renault/ proton savvy

Workshop repair manual

Petrol engine 4 cylinders

Engine type Vehicle Vehicle type

D4D 700 Clio II XB06

D4F 702 - 704 Twingo X06C - X06D

D4F 712 Clio II XB0W

77 11 296 742

"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."

FEBRUARY 2001

All copyrights reserved by Renault.

EDITION ANGLAISE

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 ENGINE AND PERIPHERALS

Introduction 10-1Engine identification 10-2Tightening torques (in daNm or degrees) 10-3Specifications

Cylinder head 10-5 Camshaft 10-11Pistons 10-12Cylinder block barrel sizes 10-13Piston rings 10-14Con rods 10-15Crankshaft 10-16Bearing shells 10-16Preparing the engine to be set on the support 10-18Consumables 10-20

Standard exchange 10-21Essential special tooling 10-22Essential equipment 10-25Overhauling the engine

Removing the upper engine 10-26Stripping the cylinder head 10-29Cleaning 10-33Checking the mating surfaces 10-33Checking the camshaft end play 10-33Rebuilding the cylinder head 10-34Assessment and repair of rocker arm rails 10-38 Removing the lower engine 10-44Extracting the gudgeon pins 10-49Fitting the con rod bearing shells 10-49Assembling the con rods - pistons 10-52Fitting the piston rings 10-55Refitting the lower engine 10-56Replacing the oil filter 10-62Refitting the upper engine 10-63Tensioning the accessories belts 10-69

ENGINE AND PERIPHERALSForeword 10110ENGINE AND PERIPHERALSForeword

USING THE MANUAL

There are two main sections in this manual:– technical specifications,– overhauling the engine.

To repair the component on the vehicle, refer to the vehicle Workshop Repair Manual and Technical Notes.

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 barReminder: 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

ENGINE AND PERIPHERALSEngine identification 10

10-2

Engine identification

The engine identification is stamped on the cylinder block.

It displays:A : the engine typeB : the engine approval letterD : the Renault identification numberE : the engine suffixF : the engine production number G : the engine factory number

Engine IndexCompression

ratioBore (mm)

Stroke (mm)

Capacity (cm3)

D4D 700 9.8/1 69 66.8 999

D4F702 704 712

9.8/1 69 76.8 1149

ENGINE AND PERIPHERALSTightening torques (in daNm or degrees) 10

10-3

Tightening torques (in daNm or degrees)

UPPER ENGINE

* 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.

Description Tightening torques

Cylinder head bolts

Coolant temperature sensor

Cylinder head coolant output unit

Rocker arm rail

Timing gear tension wheel

Camshaft pulley

Spark plugs

Cylinder head cover

Lower and intermediate timing covers

Upper timing cover

Exhaust manifold

Exhaust manifold heat shield

Ignition coil

Inlet manifold

Air filter unit bolt

*

1.5

0.9

**

2.4

3 plus an angle of 45˚±6˚

2.4

1.2

1.2

3.3

2.5

1.5

0.7

***

1

ENGINE AND PERIPHERALSTightening torques (in daNm or degrees) 10

10-4

LOWER ENGINE

Description Tightening torques

Pinking sensor

Oil level sensor

Crankshaft bearing bolts

Con rod cap bolts

Oil pump

Coolant pump

Crankshaft closure housing (flywheel side)

Strainer

Sump

Flywheel

Clutch

Accessories crankshaft pulley

Alternator mounting

Air conditioning compressor mounting

Power steering pump mounting

Air conditioning compressor

Alternator

Upper bolt

Lower bolt

Power steering pump

Oil filter

2

3.8

2 plus an angle of 76˚ ± 6˚

1.4 plus an angle of 39˚ ± 6˚

0.9

0.9

0.9

0.9

1

1.8 plus an angle of 110˚±6˚

2

4 plus an angle of 70˚± 6˚

5

5

2.5

5

2.5

5

2.2

2

ENGINE AND PERIPHERALSSpecifications 10

10-5

Specifications

CYLINDER HEAD

Cylinder head tightening procedure

REMINDER: in order to tighten the bolts correctly, use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes.

All cylinder head bolts must always be changed after removal. Do not oil the new bolts.

Tighten all the bolts to 2 daNm±0.2 daNm.

Check that all the bolts are tightened to 2 daNm, then angle tighten (bolt by bolt) by 230˚±6˚.

Do not retighten the cylinder head bolts after performing this procedure.


10-6

Thickness of the cylinder head gasket

The thickness of the cylinder head gasket is measured at (A):– thickness of the gasket when tightened:

0.49 ± 0.04 mm.

Firing order:1 - 3 - 4 - 2

Cylinder head height

H = 99 mm

Gasket face bow (mm): 0.05

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

Chamber volume with valves and spark plugs:26.775 ± 1.01 cm3


10-7

Valves

Mating surface angle

Inlet and exhaust: 90˚

Head diameter (in mm)

Inlet: 26 ± 0.12Exhaust: 22.1 ± 0.12

Valve length (in mm)

Inlet: 110.54 to 110.99Exhaust: 112.27 to 112.72

Max. valve lift (in mm)

Inlet: 8.849Exhaust: 8.850

Valve clearance settings (in mm)


Valve seats

Seat angle (∝ )

Inlet and exhaust: 89˚ 30'

Mating surface width X (in mm)

Inlet: 0.994 ± 0.403Exhaust: 1.136 ± 0.377

External seat diameter (D) (in mm)


Stem diameter (in mm)

Inlet: 5.48 0- 0.015

Exhaust: 5.47 0- 0.015


10-8

Valve guides

Length (in mm)

Inlet and exhaust: 40.15 ± 0.15

Guide external diameter (in mm)

Diameter of the guide housing in the cylinder head (in mm)

Inlet and exhaust: 11±0.01

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.

The valve stem seals must be fitted using tool Mot. 1511 or the FACOM tool part number DMJ4, for example.

NOTE: do not lubricate the valve stem seals before fitting them.

Inlet and exhaust: 11 + 0.068+ 0.05

Guide internal diameter (in mm)

Inlet and exhaust

Non machined: 5 + 0.075 0

Machined*: 5.5+ 0.018 0

* This dimension is measured with the guide fitted inthe cylinder head.


10-9

Angle of the inlet and exhaust guides (in degrees)

Inlet: A = 27Exhaust: E = 21

Position of the inlet and exhaust valve guides (in mm)

Inlet and exhaust: B = 10.3 ± 0.15


10-10

Valve springs

The valve has a conical spring.

Unloaded length (in mm): 40.20

Loaded length (in mm):14.5 daN±8 3442.8 daN±20 25.15

Meeting spires (in mm): 23.50

Diameter of wire (in mm): 3.10±0.03

Internal diameter (in mm):Upper 14.10±0.2 Lower 16.80±0.2

External diameter (in mm) :Upper 20.30±0.2 Lower 23±0.2


10-11

Camshaft

End play (in mm): 0.08 to 0.178

Number of bearings: 5

Diameter of the cylinder head camshaft bearings (in mm)

Diameter of the camshaft bearings (in mm)

Graph showing timing with a calculated clearance of zero (cannot be checked)

Inlet opening delay* - 10˚Inlet closing delay 31˚ Exhaust opening advance 25˚ Exhaust closing advance** - 8˚

1 Cylinder block top dead centre fixed mark.2 Flywheel top dead centre mobile mark.3 Flywheel bottom dead centre mobile mark.4 Inlet opening delay.5 Exhaust closing advance.6 Inlet closing delay.7 Exhaust opening advance.8 Engine operating direction (flywheel end).

Flywheel side

1

25.05±0.012

3

4

5 28.05±0.01

Timing side

Flywheel side

1

24.98±0.012

3

4

5 27.98±0.01

Timing side

* 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.


10-12

PISTONS

Fitting the gudgeon pin in the con rod and in the piston.

These engines are fitted with Mahle pistons.

Piston marking

D4F engine

D4D engine

1 Direction of fitting of Λ piston, flywheel side2 Piston diameter grade (A - B)3 Used by the supplier only4 Used by the supplier only5 Piston symmetry axis6 Gudgeon pin hole axis7 Offset between the pin hole (6) and the piston

symmetry axis (5) is 0.8 mm


10-13

Measuring the piston diameter

The piston diameter is measured at these heights (in mm).

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.

Piston diameter marking in relation to cylinder block diameter

D4D engine

D4F engine

D4D engine D4F engine

E 10 9

Position of holes T on the cylinder

block

Grade mark-ing on

the pis-tons

Piston diameter

(mm)

Barrel diameter

(mm)

1 = 5 mm A 68.956±0.006 69 ±0.015

2 = 9 mm B 68.964±0.006 69.015±0.015

Position of holes T on the cylinder

block

Grade mark-ing on

the pis-tons

Piston diameter

(mm)

Barrel diameter

(mm)

1 = 5 mm A 68.976±0.006 69 ±0.015

2 = 9 mm B 68.984±0.006 69.015±0.015


10-14

PISTON RINGS

Thickness of piston rings

Three rings (thickness in mm)

– compression ring 1.175 to 1.19

– sealing ring 1.475 to 1.49

– oil scraper ring 2.31 to 2.46 which consists of three parts:● two steel rails (1),● a spring ring (2).

Fitting the rings

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

RingsClearance at the break

(in mm)

Compression 0.20 to 0.35

Sealing 0.35 to 0.50

Scraper 0.2 to 0.9


10-15

Gudgeon pin (in mm)

The gudgeon pin is fitted with an inner collar (1).

The gudgeon pins (E) are fitted with ring B19, centre tool C19 and fitting shaft A19 (Mot. 574-25).

NOTE: the small end does not have a ring.

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.

The maximum weight difference for the con rod, piston and gudgeon pin assemblies for the same engine must be 11 grams.

Length: 54 0- 0.2

External diameter (A): 17.495 to 17.499

Internal diameter (B): 10.5 + 0.1- 0.2

Collar inner diameter (C) : 9.66±0.2

Inner collar length (D) : 8.2±0.15

CON RODS

Lateral clearance of the big end (in mm) 0.21 to 0.453

Radial clearance of the big end (in mm) 0.025 to 0.064

Centre distance between the big end and little end (in mm) 122±0.03

Diameter of the big end (in mm) 43.639+ 0.11 0

Diameter of the little end (in mm) 17.5- 0.021- 0.039


10-16

Direction of fitting of the con rod in relation to the piston

Point the V (1) on the piston downwards and the index (2) of the con rod as shown in the diagram below.

The crankshaft stroke is:

The lateral shims are located on bearing no. 3.

BEARING SHELLS

Crankshaft bearing shells

The engine is fitted with bearing shells without a locator notch.

The crankshaft bearing shells are fitted on the cylinder block and on the bearings using Mot. 1493-02.

CRANKSHAFT

Number of bearings 5

Burnished bushings: (in mm)– nominal diameter 44 ±0.01

Burnished crankpins: (in mm)– nominal diameter 40

0- 0.016

– lateral play of the crankshaft (in mm) 0.045 to 0.235

– radial play of the crankshaft (in mm) 0.02 to 0.046

D4D engine D4F engine

Crankshaft stroke (mm)

66.8±0.05 76.8±0.05


10-17

Direction of fitting:– on the cylinder block, fit the grooved shells on all

the bearings. The shell fitted with flange stops goes on bearing 3,

– on the bearing caps, fit non grooved bearing shells.

Con rod bearing shells

The engine is fitted with bearing shells without a locator notch.

The bearing shells are fitted using Mot. 1492 and Mot. 1492-04.


10-18

PREPARING THE ENGINE TO BE SET ON THE SUPPORT

Change the engine oil before fitting the engine to support Mot. 792-03.

Remove:– the air conditioning compressor belt, by unscrewing

the bolts (1) and turning the hexagon nut (2) clockwise,

– the alternator belt by unscrewing the two bolts (3),

– the air conditioning compressor and the alternator,


10-19

– the accessories multifunction supports.

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 mmY = 15 mm

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).


10-20

CONSUMABLES

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.

Type Quantity Component concerned Part no.

Cleaner - Cleaning parts 77 01 421 513

DECAPJOINT Coat Cleaning gasket faces 77 01 405 952

RHODORSEAL 5661Coat

Coolant pump, oil pump, crankshaft closing panel

77 01 404 452

Tube of RHODORSEAL 5661

BeadCoolant pump, oil pump, crankshaft closing panel

77 01 421 042

Loctite FRENETANCH 1 - 2 drops Exhaust manifold studs 77 01 394 070

ENGINE AND PERIPHERALSStandard replacement 10

10-21

Standard replacement

PREPARING THE USED ENGINE FOR RETURN

The engine should be cleaned and drained (oil and water).

Leave on the used engine or include in the return box:– the dipstick and its guide,– the flywheel,– the clutch mechanism and plate,– the water pump,– the cylinder head cover,– the oil pressure switch,– the valve timing cover,– the oil filter.

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).

ENGINE AND PERIPHERALSEssential special tooling 10Essential special tooling

Illustration Part numberPart Stores

NumberDescription

Mot. 574-25 00 00 057 425Gudgeon pin fitting tool (centre tool C19, shaft A19, and ring B19)

Mot. 582-01 00 00 058 201 Flywheel locking tool

Mot. 591-02 00 00 059 102 Magnetized pointer arm

Mot. 591-04 00 00 059 104Cylinder head bolt tightening gauge (angular measuring type)

Mot. 799-01 00 00 079 901 Timing gear tension wheel immobiliser

Mot. 1054 00 00 105 400 TDC setting pin

Mot. 1330 00 00 133 000 Oil filter removing tool

Mot. 1335 00 00 133 500 Tool for removing valve stem seals

10-22

ENGINE AND PERIPHERALSEssential special tooling 10

10-23


NumberDescription

Mot. 1354 00 00 135 400 Crankshaft seal gasket fitting tool (flywheel side)

Mot. 1355 00 00 135 500 Oil pump seal gasket fitting tool

Mot. 1360-01 00 00 136 001 Additional to Mot. 792-03 containing rod W1 and plate H1

Mot. 1374 00 00 137 400 Oil pump seal gasket removal tool

Mot. 1377 00 00 137 700 Crankshaft seal gasket removal tool (flywheel side)

Mot. 1381 00 00 138 100 Camshaft seal gasket removal tool

Elé. 1382-01 00 00 138 201 Spark plug key

Mot. 1492 00 00 149 200 Tool for fitting con rod bearing shells

ENGINE AND PERIPHERALSEssential special tooling 10

10-24


NumberDescription

Mot. 1492-04 00 00 149 204 Adaptation kit for fitting the con rod bearing shells

Mot. 1493-02 00 00 149 302 Tool for fitting crankshaft bearing shells

Mot. 1502 00 00 150 200 Valve spring compressor tool

Mot. 1505 00 00 150 500 Belt tension setting tool

Mot. 1511 00 00 151 100 Tool for fitting valve stem seals

Mot. 1573 00 00 157 300 Cylinder head support

Mot. 1587 00 00 158 700 Tool for fitting inlet camshaft seals

Mot. 1605 00 00 160 500 Tool for fitting cylinder head adjuster

ENGINE AND PERIPHERALSEssential equipment 10

10-25

Essential equipment

Description

Ring for fitting piston with ring in the cylinder block.

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.

Standard 1/2" 12 female torx socket (12.7 mm squared).

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.

Gun for using tube of RHODORSEAL 5661.

FACOM spark plug key, part number B.J 14 BH2.

Angled tweezers (pliers) from:– SAM, part number 366.1 for example,– FACOM, part number 151 for example.

ENGINE AND PERIPHERALSOverhauling the engine 10

10-26

Overhauling the engine

REMOVING THE UPPER ENGINE

Fit the flywheel block Mot. 582-01.

Remove:– the upper timing housing (1),– the crankshaft accessories pulley (2),– the intermediate timing cover (3),

– the lower timing cover (4).

Remove the flywheel block Mot. 582-01.


10-27

Adjusting the timing

Turn the crankshaft clockwise (timing side) until it is one half-tooth from alignment with the mark (5) on the crankshaft sprocket and the fixed mark (6) on the oil pump body.

Insert the TDC setting pin Mot. 1054, then turn the crankshaft until it is pinned.

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.


10-28

Remove:– the ignition coil and the spark plug wires,– the four upper bolts (1) on the inlet manifold (do not

pull the section of the wiring harness labelled (2) as it is held between the cylinder head cover and the manifold),

– the eight lower bolts (3) on the inlet manifold.

Disengage the electric wiring harness from the inlet manifold.

Remove:– the cylinder head cover,

– the cylinder head bolts,– the cylinder head.


10-29

STRIPPING THE CYLINDER HEAD

Place the cylinder head on cylinder head support Mot. 1573.

Remove:– the exhaust heat shield,

– the exhaust manifold,– the fuel pipe retaining brackets (1),

– the camshaft pulley,– the timing gear tension wheel,

– the camshaft seal gasket by screwing the puller tool Mot. 1381 into the seal gasket.


10-30

Remove the seal gasket by screwing the bolt (1) on tool Mot. 1381.

Remove:– the lifting rings,– the cylinder head coolant output unit,– the camshaft adjuster,

– the rocker arm rails by removing the bolts (2).

Mark the camshaft bearing caps with a permanent marker pen.


10-31

Remove:– the camshaft bearing caps,

– the camshaft,

– the valve springs using tool Mot. 1502.


10-32

To compress the valve springs correctly, the piston (1) of the Mot. 1502 tool must be centred on the valve stem. The spring upper retaining cup must fit into the cavity (2) of the socket (3) on tool Mot. 1502.

Remove:– the pins,– the upper cups,– the springs,– the valves,– the valve guide seal gaskets using the Mot. 1335

pliers.


10-33

CLEANING

It is very important not to scratch the mating surfaces of any aluminium components.

Wear gloves whilst carrying out this operation.

Use the Décapjoint product to dissolve any part of the gasket which remains attached.

Apply the product to the parts to be cleaned; wait about ten minutes, then remove it using a wooden spatula.

Do not allow this agent to drip on to the paintwork.

Great care should be taken when performing this operation, to prevent foreign objects entering the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover) and the oil return pipes.

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.

CHECKING THE CAMSHAFT END PLAY

Refit:– the camshaft,– the camshaft bearing caps,– the rocker arm shafts.

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 50˚±6˚.

Repeat the process for bolts (4), (5), (6), (7), (8), (9), (10), (11) and (12).


10-34

Check the end play, which must be between 0.08 and 0.178 mm.

Remove the rocker arm shafts, the camshaft bearing caps and the camshaft.

REBUILDING THE CYLINDER HEAD

Lubricate the inside of the valve guide.

The valve stem seals must be fitted using tool Mot. 1511 or the FACOM tool, part number DMJ4.

NOTE: do not lubricate the valve stem seals before fitting them.


10-35

Fitting new valve stem seals

Place the valve in the cylinder head.

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).

Keep the valve pressed against its seat.

Place the valve stem seal (not lubricated) over the tool barrel.

Push the valve stem seal past the tool barrel, then withdraw the barrel.


10-36

Place the pushrod (1) over the valve stem seal.

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.

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.

Repeat these operations for all the valves.


10-37

Fit:– the springs,– the upper cups,

To compress the valve springs correctly, the piston (1) of the Mot. 1502 tool must be centred on the valve stem. The spring upper retaining cup must fit into the cavity (2) of the socket (3) on tool Mot. 1502.

Refit the keys using tweezers.


10-38

ASSESSMENT AND REPAIR OF ROCKER ARM RAILS

Mark the position of the rocker arms in relation to the rails, then remove the rocker arm rails.

Examine the condition of the bearing surfaces and the rocker arm bolts.

Check that the cam/tappet lubricating holes are not blocked up.

Replace worn parts.

Refit the rocker arm rails, placing the rails in the correct position in relation to the tappets:– for the inlet rocker arm rail, put the

mark (1) on the timing side,– for the exhaust rocker arm rail, put

the mark (2) on the flywheel side.


10-39

Grease the camshaft bearings with engine oil.

Refit the camshaft.

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.

Refit:– the camshaft bearing caps by tightening the bolts (1)

and (2) to a torque of 0.9 daNm.


10-40

– the rocker arm rails by placing them in the correct position and tightening the bolts in the recommended order to a torque of 0.5 daNm. Then unscrew bolt (3) until it is free, then tighten bolt (3) to a torque of 0.7 daNm plus an angle of 50˚±6˚.

Repeat the process for the other bolts.

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.


10-41

Fitting the camshaft seal gasket.

IMPORTANT: this type of seal gasket is extremely FRAGILE. Only touch the protector part (1) when handling the gasket. It is strictly forbidden to touch the seal (2). This is to ensure that there will be no oil leaks once the gasket is fitted on the engine.

Fit the seal gasket using tool Mot. 1587.

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.


10-42

Fit the canister (4) and the collar nut (5) from Mot. 1587.

Screw the collar nut until the canister touches the cylinder head.

Remove the nut, the canister, the protector and the threaded rod.


10-43

Refit:– the camshaft pulley by tightening the bolts to a torque

of 3 daNm plus an angle of 45˚±6˚,

– the tension wheel by positioning it correctly.

Fit the tension wheel notch (5) into the cylinder wheel rib (6).

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 exhaust heat shield by tightening the bolts to a torque of 1.5 daNm.


Setting the valve clearances

Valve clearance setting values (in mm)

– inlet 0.05 to 0.12– exhaust 0.15 to 0.22

Open exhaust valve method

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.

Exhaust valve to be fully opened.

Inlet valve to be adjusted. Exhaust valve to be adjusted.

10-44


10-45

REMOVING THE LOWER ENGINE

Fit flywheel block Mot. 582-01.

Remove:– the clutch,

– the flywheel,

– the sump,

– the crankshaft seal gasket on the flywheel side by screwing puller tool Mot. 1377 into the seal gasket.


10-46

Remove the seal by screwing the bolt (1) of tool Mot. 1377.

Remove:– the crankshaft seal supporting ring,

– 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.


10-47

Remove:– the strainer and its seal,– the oil pump (the oil pump cannot be repaired),

– the coolant pump,

– the oil pressure supply seal.

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.


10-48

Remove:– the bearing caps and the con rod/piston assemblies.

– the crankshaft bearing caps,

– the crankshaft bearing shells,

Clean:– the cylinder block,– the oil pump,– the coolant pump,– the crankshaft,– the seal supporting ring,


10-49

EXTRACTING THE GUDGEON PINS

Remove the piston rings.

Place the piston on the V of the support, the shaft aligned with the removal hole.

Drive out the gudgeon pin on the press with the extraction mandrel (E).

FITTING THE CON ROD SHELLS

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.


10-50

Slide the shell support (3) from Mot. 1492-04 into the groove (4) on the base of Mot. 1492, then place the rail (5) from Mot. 1492-04 on the base (as shown in the diagram).

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.

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.

Remove the con rod body support and repeat the operation for the remaining con rod bodies.


10-51

On the con rod cap

Fit the bar (8) and the con rod cap as shown in the diagram.

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.

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.

Remove the con rod cap support and repeat the operation for the remaining con rod caps.


10-52

ASSEMBLING THE CON RODS - PISTONS

Preparing the piston/gudgeon pins assembly

The parts supplied in the set are identical.

Mark the parts in each box from A to D to ensure they remain identical.

Completely dissolve the non-stick film without scratching the parts.

Fitting the gudgeon pins

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,


10-53

Preparing the con rods

Visually inspect the condition of the con rod (piercings/level),

Use a 1500 W heating plate.

Place the small ends on the heating plate.

Ensure that all the small end surfaces are in contact with the plate.

To test the temperature, place a solder on each small end at (a) where the fusion point is approximately 250˚ C.

Heat each small end until the test solder welds.

Preparing the gudgeon pins

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.


10-54

Assembling the con rods/pistons

The piston heads are stamped with an arrow pointing to the flywheel side.

Position the Λ (1) engraved on the piston head to point downwards and at thesame side as the boss (2) of the small end (as shown in the diagram) (or the dipstick side on the cylinder block).

Follow these instructions when assembling the piston and con rod:

● 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.

● Drive the gudgeon pin into the assembly to check that it can move freely and re-centre the piston if necessary.


10-55

The following operations should be performed as quickly as possible to keep heat loss at a minimum.

When the solder reaches welding point (becomes liquid):

– wipe off the solder,– engage the centring guide in the piston,– fit the con rod in the piston,– quickly drive in the gudgeon pin until the guide

reaches the bottom of the support base.

Ensure that the gudgeon pin remains set back from the piston diameter for all the positions of the con rod in the piston .

FITTING THE RINGS

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.


10-56

REFITTING THE LOWER ENGINE

Fitting the bearing shells in the cylinder block.

Position tool Mot. 1493-02 on the cylinder block.

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

Fitting the bearing shells on the bearings.

Position Mot. 1493-02 on the bearing.

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).


10-57

Refit the crankshaft.

Grease the crankpins and bushings with engine oil.

Fit the crankshaft bearing caps (so that the arrows (1) engraved on the bearings are pointing to the flywheel side), then tighten the bolts to a torque of 2 daNm plus an angle of 76˚±6˚.

Check the crankshaft clearance which should be between 0.045 and 0.235 mm.

Check that the crankshaft rotates freely.

Refit the con rod/piston assemblies using the fitting ring.

Fit the con rod caps, ensuring that they are correctly matched (use the marks made on removal).


10-58

Refit the con rod caps by tightening the bolts to a torque of 1.4 daNm plus an angle of 39˚±6˚.

Check the lateral clearance of the big end which should be between 0.21 and 0.453 mm.

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.

Tighten the crankshaft closure panel bolts on the flywheel side to a torque of 0.9 daNm in the recommended order.


10-59

NOTE: the coolant pump is sealed with RHODORSEAL 5661. The band (2) must be 1.3 mm wide and be applied as shown in the diagram below.

Tighten the coolant pump bolts to a torque of 0.9 daNm in the recommended order.

Systematically replace the oil pressure supply seal (3).

IMPORTANT: the oil pump is driven by two studs located on the crankshaft.

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 ]


10-60

Tighten the oil pump bolts to a torque of 0.9 daNm in the recommended order.

Fitting the crankshaft seal gaskets

– flywheel side, use tool Mot. 1354.

– oil pump side, use tool Mot. 1355.

Replace the strainer fitted with a new O-ring by tightening the bolts to a torque of 0.9 daNm.


10-61

NOTE: the sump must only be sealed with a special After Sales seal. Place the flat surface on the cylinder block side.

Refit:– the sump, tightening the bolts to a torque of 1 daNm

in the recommended order.

– the flywheel by tightening the new bolts to a torque of 1.8 daNm, then turning to an angle of 110˚±6˚ (blocking the flywheel with Mot. 582-01).

– the clutch, tightening the bolts to a torque of 2 daNm.

Remove flywheel block Mot. 582-01.


10-62

Replacing the oil filter

The two seal gaskets (2) must be replaced when the oil filter (1) is replaced.

Hold the filter upside down and tap it on a piece of wood to remove the filter element.

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.

Tighten the coolant pipe bolts to a torque of 0.9 daNm.


10-63

REFITTING THE UPPER ENGINE

Refitting the cylinder head

Position the pistons at mid-stroke.

Fit the cylinder head gasket using the centring sockets of the cylinder block.

Tighten the cylinder head (see the section on cylinder head specifications).

Paste lines (1) of Rhodorseal 5661 around the cylinder head cover mounting bolts and on camshaft bearings 1 and 5 as shown in the diagrams below.

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.


10-64

Refit the spark plug well seals using a socket with an external diameter of 41 mm (32 mm socket for example).

Check that the wiring harness is correctly positioned at (1) and (2) before refitting the inlet manifold.

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.


10-65

Tighten the four upper bolts in a cross on the inlet manifold to a torque of 1 daNm.

Adjusting the timing

Check:– that the tension wheel notch (5) is correctly

positioned in the cylinder wheel rib (6).

– that the TDC pin Mot. 1054 is in place,

– that the crankshaft timing sprocket mark (7) is facing the oil pump body mark (8).


10-66

– that the camshaft pulley mark (9) is facing the cylinder head cover mark (10).

Tighten the crankshaft accessories pulley bolt fitted with its washer to a torque of 1.5 daNm, to hold the timing sprocket in place.

Fit the timing belt by aligning the belt markings with those on the camshaft and crankshaft sprockets.

Remove the TDC setting pin Mot. 1054.

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 tension wheel nut to a torque of 2.4 daNm.

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.


10-67

Unscrew the tension wheel nut no more than one turn with a 6 mm Allen key, then turn the mobile index (11) in a clockwise direction until it is in the middle of the timing window (12). Then tighten the timing gear tension wheel nut to a torque of 2.4 daNm.

NOTE: it is vital that you tighten the tension wheel nut to torque to avoid any loosening which may cause damage to the engine.

Fit the flywheel block Mot. 582-01.

Remove the accessory crankshaft pulley bolt.

Refit:– the lower timing cover,


10-68

– the timing intermediate housing (3), tightening the bolts to a torque of 1 daNm ,

– the timing upper housing (1), tightening the bolts to a torque of 3.3 daNm,

– the accessories crankshaft pulley (2), tightening the bolts to a torque of 4 daNm plus an angle of 70˚±6˚.

Remove the flywheel block Mot. 582-01.

Remove the engine from support Mot. 792-03.

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,

– 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.


10-69

Tensioning the accessory belts

measure the tension of the accessory belts with tool Mot. 1505.

Alternator belt

Air conditioning and power assisted steering belt

Power assisted steering belt

Air conditioning belt

ABCDGT

CrankshaftAlternatorPower assisted steering pumpAir conditioning compressorTensionWheelPoint for checking belt tension


10-70

Table of fitting tension values

TENSION(Hertz)

Alternator beltPower assisted

steering beltAir conditioning belt

Air conditioning and power assisted

steering belt

Fitting tension 260 ± 5 210 ± 5 210 ± 5 210 ± 5

Documents

renault/ proton savvy