwise replace all the
bolts).
REMINDER: in order to obtain the correct tightening of the bolts, use a syringe to remove any oil which may have
entered the cylinder head mounting bolt holes.
Do not oil new bolts. However, when reusing bolts, they must be oiled with engine oil.
Check that all the bolts are tightened to 2 daN.m, then perform angular tightening (bolt by bolt) of 200˚ ± 6˚.
Do not retighten the cylinder head bolts after applying this procedure.
10-8
ENGINE AND PERIPHERALS
Specifications 10
Thickness of the cylinder head gasket Cylinder head height
– thickness of the
compressed gasket: 0.65 ± 0.02 mm.
R
R
10-9
ENGINE AND PERIPHERALS
Specifications 10
Hydraulic tappets Setting angle
VALVE SEATS
Seat angle α
10-10
ENGINE AND PERIPHERALS
Specifications 10
VALVE GUIDES Fitting valve stem seals
+ 0.068
Inlet and exhaust: 11 + 0.05
+ 0.075
Non machined: 5 0
+ 0.018
Machined*: 5.5 0
15771-1S
10-11
ENGINE AND PERIPHERALS
Specifications 10
Keep the valve pressing against its seat. Fit the pushrod (1) on the valve stem seal.
Fit the valve stem seal (non oiled) onto the plug.
15771-5R
15771-2S
NOTE: the internal diameter of the pushrod must
be the same as that of the valve stem. In addition,
Push on the valve stem seal until its goes past the plug the bottom of the pushrod must press against the
then remove the plug. part of the valve stem seal which acts as the lower
bearing washer for the valve spring.
15771-3S
10-12
ENGINE AND PERIPHERALS
Specifications 10
Press the valve stem seal down by tapping with the Angle of the inlet and exhaust guides (in degrees)
palm of your hand on the top of the pushrod, until
the valve stem seal touches the cylinder head.
Inlet: 63˚
15771-6S 15646S
Exhaust: 61˚
15770S
10-13
ENGINE AND PERIPHERALS
Specifications 10
Position of the inlet and exhaust valve guides CAMSHAFT
(in mm)
The camshaft can be identified with a marking (A).
Inlet: A = 9.5 ± 0.15
Exhaust: A = 9.5 ± 0.15
Number of coils: 23
10-14
ENGINE AND PERIPHERALS
Specifications 10
Longitudinal clearance (in mm) Timing diagram (cannot be checked)
Flywheel side
2
0
3 25 – 0.021
4 R
5
A) A4 - 1 = Inlet of cylinder 4 and cam n˚ 1.
0
6 28 – 0.021 or
E4 - 1 = Exhaust of cylinder 4 and cam n˚ 1.
Timing side
B) A4 - 2 = Inlet of cylinder 4 and cam n˚ 2.
or
E4 - 2 = Exhaust of cylinder 4 and cam n˚ 2.
10-15
ENGINE AND PERIPHERALS
Specifications 10
PISTONS
MAHLE piston
Piston marking
82.710 inclusive
2 or B 82.680 ± 0.007 to
82.720
exclusive
82.720 inclusive
3 or C 82.690 ± 0.007 to
82.730 inclusive
10-16
ENGINE AND PERIPHERALS
Specifications 10
Class of cylinder block barrels
Position of the holes T Reference of the class Barrel diameter Piston diameter
on the cylinder block on the piston (mm) (mm)
82.710 inclusive
T = 13 mm 2 or B to 82.680 ± 0.007
82.720 exclusive
82.720 inclusive
T = 19 mm 3 or C to 82.690 ± 0.007
82.730 inclusive
10-17
ENGINE AND PERIPHERALS
Specifications 10
Measuring the piston diameter RINGS
– 0.01
– Sealing: 1.5
– 0.03
10-18
ENGINE AND PERIPHERALS
Specifications 10
Fitting the rings
Gudgeon pin (in mm)
15650S
CON RODS
0.22 to 0.402
0.020 to 0.071
144 ± 0.035
23 (without ring)
21 (with ring)
10-19
ENGINE AND PERIPHERALS
Specifications 10
WARNING: do not use a punch
to reference the con rod caps in
relation to their body to prevent
creating a fracture line in the
con rod.
15183S
10-20
ENGINE AND PERIPHERALS
Specifications 10
Direction of fitting of the con rod in relation to the CRANKSHAFT
piston
Number of bearings: 5
Position the "Λ" (1) engraved on the top of the piston
downwards and the lubrication hole (2) of the little end
in line with the vertical axis (as shown on the diagram Burnished main bearing journals:
below).
– nominal diameter (in mm) 54.795 ± 0.010
0.04 to 0.075
BEARING SHELLS
R
Crankshaft bearing shells
NOTE: put the break in the spring ring of the The engine is fitted with bearing shells without a
gudgeon pin at the top at ± 45˚ to the vertical axis foolproofing device.
of the piston.
15197S
16082S
10-21
ENGINE AND PERIPHERALS
Specifications 10
Direction of fitting
– on the cylinder block, fit grooved bearing shells on all the bearings,
– on the bearing cap, fit non grooved bearing shells on all the bearing caps.
15181S
Cylinder block Fit the bearing shell in tool Mot. 1493, then press at
(A) until the bearing shell is touching tool Mot. 1493 at
Fit tool Mot. 1493 on the cylinder block. (B).
R 15469-1R
10-22
ENGINE AND PERIPHERALS
Specifications 10
Bearings
10-23
ENGINE AND PERIPHERALS
Specifications 10
CON ROD BEARING SHELLS Fitting the bearing shell in the con rod body
The engine is fitted with bearing shells without a Select the bearing shell support (1) corresponding to
foolproofing device. the engine (engine type (2) marked on the support).
15655S
15743R1
10-24
ENGINE AND PERIPHERALS
Specifications 10
Place the bearing shell (5) on the bearing shell support Fitting the bearing shell on the con rod cap
as shown on the diagram below.
Place the con rod cap against the pins (6) of the base,
then position the bearing shell (7) on the bearing shell
support.
15744-1R
15745S
Then release the support from the con rod body and
proceed in the same manner for the other con rods. 15747S
10-25
ENGINE AND PERIPHERALS
Specifications 10
OIL PUMP
Dismantling
Remove the five bolts (1), lift off the cover and remove:
– the clip (2),
– the end stop (3),
– the spring (4),
– the valve (5).
R 10024
10-26
ENGINE AND PERIPHERALS
Specifications 10
Checking the oil pump clearances
– min 0.110
– max 0.249
– min 0.020
– max 0.086
10-27
ENGINE AND PERIPHERALS
Specifications 10
Reassembling
Refit:
– the valve (5),
– the spring (4),
– the end stop (3),
– the clip (2) by fitting it in the same direction as shown on the diagram
below,
– the pump cover (bolts 1).
R 10024
10-28
ENGINE AND PERIPHERALS
Specifications 10
Before mounting the engine on the
stand Mot. 792-03, the engine's
electrical harness must be
removed and the engine oil
drained.
Remove:
– the exhaust heat shield,
16079S1
Remove:
– the EGR valve / hose assembly,
– the oxygen sensor using tool
Mot. 1495.
16080S
10-29
ENGINE AND PERIPHERALS
Specifications 10
– the exhaust manifold.
15619S
15619-2R
10-30
ENGINE AND PERIPHERALS
Specifications 10
CONSUMABLES
– Injector clips.
10-31
ENGINE AND PERIPHERALS
Standard replacement 10
PREPARING THE USED ENGINE FOR RETURN
Remember to remove:
– all coolant flexible hoses,
– the belt or belts (except the timing belt).
10-32
ENGINE AND PERIPHERALS
Essential special tooling 10
Method Part
Illustration Description
Reference Number
69716S1
10-33
ENGINE AND PERIPHERALS
Essential special tooling 10
Method Part
Illustration Description
Reference Number
Mot. 990-03 00 00 099 003 Tool for fitting crankshaft seal, timing side.
96897S
Mot. 991-01 00 00 099 101 Tool for fitting crankshaft seal, flywheel side.
96898S
Mot. 995 00 00 099 500 Set of 2 rods (used with engine plate Mot. 793-03).
84900S1
97160-1S1
Mot. 1335 00 00 133 500 Pliers for removing valve steam seals.
12875S1
10-34
ENGINE AND PERIPHERALS
Essential special tooling 10
Method Part
Illustration Description
Reference Number
15868S1
Mot. 1488 00 00 148 800 Tool for refitting exhaust camshaft covers.
Mot. 1492 00 00 149 200 Tool for fitting con rod bearing shells.
15867S1
Mot. 1493 00 00 149 300 Tool for fitting crankshaft bearing shells.
15866S1
Mot. 1495 00 00 149 500 Socket for removing and refitting oxygen sensor.
Mot. 1511 00 00 151 100 Tool for fitting valve stem seals.
15737S1
10-35
ENGINE AND PERIPHERALS
Essential special tooling 10
Method Part
Illustration Description
Reference Number
Mot. 1516 00 00 151 600 Tool for fitting piston coolers orientated at 5˚.
15863S1
Mot. 1532 00 00 153 200 Tool for removing petrol injection rail.
Mot. 1533 00 00 153 300 Tool for fitting injector Teflon seals.
10-36
ENGINE AND PERIPHERALS
Essential equipment 10
Description
Standard 1/2" 22 mm long socket (12.7 mm square) for removing oil pressure
gauge.
Tooling for testing the cylinder head including : a container and the various kits
suited to each cylinder head model (plug, sealing plate, blank). The approval
number of the cylinder head test container is 664 000
Tool for fitting valve stem seals from FACOM, part number DM 6J4 for example.
10-37
ENGINE AND PERIPHERALS
Overhauling the engine 10
Removing the engine – the inlet manifold,
Remove:
– the air expansion chamber,
15616S
15618S
– the high pressure fuel pipe using the Mot. 1383 tool,
– the high pressure fuel pump.
– the coil and the ignition harness,
15617R3
15615S
10-38
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove: – the Top Dead Centre setting pin cap,
– the accessories drive belt by turning the spanner to
the right to slacken the belt.
Lock the roller using a 6 mm Allen key (1),
15102-1R
15578-3S
10-39
ENGINE AND PERIPHERALS
Overhauling the engine 10
Positioning the belt at the timing
point
Method
Position the exhaust camshaft
pulley mark (1) one tooth before the
exhaust camshaft sensor mounting
(2). The camshaft grooves must be
below and almost horizontal as
shown in the following
illustration.
15740-1R
15614-1S
10-40
ENGINE AND PERIPHERALS
Overhauling the engine 10
Then insert the Top Dead Centre setting pin Correct position (crankshaft locked)
Mot. 1054, so that it is between the balancing hole
and the crankshaft locking slot.
15163-1S
15163-2S
Incorrect position
15163S
10-41
ENGINE AND PERIPHERALS
Overhauling the engine 10
Turn the engine clockwise (from
timing side), until the timing point is
reached.
The camshaft grooves must be
horizontal and off-centred
downwards as shown in the
illustration. Also, the camshaft
pulley mark must be opposite the
sensor mounting.
15614S
15740S 15163-1S
10-42
ENGINE AND PERIPHERALS
Overhauling the engine 10
Fit the flywheel lock Mot. 582-01,
and remove the Top Dead Centre
pin (otherwise, there is a risk of
breaking the crankshaft).
Remove:
– the middle timing cover,
15578-5S
10-43
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the lower timing cover,
15578-2S
15578-1S
10-44
ENGINE AND PERIPHERALS
Overhauling the engine 10
Slacken the tension wheel securing
nut (3).
Remove:
– the pulley (4),
15578R1
16078R3
10-45
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the power steering pump pulley, – the power steering pump mounting bolts (2) and nut
(3),
15576-2S
15575R1
15576-4R
15576-3S
10-46
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the air conditioning compressor, – the rear timing protection strip by removing the bolt
(1),
15576-1S
15574R1
15576R1
10-47
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the harness securing bolts.
15613R3
The gallery is extracted using the Mot. 1532 tool. Screw the sockets (1) to the gallery in place of the
gallery securing bolts.
Locate the bolts (2) in the sockets (1), then extract the
gallery by progressively tightening the bolts (2).
16126R1
10-48
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove the injector clips. Fit the Mot. 1530 tool to the injector, then rotate it to
break the oil-carbon deposit on the head of the
Fit the protective blanking pieces over the injector injector.
inlet holes.
16635S
Remove:
– the oil filler orifice,
15612S
10-49
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the EGR valve mounting,
15612-3R
15612-2S
10-50
ENGINE AND PERIPHERALS
Overhauling the engine 10
Vertically loosen:
– the inlet camshaft bearing cap
cover by tapping the lugs (1) with
a mallet,
15612-1R
15660-1R
10-51
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove:
– the camshafts,
15656S
15657S
10-52
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the cylinder head.
15659S
10-53
ENGINE AND PERIPHERALS
Overhauling the engine 10
The valve springs are compressed using the
Mot. 1502 tool.
16086S
16085S
10-54
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove: CHECKING THE GASKET FACE
– the pins,
– the upper cups, Check for gasket face bow using a straight edge and a
– the springs, set of shims.
– the valves,
– the valve guide seals using the Mot. 1335 clamp.
Maximum bow 0.05 mm
It is very important not to scratch the gasket faces of Check the cylinder head for cracks.
the aluminium components.
10-55
ENGINE AND PERIPHERALS
Overhauling the engine 10
Checking camshaft end play
Refit:
– the camshafts, positioning them
correctly (see identification of the
camshafts in the "Technical
data" section),
– the camshaft bearing cap covers,
tightening the bolts to a torque
value of 1.2 daN.m and in the
recommended order.
15612-2R
10-56
ENGINE AND PERIPHERALS
Overhauling the engine 10
Measurement of exhaust camshaft play. REASSEMBLING THE CYLINDER HEAD
15742S
10-57
ENGINE AND PERIPHERALS
Overhauling the engine 10
Fitting the valve stem seals Keep the valve pressed against its seat.
Locate the valve in the cylinder head. Place the valve stem seal (not lubricated) over the tool
barrel.
15771S
15771-2S
Place the barrel of the Mot. 1511 tool over the valve
stem (the internal diameter of the barrel must be Push the valve stem seal past the tool barrel, then
identical to that of the valve stem). withdraw the barrel.
15771-1S 15771-3S
10-58
ENGINE AND PERIPHERALS
Overhauling the engine 10
Place the pushrod (1) over the valve stem seal. Push home the valve stem seal by gently striking the
top of the pushrod with the palm of the hand, until
the valve stem seal makes contact with the cylinder
head.
15771-5R
15770S
10-59
ENGINE AND PERIPHERALS
Overhauling the engine 10
Fitting:
– the springs,
– the upper cups,
16086S
16087R
16084S
16085S
10-60
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove:
– the clutch and the engine 1
flywheel,
– the various components
(illustrations 1 to 7).
15159S1
15159-1S1
10-61
ENGINE AND PERIPHERALS
Overhauling the engine 10
3 5
15160-2S 15161-1S
15161S
10-62
ENGINE AND PERIPHERALS
Overhauling the engine 10
WARNING: do not use a sharp
point to mark the big end caps in 6
relation to their connecting rod,
to avoid initiating a crack in the
rod. Use an indelible marker pen.
15183S
15184S
10-63
ENGINE AND PERIPHERALS
Overhauling the engine 10
NOTE: the crankshaft main bearing
caps are numbered from 1 to 5.
15182S
10-64
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove the crankshaft main bearing caps, using the Remove:
Mot. 1423 tool exclusively for bearing N˚ 1. – the oil filter,
– the coolant hose,
– the knock detector,
– the oil pressure sensor.
10-65
ENGINE AND PERIPHERALS
Overhauling the engine 10
Extracting the gudgeon pins Fitting the connecting rod shells
To extract the gudgeon pin, remove the spring ring The shells are fitted using the Mot. 1492 tool.
using a screwdriver, then release the pin.
15743R1
15654S
On the connecting rod
It is essential to mark the position of the
connecting rod shells, as the category may be Choose the shell mounting (1) corresponding to the
different for each rod. engine (engine type (2) marked on the mounting).
Slide the shell mounting into the slot (3) in the base of
the tool.
10-66
ENGINE AND PERIPHERALS
Overhauling the engine 10
Lay the connecting rod on the base of the tool (as Push against the shell mounting (in the direction of the
shown in the illustration below). Ensure that the lower arrow) until it is hard up against the body of the
part (4) of the small end of the connecting rod is in connecting rod.
contact with the guide pin.
15745S
R
15744-1R
10-67
ENGINE AND PERIPHERALS
Overhauling the engine 10
On the big end cap Replacement of the piston base cooling jets
Place the big end cap against the guide pins (6) on the Removal
base of the tool, then fit the shell (7) against the shell
mounting. To remove the piston base cooling jets (1), they must
be drilled with a 7 mm diameter drill. This is necessary
in order to remove the spring stop (2) and the spring
(3).
15747S
10-68
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove the swarf using a brush.
15179-1S
Screw :
– the Mot. 1485 or Mot. 1485-01 tool into the drilled out
jets using a 6 mm Allen key which you slide inside
the tool
10-69
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the Emb. 880 inertia extractor to the Mot. 1485 or Mot. 1485-01 tool and extract the jet.
15178-1R1
The jets must be fitted using the Mot. 1516 tool and
the Mot. 1516-01 plate.
10-70
ENGINE AND PERIPHERALS
Overhauling the engine 10
Fitting the jets for cylinders 1 et 3 Tighten the two bolts (1), then withdraw the guide rod.
Locate the plate (3) of the Mot.1516-01 tool on the Insert the jet in the pushrod.
cylinder block (as shown in the illustration below)
without tightening the two bolts (1) of Mot. 1516 tool. NOTE: ensure the correct alignment of the jet, the
jet tip (4) should be pointing towards the centre of
the cylinder.
15572-2R
15262-1R
Insert the guide rod (2) of the Mot. 1516 tool into the
plate (3) and the end of the guide rod into the jet Insert the pushrod in place of the guide rod.
orifice, in order to centre the plate (3).
Using a mallet, tap the pushrod until its shoulder (5)
makes contact with plate (3).
15572-1R
15572R1
10-71
ENGINE AND PERIPHERALS
Overhauling the engine 10
Fitting the coolers in cylinders 2 and 4 Tighten the two bolts (1), the remove the guide rod.
Position the plate (3) of tool Mot. 1516-01 on the Insert the cooler into the pushrod.
cylinder block (as shown in the diagram below) without
tightening the two bolts (1) of tool Mot 1516. NOTE: check the cooler is correctly orientated with
the end of the cooler (4) directed towards the
centre of the cylinder.
15571-2R
15262R1
Position the guide rod (2) of tool Mot. 1516 in the plate
(3) and the end of the guide rod in the cooler hole, in Fit the pushrod in place and instead of the guide rod.
order to centre the plate (3).
With a hammer, tap the pushrod until the shoulder (5)
of the pushrod comes into contact with the plate (3).
15571-1R
15571R1
10-72
ENGINE AND PERIPHERALS
Overhauling the engine 10
Orientation of the piston coolers (see diagram below). Direction of fitting of the con rod in relation to the
piston
R
Reassembling the engine
Clean the cylinder block. NOTE: put the break in the spring ring of the
gudgeon pin at the top at ± 45˚ to the vertical axis
Refit: of the piston.
– the new oil filter,
– the coolant pipe fitted with a new seal,
– the oil pressure sensor,
– the pinking sensor.
16082S
10-73
ENGINE AND PERIPHERALS
Overhauling the engine 10
FITTING THE CRANKSHAFT BEARING SHELLS Fit the grooved bearing shell in tool Mot. 1493, then
press at (A) until the bearing shell is touching tool
On the cylinder block Mot. 1493 at (B).
15469-1R
10-74
ENGINE AND PERIPHERALS
Overhauling the engine 10
On the bearings
10-75
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit the crankshaft.
Oil the main journal bearings with
engine oil.
Refit the crankshaft bearing caps
except cap N˚ 1 (these are
numbered from 1 to 5) and tighten
the bolts to a torque of
6 to 6.7 daN.m.
15182S
86909S
10-76
ENGINE AND PERIPHERALS
Overhauling the engine 10
FITTING BEARING N˚ 1 WITH SILICON INJECTION
Allow to dry.
R 92791
89195S
10-77
ENGINE AND PERIPHERALS
Overhauling the engine 10
Insert the mixture into the syringe and inject it into the Using a cloth, wipe off the excess mixture, both inside
grooves of the crankshaft bearing cap. and outside the cylinder block.
92794S 89197S
Allow the mixture to flow out slightly on either side of Allow to dry for a few moments and cut the excess off
the grooves of the crankshaft bearing cap, to ensure the gasket face.
that the injected mixture has totally filled the sealing
groove.
92797S
92795S
10-78
ENGINE AND PERIPHERALS
Overhauling the engine 10
FITTING THE RINGS
Ensure the rings are fitted the correct way round with
the word TOP pointing upwards.
15650S
10-79
ENGINE AND PERIPHERALS
Overhauling the engine 10
REFITTING
Oil the pistons.
Fit the con rod - piston assemblies
into the cylinder block using the
ring (e.g.: FACOM 750 TB), paying
attention to the direction
("V" towards the flywheel).
Fit the con rods onto the oiled big
end journals of the crankshaft.
Fit the con rod caps, ensuring they
are correctly matched (marks
made when dismantling).
15183-1S1
15184S
10-80
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit the oil pump chain. Refit:
– the crankshaft closure panel, tightening it to a torque
of 1.5 daN.m,
– the water pump (fitted with a new seal), tightening it
to a torque of 1.7 daN.m,
15161-1S
R 16247
15160-2R
10-81
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit:
– the anti-emulsion plate,
– the oil pump tightening it to a
torque of 2.2 to 2.7 daN.m,
– the oil level sensor.
15159-1S1
15159-2R1
10-82
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit the sump with a new seal, pre-tightening it to a Fitting the crankshaft seals
torque of 0.8 daN.m, then finally tightening it to a
torque of 1.2 to 1.5 daN.m in the recommended order. – Flywheel side, use tool Mot 991-01.
The alignment of the cylinder block and the sump must
be complied with on the flywheel side to prevent the
clutch housing from being damaged when fitting the
gearbox.
15158-2R
15160-3R
12350S
Refit:
– the flywheel tightening the new bolts to a torque of
5 to 5.5 daN.m (tightening in a star sequence),
– the clutch, tightening it to a torque of 2 daN.m.
10-83
ENGINE AND PERIPHERALS
Overhauling the engine 10
REFITTING THE CYLINDER HEAD After a certain amount of time, the hydraulic tappet
may have drained itself and it must be reprimed.
Position the pistons at mid-stroke.
To check whether it needs repriming, press the top of
Position the cylinder head gasket then the cylinder the tappet at (A) with your thumb. If the piston can be
head. pressed into the tappet, immerse it in a container filled
with diesel.
Check the bolts, then tighten the cylinder head
(see "Cylinder head specifications" section). Refit the hydraulic tappets and valve rockers.
15640S
10-84
ENGINE AND PERIPHERALS
Overhauling the engine 10
Oil the camshaft bearings.
Be careful not to spill oil onto the
gasket face of the camshaft
bearing cap housings.
Refit the camshaft, ensuring it is
correctly positioned.
The inlet camshaft has a drive for
the petrol high pressure pump.
15656S
15656-1S
10-85
ENGINE AND PERIPHERALS
Overhauling the engine 10
Position the grooves of the
camshafts as shown on the
diagram.
15614S
10-86
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit:
– the camshaft bearing cap
housings tightening them to a
torque of 1.2 daN.m,
15612-2R
15612-3S
10-87
ENGINE AND PERIPHERALS
Overhauling the engine 10
NOTE: the gasket faces must be clean, dry and
free from grease (in particular, avoid finger marks).
Refit:
– the oil separator, tightening it to a
torque of 1.3 daN.m in the
recommended order (self-
tapping bolts must be tightened
to the correct torque using a
torque wrench).
10-88
ENGINE AND PERIPHERALS
Overhauling the engine 10
Fit:
Before refitting the injectors on the rail, the
– the cone of tool Mot. 1533 on the tip of the injector,
Teflon seals of the injectors must be replaced.
– the seal.
To do this:
– clean the tip of the injector by immersing it in suitable
clean thinner. The use of a wire brush, sand paper
or an ultrasound cleaner is forbidden,
– wipe the tip of the injector using a lint free cloth,
– carefully cut the seal with circlip pliers taking
care not to mark the injector,
16373S
16375S
10-89
ENGINE AND PERIPHERALS
Overhauling the engine 10
The Teflon seal must be shrunk. To do this, insert the Replace:
body of tool Mot. 1533 until the body comes into – the injector clips,
contact with part (1) of the injector. – the injector O-rings.
16376R1
16125S
10-90
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit:
– the petrol rail fitted with the
injectors tightening the bolts to a
torque of 1.5 daN.m,
15613S
15574S1
10-91
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the camshaft seals using tool Mot. 1512 (use the old – the air conditioning compressor, tightening the bolts
nuts (B)), to a torque of 2.1 daN.m,
15644R1 15576-1S
– the multifunction support, tightening the bolts and – the alternator, tightening the bolts to a torque of
stud to a torque of 4.4 daN.m, 2.1 daN.m,
15576S 15576-3S
10-92
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the bolts and nut (1) of the assisted steering pump – the assisted steering pump pulley,
bracket and the bolts (2) of the assisted steering
pump to a torque of 2.1 daN.m,
15576-2S
15576-4R1
R
10-93
ENGINE AND PERIPHERALS
Overhauling the engine 10
Adjusting the timing
WARNING: it is essential to
degrease the following: the end
of the crankshaft (timing side),
the bore of the timing pinion, the
bearing faces of the accessories
belt as well as the ends of the
camshafts (timing side) and the
bores of the camshaft pulleys, to
prevent there being any slip
between the timing, crankshaft
and camshaft pulleys which may
damage the engine.
R 16077
10-94
ENGINE AND PERIPHERALS
Overhauling the engine 10
Check that the crankshaft is correctly pinned at Correct position
Top Dead Centre and not in the balancing hole.
Incorrect position
15163-1S
15163S
15577R1
10-95
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit:
– the timing belt,
– the tensioning roller applying
Loctite Frenetanch, then
tighten the mounting bolt to a
torque of 5 daN.m.
15578S
15578-1S
10-96
ENGINE AND PERIPHERALS
Overhauling the engine 10
Belt tension Position reference (8) of the exhaust camshaft pulley
opposite the thread (9) of the exhaust camshaft
Check that there is always a clearance of sensor.
0.5 to 1 mm between the nuts and pulleys of the
camshafts.
10-97
ENGINE AND PERIPHERALS
Overhauling the engine 10
Lock the flywheel using tool Mot. 582-01 or a large Incorrect position
screwdriver, then turn the bolt of the accessories
crankshaft pulley through an angle of 115˚ ± 15˚.
15163S
Fit the tool for locking the camshaft pulleys Mot. 1535
15108S (put the bolt of the intermediate timing housing in the
hole (5) in order to lock tool Mot. 1535).
Pin the crankshaft using the reference of the exhaust
camshaft pulley and the thread of the camshaft sensor
(the references should be aligned) which will ensure
that the pin is in the pinning hole and not in a
crankshaft balancing hole.
Correct position
16078R3
10-98
ENGINE AND PERIPHERALS
Overhauling the engine 10
Remove tool Mot. 1526 for setting the camshaft, tool Remove the Top Dead Centre pin.
Mot. 1535 for locking the camshaft pulleys, and tool
Mot. 1054 the Top Dead Centre pin. Check that the references of the tensioning roller are
correctly aligned, otherwise repeat the tensioning
Checking the timing and the tension operation.
Checking the tension: Slacken the nut of the tensioning roller by a maximum
of one turn, holding it with a 6 mm Allen key.
Rotate the crankshaft through two revolutions in a
clockwise direction (timing side), before the end of the Align the references of the tensioning roller and tighten
two revolutions in other words, half a tooth before the nut finally to a torque of 2.8 daN.m.
the exhaust camshaft reference and the camshaft
sensor thread are aligned. Checking the timing:
Fit the Top Dead Centre pin (check that the reference
of the exhaust camshaft pulley and the camshaft
sensor thread are aligned).
15740-1S
R 16077
10-99
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit:
– the plug of the Top Dead Centre
pin, putting a drop of
RHODORSEAL 5661 on the
thread,
– the intermediate housing
tightening the bolts to a torque of
1 daN.m,
15578-2S
15578-5S
10-100
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the upper timing belt cover,
15578-3S
– the accessories belt. To position the belt, pivot the NOTE: when fitting the belt it is essential to ensure
key to the right. that the tooth (which corresponds to X) inside the
pulleys remains "FREE".
Block the tensioner using a 6 mm Allen key (1).
R
15579-1R
10-101
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit: – the rail and the ignition coil (check that the spark plug
– the petrol high pressure pump (fitted with a new leads are not touching the inlet manifold),
shim), tightening the bolts to a torque of 1.2 daN.m,
– the high pressure pipe,
– the seal between the EGR valve support and the
manifold,
15617S
15615S
15616S
10-102
ENGINE AND PERIPHERALS
Overhauling the engine 10
– the air resonator.
15618S
15619R1
10-103
ENGINE AND PERIPHERALS
Overhauling the engine 10
Refit the oxygen sensor using tool
Mot. 1495 , tightening it to a torque
of 4.5 daN.m.
Refit:
– the EGR valve, tightening the two
bolts to a torque of 2.7 daN.m,
16080S
16079S1
10-104