Renault Technical note 6044A

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© Renault s.a.s 2010

"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".

All rights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault.

NOVEMBER 2010 EDITION ANGLAISE

Technical Note6044A

X38, H4M - X95, H4J

H4J - H4M engines

Edition 4



H4J - H4M engines

Contents

Pages

H4J - H4M enginesContentsPages

10A ENGINE AND CYLINDER BLOCKASSEMBLY

Engine: Precautions for therepair 10A-1

Engine: Specications 10A-5

Engine: New replacement 10A-8

Engine: Repair 10A-10

Engine support equipment:Use 10A-19

Camshaft: Check 10A-25

Valve: Remo val - Retting 10A-32

Valve: Check 10A-46

Cylinder head: Stripping -Rebuilding 10A-57

Cylinder head: Cleaning 10A-64

Cylinder head: Check 10A-67

Cylinder block base plate:Removal - Retting 10A-73

Piston - Con rod: Removal -Retting 10A-88

Piston - Con rod: Check 10A-105

Crankshaft: Removal -Retting 10A-120

Crankshaft: Check 10A-134

Cylinder block: Removal -Retting 10A-153

Cylinder block: Cleaning 10A-167

Cylinder block: Check 10A-168

Piston base cooling jet:Removal - Retting 10A-172

10A ENGINE AND CYLINDER BLOCKASSEMBLY


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ENGINE AND CYLINDER BLOCK ASSEMBLYEngine: Precautions for the repair

X95 – X38, RENAULT BRAND

10AI - SAFETY

General information

All information contained in these manuals is intendedexclusively for automotive industry professionals.

The documentation is intended to cover all vehicles inthe RENAULT range throughout the world, but may notcover equipment designed for use in specific countries.

The procedures and fault finding procedures recom-mended and described in this manual have been de-signed by automotive industry repair professionals.

a - General recommendations

Observe basic principles of vehicle repair.

The quality of repair depends first and foremost on thecare exercised by the person in carrying it out.

To ensure good repair:

- use recommended professional products and originalparts,

- observe the tightening torques,

- observe the recommendations for parts that should

always be replaced after removal, refitting or replace-ment operations,

- clean and degrease the sections to be bonded, to en-sure they bond correctly.

The design quality of the vehicles demands that noth-ing be left to chance during repair. Consequently, partsor components must be refitted in their original posi-tions (for example: heat shields, wiring routing, piperouting).

Use professional products and apply them with care.For example, do not apply too much sealant to jointfaces, in order to avoid plugging engine oil or coolantpipes.

b - Special tooling - ease of use

The repair procedures have been designed using spe-cial tools; they must therefore be carried out usingthese tools to ensure a high degree of working safetyand quality of repair.

The equipment we have approved has undergonecareful research and testing, and must be used andmaintained with care.

c - Safety

Certain devices and parts must be handled with partic-ular attention to safety and cleanliness and, above all,with due care.

The safety symbol used in this manual indicates thatspecial attention must be paid to the procedure or thetightening torque values.

Working safely:

- use suitable tools which are in good condition (use of« multi-purpose » tools, such as adjustable pliers,etc., should be avoided wherever possible),

- use supports and adopt a correct posture when per-forming heavy work or raising loads,

- check that the working area is clean and tidy duringthe operation,

- use personal protection (gloves, goggles, workshoes, masks, skin protection, etc.),

- always follow the safety instructions associated withthe operation to be performed,

- do not smoke when working on vehicles,

- do not use harmful products in unventilated rooms,

- do not ingest any chemicals (brake fluid, coolant,etc.).

Respecting the environment:- sort waste according to its particular qualities,

- do not burn discarded products (tyres, etc.).

WARNINGTo ensure proper sealing, the gasket surfaces mustbe clean, dry and not greasy (avoid any ngermarks).

WARNINGDo not scrape the joint faces of the aluminium, anydamage caused to the joint face will result in a riskof leaks.

WARNINGApplying excess sealant could cause it to be

squeezed out when parts are tightened. A mixtureof sealant and uid could damage certain compo-nents (engine, radiator, etc.).





10Ad - Conclusion

The procedures contained in this document merit yourattention. Please read them carefully in order to reducethe risk of injury, and avoid using incorrect procedures

that could damage the vehicle or make it dangerous inuse.

Following the recommended procedures will help youto provide a quality of service which will ensure the ve-hicles achieve the highest levels of performance andreliability.

Maintenance and repair operations must be carried outunder the proper conditions to ensure that our vehiclesrun safely and reliably.

II - CLEANLINESS

Risks relating to contamination

Protective bags

Use hermetically-resealable plastic bags, using adhe-sive tape, for example, to store components which willbe refitted and reused. Stored parts will therefore beless subject to the risk of contamination.

These are single-use bags: after use they must be dis-carded.




X38, SAMSUNG BRAND

10AI - SAFETY

1 - General information

All the information provided in this workshop manual isintended for use by professional mechanics.

Except for some vehicles, the information providedherein apply to most Renault Samsung Motors vehi-cles.

This manual describes the procedures recommendedby professionals regarding fault finding and fault detec-tion.

2 - General recommendations

Learn the basic principles of automobile maintenance.

The mechanic must focus his full attention and concen-tration in order to provide top quality maintenance op-erations.

To provide top quality maintenance:

- use original Renault Samsung Motors parts and theaccessories recommended,

- check the tightening torques,

- after any stripping operation, replace the studs, nuts,bolts etc. with original parts,

- clean the contact surfaces and check their condition.

Ensure that no parts are left over or missing after main-tenance operations. This point must always be takeninto account when refitting spare parts (e.g.: heat-re-sistant plates, routing of wiring harnesses, pipe rout-ing).

Make sure that products such as sealants are used ap-propriately. Do not spread too much sealant on thecontact surface.

3 - Special tools

It is requested that special tools be used to performmaintenance procedures. For top quality maintenanceand in order to ensure safety during operations, specialtools must be used.

Special Renault Samsung Motors tools have beendesigned based on studies and tests. Special caremust be taken when using these tools. The tools mustalso be regularly maintained.

4 - Reliability

The technical specifications of the parts are continu-ously being improved and developed. It is thereforenecessary to regularly check for updated informationon new spare parts in the technical bulletins.

5 - Safety

Safety and hygiene are the basic criteria for the main-tenance of equipment and parts.

Information in bold type in the manual indicate the pro-cedures that require special care or indicate tighteningtorque values.

For safety during operations:

- use tools that are most suited to the task (avoid usingas much as possible multi-use tools, such as adjust-

able pliers),- when handling heavy objects, install them correctly

on their supports and adopt the correct working posi-tion,

- maintain hygiene in the mechanical workshop and inthe vicinity during operations,

- wear personal protective equipment (gloves, goggles,safety shoes, masks, protective skin cream, etc.),

- follow the safety instructions for the maintenancework to be performed,

- do not smoke during maintenance operations,

- do not handle dangerous products in a closed area,

- no chemicals must be swallowed or come into contactwith the skin (brake fluid, antifreeze fluid, etc.).

To protect the environment:

- sort waste,

- do not burn waste (tyres, etc.).

6 - ConclusionBodily injury must be limited as much as possible byfollowing the work procedures set out in this manualand by avoiding procedures that might damage the ve-hicle or create dangerous situations.

By following the abovementioned procedures, it will bepossible to ensure that top quality maintenance, topvehicle performance and reliability are all obtained.

II - CLEANLINESS

1 - Cleaning the engine

Cover adjacent parts to protect them from water andcleaning products.

Note:

Do not use ammable products to clean parts.




X38, SAMSUNG BRAND

10AMake sure that air inlet parts do not come into contactwith water.

2 - Cleaning engine parts

3 - Repairing threads

The threading holes of the engine assembly (excludingthe rocker cover) may be repaired using the thread re-pair kit.

WARNINGWhen cleaning the parts, never tap a mountingcomponent such as the contact surface of parts, asthis could damage the parts and change theirdimensions which could consequently damage theengine.



ENGINE AND CYLINDER BLOCK ASSEMBLYEngine: Specifications


10AI - ENGINE IDENTIFICATION

Engine identification is located:

- on the cylinder block, by an engraving ( A) , betweenthe starter and the flywheel,

- on the timing cover, by a label ( B) .

Detail of the marking (A):

Detail of the marking (B):

X95

139836

139835

135515

(1) the engine type (2) the engine approval letter

(3) the engine sufx

(4) the engine production number

140017

(5) the engine type

(6) the engine approval letter (7) the engine sufx

(8) the assembled engine part num-ber

(9) the fabrication number





10AThe engine identification is engraved on the cylinderblock at ( C) .

II - TABLE OF ENGINE SPECIFICATIONS

X38

146979

X95

Engine type Engine sufx Cubic capacity

(cc)

Bore

(mm)

Stroke

(mm)

Compression

ratio

H4J 700 1397 78 73.1 9.2 / 1

X38

Engine type Engine sufx Cubic capacity

(cc)

Bore

(mm)

Stroke

(mm)

Compression

ratio

H4M720

1598 78 83.6 10.7:1721




X38, SAMSUNG BRAND

10AThe engine serial number is engraved at ( 1) on the cyl-inder block.

147908

Engine type Cubic capacity

(cc)

Bore

(mm)

Stroke

(mm)

Compression

ratio

H4M 1598 78 83.6 10.7:1



ENGINE AND CYLINDER BLOCK ASSEMBLYEngine: New replacement

X95 – X38

10ANEW REPLACEMENT ENGINE

1 - Preparing the old engine to be returned to theengine renovation plant

a Clean the engine.

a Drain:

- the engine oil (see Engine oil: Draining - Refill-ing ) ,

- the coolant (see Cooling system: Draining - Re-filling ) .

a Secure the old engine to the stand and in the sameconditions as the standard replacement engine:

- fit the plastic plug welds and covers,

- fit the cardboard cover over the whole assembly.

2 - Parts to leave on the old engine or to include inthe return box:

a Parts to leave on the old engine or to include in thereturn box:

- dipstick guide ,

- the oil filter,

- the coolant - oil heat exchanger,

- the oil level sensor,

- the rocker cover,

- the coolant pump,

- the « injector rail - injector » assembly,

- the spark plugs,

- the timing chain,

- the timing chain tensioner,

- the timing chain guides,

- the crankshaft sprocket,

- the exhaust camshaft sprocket,

- the inlet camshaft dephaser,

- the timing cover,

- the crankshaft accessories pulley,

- the water chamber,

- the thermostat support,

- the thermostat,

- the lifting rings,

- the camshaft position sensor,

- the coolant temperature sensor,

- the cylinder head right-hand suspended mounting.

3 - Parts to be removed from the old engine andfitted on the new engine

a Parts to be removed from the old engine and fittedon the new engine:

- the cooling system hose assembly,

- the oil pressure sensor,

- the pinking sensor,

- the inlet distributor,

- the exhaust manifold,

- the exhaust manifold heat shield,

- the exhaust manifold heat shields,- the starter,

- the alternator,

- the water pump pulley,

- the air conditioning compressor ,

- the multifunction support,

- the clutch,

- the flywheel.

a Parts to be removed from the old engine and fittedon the new engine:

- the catalytic converter,

- the turbocharger,

- the turbocharger oil pipes,

- the turbocharger coolant pipes.

4 - Parts always to be replaced

a Parts always to be replaced:

- the inlet distributor seal,

- the exhaust manifold gasket,

- the studs of the exhaust manifold (if loosened),

- the exhaust manifold nuts,

- the flywheel bolts,

- the oil pressure sensor seal,

- the accessories belt,

- the accessories belt tensioning roller,

X95



ENGINE AND CYLINDER BLOCK ASSEMBLYEngine: New replacement

X95 – X38

10A- the bolt for the accessories belt tensioning roller,

- the cooling circuit hoses (if damaged).

a Part always to be replaced:

- the catalytic converter seal,

- the turbocharger seal,

- the turbocharger nuts,

- the turbocharger oil pipe seals,

- the turbocharger coolant pipe seals,

- the accessories belt fixed roller.

a Refit the parts removed from the old engine on thenew engine.

X95



ENGINE AND CYLINDER BLOCK ASSEMBLYEngine: Repair


10A

REMOVAL

I - ENGINE REPAIR PREPARATION OPERATION

a

a Remove the « engine and gearbox » assembly (seeEngine - gearbox assembly: Removal - Refitting ).

a Disconnect the manual gearbox from the engine(see Manual gearbox: Removal - Refitting ) (21A,Manual gearbox).

a Disconnect the automatic gearbox from the engine

(see Automatic gearbox: Removal - Refitting )(23A, Automatic transmission).

a Position the engine on the component support(see 10A , Engine and cylinder block assembly ,Engine support equipment: Use , page 10A-19 ) .

a Drain the engine (see Engine oil: Draining - Refill-ing ) .

II - UPPER ENGINE REMOVAL OPERATION

a Loosen the bolts ( 1 ) of the coolant pump pulley,locking the coolant pump pulley using a screwdriver.

a Remove the accessories belt (see Accessoriesbelt: Removal - Refitting ) .

a Remove the inlet distributor (see Inlet distributor:Removal - Refitting ) .

a Remove:

- the coils (see Coils: Removal - Refitting ) ,

- the rocker cover (see Rocker cover: Removal -Refitting ) .

Special tooling required

Mot. 1431 Flywheel locking tool.

Equipment required

component support

Tightening torques m

bolts on the coolantpump pulley

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and ope-ration recommendations before carrying out anyrepair:

- (see 10A , Engine and cylinder block assem-

bly , Engine: Precautions for the repair , page10A-1 ) ,

- (see Vehicle: Precautions for the repair )(01D, Mechanical introduction).

WARNING

It is strictly forbidden to apply any pressure to theengine oil sump. Damage to the sump will irrepa-rably damage the engine by:

- blocking the strainer,- raising the oil level above maximum, with a risk

of engine racing.

X95 – X38, JH3

X38, CK1

139484

X38





10A

a Turn the crankshaft clockwise until the mark ( 2) (notpainted) on the crankshaft accessories pulley isaligned with the mark ( 3) on the timing cover.

a Check that the marks ( 4) of the camshaft dephaserand the marks ( 5) of the exhaust camshaft sprocketare in the same position as shown in the illustration.

a If they are not, turn the crankshaft an additional turnuntil the unpainted mark on the crankshaft accesso-ries pulley is aligned with the mark on the timing cov-er.

a Fit the flywheel locking tool (Mot. 1431) (6) .

a Remove:

- the crankshaft accessories pulley (see Crankshaftaccessories pulley: Removal - Refitting ) ,

- the crankshaft seal on the timing side (see Crank-

shaft seal on timing end: Removal - Refitting ) ,- the timing chain (see Timing chain: Removal -

Refitting ) ,

- the camshaft dephaser (see Camshaft dephaser:Removal - Refitting ) ,

- the camshafts (see Camshaft: Removal - Refit-ting ) .

a Remove:

- the catalytic converter (see Catalytic converter:Removal - Refitting ) ,

- the turbocharger oil pipes (see Turbocharger oilpipe: Removal - Refitting ) .

a Remove:

- the spark plugs (see Plugs: Removal - Refitting ) ,

- the camshaft dephaser solenoid valve (see Cam-

shaft dephaser solenoid valve: Removal - Refit-ting ) ,

- the cylinder head (see Cylinder head: Removal -Refitting ) .

141016

141017

141008

X95





10AIII - UPPER ENGINE REPAIR OPERATION

a Remove:

- the turbocharger (see Turbocharger: Removal -Refitting ) ,

- the inlet distributor (see Inlet distributor: Remov-al - Refitting ) .

a Remove:

- the exhaust manifold (see Exhaust manifold: Re-moval - Refitting ) ,

- the valves (see 10A , Engine and cylinder blockassembly , Valve: Removal - Refitting , page 10A-32) ,

- the lifting eye on the flywheel end (see Liftingeyes: Removal - Refitting ) ,

- the water chamber (see Water chamber: Remov-al - Refitting ) ,

- the camshaft position sensor (see Camshaft posi-

tion sensor: Removal - Refitting) ,

- the « injector rail - injector » assembly (see Injec-tor rail - Injectors: Removal - Refitting ) .

a Strip the cylinder head (see 10A , Engine and cylin-der block assembly , Cylinder head: Stripping -Rebuilding , page 10A-57 ) .

a Clean the cylinder head (see 10A , Engine and cyl-inder block assembly , Cylinder head: Cleaning ,page 10A-64 ) .

a Check:

- the cylinder head (see 10A , Engine and cylinderblock assembly , Cylinder head: Check , page10A-67 ) ,

- the camshafts (see 10A , Engine and cylinderblock assembly , Camshaft: Check , page 10A-25) ,

- the valves and the valve springs (see 10A , Engineand cylinder block assembly , Valve: Check ,page 10A-46 ) .

IV - LOWER ENGINE REMOVAL OPERATION

a Remove:

- the compressor (see Compressor: Removal - Re-

fitting ) (62A, Air conditioning),- the oil filter (see Oil filter: Removal - Refitting ) ,

- the « pressure plate - disc » assembly (see Pres-sure plate - Disc: Removal - Refitting ) (20A,Clutch),

- the flywheel (see Flywheel: Removal - Refitting ) ,

- the crankshaft seal on the gearbox side (seeCrankshaft seal, gearbox end: Removal - Refit-ting ) ,

- the sump (see Lower cover: Removal - Refitting ),

- the cylinder block base plate (see 10A , Engineand cylinder block assembly , Cylinder blockbase plate: Removal - Refitting , page 10A-73 ) ,

- the « piston - con rod » assembly (see 10A , En-gine and cylinder block assembly , Piston - Conrod: Removal - Refitting , page 10A-88 ) ,

- the crankshaft (see 10 A , Engine and cylinderblock assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) .

a Remove the piston base cooling jets (see 10A , En-gine and cylinder block assembly , Piston basecooling jet: Removal - Refitting , page 10A-172 ) .

a Remove:

- the alternator (see Alternator: Removal - Refit-ting ) ,

- the multifunction support (see Multifunction sup-port: Removal - Refitting ) ,

- the coolant pump (see Coolant pump: Removal -Refitting ) ,

- the thermostat (see Thermostat: Removal - Refit-ting ) ,

- the pinking sensor (see Pinking sensor: Removal- Refitting ) ,

- the oil pressure sensor (see Oil pressure sensor:

Removal - Refitting ) ,- the cylinder block (see 10A , Engine and cylinder

block assembly , Cylinder block: Removal - Re-fitting , page 10A-153 ) .

X95

Note:

Replace the parts whose values are outside thepermitted tolerance values.

X95





10AV - LOWER ENGINE REPAIR OPERATION

a Clean the cylinder block (see 10A , Engine and cyl-inder block assembly , Cylinder block: Cleaning ,page 10A-167 ) .

a Check:

- the cylinder block and the cylinder block base plate(see 10A , Engine and cylinder block assembly ,Cylinder block: Check , page 10A-168 ) ,

- the "con rod - piston" assemblies (see 10A , Engineand cylinder block assembly , Piston - Con rod:Check , page 10A-105 ) ,

- the crankshaft (see 10A , Engine and cylinderblock assembly , Crankshaft: Check , page 10A-134 ) .

REFITTING

I - REFITTING PREPARATION OPERATION

a Parts always to be replaced:

- all seals,

- the cooling circuit hoses if they are damaged,


- the accessories belt tensioning roller,

- the timing chain,

- the timing chain tensioner,

- the timing chain guides,

- the cylinder head gasket,

- the cylinder head bolts,

- the camshaft dephaser filter,

- the crankshaft accessories pulley bolt,

- the exhaust manifold nuts,

- the exhaust manifold studs (if removed),

- the oil filter,

- the flywheel bolts,

- the con rod cap bolts,

- the crankshaft bearing cap bolts,

- the crankshaft bearing shells,

- the con rod bearing shells,

- the oil pump chain,

- the oil pump chain tensioning roller.

a Part always to be replaced:

- the accessories belt fixed roller,

- the turbocharger nuts,

- the turbocharger studs (if removed),

- the catalytic converter nuts.

a

a When replacing the crankshaft or the crankshaftbearing shells, it is essential to determine the thick-ness class for each bearing shell to be refitted oneach crankshaft bearing to ensure that the journalclearance is within the tolerances (see 10A , Engineand cylinder block assembly , Cylinder block:Check , page 10A-168 ) and (see 10A , Engine andcylinder block assembly , Crankshaft: Check ,page 10A-134 ) .

a When replacing the crankshaft, the « piston - conrod » assembly or the big end bearing shells, alwaysdetermine the bearing shell thickness class to refit toeach big end to ensure that the crankpin clearanceis within the tolerances (see 10A , Engine and cylin-der block assembly , Crankshaft: Check , page

Note:

Replace the parts whose values are outside thepermitted tolerance values.

X95

WARNINGThe gasket faces must be clean, dry and freefrom grease (avoid nger marks)

WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and uid could damage certain

components (engine, radiator, etc.).

Note:

Any clearances of the crankshaft journal outsidethe tolerances can cause engine damage.

Note:

Any clearances of the crankshaft crankpin out-side the tolerances can cause engine damage.





10A10A-134 ) and (see 10A , Engine and cylinderblock assembly , Piston - Con rod: Check , page10A-105 ) .

If replacing the cylinder block base plate

a Remove the coolant-oil heat exchanger from the oldcylinder block base plate (see Oil-coolant heat ex-changer: Removal - Refitting ) .

a

Remove the oil level sensor from the old cylinderblock base plate (see Oil level sensor: Removal -Refitting ) .

a Refit the oil level sensor on the new cylinder blockbase plate (see Oil level sensor: Removal - Refit-ting ) .

a Refit the coolant-oil heat exchanger on the new cyl-inder block base plate (see Oil-coolant heat ex-

changer: Removal - Refitting ) .

II - LOWER ENGINE REFITTING OPERATION

a Refit:

- the cylinder block (see 10A , Engine and cylinderblock assembly , Cylinder block: Removal - Re-fitting , page 10A-153 ) ,

- the oil pressure sensor (see Oil pressure sensor:Removal - Refitting ) ,

- the pinking sensor (see Pinking sensor: Removal- Refitting ) ,

- the thermostat (see Thermostat: Removal - Refit-ting ) ,

- the coolant pump (see Coolant pump: Removal -Refitting ) ,

- the multifunction support (see Multifunction sup-port: Removal - Refitting ) ,

- the alternator (see Alternator: Removal - Refit-ting ) .

a Refit the piston base cooling jets (see 10A , Engine

and cylinder block assembly , Piston base cool-ing jet: Removal - Refitting , page 10A-172 ) .

a Refit:

- the crankshaft (see 10 A , Engine and cylinderblock assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) ,

- the « piston - con rod » assembly (see 10A , En-gine and cylinder block assembly , Piston - Con

rod: Removal - Refitting , page 10A-88 ) ,- the cylinder block base plate (see 10A , Engine

and cylinder block assembly , Cylinder blockbase plate: Removal - Refitting , page 10A-73 ) ,




- the « pressure plate - disc » assembly (20A, Clutch(see Pressure plate - Disc: Removal - Refitting )),

- the oil filter (see Oil filter: Removal - Refitting ) ,

- the compressor (see Compressor: Removal - Re-fitting ) (62A, Air conditioning).

III - UPPER ENGINE REFITTING OPERATION

a Rebuild the cylinder head (see 10A , Engine andcylinder block assembly , Cylinder head: Strip-ping - Rebuilding , page 10A-57 ) .

a Refit:

- the « injector rail - injector » assembly (see Injec-tor rail - Injectors: Removal - Refitting ) ,

- the camshaft position sensor (see Camshaft posi-tion sensor: Removal - Refitting ) ,


- the lifting eye on the flywheel end (see Lifting

eyes: Removal - Refitting ) ,- the valves (see 10A , Engine and cylinder block

assembly , Valve: Removal - Refitting , page 10A-32 ) ,

X95

X95

X95





10A- the exhaust manifold (see Exhaust manifold: Re-moval - Refitting ) .

a Refit:

- the inlet distributor (see Inlet distributor: Remov-al - Refitting ) ,

- the turbocharger (see Turbocharger: Removal -Refitting ) .

a Refit:

- the cylinder head (see Cylinder head: Removal -Refitting ) ,

- the camshaft dephaser solenoid valve (see Cam-shaft dephaser solenoid valve: Removal - Refit-ting ) ,

- the spark plugs (see Plugs: Removal - Refitting ) .

a Refit:

- the turbocharger oil pipes (see Turbocharger oil

pipe: Removal - Refitting ) ,- the catalytic converter (see Catalytic converter:Removal - Refitting ) .

a Refit:

- the camshafts (see Camshaft: Removal - Refit-ting ) ,


- the timing chain (see Timing chain: Removal -Refitting ) ,

- the crankshaft seal on the timing side (see Crank-shaft seal on timing end: Removal - Refitting ) .

a Position the (Mot. 1431) .

a Refit the crankshaft accessories pulley (see Crank-shaft accessories pulley: Removal - Refitting ) .

a Remove the tool (Mot. 1431) .

a Refit:

- the rocker cover (see Rocker cover: Removal -Refitting ) ,

- the coils (see Coils: Removal - Refitting ) .

a Refit the inlet distributor (see Inlet distributor: Re-

moval - Refitting ) .

a Refit the accessories belt (see Accessories belt:Removal - Refitting ) .

a Torque tighten the bolts on the coolant pump pul-ley (8 N.m) locking the coolant pump pulley using ascrewdriver.

IV - FINAL OPERATION

a Fill up the engine oil (see Engine oil: Draining - Re-filling ) .

a Remove the engine from component support (see10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .

a Connect the manual gearbox to the engine (seeManual gearbox: Removal - Refitting ) (21A, Man-ual gearbox).

a Connect the automatic gearbox to the engine (seeAutomatic gearbox: Removal - Refitting ) (23A,Automatic gearbox).

a Refit the « engine and gearbox » assembly (see En-

gine - gearbox assembly: Removal - Refitting ) .

X95

X95

X38

X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10AREMOVAL

I - PREPARING TO REMOVE THE ENGINE

a

a Drain the engine oil (see Engine oil: Draining - Re-filling ) .

a Remove the engine and transmission assembly (seeEngine - gearbox assembly: Removal - Refitting ).

a Place the engine assembly on the engine stand (see10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .

II - CYLINDER HEAD REMOVALa Remove or disconnect the following parts:

- the throttle valve (see Throttle valve: Removal -Refitting ) ,

- the inlet manifold (see Inlet distributor: Removal- Refitting ) ,


- the ignition coils (see Coils: Removal - Refitting ) ,

- the injector rail protector (seeRocker cover: Re-moval - Refitting ) ,

- the injector rail - injectors assembly (see Injectorrail - Injectors: Removal - Refitting ) ,


- the timing cover (see Timing chain: Removal -Refitting ) ,

- the front oil seal (see Timing chain: Removal -Refitting ) ,


- the oil pump chain (see Timing chain: Removal -Refitting ) ,

- the camshaft sprocket (see Camshaft dephaser:Removal - Refitting ) ,

- the camshaft (see Camshaft: Removal - Refit-ting ) ,


- the valves (see 10A , Engine and cylinder blockassembly , Valve: Removal - Refitting , page 10A-32 ) ,

- the valve stem seals (see 10A , Engine and cylin-der block assembly , Valve: Removal - Refitting ,page 10A-32 ) .

III - CYLINDER HEAD MAINTENANCE


a Service the following parts:

- the cylinder head (see 10A , Engine and cylinderblock assembly , Cylinder head: Check , page10A-67 ) ,

- the camshaft (see 10A , Engine and cylinderblock assembly , Camshaft: Check , page 10A-

25 ) ,- the valves (see 10A , Engine and cylinder block

assembly , Valve: Check , page 10A-46 ) .

IV - REMOVING THE CYLINDER BLOCK

a Remove or disconnect the following parts:- the rear oil seal (see 10A , Engine and cylinder

block assembly , Cylinder block base plate: Re-moval - Refitting , page 10A-73 ) ,

- the lower plate of the cylinder block (see 10A , En-gine and cylinder block assembly , Cylinderblock base plate: Removal - Refitting , page 10A-73 ) ,

- the piston - con rod (see 10A , Engine and cylin-der block assembly , Piston - Con rod: Removal

- Refitting , page 10A-88 ) ,- the crankshaft (see 10 A , Engine and cylinder

block assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) ,

IMPORTANTTo avoid all risk of damage to the systems, applythe safety and cleanliness instructions and oper-ation recommendations before carrying out anyrepair (see 10A , Engine and cylinder blockassembly , Engine: Precautions for the repair ,page 10A-1 ) .

WARNING

Wear protective gloves during the operations.

Note:

All parts that have exceeded their wear limit mustbe replaced.




X38, SAMSUNG BRAND

10A- the cylinder block (see 10A , Engine and cylinderblock assembly , Cylinder block: Removal - Re-fitting , page 10A-153 ) .

V - CYLINDER BLOCK MAINTENANCEa Clean the cylinder block (see 10A , Engine and cyl-

inder block assembly , Cylinder block: Cleaning ,page 10A-167 ) .

a Service the following parts:

- the cylinder block (see 10A , Engine and cylinderblock assembly , Cylinder block: Check , page10A-168 ) ,

- the crankshaft (see 10A , Engine and cylinderblock assembly , Crankshaft: Check , page 10A-

134 ) ,- the piston - con rod (see 10A , Engine and cylin-der block assembly , Piston - Con rod: Check ,page 10A-105 ) .

REFITTING

I - PREPARATION FOR REFITTING

a Replace the following parts with new parts:


- the loose pulley,

- the oil pump chain,

- the oil pump chain tensioner,

- the timing chain,

- the timing chain tensioning roller,

- the guide shoe of the timing chain,

- the timing chain tensioner pad,

- the front oil seal,

- the crankshaft main bearing cap mounting bolt,

- the con rod cap mounting bolt,

- the front oil seal,

- the O-ring of the cylinder block lower plate,

- the crankshaft position sensor O-ring,

- the coolant inlet rubber washer,

- the dipstick tube O-ring,

- the coolant pump seal,

- the exhaust manifold seal,

- the inlet manifold seal A, B,

- the cylinder head gasket,- the rocker cover seal,

- the oil filter,

- the drain plug washer,

- the O-ring of the continuously variable inlet sole-noid valve (CVTC),

- the camshaft sensor O-ring,

- the valve stem seal,

- the cylinder head mounting bolts.

II - REFITTING THE CYLINDER BLOCK

a Refit the following parts:

- the cylinder block (see 10A , Engine and cylinderblock assembly , Cylinder block: Removal - Re-fitting , page 10A-153 ) ,

- the crankshaft (see 10 A , Engine and cylinderblock assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) ,

- the piston - con rod (see 10A , Engine and cylin-der block assembly , Piston - Con rod: Removal- Refitting , page 10A-88 ) ,


- the rear oil seal (see 10A , Engine and cylinderblock assembly , Cylinder block base plate: Re-moval - Refitting , page 10A-73 ) .

III - REFITTING OF THE CYLINDER HEADa Refit the following parts:

- the valve stem seals (see 10A , Engine and cylin-der block assembly , Valve: Removal - Refitting ,page 10A-32 ) ,

- the valves (see 10A , Engine and cylinder blockassembly , Valve: Removal - Refitting , page 10A-32 ) ,




Note:

All parts that have exceeded their wear limit mustbe replaced.




X38, SAMSUNG BRAND

10A- the oil pump chain (see Timing chain: Removal -Refitting ) ,






- the injector rail protector (see Rocker cover: Re-moval - Refitting ) ,




- the throttle valve (see Throttle valve: Removal -Refitting ) .

IV - FINAL OPERATIONS

a Remove the engine assembly from the engine stand(see 10A , Engine and cylinder block assembly ,Engine support equipment: Use , page 10A-19 ) .

a Refit the engine and transmission assembly (seeEngine - gearbox assembly: Removal - Refitting ).

a Refill the engine oil (see Engine oil: Draining - Re-filling ) .



ENGINE AND CYLINDER BLOCK ASSEMBLYEngine support equipment: Use


10A

I - PREPARATION OPERATION FOR FITTING THEENGINE ON THE COMPONENT SUPPORT

a


a Disconnect the manual gearbox from the engine

(see Manual gearbox: Removal - Refitting ) (21A,Manual gearbox).

a Disconnect the automatic gearbox from the engine(see Automatic gearbox: Removal - Refitting )(23A, Automatic transmission).

a Fit the studs ( 1) of component support on the cyl-inder block on the flywheel end.

Equipment required

component support

workshop hoist

load balancer

117508

IMPORTANTTo work in complete safety, it is essential to use acomponent stand.

WARNINGIt is strictly forbidden to apply any pressure to theengine oil sump. Damage to the sump will irrepa-rably damage the engine by:

- blocking the strainer,

- raising the oil level above maximum, with a riskof engine racing.

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X38, CK1

X95

141090





10A

a Fit the studs ( 1) of component support on the cyl-inder block on the flywheel end.

a Fit the support bars ( 2) on the studs of componentsupport .

a Fit the support bar nuts ( 3) , without tightening them.

II - FITTING THE ENGINE ON THE COMPONENTSUPPORT

a Fit the "engine - studs - support bars" assembly onthe component support using a workshop hoistand a load balancer .

a Tighten the support bar bolts ( 4) on the componentsupport .

a Remove the load balancer .

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10AIII - OPERATION FOR REMOVING THE ENGINEFROM COMPONENT SUPPORT

a Support the "engine - studs - support bars" assem-bly on the component support using a workshophoist and a load balancer .

a Remove the support bar bolts on the componentsupport .

a Separate the "engine - studs - support bars" assem-bly from the component support using a work-shop hoist and a load balancer .


a Remove:

- the support bar nuts,

- the support bars,

- the studs.



a Refit the « engine and gearbox » assembly (see En-gine - gearbox assembly: Removal - Refitting ) .

X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A

I - PREPARATIONS BEFORE THE OPERATIONa



a Disconnect the automatic gearbox from the engine

(see Automatic gearbox: Removal - Refitting )(23A, Automatic transmission).

a

a Pretighten the following parts:

- mounting nuts ( 1) of the tubes ( 3) and arm ( 4) ofthe special tool (RSM 9000) ,

- mounting bolt ( 2) of the tubes ( 3) and arm ( 4) of thespecial tool (RSM 9000) .

II - POSITIONING THE ENGINEa Using the workshop hoist , place the engine as-

sembly in the centre of the engine stand .

Equipment required

engine stand

workshop hoist


mounting bolts of thebody of the special tool(RSM 9000)

196 N.m

mounting bolt of thearms on the body of thespecial tool (RSM 9000)

160 N.m

mounting bolt of thearms on the tubes of thespecial tool (RSM 9000)

95 N.m

mounting nuts of thearms on the tubes of thespecial tool (RSM 9000)

95 N.m

WARNINGFor the safety of the operation, use the appropri-ate engine stand for the engine.

The engine stand should have a load capacityof at least 135 kg.

Wear protective gloves during the operation.

JH3

CK1

147909

WARNINGWhen using the engine stand , it is advisable toinstall at least 4 sets of engine mounting equip-ment in order to guarantee safety.




X38, SAMSUNG BRAND

10A

a Install the following parts on the engine stand (5) :

- body ( 6) of the special tool (RSM 9000) ,

- mounting bolt of the body ( 8 ) of the special tool(RSM 9000) .

a Torque tighten the mounting bolts of the body ofthe special tool (RSM 9000) (196 N.m) (8) .

a Pretighten the bolts of the following parts on the en-gine stand (5) :

- arm ( 7) of the special tool (RSM 9000) ,

- mounting bolt of the arms ( 9 ) of the special tool(RSM 9000) .

a Adjust the position of the arms ( 7) of the special tool(RSM 9000) on the engine assembly.

a Tighten the following parts to the tightening torquesdefined:

- mounting bolt of the arms on the body of thespecial tool (RSM 9000) (160 N.m) ,

- mounting bolt of the arms on the tubes of thespecial tool (RSM 9000) (95 N.m) ,

- mounting nuts of the arms on the tubes of thespecial tool (RSM 9000) (95 N.m) .

a

a Remove the workshop hoist (10 ) .

III - REMOVING FROM THE ENGINE

a Connect the workshop hoist .

a Remove the following parts:

- mounting nuts on the tubes and arm of the specialtool (RSM 9000) ,

- mounting bolt on the tubes and arm of the specialtool (RSM 9000) ,

- tube of the special tool (RSM 9000) .

a Remove the engine assembly of the special tool(RSM 9000) .

147910

147911

147912

WARNINGFor your safety, gently remove the workshophoist from the engine stand .




X38, SAMSUNG BRAND

10Aa Remove the following parts:

- mounting bolt on the body of the special tool (RSM9000) ,

- arm of the special tool (RSM 9000) ,- mounting bolt of the body of the special tool (RSM9000) ,

- body of the special tool (RSM 9000) .


a Refit the manual gearbox to the engine (see Manualgearbox: Removal - Refitting ) .

a Refit the automatic gearbox to the engine (see Au-tomatic gearbox: Removal - Refitting ) .


JH3

CK1



ENGINE AND CYLINDER BLOCK ASSEMBLYCamshaft: Check


10A

I - PREPARATION OPERATION FOR CHECK

Remove the « engine and gearbox » assembly (seeEngine - gearbox assembly: Removal - Refitting ) .

Disconnect the manual gearbox from the engine (seeManual gearbox: Removal - Refitting ) (21A, Manualgearbox).

Disconnect the automatic gearbox from the engine(see Automatic gearbox: Removal - Refitting ) (23A,Automatic transmission).

Fit the engine on the component support (see 10A ,Engine and cylinder block assembly , Engine sup-port equipment: Use , page 10A-19 ) .

Remove the camshafts (see Camshaft: Removal -Refitting ) .

Before any checks:

- use SURFACE CLEANER (see Vehicle: Parts andconsumables for the repair ) (04B, Consumables -Products) to clean the camshaft,

- check that the camshafts are not scratched and donot show signs of impact or abnormal wear (replacethe camshaft if necessary).

II - CAMSHAFT CHECKING OPERATION

1 - Identification of the camshafts

There are 5 camshaft bearings.

Equipment required

component support

dial gauge support

Dial gauge

external micrometer

radial play measuring tape

IMPORTANTTo avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair:

- (see 10A , Engine and cylinder block assembly ,Engine: Precautions for the repair , page 10A-1 ),

- (see Vehicle: Precautions for the repair ) (01D,Mechanical introduction).

WARNING

It is strictly forbidden to apply any pressure to theengine oil sump. Damage to the sump will irrepara-bly damage the engine by:


- raising the oil level above maximum, with a risk ofengine racing.

X95 – X38, JH3

X38, CK1

115892

(1) Exhaust camshaft

(2) Inlet camshaft (3) Camshaft position sensor target

(4) Camshaft dephaser supplyopenings





10A2 - Checking the concentricity of the camshaftjournals

Place the camshaft on two slightly oiled v-blocks ( 5) .

Fit:

- the dial gauge support (6 ) ,

- the Dial gauge (7 ) .

Fit the sensor of the Dial gauge against the centre ofthe camshaft journal mating face.

Calibrate the Dial gauge to zero .

Rotate the camshaft one turn while avoiding the lubri-cation holes to check the journal concentricity, whichshould be a maximum of 0.05 mm .

Rotate the camshaft one turn while avoiding the lubri-cation holes to check the journal concentricity, which

should be a maximum of 0.02 mm .

3 - Checking the diameter of the camshaft journals

Use a external micrometer to measure the diameter (X1) of each camshaft journal which should bebetween:

- bearing No.1: 27.04 and 27.06 mm ,

- bearings No.2, 3, 4 and 5: 24.95 and 24.97 mm .

Use a external micrometer to measure the diameter (X1) of each camshaft journal which should bebetween:

- bearing No.1: 27.94 and 27.96 mm ,


103148

X95

X38

102772

X95

X38





10A4 - Checking the height of the cam lobes

Place the camshaft on two slightly oiled v-blocks.

Use a external micrometer to measure the height ofthe cams (H) which should be between:

- inlet cam: 39.58 and 39.77 mm ,

- exhaust cam: 40.92 and 42 mm .

Use a external micrometer to measure the height ofthe cams (H) which should be between:

- inlet cam: 41.71 and 41.90 mm ,

- exhaust cam: 40.18 and 40.37 mm .

5 - Checking the camshaft radial play

Remove any oil that may be on the camshaft bearingsand on the camshaft bearing caps.

Cut 10 pieces of radial play measuring tape the widthof the camshaft journal mating face.

Place each piece of wire in line with the camshaft onthe camshaft journal mating faces on the cylinder headat ( 8) and ( 9 ) .

Refit (see Camshaft: Removal - Refitting ) :

- the camshafts,

- the camshaft bearing caps,

- the camshaft bearing cap bolts.Remove (see Camshaft: Removal - Refitting ) :

- the camshaft bearing cap bolts,

- the camshaft bearing caps,

- the camshafts.

103149

102771

X95

X38

141041

Note:

Do not allow the camshaft to rotate during the oper-ation in order to avoid distorting the measurement.





10A

Measure the flatness of the radial play measuringtape using the gauge ( 10) printed on the wrapping pa-per of the measuring tape, which should be between:

- bearing No.1: 0.04 to 0.08 mm ,


6 - Checking the camshaft longitudinal play

Refit the camshafts on the cylinder head (see Cam-shaft: Removal - Refitting ) .

Fit:

- the dial gauge support (11 ) ,

- the Dial gauge (12 ) .

Position the dial gauge sensor against the end of thecamshaft.

Move the camshaft towards the dial gauge until it hits astop.

Calibrate the dial gauge to zero .

Move the camshaft towards the side opposite the dialgauge until it hits the other stop.

Check the longitudinal play, which should be between0.08 and 0.16 mm .

III - FINAL OPERATION

Refit the camshafts (see Camshaft: Removal - Refit-

ting ) .Remove the engine from component support (see10A , Engine and cylinder block assembly , Enginesupport equipment: Use , page 10A-19 ) .

Connect the manual gearbox to the engine (see Manu-al gearbox: Removal - Refitting ) (21A, Manual gear-box).

Connect the automatic gearbox to the engine (see Au-tomatic gearbox: Removal - Refitting ) (23A, Auto-matic gearbox).

Refit the « engine and gearbox » assembly (see En-gine - gearbox assembly: Removal - Refitting ) .

102807

139706

X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A

I - PREPARATION FOR THE CHECK

Remove the engine and transmission assembly (seeEngine - gearbox assembly: Removal - Refitting ) .

Place the engine assembly on the engine mount (see10A , Engine and cylinder block assembly , Enginesupport equipment: Use , page 10A-19 ) .

Remove the camshaft (see Camshaft: Removal - Re-fitting ) .

Before performing the check:

- clean the camshaft,

- Check for possible scratches or damage caused byan impact on the surface of the camshaft.

II - CHECKING THE CAMSHAFT

1 - Camshaft end float

Measure the end float using the Dial gauge (1 ) whilemoving the camshaft towards the shaft.

The normal value of the end float of the camshaft is be-tween 0.075 and 0.153 mm .

If the end float of the camshaft is not within the normalvalues, check the following lengths:

- A: camshaft support bearing no.1 4.000 - 4.030 mm .

Equipment required

Dial gauge

external micrometer

Note:

Before performing the repair operations, check thedirectives concerning safety, hygiene and the pro-cedures (see 10A , Engine and cylinder blockassembly , Engine: Precautions for the repair ,

page 10A-1 ) .

WARNINGWear protective gloves during the operations.

147956

147957




X38, SAMSUNG BRAND

10A

2 - Operating play of the camshaft journals

Perfectly clean the journals and the camshaft support.

The operating clearances of the camshaft journalsmust be between 0.045 and 0.086 mm for journal no.1. and between 0.030 and 0.071 mm for journals no. 2,3, 4 and 5.

3 - Camshaft eccentricity

The camshaft eccentricity must not exceed 0.02 mm .

4 - Normal values for the camshaft bearings

Note:

The position of camshaft journal no. 1 is located on

the side of the timing chain.

147960

(A) Measuring tape

(B ) Measurement sheet of operatingclearances

Note:

For the accuracy of the measurements, do notrotate the camshaft during measurement.

147961

Bearing no. Internal diame-ter of the cam-shaft support(mm)

Camshaft jour-nal diameter(mm)

No. 1 28.000 - 28.021 27.935 - 27.955

No. 2

25.000 - 25.021 24.950 - 24.970No. 3

No. 4

No. 5




X38, SAMSUNG BRAND

10A5 - Cam height

Measure the cam height using the external microme-ter .

III - FINAL OPERATIONS

Refit the camshaft (see Camshaft: Removal - Refit-ting ) .

Remove the engine assembly from the engine stand(see 10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .

Refit the engine and transmission assembly (see En-gine - gearbox assembly: Removal - Refitting ) .

147962

Inlet (mm) Exhaust (mm)

Cam height 41.705 - 41.895 40.175 - 40.365



ENGINE AND CYLINDER BLOCK ASSEMBLYValve: Removal - Refitting


10AREMOVAL

I - REMOVAL PREPARATION OPERATION

a




a Position the engine on the component support

(see 10A , Engine and cylinder block assembly ,Engine support equipment: Use , page 10A-19 ) .




Mot. 1573 Cylinder head support

Mot. 1502 Tool for removing the pinsfrom valve stems.

Mot. 1849 Slide hammer valve lifter.

Mot. 1511 Tool for tting valve stemseals.

Mot. 1335 Pliers for removing valvestem seals.

Equipment required

component support

indelible pencil

tweezers



8 N.m

IMPORTANT


- (see 10A , Engine and cylinder block assem-bly , Engine: Precautions for the repair , page10A-1 ) ,

- (see V ehicle: Precautions for the repair )(01D, Mechanical introduction).

WARNING




X95 – X38, JH3

X38, CK1





10A

a Loosen the bolts ( 1) of the coolant pump pulley,locking the coolant pump pulley using a screwdriver.



a Remove:





a If they are not, turn the crankshaft an additional turnuntil the unpainted crankshaft accessories pulleymark and the timing cover mark are aligned.

139484

X38

141016

141017





10A


a Remove:



shaft seal on timing end: Removal - Refitting ) ,- the timing chain (see Timing chain: Removal -Refitting ) ,



a Remove:



a Remove:





a Fit the cylinder head on the tool (Mot. 1573) or on acylinder head support.

a Remove:



a Remove the exhaust manifold (see Exhaust mani-fold: Removal - Refitting ) .

II - VALVE REMOVAL OPERATION

a Mark the position of the valve tappets using a indel-ible pencil .

a Remove the valve tappets.

141008

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139838

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139705





10A

a Compress the valve springs using the tool (Mot.1502) or the tool (Mot. 1849) (7 ) .

a Remove:

- the collets ( 8) using a tweezers (9 ) ,

-the (Mot. 1502) or (Mot. 1849) ,

- the valve spring cups ( 10 ) ,

- the valve springs.

a

a Normal value (H) : 13.2 -13.8 mm.

116011

116012

15738

Note:

Before removing the valve stem seals, alwaystake the dimension ( H) of the old seals on theinlet side and then on the exhaust side using thetool (Mot. 1511) .

X38





10A

a

a Fit the pushrod ( 11) of the tool (Mot. 1511) until thepushrod is in contact with the valve stem seal.

a Fit the guide tube ( 12) of the tool (Mot. 1511) overthe pushrod until the guide tube comes into contactwith the cylinder head.

a Insert the sleeve ( 13 ) of the tool (Mot. 1511) in theguide tube until the sleeve comes into contact withthe pushrod.

a Lock the sleeve using tumblewheel ( 14 ) .

a Remove the « pushrod - guide tube - sleeve » as-sembly, taking care not to loosen the wheel.

a Repeat the operation for the other valves.

a Remove:- the valves,

- the valve stem seals using tool (Mot. 1335) (15 ) ,

15738-1

Note:

The internal diameter of the pushrod must beidentical to that of the valve. In addition, the bot-tom of the pushrod must cover the metal uppersection of the valve stem seal.

15738-2

15738-3

116002





10A- the lower washers of the valve spring.

REFITTING


a parts always to be replaced: Valve stem seal

a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair ) (04B, Consuma-bles - Products) to clean:

- the valves,

- the valve springs,

- the valve spring cups,

- the valve collets,

- the valve guides.

II - VALVE REFITTING OPERATION

a Refit:

- the lower valve spring washer,

- the valve.

a Fit the fitting protector ( 16 ) of the tool (Mot. 1511) onthe valve.

a Keep the valve pressed against its seat.

a Fit a new valve stem seal (not lubricated) on the pro-tector.

a Push the valve stem seal until it protrudes from theprotector.

15739

15739-1

15739-2





10A

a Remove the fitting protector.

a Fit the « pushrod - guide tube - sleeve » assemblywhich was previously adjusted on the valve stemseal.

a Push the valve stem seal down by tapping thesleeve of the tool (Mot. 1511) with the palm of yourhand until the guide tube comes into contact with thecylinder head.

a Repeat the operation for all of the inlet and exhaust

valves.a Refit:

- the valve springs,

- the valve spring cups.

a Compress the valve springs using the tool (Mot.1502) or the tool (Mot. 1849) .

a Refit the collets using a tweezers .

a Remove the tool (Mot. 1502) or the tool (Mot. 1849) .

a Refit the valve tappets, observing their respectivepositions.

15739-3

15739-4





10AIII - FINAL OPERATION

a Refit:



a Refit the exhaust manifold (see Exhaust manifold:

Removal - Refitting ) .a Remove the cylinder head from the tool (Mot. 1573)

or from the cylinder head support.

a Refit:




a Refit:

- the turbocharger oil pipes (see Turbocharger oilpipe: Removal - Refitting ) ,

- the catalytic converter (see Catalytic converter:Removal - Refitting ) .

a Refit:





a Fit the (Mot. 1431) .



a Refit:



a Refit the inlet distributor (see Inlet distributor: Re-moval - Refitting ) .








X95

X95

X95

X38

X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10AREMOVAL


a



a Fit the engine assembly on the engine mount (see10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .





- ignition coils (see Coils: Removal - Refitting ) ,




- the accessories belt (see Accessories belt: Re-moval - Refitting ) ,

- crankshaft seal on the timing side (see Crankshaftseal on timing end: Removal - Refitting ) ,

- timing cover (see Timing chain: Removal - Refit-ting ) ,



- camshaft (see Camshaft: Removal - Refitting ) ,

- cylinder head (see Cylinder head: Removal - Re-fitting ) .

II - REMOVAL OF THE PARTS CONCERNED

a Assemble the special tools (RSM 9139) (1 ) and(RSM 9007) (2) .

a Fit:

- special tool (RSM 9139) (1) on the mounting holeof the spark plug,

- Special tool (RSM 9007) (2) on the upper sectionof the valve spring cup.

WARNINGBefore performing the repair operations, checkthe directives concerning safety, hygiene and theprocedures (see 10A , Engine and cylinderblock assembly , Engine: Precautions for therepair , page 10A-1 ) .


148064

Note:

If the operation is performed without removingthe cylinder head, connect the air pipe adapterso that the valves do not enter the cylinders, thenreplace the valve stem seals.




X38, SAMSUNG BRAND

10A

a Compress the valve springs using the special tool(RSM 9139) .


- valve cotters,

- valve spring cups

- valve springs.

a

148065

Note:

Remove the valve cotters using a magnetic strut.

148066

(A) cylinder head

(B) valve guide

(C) valve stem seal

Note:Before removing the valve stem seal for replace-ment, measure its current exact height ( H) usingthe special tool (not yet attached) and recordthe data. The heights of the inlet and exhaustvalve stem seals may differ.

Normal values ( H) : 13.2 - 13.8 mm




X38, SAMSUNG BRAND

10A

a Install the pushrod ( 3) of the special tool (RSM 9203)on the valve stem seal.

a Insert the sleeve guide ( 4) of the special tool (RSM9203) until it is in contact with the cylinder head.

a Fit the pushrod ( 4) of the special tool (RSM 9203)using the wheel ( 5) .

a Remove the special tool (RSM 9203) .


- valve stem seal using the tool (RSM 9189) (6) ,

- valve.

REFITTING


a Replace the valve stem seal with a new one.

a Clean the following parts using a CAN OF STRONGCLEANER (part no.: KC1048901070 ):

- valves,

- valve springs,

- the valve spring cups,

- valve cotters,

- valve guides.

II - REFITTING THE PARTS CONCERNEDa Grease the internal section of the new valve guides

with new engine oil.

148067

148068

116002




X38, SAMSUNG BRAND

10A


- valves ( 1) ,

- seal insertion guide ( 2) .

a

148070

Note:

Technical specications of va lve seats andguides (see 10A , Engine and cylinder blockassembly , Valve: Check , page 10A-46 ) .

148071

(A) cylinder head

(B) valve guide

(C) valve stem seal

Note:Before removing the valve stem seal for replace-ment, measure its current exact height ( H) usingthe special tool (not yet attached) and recordthe data. The heights of the inlet and exhaustvalve stem seals may differ.

Normal values ( H) : 13.2 - 13.8 mm




X38, SAMSUNG BRAND

10A

a Refit the new valve stem seal ( 3) using the specifictool (RSM 9203) .

a

a Manually push the sleeve guide and the pushrod ofthe special tool (RSM 9203) until it is in contact withthe cylinder head to refit the new valve stem seal.

a Remove the seal insertion guide.


- valve springs,

- valve spring cups.

a Compress the valve springs using the special tool

(RSM 9139) .a Refit the valve cotters.



- cylinder head (see Cylinder head: Removal - Re-fitting ) ,

- camshaft (see Camshaft: Removal - Refitting ) ,



- timing cover (see Timing chain: Removal - Refit-ting ) ,

- crankshaft seal on the timing side (see Crankshaftseal on timing end: Removal - Refitting ) ,




148072

148073

Note:

When tting the valve stem seal, do not use toolssuch as a hammer. This could damage the cylin-der head and the valve.

148074




X38, SAMSUNG BRAND

10A- the injector rail protector (see Rocker cover: Re-moval - Refitting ) ,

- ignition coils (see Coils: Removal - Refitting ) ,



- throttle valve (see Throttle valve: Removal - Re-fitting ) .



a Fill the engine oil (see Engine oil: Draining - Refill-ing ) .



ENGINE AND CYLINDER BLOCK ASSEMBLYValve: Check


10A




Disconnect the automatic gearbox from the engine

(see Automatic gearbox: Removal - Refitting ) (23A,Automatic transmission).

Position the engine on the component support (see10A , Engine and cylinder block assembly , Enginesupport equipment: Use , page 10A-19 ) .

Remove the valves (see 10A , Engine and cylinderblock assembly , Valve: Removal - Refitting , page

10A-32 ) .Before any checks:

- clean the parts to be checked with SURFACECLEANER (see Vehicle: Parts and consumablesfor the repair ) (04B, Consumables - Products) anddry them using a compressed air nozzle ,

- check that the parts are not scratched and do notshow signs of impact or abnormal wear (replace thepart if necessary),

- check that the valves slide freely in the valve guides.

II - VALVE CHECK OPERATION

1 - Valve identification

Equipment required

component support

compressed air nozzle

external micrometer

dial gauge support

Dial gauge

internal micrometer

set of feeler gauges

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair:



WARNING


- blocking the strainer,- raising the oil level above maximum, with a risk of

engine racing.

X95 – X38, JH3

X38, CK1

139709





10A

2 - Checking the valve size

Measure using a external micrometer :

- the diameter ( d ) of the valve stem,

- the valve length ( L) .

3 - Clearance check between the valve and thevalve guide

The clearance between the valve and the guide can bechecked in two ways.

Position the valve head at a distance of ( L2) = 25 mmfrom the valve seat.

X95

Inlet valve (A) Exhaust valve(B)

Diameter ( D) ofthe valve face

29.6 ±±±± 0.15mm

25.45 ±±±± 0.15mm

Thickness ( e )of the valvehead

0.98 mm 0.98 mm

X38

Inlet valve (A) Exhaust valve(B)

Diameter ( D) ofthe valve face

31.15 ±±±± 0.15mm

25.45 ±±±± 0.15mm

Thickness ( e )of the valve

head

1.00 mm 1.00 mm

139709

X95

Inlet valve Exhaust valve

Diameter ( d) ofthe valve stem

4.97 ±±±± 0.01mm

5.46 ±±±± 0.01mm

Length ( L) ofthe valve

101.32 mm 102.49 mm

X38


Diameter ( d) ofthe valve stem

4.97 ±±±± 0.01mm

4.96 ±±±± 0.01mm

Length ( L) of

the valve

101.65 mm 102.46 mm

102777





10AFit:

- the dial gauge support ,

- the Dial gauge on the mounting.

Position the dial gauge feeler against the valve head ata 90˚ angle in relation to the valve shaft.

Push the valve head towards the dial gauge.

Calibrate the dial gauge to zero.

Push the valve head towards the side opposite the dialgauge.

Note the value displayed on the dial gauge.

Calculate the actual clearance between the valve andthe valve guide by dividing the value measured on thedial gauge by two.

Or measure:

- the internal diameter ( 1) of the valve guide using a in-ternal micrometer ,

- using a external micrometer the diameter ( X1) of thevalve stem.

Calculate the actual clearance = internal diameter ofthe valve guide ( X1) - the diameter of the valve stem(1) .

The clearance between the valve and the valve guidemust be between:

- 0.02 and 0.05 mm for the inlet valve,

- 0.03 to 0.06 mm for the exhaust valve.

III - VALVE SPRING CHECK OPERATION

1 - Valve spring identification

102782

104720

X95

Inlet spring Exhaustspring

Mark on theouter diameterof the spring

Yellow White or Green

Internal diame-ter ( X2)

17.8 ±±±± 0.2 mm

Wire diameter(X3)

2.7 ±±±± 0.02 mm 2.75 ±±±± 0.02mm

Outer diame-ter ( X4)

23.2 ±±±± 0.2 mm 23.3 ±±±± 0.2 mm

Free length(X5)

46.73 mm 54.3 mm







10AUse a set of feeler gauges to measure the valve clea-rance which should be (when cold):

- Inlet: 0.26 to 0.34 mm ,

- Exhaust: 0.29 to 0.37 mm .Compare the values noted with the specified values.

139834

Note:

The tappet class is given at ( 4) .

Tappet class Tappet thickness (mm)

300 3.00

302 3.02

304 3.04

306 3.06

308 3.08

310 3.10

312 3.12

314 3.14

316 3.16

318 3.18

320 3.20

322 3.22

324 3.24

326 3.26

328 3.28

330 3.30

332 3.32

334 3.34

336 3.36

338 3.38

340 3.40

342 3.42

344 3.44

346 3.46

348 3.48

350 3.50

139837

Tappet class Tappet thickness (mm)





10AReplace the tappets if they are not within the toleran-ces.

- measure the thickness of the tappet using a externalmicrometer and carry out the operation again for the

tappets with valve clearances outside the permittedtolerances,

- to select the different thicknesses of tappets, see theSPARE PARTS CATALOGUE for the vehicle con-cerned.

V - FINAL OPERATION

Refit the valves (see 10A , Engine and cylinder blockassembly , Valve: Removal - Refitting , page 10A-32 ).

Remove the engine from component support (see10A , Engine and cylinder block assembly , Enginesupport equipment: Use , page 10A-19 ) .




X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A




Remove the valves (see 10A , Engine and cylinder

block assembly , Valve: Removal - Refitting , page10A-32 ) .

Carry out the following:

- Clean the valves and the valve tappets,

- Check for possible scratches or damage caused byan impact on the surface of the valve tappets.

II - CHECKING THE VALVE TAPPETS

1 - Outer diameter of the valve tappets

The exterior diameter of the valve tappet must be be-tween 29.977 and 29.987 mm .

2 - Cylinder head valve tappet housing bore

Measure the diameter of the housings of the cylinderhead valve tappet using the internal micrometer (1 ) .

The standard value is between 30.000 and 30.021mm .

3 - Play between the cylinder head valve tappetsand their housings

The play between the cylinder head valve tappets andtheir housings must be between 0.013 and 0.044 mm .

4 - Checking the valve tappets

Equipment required

internal micrometer

WARNINGBefore performing the repair operations, check thedirectives concerning safety, hygiene and the pro-cedures (see 10A , Engine and cylinder blockassembly , Engine: Precautions for the repair ,page 10A-1 ) .


148075

148076

148077




X38, SAMSUNG BRAND

10ACheck the status of the valve tappets (wear or crackson the coating).

5 - Adjusting valve clearances

Turn the camshaft until the valve cam to be checked isfacing outwards.

The play of the inlet valves must be between 0.260 and0.340 mm when cold.

The play of the inlet valves must be between 0.304 and0.416 mm when hot.

The play of the exhaust valves must be between 0.290and 0.370 mm when cold.

The play of the exhaust valves must be between 0.308and 0.432 mm when hot.

148078

148079

Valve tappet thick-ness (T) (mm)

Identication code(S)

3.00 300

3.02 302

3.04 304

3.06 306

3.08 308

3.10 310

3.12 312

3.14 314

3.16 3163.18 318

3.20 320

3.22 322

3.24 324

3.26 326

3.28 328

3.30 330

3.32 332




X38, SAMSUNG BRAND

10A

6 - Valve springs

7 - Perpendicularity of the valve spring

The limit value of perpendicularity of the spring ( H) notto be exceeded is 1,8 mm .

The valve spring is to be replaced in the case of thelimit value being exceeded.

8 - Valves

3.34 334

3.36 336

3.38 338

3.40 340

3.42 342

3.44 344

3.46 346

3.48 348

3.50 350

148080

Inlet valvespring (mm)

Exhaust valvespring (mm)

No load length 42.26

Length wi thload (136 - 154NS)

32.40

Valve tappet thick-ness (T) (mm)

Identication code(S)

148081

Note:

It is not necessary to dismantle the valve springseat.

148082




X38, SAMSUNG BRAND

10A

9 - Valve seats


Diameter of the valve head (D) 31.0 - 31.3 mm 25.3 - 25.6 mm

Valve length (a) 101.65 mm 102.46 mm

Valve stem diameter (d) 4.965 - 4.980 mm 4.955 - 4.970 mm

Angle of the mating face of thevalve (˚)

45 ° 15 ° << -45 ° 45 ° << 45 ° 15 ° << -45 ° 45 ° <<

"b" 1.0 mm 1.0 mm

"c" 2.1 - 2.8 mm 2.3 - 3.0 mm

"c˚<<" 3.0 mm 3.0 mm

148083

Category Inlet valve seat Exhaust valve seat

Bore of the valve seathousing in the cylinderhead (D)

Standard value 31.400 - 31.416 mm 25.900 - 25.916 mm

Limit value (0.5 mm) 31.900 - 31.916 mm 26.400 - 26.416 mm

Valve stem exterior diam-eter (d)

Standard value 31.497 - 35.513 mm 25.997 - 26.013 mm

Limit value (0.5 mm) 31.997 - 32.013 mm 26.497 - 26.513 mm

Play at the contact surfaces of the valve seat

(play between the internal diameter of the valve seathousing (D) and the outer diameter of the valve seat

(d) in the cylinder)

0.081 - 0.113 mm 0.081 - 0.113 mm




X38, SAMSUNG BRAND

10A

*1: bore obtained from the distance between the inter-sections of the angles (1) and (2)

*2: bore obtained from the distance between the inter-sections of the angles (2) and (3)

*3: data processed


Refit the valves (see 10A , Engine and cylinder block

assembly , Valve: Removal - Refitting , page 10A-32 ).

Remove the engine assembly from the engine mount(see 10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .


Bore (d1)*1 29.0 mm 23.0 mm

Bore (d2)*2 30.3 - 30.8 mm 24.6 - 25.1 mm

Angle (1) 60˚ 45˚

Angle (2) 88 ° 45 ° <<- 90 ° 15 ° << 88 ° 45 ° <<- 90 ° 15 ° <<

Angle (3) 120˚ 120˚

Contact surface (W)*3 1.05 - 1.35 mm 1.25 - 1.55 mm

Height (h) Standard value 6.0 mm 6.0 mm

Limit value 5.45 mm 5.43 mm

Height (H) 6.0 mm 6.0 mm

Category Inlet valve seat Exhaust valve seat





ENGINE AND CYLINDER BLOCK ASSEMBLYCylinder head: Stripping - Rebuilding


10A

a Remove the inlet distributor (see Inlet distributor:

Removal - Refitting ) .

a Remove:





a If they are not, turn the crankshaft an additional turnuntil the unpainted mark on the crankshaft accesso-ries pulley is aligned with the mark on the timing cov-

er.


a Remove:


X38

141016

141017

141008





10A- the crankshaft seal on the timing side (see Crank-shaft seal on timing end: Removal - Refitting ) ,




a Remove:



a Remove:




II - STRIPPING DOWN THE CYLINDER HEAD

a Fit the cylinder head on the tool (Mot. 1573) or on acylinder head support.

a Remove:



a Remove:


- the gearbox side lifting eye (see Lifting eyes: Re-moval - Refitting ) ,




- the valves (see 10A , Engine and cylinder blockassembly , Valve: Removal - Refitting , page 10A-32) .

aRemove:- the rail protector spacers ( 7 ) ,

- the bolts ( 8 ) of the inlet distributor protector,

- the inlet distributor protector.

REBUILDING

I - REBUILDING PREPARATION OPERATIONa Clean the cylinder head (see 10A , Engine and cyl-

inder block assembly , Cylinder head: Cleaning ,page 10A-64 ) .

X95

139838

X95

X95

139839





10AII - OPERATION FOR REFITTING THE CYLINDERHEAD

a Refit:





- the gearbox side lifting eye (see Lifting eyes: Re-moval - Refitting ) ,

- the exhaust manifold (see Exhaust manifold: Re-moval - Refitting ) .

a Refit:

- the inlet distributor protector,

- the rail protector spacers,




a Refit:




a Refit:


- the catalytic converter (seeCatalytic converter:Removal - Refitting ) .

a Refit:





a Fit the (Mot. 1431) .



a Refit:









X95

X95

X38

X95 – X38, JH3





10A

a Connect the automatic gearbox to the engine (see

Automatic gearbox: Removal - Refitting ) (23A,Automatic gearbox).


X38, CK1




X38, SAMSUNG BRAND

10ASTRIPPING

I - PREPARATION FOR STRIPPING

a




a Remove:














II - STRIPPING DOWN THE CYLINDER HEAD

a Mark the positions of the valve tappets ( 1) during re-moval in order to replace them in their initial positionwhen refitting.

a Remove:


- the valve oil seals (see 10A , Engine and cylinderblock assembly , Valve: Removal - Refitting ,page 10A-32 ) .

REBUILDING



II - REASSEMBLING THE CYLINDER HEAD

a Refit:

- the valve oil seals (see 10A , Engine and cylinderblock assembly , Valve: Removal - Refitting ,page 10A-32 ) ,


- the valve tappets in their original positions.



148046




X38, SAMSUNG BRAND

10AIII - FINAL OPERATIONS

a Refit:

- the cylinder head (see Cylinder head: Removal -

Refitting ) ,- the camshaft (see Camshaft: Removal - Refit-ting ) ,




- the accessories belt (see Accessories belt: Re-

moval - Refitting ) ,- the rocker cover (see Rocker cover: Removal -Refitting ) ,









a Fill the engine with engine oil (see Engine oil:Draining - Refilling ) .



ENGINE AND CYLINDER BLOCK ASSEMBLYCylinder head: Cleaning


10A

I - CLEANING PREPARATION OPERATION

a

a Remove the engine - gearbox assembly (see En-gine - gearbox assembly: Removal - Refitting ) .


a Remove the cylinder head (see Cylinder head: Re-moval - Refitting ) .

a Strip the cylinder head (see 10A , Engine and cylin-der block assembly , Cylinder head: Stripping -Rebuilding , page 10A-57 ) .

II - CLEANING THE CYLINDER HEAD

a Clean the joint face of the cylinder head using SU-PER CLEANING AGENT FOR JOINT FACES (seeVehicle: Parts and consumables for the repair )(04B, Consumables - Products).

a Remove the residue using a wooden spatula

a Finish cleaning the parts using a GREY ABRASIVEPAD (see Vehicle: Parts and consumables forthe repair ) (04B, Consumables - Products).

a Wash the cylinder head using a parts washer or acleaning trough .

Equipment required

component support

parts washer

cleaning trough

WARNINGDo not scrape the joint faces of the aluminium,any damage caused to the joint face will result ina risk of leaks.

IMPORTANTWear goggles with side protectors for this opera-tion.

IMPORTANTWear leaktight gloves (Nitrile type) for this opera-

tion.

WARNINGDo not allow this product to drip onto the paint-work.

Clean the cylinder head carefully to avoid anyforeign bodies entering the oil return and supplypipes.

Failure to follow this advice could lead to theblocking of the various oil inlet galleries, whichwould quickly result in engine damage.

113553

113592






a Rebuild the cylinder head (see 10A , Engine andcylinder block assembly , Cylinder head: Strip-ping - Rebuilding , page 10A-57 ) .

a Refit the cylinder head (see Cylinder head: Re-moval - Refitting ) .


a Refit the engine - gearbox assembly (see Engine -gearbox assembly: Removal - Refitting ) .




X38, SAMSUNG BRAND

10AI - PREPARATION FOR CLEANING

a


a Place the engine assembly on the engine mount(see 10A , Engine and cylinder block assembly ,Engine support equipment: Use , page 10A-19 ) .

a Remove the cylinder head (see Cylinder head: Re-moval - Refitting ) .

a Remove the parts fitted on the cylinder head (see10A , Engine and cylinder block assembly , Cylin-der head: Stripping - Rebuilding , page 10A-57 ) .

II - CLEANING THE CYLINDER HEAD

a Spread the CLEANING AGENT FOR SEALS :KC1048931000 ) on the section to be cleaned.

a Wait approximately ten minutes.a Remove residues with a wooden spatula.

a Finalise cleaning of the part.


a Refit the parts fitted on the cylinder head (see 10A ,Engine and cylinder block assembly , Cylinderhead: Stripping - Rebuilding , page 10A-57 ) .

a Refit the cylinder head (see Cylinder head: Re-moval - Refitting ) .

a Remove the engine assembly from the enginemount (see 10A , Engine and cylinder block as-sembly , Engine support equipment: Use , page10A-19 ) .


WARNING

Wear protective goggles during the operations.


Note:

Be careful not to scratch the aluminium seal sur-face. A scratch can cause a leak of water or oil.

Note:

During cleaning, be careful not to drop cleaningagent on the painted surface of the vehicle.Clean while ensuring that no foreign matterenters the cylinder head lubrication passage. Inthe event that the lubrication passage is blocked,the engine could be damaged very quickly.

Note:

During cleaning, ensure that the parts do notknock against each other. Damage to a matingsurface can change the alignment of parts andrisks damage to the engine.



ENGINE AND CYLINDER BLOCK ASSEMBLYCylinder head: Check


10A







Remove the cylinder head (see Cylinder head: Re-moval - Refitting ) .

Strip down the cylinder head, if required by the check

(see 10A , Engine and cylinder block assembly , Cyl-inder head: Stripping - Rebuilding , page 10A-57 ) .

Before any checks:

- clean the cylinder head (see 10A , Engine and cylin-der block assembly , Cylinder head: Cleaning ,page 10A-64 ) ,

- check that the cylinder head does not have anyscratches, any traces of impact or abnormal wear (ifnecessary replace the cylinder head).

II - CAMSHAFT CHECKING OPERATION

1 - Checking the height of the cylinder head

Use a mortice gauge , or a depth gauge to measurethe height ( H) of the cylinder head which should be124.8 mm .

Equipment required

component support

mortice gauge

depth gauge

cylinder head rule


internal micrometer

cylinder head testing tools

external micrometer

IMPORTANT




WARNING




X95 – X38, JH3

X38, CK1

102767

X95





10A

Use a mortice gauge , or a depth gauge to measure

the height ( H) of the cylinder head which should be 125mm .

2 - Checking the flatness of the cylinder head

Use a ruler ( 1 ) and a « dial gauge - dial gaugesupport » assembly ( 2) or a cylinder head rule and aset of feeler gauges to check the flatness of the cylin-der head gasket face.

Cylinder head joint face maximum deformation: 0.1mm .

3 - Checking the camshaft bearing diameters

Use a internal micrometer to measure the diameter(X1) of each camshaft bearing which should be:

- bearing No.1 ( 3) : 28 ±±±± 0.01 mm ,

- bearings No.2, 3, 4 and 5 ( 4) : 25 ±±±± 0.01 mm .

Use a internal micrometer to measure the diameter(X1) of each camshaft bearing which should be:

- bearing No.1 ( 3) : 28.01 ±±±± 0.01 mm ,

- bearings No.2, 3, 4 and 5 ( 4) : 25.01 ±±±± 0.01 mm .

X38

114879

WARNINGNo regrinding of the cylinder head is permitted.

139846

X95

X38





10A4 - Check the diameter of the valve guide

Use a internal micrometer to measure the diameters(X2) of the valve guides which should be:

- inlet: 5 ±±±± 0.1 mm ,

- exhaust: 5.5 ±±±± 0.1 mm .

Use a internal micrometer to measure the diameters(X2) of the valve guides which should be:

- inlet: 5 ±±±± 0.1 mm ,

- exhaust: 5 ±±±± 0.1 mm .

5 - Cylinder head testing

Test the cylinder head for any cracks using the cylin-der head testing tools (see Cylinder head test tank:Use ) (Technical Note 6026A, 11A, Top and front of en-gine).

III - CHECKING THE MECHANICAL TAPPET

1 - Check the external diameter of the tappets

Check the condition of the tappet (worn or coatingcracked ( 5 ) )

Use a external micrometer to measure the outer di-ameter ( X3) of the tappets which should be between29.98 and 29.99 mm .

14564-1

X95

X38

103156

103157





10A2 - Checking the housing in the cylinder head

Use a internal micrometer to measure the diameter(X4) of the housings of the tappets in the cylinder headwhich should be between 30 and 30.02 mm .

3 - Checking the clearance between the tappet andthe housing in the cylinder head

Measure:

- the internal diameter (X4) of the tappet housing usinga internal micrometer ,

- the external diameter (X3) of the tappet using a exter-nal micrometer .

The actual clearance = internal diameter (X4) of thetappet housing - external diameter (X3) of the tappet.

The clearance between the tappet and the housing inthe cylinder head should be 0.01 to 0.04 mm .


Rebuild the cylinder head, if necessary (see 10A , En-gine and cylinder block assembly , Cylinder head:Stripping - Rebuilding , page 10A-57 ) .

Refit the cylinder head (see Cylinder head: Removal- Refitting ) .



Connect the automatic gearbox to the engine (see Au-

tomatic gearbox: Removal - Refitting ) (23A, Auto-matic gearbox).


139708

X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A




Remove:- the cylinder head (see Cylinder head: Removal -

Refitting ) ,

- the parts fitted on the cylinder head (see 10A , Engineand cylinder block assembly , Cylinder head:Stripping - Rebuilding , page 10A-57 ) .

Carry out the following:

- clean the cylinder head (see 10A , Engine and cylin-der block assembly , Cylinder head: Cleaning ,page 10A-64 ) ,

- Check for possible scratches or damage caused byan impact on the surface of the cylinder head.

II - CHECKING THE CYLINDER HEAD

1 - Cylinder head height

The cylinder head height (H) is 125 mm .

2 - Deformation of the surface of the cylinder headgasket check

Using the cylinder head rule and a set of feelergauges , measure the cracks in the surface of the cylin-der head gasket.

The limit value is 0.1 mm .

If the limit value is exceeded, replace the cylinderhead.

Equipment required

cylinder head rule




148059

148060




X38, SAMSUNG BRAND

10A3 - Repolishing the cylinder head


Refit:

- the parts fitted on the cylinder head (see 10A , Engineand cylinder block assembly , Cylinder head:Stripping - Rebuilding , page 10A-57 ) ,


Remove the engine assembly from the engine mount(see 10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .


Note:

Never polish the surface of the cylinder head.



ENGINE AND CYLINDER BLOCK ASSEMBLYCylinder block base plate: Removal - Refitting


10A

REMOVAL


a











Mot. 1716 Removes housing with sili-cone seals.

Equipment required

component support


cylinder block baseplate bolts

25 N.m


8 N.m

IMPORTANT




WARNING




X95 – X38, JH3

X38, CK1

139484





10A

a Remove the inlet distributor (see Inlet distributor:

Removal - Refitting ) .

a Remove:





a If they are not, turn the crankshaft an additional turnuntil the unpainted mark on the crankshaft accesso-ries pulley is aligned with the mark on the timing cov-

er.


a Remove:


X38

141016

141017

141008






- the water pump pulley bolts,

- the water pump pulley,- the timing chain (see Timing chain: Removal -Refitting ) .

a Pivot the oil pump chain tensioner anti-clockwise ( 7).

a Remove:

- the oil pump chain tensioner from its shaft ( 8 ) ,

- the cylinder block tensioner spring at ( 9) .

a Remove the oil pump sprocket nut ( 10 ) .

a Remove the « oil pump sprocket - oil pump chain »assembly ( 11 ) .

141015

141014

141013





10A

a Remove the crankshaft sprocket ( 12) .

a Remove:

- the compressor (see Compressor: Removal - Re-fitting ) (62A, Air conditioning),





- the oil filter (see Oil filter: Removal - Refitting ) .

II - OPERATION FOR REMOVING THE CYLINDERBLOCK BASE PLATE

a When checking or replacing the cylinder block baseplate, remove the coolant - oil heat exchanger (seeAir-oil heat exchanger: Removal - Refitting ) .

a When checking or replacing the cylinder block baseplate, remove the oil level sensor (see Oil level sen-sor: Removal - Refitting ) .

a Remove the bolts ( 13 ) from the cylinder block baseplate.

141012

X95

139704





10A

a Very carefully separate the cylinder block base plate(14) using a screwdriver at ( 15) .

a Detach the cylinder block base plate using the tool(Mot. 1716) (16 ) and a mallet.

a Remove the cylinder block base plate.

a Remove the O-ring ( 17) from the cylinder block baseplate.

139419

139711

139420

139418





10AREFITTING


a Use SUPER CLEANING AGENT FOR JOINT FA-CES (see Vehicle: Parts and consumables forthe repair ) (04B, Consumables - Products) to cleanthe gasket faces:

- of the cylinder block,

- the cylinder head,

- of the cylinder block base plate,

- of the timing cover.

a Remove the residue using a plastic spatula.

a Finish cleaning using a GREY ABRASIVE PAD(see Vehicle: Parts and consumables for the re-pair ) (04B, Consumables - Products).

a Use a SURFACE CLEANER (see Vehicle: Partsand consumables for the repair ) (04B, Consuma-bles - Products) to clean the joint faces:

- of the cylinder block,

- the cylinder head,

- of the cylinder block base plate,

- of the timing cover

a parts always to be replaced: Oil pump drivechain

a Always replace:

- the O-ring on the cylinder block base plate,

- the oil pump pinion,

- the crankshaft sprocket.

a

a Apply a bead of SILICONE ADHESIVE SEALANT(see Vehicle: Parts and consumables for the re-pair ) (04B, Consumables - Products) with a diame-ter ( A) 4 to 5 mm on the cylinder block joint faceplaced at a distance ( B) of 7.5 to 9.5 mm from theinside edge of the cylinder block base plate.

II - OPERATION FOR REFITTING THE CYLINDERBLOCK BASE PLATE

a Refit the cylinder block base plate.

a Torque tighten in order the cylinder block base

plate bolts (25 N.m) .a When checking or replacing the cylinder block base

plate, refit the oil level sensor (see Oil level sensor:Removal - Refitting ) .


WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any n-ger marks).

139713

WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and uid could damage certaincomponents (engine, radiator, etc.).

139712





10A

a When checking or replacing the cylinder block base

plate, refit the coolant - oil heat exchanger (see Air-oil heat exchanger: Removal - Refitting ) .


a Refit:






- the compressor (see Compressor: Removal - Re-

fitting ) (62A, Air conditioning),- a new crankshaft sprocket,

- a new « oil pump sprocket - oil pump chain » as-sembly,

- the oil pump chain tensioner spring on the cylinderblock,

- the oil pump chain tensioner on its shaft,


- the water pump pulley,





a Refit:



a Refit the inlet distributor (see Inlet distributor: Re-

moval - Refitting ) .


a Torque tighten the bolts on the coolant pump pul-ley (8 N.m) , locking the coolant pump pulley using ascrewdriver.






X95 X38

X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10AREMOVAL


a



a Place the engine on the engine stand (see 10A , En-gine and cylinder block assembly , Engine sup-port equipment: Use , page 10A-19 ) .








- the coolant pump pulley (see Timing chain: Re-moval - Refitting ) ,



- the timing chain (see Timing chain: Removal -Refitting ) .


mounting bolts of thecylinder block lowerplate

25 N.m

sump mounting bolts 10 N.m

oil drain plug 34 N.m

ywheel mounting bolts 108 N.m

mounting bolts of themechanism housing(rst tightening)

15 N.m

mounting bolts of themechanism housing(second tightening)

20 N.m

mounting bolts of themechanism housing(third tightening)

25 N.m

mounting bolts of thedrive plate

108 N.m

oil level sensor mount-ing bolts

8 N.m

oil lter mounting stud 34 N.m

oil lter 18 N.m

air conditioning com-pressor mounting bolts

25 N.m


WARNING

Wear protective gloves during the operations.




X38, SAMSUNG BRAND

10A


- the dipstick ( 1) ,

- the air conditioning compressor mounting bolts ( 2) ,

- the air conditioning compressor ( 3) .

a Remove the oil filter ( 4) .

a Remove the oil filter mounting stud ( 5 )


- the oil level sensor mounting bolt ( 6) ,

- the oil level sensor ( 7) .

148090

148091

148092

148093




X38, SAMSUNG BRAND

10A

a Fit the special tool (RSM 9248)

(8

) .


- the mounting bolts from the mechanism housing(9) ,

- the mechanism housing ( 10) ,

- the clutch plate.

a Remove the following parts:- the flywheel mounting bolts ( 11 ) ,

- the flywheel ( 12) ,

- the special tool (RSM 9248) (13 ) .


- the mounting bolts of the drive plate ( 14) ,- the reinforcement plate ( 15) ,

- the drive plate ( 16) ,

148094

JH3

148095

148096

CK1

148106




X38, SAMSUNG BRAND

10A- the special tool (RSM 9248) (17 ) .

a Remove the oil drain plug ( 18) .

a Remove the sump bolts in the order indicated.

a Remove the sump using the special tool (RSM9100) (19) .


a Remove the mounting bolts of the cylinder blocklower plate in the order indicated.

148097

148098

148099

148100






X38, SAMSUNG BRAND

10A


- the cylinder block lower plate,

- the mounting bolts of the cylinder block lower plate.

a Torque tighten in order the mounting bolts of thecylinder block lower plate (25 N.m) .


a Spread SILICONE ADHESIVE (part number:KC111TB1217G ) on the seal surface of the sump ata distance ( X1) : approximately 8 mm with a diame-ter ( X2) : 4.5 mm .

a Refit the oil sump.

a Refit the sump mounting bolts.

a Manually tighten in order the sump mounting boltsuntil contact with the sump.

a Torque tighten the sump mounting bolts (10 N.m) .

a Refit the oil drain plug.

a Torque tighten the oil drain plug (34 N.m) .

148104

Note:

The standard for mounting bolts of the cylinderblock lower plate is the following:

- M8 x 25 mm : no. 4, 7, 8

- M8 x 90 mm : no. 1, 2, 3, 5, 6

- M8 x 179 mm : no. 9, 10

148105

148098




X38, SAMSUNG BRAND

10A

aRefit the new rear oil seal ( 1) using the special tool(RSM 9002) .

a Refit the new rear oil seal ( 2) taking care not to mixup the sides.

a The space ( 4) between the cylinder block surface ( 3 )and the rear oil seal contact surface must be 0 to 0.5mm .


- the flywheel,

- the flywheel mounting bolts,

- the special tool (RSM 9248) .

a Torque tighten the flywheel mounting bolts (108N.m) .

aRefit the clutch plate as well as the mechanismhousing.

a Torque tighten in order the mounting bolts of themechanism housing (first tightening) (15 N.m) .

a Torque tighten in order the mounting bolts of themechanism housing (second tightening) (20N.m) .

a Torque tighten in order the mounting bolts of themechanism housing (third tightening) (25 N.m) .


- the drive plate,

- the reinforcement plate,

- the mounting bolts of the drive plate,

- the special tool (RSM 9248) .

a Torque tighten the mounting bolts of the driveplate (108 N.m) .

a Remove the special tool (RSM 9248) .


- the oil level sensor,

- the oil level sensor mounting bolts.

a Torque tighten the oil level sensor mounting bolts(8 N.m) .

a Refit the oil filter mounting stud.

a Torque tighten the oil filter mounting stud (34N.m) .

148107

148468

JH3

148095

CK1




X38, SAMSUNG BRAND

10A

a Lubricate the new oil filter seal ( 5) with new engineoil.

a Refit the oil filter.

a Manually tighten the oil filter 2/3 of a turn or torquetighten the oil filter (18 N.m) .


- the oil level dipstick,- the air conditioning compressor,

- the air conditioning compressor mounting bolts.

a Tighten to torque the air conditioning compressormounting bolts (25 N.m) .


- the oil pump chain (see Timing chain: Removal -Refitting ) ,










- the throttle valve (see Throttle valve: Removal -

Refitting ) .a Remove the engine assembly from the engine stand




147998

148109



ENGINE AND CYLINDER BLOCK ASSEMBLYPiston - Con rod: Removal - Refitting


10AREMOVAL


a









Mot. 574-22 Tooling for replacing gud-geon pins.

Equipment required

component support

indelible pencil

piston ring compressor



piston mounting ring


con rod cap bolts 20 N.m + 62˚ ±±±±

2˚


8 N.m

IMPORTANT




WARNING




X95 – X38, JH3

X38, CK1





10A




a Remove:






139484

X38

141016

141017







10A

a Remove:

- the con rod cap bolts,

- the con rod cap.

a Remove the bearing shell from the con rod cap.

a Mark the bearing shell in relation to the con rod capusing an indelible pencil .

a

a Remove:

- the « piston - con rod » assembly through the cylin-

der head side of the cylinder block,- the con rod body bearing.

a Mark the bearing shell in relation to the con rod bodyusing a indelible pencil .

a Repeat the above operations on the other cylinders.

X38

147006

X95

107454

IMPORTANTWear cut-resistant gloves during the operation.

Note:

Do not damage the piston base cooling jet noz-zles ( 7 ) when extracting the « piston - con rod »assembly.





10A1 - Piston ring removal operation

a

a If re-using, mark the piston rings in relation to thepiston using a indelible pencil .

a Remove the piston rings using a piston ring com-pressor .

2 - Operation to separate the con rod and piston

a

a Mark the piston in relation to the cylinders using a in-delible pencil .

a Remove the gudgeon pin locking spring ring using ascratch awl (apply pressure in the piston groove ( 8)).

a Remove the gudgeon pin by hand.

a Mark the pin in relation to the piston using an indel-ible pencil .

a Repeat the above operations for the other pistons.

a

Note:

This operation must only be carried out whenreplacing or checking the piston rings (see 10A ,Engine and cylinder block assembly , Piston -Con rod: Check , page 10A-105 ) .

Note:

Take care not to damage the piston when remov-ing the rings. Do not open the rings too much asthey risk becoming damaged.

115987

Note:

This operation must only be carried out whenreplacing or checking the piston or con rod (see10A , Engine and cylinder block assembly ,Piston - Con rod: Check , page 10A-105 ) .

X95

139424

X38

Note:

The gudgeon pins are tight in the con rods andfree in the pistons.





10A

aRemove the gudgeon pin using the tool kit (Mot.574-22) .

REFITTING


a parts always to be replaced: con rod cap bolts

a parts always to be replaced: Con rod bearingshell

a Clean the « piston - con rod » assembly using SUR-FACE CLEANER (see Vehicle: Parts and con-sumables for the repair ) (04B, Consumables -Products).

a Dry the « piston - con rod » assembly using a com-pressed air nozzle .

1 - Piston ring refitting operation

a

a Refit the piston rings using a piston ring compres-sor .

a Position:

- the gap in the "compression" ring ( 9) opposite thegap in the "sealing" ring ( 10 ) (same axis as gud-geon pin),

- the gap in the "scraper" ring ( 11 ) opposite the gapin the "sealing" ring ( 10 ) (same axis as gudgeonpin).

2 - Piston and con rod assembly operationa

10052

WARNINGWhen cleaning parts, it is essential that the partsdo not impact on each other, otherwise their mat-ing faces may be damaged and therefore theiradjustments may be altered, which could dam-age the engine.

Note:

Do not knock or lean against the cap matingfaces and the con rod body to prevent damagingthe con rod.


Note:

This operation must only be carried out whenreplacing or checking the piston rings (see 10A ,Engine and cylinder block assembly , Piston -Con rod: Check , page 10A-105 ) .

102794

Note:

This operation must only be carried out whenreplacing or checking the piston or con rod (see10A , Engine and cylinder block assembly ,Piston - Con rod: Check , page 10A-105 ) .





10A

a Lubricate gudgeon pin with engine oil.

a When assembling the piston and con rod, align thepiston mark ( 12) with the boss ( 13 ) on the con rod.

a Engage the pin in the piston and in the small end.

a

a Refit the gudgeon pin locking spring ring using ascratch awl (apply pressure in the piston groove ( 15 )).

X95

139415

Note:

Check that the gudgeon pin slides and rotateseasily in the piston and the small end.

139425

Note:

Position the opening ( 14) in the locking springring opposite the piston groove ( 15 ) .









10Aa Position the big end on the crankshaft crankpin.

a Fit the con rod cap while observing the pairing of thecon rod cap - con rod body.

a

Fit the new con rod cap bolts without tighteningthem.

a Torque tighten the con rod cap bolts (28 N.m) .

aCompletely loosen the con rod cap bolts.

a Torque tighten the con rod cap bolts (20 N.m + 62˚±±±± 2˚).

a Check that the rotating parts turns freely, with no re-sistance.

a Repeat the previous operations for the remainingcylinders.

III - FINAL OPERATIONa Refit:

- the cylinder block base plate (see 10 A , Engineand cylinder block assembly , Cylinder blockbase plate: Removal - Refitting , page 10A-73 ) ,










a Refit:



a Refit:


- the timing sprockets (see Timing sprocket: Re-moval - Refitting ) ,






a Refit:






a Fill up the engine oil (see Engine oil: Draining - Re-

filling) .


Note:

Check that the con rod cap and the con rod bodyare in contact before tightening the bolts.

X38

X95

X38





10A





X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A

REMOVAL


a




















- the lower plate of the cylinder block (see 10A , En-gine and cylinder block assembly , Cylinderblock base plate: Removal - Refitting , page 10A-73) .



- the mounting bolt of the con rod bearing shell cap,

- the con rod bearing shell caps ( 1) ,

Equipment required

piston ring compressor


new mounting bolts ofthe con rod cap (rsttightening)

28 N.m

new mounting bolts ofthe con rod cap (sec-ond tightening)

20 N.m + 60 °°°°



148184




X38, SAMSUNG BRAND

10A- the lower con rod bearing shells,

- the "con rod - piston" assemblies,

- the upper con rod bearing shells.

a Remove the piston rings using the piston ring com-pressor .

a Place the special tool (RSM 9204 ) (2) and (RSM9204) (3 ) on the "piston - con rod" assembly ( 4) .

a Place the special tool (RSM 9204) (5) on the presstool.

a Install the "piston - con rod" assembly ( 6) .

a Using the notching tool ( 7) , drive out the gudgeonpin using the press.

148185

148186

148187

148188




X38, SAMSUNG BRAND

10A

a Remove the gudgeon pin ( 8) .

REFITTING


a Replace the con rod cap bolts.a Clean the piston, the con rod and the gudgeon pin

with the CAN OF POWERFUL CLEANER (part no.:KC1048901070 ).

a Grease the operating parts with new engine oil.

II - REFITTING THE PARTS CONCERNED

a Place the special tool (RSM 9204) on the gudgeonpin ( 1) .

a Place the special tool (RSM 9204) (2) on the presstool.

148189148190

148187






X38, SAMSUNG BRAND

10A


- the upper con rod bearing shell on the con rod,

- the lower con rod bearing shell on the con rod cap.

a Taking care not to mix up the cylinder numbers, startto insert the "piston - con rod" assemblies using thepiston ring compressor ( 7 ) , positioning the pistonfrontal mark towards the timing chain.

148195

b () Front of engine

(1) Con rod

(2) Upper con rod bearing shell

(3) Lower con rod bearing shell

(4) Con rod cap

(A) Play: 1.7 - 2.1 mm

Note:

The play ( A) must be adjusted between 1.7 and2.1 mm .

148196

148197

(A) Frontal mark

(B) Lubrication hole

(C) Cylinder number

(D) Big end diameter




X38, SAMSUNG BRAND

10Aa Match the frontal mark on the con rod cap with the

frontal mark on the piston, and fit it on the gudgeonpin of the crankshaft.

a Torque tighten the new mounting bolts of the conrod cap (first tightening) (28 N.m) .

a Completely loosen the new con rod cap mountingbolts.

a Torque tighten the new mounting bolts of the conrod cap (second tightening) (20 N.m + 60 °°°° ) with aspanner.

a Rotate the crankshaft and check that the pistons canmove up and down freely.



- the lower plate of the cylinder block (see 10A , En-gine and cylinder block assembly , Cylinderblock base plate: Removal - Refitting , page 10A-73 ) .













- the exhaust manifold (see Exhaust manifold: Re-

moval - Refitting ) ,- the inlet manifold (see Inlet distributor: Removal

- Refitting ) ,


a Remove the engine assembly from the engine stand(see 10A , Engine and cylinder block assembly ,Engine support equipment: Use , page 10A-19 ) ,

a Refit the engine and transmission assembly (seeEngine - gearbox assembly: Removal - Refitting ),

a Refill the engine oil (see Engine oil: Draining - Re-filling ) .

Note:

Grease the crankshaft journal and the con rodcaps at the bearings with new engine oil.



ENGINE AND CYLINDER BLOCK ASSEMBLYPiston - Con rod: Check


10A







Remove the « piston - con rod » assemblies (see 10A ,Engine and cylinder block assembly , Piston - Conrod: Removal - Refitting , page 10A-88 ) .

Separate the con rod from the piston, if required by thecheck (see 10A , Engine and cylinder block assem-bly , Piston - Con rod: Removal - Refitting , page10A-88 ) .

Remove the piston rings, if required by the check (see10A , Engine and cylinder block assembly , Piston -Con rod: Removal - Refitting , page 10A-88 ) .

Before any checks:

- clean the part using SURFACE CLEANER (see Ve-hicle: Parts and consumables for the repair ) (04B,Consumables - Products),

- check that the part does not have any scratches, anytrace of impact or abnormal wear (if necessary re-place the part).

Equipment required

component support

external micrometer

internal micrometer






WARNING




X95 – X38, JH3

X38, CK1





10AII - PISTON CHECKING OPERATION

1 - Identification

Piston identification

Gudgeon pin identification

X95

141009

(1) Direction of tting for the piston(towards timing end)

(2) Piston category

Piston category Internal diameter ofthe gudgeon pin hole(mm)

A 19.993 to 19.999

B 19.999 to 20.005

141316

(3) Date of manufacture

(4) Gudgeon pin category

Gudgeon pin category Gudgeon pin externaldiameter (mm)

A 19.989 to 19.995

B 19.995 to 20.001





10A2 - Piston check

a - Gudgeon pin check

Check that the pin slides freely in the piston beforechecking it.

Measure using a external micrometer :

- the external diameter ( X1) of the gudgeon pin, whichmust be between 19.989 mm and 20.001 mm ,

- the length ( X2) of the gudgeon pin, which must be be-tween 52.1 and 52.4 mm .

Compare the external diameter value measured withthe category marked on the gudgeon pin.

b - Checking the play between the gudgeon pin andthe piston

Use a internal micrometer to measure the internal di-ameter of the piston.

The internal diameter of the piston must be between

19.993 and 20.005 mm.

Compare the value measured with the categorymarked on the piston.

Calculate the actual play = the internal diameter of thepiston - the outer diameter of the gudgeon pin.

The clearance between the piston and the gudgeon pinmust be between 0.002 and 0.006 mm .

c - Checking play between the gudgeon pin and thesmall end

Use a internal micrometer to measure the internal di-ameter of the small end.

The internal diameter of the small end must be be-tween 20.000 and 20.006 mm .

Calculate the actual play = the internal diameter of thesmall end - the outer diameter of the gudgeon pin.

The clearance between the gudgeon pin and the smallend should be between 0.005 and 0.017 mm .

d - Checking the piston rings

Use an external micrometer to measure the thicknessof the piston rings:

- compression ring ( X5) : 1.17 to 1.19 mm ,

- sealing ring ( X6) : 1.17 to 1.19 mm ,

- scraper ring ( X7) : 1.91 to 1.97 mm .

e - Checking the piston diameter

Use a external micrometer to measure the externaldiameter ( X3) of the piston at ( X4) = 13 mm , whichmust be between 77.966 and 77.980 mm .

X95

12962

102794

10027





10Af - Checking clearances between the piston ringsand grooves

Measure the clearance between the piston groove andthe ring ( 5) using a set of feeler gauges (6) (measureat three points 120˚ apart):

- compression ring - clearance between 0.04 and 0.08mm ,

- sealing ring - clearance between 0.03 and 0.07 mm ,

- scraper ring - clearance between 0.045 and 0.125mm .

If the clearance is not within tolerance, replace the« piston-gudgeon pin » assembly, or the piston rings.

g - Checking play at the ring section

Fit the ring ( 7) to be checked in the cylinder.

Push the piston ring ( 8) to the centre of the cylinder us-ing the piston.

Use a set of feeler gauges (9) to measure the ringend clearance, which must be:

- compression ring - clearance of 0.20 to 0.30 mm ,

- sealing ring - clearance of 0.35 to 0.50 mm ,- scraper ring - clearance of 0.20 to 0.60 mm .

III - CON ROD CHECKING OPERATION

1 - Identification

Small end diameter category

102795

(A) Set of shims incorrectly posi-tioned

(B ) Set of shims correctly positioned

102793

139721

(10) Timing end mark

(11 ) Cylinder number

(12) Small end diameter category

(13) Big end diameter category

X95

Letter indicating thesmall end category

Small end diameter(mm)

A 20 to 20.006





10ABig end diameter categories

Con rod bearing shell thickness classes (the upperand lower bearing shells are the same colour)

Con rod bearing shell thickness classes (the upper and lower bearing shells are different colours)

Letter indicating thebig end category

Big end diameters(mm)

A 47 to 47.001

B 47.001 to 47.002

C 47.002 to 47.003

D 47.003 to 47.004

E 47.004 to 47.005

F 47.005 to 47.006

G 47.006 to 47.007

H 47.007 to 47.008

J 47.008 to 47.009

K 47.009 to 47.010

L 47.010 to 47.011

M 47.011 to 47.012

N 47.012 to 47.013

Categorynumber

Bearing shellthickness(mm)

Identicationcolour

0 1.494 to 1.497 Black

1 1.497 to 1.5 Brown2 1.5 to 1.503 Green

3 1.503 to 1.506 Yellow

4 1.506 to 1.509 Blue



Category number Lower or upper bearingshells

Bearing shell thickness(mm)

Identication colour

01upper 1.494 to 1.497 Black

lower 1.497 to 1.5 Brown

12upper 1.497 to 1.5 Brown

lower 1.5 to 1.503 Green

23upper 1.5 to 1.503 Green

lower 1.503 to 1.506 Yellow

34upper 1.503 to 1.506 Yellow

lower 1.506 to 1.509 Blue





10A

Big end diameter categories

Con rod bearing shell thickness classes (the upperand lower bearing shells are the same colour)

Con rod bearing shell thickness classes (the upper and lower bearing shells are different colours)

X38



A 43 to 43.001

B 43.001 to 43.002

C 43.002 to 43.003

D 43.003 to 43.004

E 43.004 to 43.005F 43.005 to 43.006

G 43.006 to 43.007

H 43.007 to 43.008

J 43.008 to 43.009

K 43.009 to 43.010

L 43.010 to 43.011

M 43.011 to 43.012

N 43.012 to 43.013

Categorynumber


Identicationcolour

0 1.498 to 1.501 Black1 1.501 to 1.504 Brown

2 1.504 to 1.507 Green

3 1.507 to 1.510 Yellow

4 1.510 to 1.513 Blue





Identication colour















10A

2 - Checking the con rod

a - Checking the diameters of the big end and smallend

Measure using a internal micrometer :

- the internal diameter ( X8) of the big end must be be-tween 47 and 47.013 mm ,

- the internal diameter ( X9) of the small end must bebetween 20 and 20.006 mm .

Compare the values measured with the classesmarked on the con rod.

b - Checking the thickness of the big ends

Use a external micrometer to measure the thickness(X10) of the con rod big end, which must be between20.45 and 20.50 mm .

S 12 2 23 23 23 3 3 3 34 34 34 4 4

T 2 23 23 23 3 3 3 34 34 34 4 4 4

U 23 23 23 3 3 3 34 34 34 4 4 4 4

Crankshaftjournal diam-eter classes

Big end diameter classes

A B C D E F G H J K L M N

X95

139722

127878





10Ac - Checking the diametric clearance of the bigends

Cut pieces of radial play measuring tape .

Insert the wire ( 14 ) into the axis of the crankshaftcrankpins (avoiding the bearing lubrication holes).

Refit the piston - con rod assembly (see 10A , Engineand cylinder block assembly , Piston - Con rod: Re-moval - Refitting , page 10A-88 ) .

Remove the piston - con rod assembly (see 10A , En-gine and cylinder block assembly , Piston - Conrod: Removal - Refitting , page 10A-88 ) .

Measure the flattening of the play measuring wire us-ing the gauge printed on the wrapping paper ( 15) of thewire.

Check the clearance value, which must be between0.01 and 0.07 mm .

Clean off of any remaining parts of the measuring wireon the crankshaft and bearing shells.

d - Checking the lateral play of the con rod

Use a set of feeler gauges to check that the clearance(J1 ) between the con rod and the crankshaft is be-tween 0.2 and 0.35 mm .

127838

Note:

Do not rotate the con rod or crankshaft during thefollowing steps.

102807

114831





10AIV - FINAL OPERATION

Refit the piston rings (if removed) (see 10A , Engineand cylinder block assembly , Piston - Con rod: Re-moval - Refitting , page 10A-88 ) .

Assemble the con rod and the piston (if separated)(see 10A , Engine and cylinder block assembly , Pis-ton - Con rod: Removal - Refitting , page 10A-88 ) .

Refit the « piston - con rod » assembly (see 10A , En-gine and cylinder block assembly , Piston - Conrod: Removal - Refitting , page 10A-88 ) .



Connect the automatic gearbox to the engine (see Au-tomatic gearbox: Removal - Refitting ) (23A, Auto-

matic gearbox).


X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A



Put the engine assembly on the engine stand (see10A , Engine and cylinder block assembly , Enginesupport equipment: Use , page 10A-19 ) .

Remove the "piston - con rod" assembly (see 10A , En-gine and cylinder block assembly , Piston - Conrod: Removal - Refitting , page 10A-88 ) .

Perform the following:

- clean the "piston - con rod" assembly,

- check for possible scratches or damage caused by animpact on the surface of the "piston - con rod" assem-bly.

II - PISTONS

1 - Lateral play between the piston rings and thepiston grooves

Check the following:

- (A) incorrect placement of the set of feeler gauges

- (B) correct placement of the set of feeler gauges

Using a set of feeler gauges (1) , measure the lateralplay of the piston rings ( 2) :

- upper compression ring 0.040 - 0.080 mm ,

- lower compression ring 0.030 - 0.070 mm ,

- scraper ring and rail 0.045 - 0.125 mm .

Equipment required


external micrometer

internal micrometer



148198






X38, SAMSUNG BRAND

10ATable of big end diameter classes

Con rod bearing shell selection table

Diameter (Category) Con rod (Head diame-ter (mm))

A 43.000 - 43.001

B 43.001 to 43.002

C 43.002 to 43.003

D 43.003 to 43.004

E 43.004 to 43.005

F 43.005 to 43.006

G 43.006 to 43.007

H 43.007 to 43.008

J 43.008 to 43.009

K 43.009 to 43.010

L 43.010 to 43.011

M 43.011 to 43.012

N 43.012 to 43.013

Diameter (Category) Con rod (Head diame-ter (mm))

Crankshaftcrankpin jour-nal diameterclasses

Big end diameter classes

A B C D E F G H J K L M N

A 0 0 0 0 0 01 01 01 1 1 1 12 12

B 0 0 0 0 01 01 01 1 1 1 12 12 12

C 0 0 0 01 01 01 1 1 1 12 12 12 2

D 0 0 01 01 01 1 1 1 12 12 12 2 2

E 0 01 01 01 1 1 1 12 12 12 2 2 2

F 01 01 01 1 1 1 12 12 12 2 2 2 23

G 01 01 1 1 1 12 12 12 2 2 2 23 23

H 01 1 1 1 12 12 12 2 2 2 23 23 23

J 1 1 1 12 12 12 2 2 2 23 23 23 3

K 1 1 12 12 12 2 2 2 23 23 23 3 3

L 1 12 12 12 2 2 2 23 23 23 3 3 3

M 12 12 12 2 2 2 23 23 23 3 3 3 34

N 12 12 2 2 2 23 23 23 3 3 3 34 34

P 12 2 2 2 23 23 23 3 3 3 34 34 34

R 2 2 2 23 23 23 3 3 3 34 34 34 4

S 12 2 23 23 23 3 3 3 34 34 34 4 4

T 2 23 23 23 3 3 3 34 34 34 4 4 4

U 23 23 23 3 3 3 34 34 34 4 4 4 4




X38, SAMSUNG BRAND

10ATable of con rod bearing shell classes

3 - Method of replacing the bearing shell if reusingthe con rod and the crankshaft

Categorynumber

Bearing shellthickness

(mm)

Identicationcolour

Notes

0 1.498 to 1.501 BlackThe classesand coloursare the samefor the con rodu p p e r a n dlower bearingshells

1 1.501 to 1.504 Brown

2 1.504 to 1.507 Green

3 1.507 to 1.510 Yellow

4 1.510 to 1.513 Blue

Category number Lower or upperbearing shells

Bear ing she l lthickness (mm)

Identicationcolour

Notes


The classes andcolours are differ-ent between the conrod upper and lowerbearing shells








148202




X38, SAMSUNG BRAND

10ARefit the following parts:

- the con rod and con rod cap,

- the con rod cap mounting bolt.

Measure the bore using the internal micrometer (X1).

Measure the external diameter of the crankshaft crank-pin journal using the external micrometer (see 10A ,Engine and cylinder block assembly , Crankshaft:Check , page 10A-134 ) .

Calculate the operating play = (X1) - external diameterof the crankshaft crankpin journal.

The standard value is between 0.029 and 0.034 mm ,and the limit value is 0.010 mm .


Refit the "piston - con rod" assembly (see 10A , Engineand cylinder block assembly , Piston - Con rod: Re-moval - Refitting , page 10A-88 ) .



Note:

If the limit value is exceeded, use the bearing shellreplacement method for a new con rod and newcrankshaft.



ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft: Removal - Refitting


10A

REMOVAL


a





a Drain the engine (see Engine oil: Draining - Refill-

ing ) .





Equipment required

component support

indelible pencil




bolts of the crankshaftposition sensor target

22 N.m

crankshaft bearing capbolts

32 N.m + 62˚ ±±±±

2˚

reinforcement strut bolts 25 N.m


8 N.m

IMPORTANT


- (see10A

,Engine and cylinder block assem-bly , Engine: Precautions for the repair , page

10A-1 ) ,


WARNING




X95 – X38, JH3

X38, CK1

139484











a Remove:



a Remove:







- the « pressure plate - disc » assembly (see Pres-sure plate - Disc: Removal - Refitting ) (20A,

Clutch),- the flywheel (see Flywheel: Removal - Refitting ) ,




- the « piston - con rod » assembly (see 10A , En-gine and cylinder block assembly , Piston - Conrod: Removal - Refitting , page 10A-88 ) .

II - CRANKSHAFT REMOVAL OPERATION

a Remove:

- the bolts ( 7) of the crankshaft bearing cap rein-forcement strut,

- the crankshaft bearing cap reinforcement strut.

a Mark the position of the bearing caps in relation tothe cylinder block using a indelible pencil .

a Remove:- the crankshaft bearing cap bolts,

- the crankshaft bearing caps,

X95

X95

139423

X38

139285







10A2 - Preparation for refitting if replacing thecrankshaft

a

a When replacing the crankshaft or crankshaft bearingshells, always identify the thickness class for eachbearing shell that will be refitted on each crankshaftbearing, to ensure that the journal clearances re-main within the tolerances, before refitting the crank-shaft (see 1 0 A , Engine and cylinder blockassembly , Crankshaft: Check , page 10A-134 ) .

II - CRANKSHAFT REFITTING OPERATION

a Refit the crankshaft position sensor target and thepositioning pin ( 12 ) on the crankshaft.

a Adjust the target position with the positioning pin.

a Torque tighten the bolts of the crankshaft positionsensor target (22 N.m) .

a Remove the positioning pin.

a Centre a new grooved bearing shell on the cylinderblock bearing by aligning the bearing shell groovewith the bearing groove.

a Secure the flush bearing shell at ( 13 ) and push fromthe opposite side to position the bearing shell flushwith the bearing.

a Repeat the previous operations for the other bear-ings.

aAdjust the bearing position on each side of the cylin-der block bearing using a rectified shim and a set offeeler gauges :

- bearing no.1: between 1.65 and 2.05 mm ,

Note:

Any clearances of the crankshaft journal outsidethe tolerances can cause engine damage.

X38

147007

139282

139422





10A- bearing no.2: between 1.25 and 1.65 mm ,



- bearing no.5: between 1.65 and 2.00 mm .

a On the body jig bench, place:

- the bearing cap,- a new non-grooved bearing shell.

a Secure the flush bearing shell with the bearing capat ( 14) and push from the opposite side to bring thebearing shell flush with the bearing cap.

a Repeat the previous operations for the other bearingcaps.

a

114895

X95

139284

Note:

Bearing caps are identied by the number at ( 15)

.








a Refit:

- the « piston - con rod » assembly (see 10A , En-

gine and cylinder block assembly , Piston - Conrod: Removal - Refitting , page 10A-88 ) ,




- the flywheel (see Flywheel: Removal - Refitting ) ,- the « pressure plate - disc » assembly (20A, Clutch

(see Pressure plate - Disc: Removal - Refitting )),







a Refit:


- the catalytic converter (see Catalytic converter:

Removal - Refitting) .

a Refit:





a Fit the flywheel locking tool (Mot. 1431) .


a Remove the flywheel locking tool (Mot. 1431) .

a Refit:











X95

X38

X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A

REMOVAL


a


a Put the engine assembly on the engine stand (see10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .



















- the piston - con rod (see 10A , Engine and cylin-der block assembly , Piston - Con rod: Removal- Refitting , page 10A-88 ) .


mounting bolts of thecrankshaft position sen-sor target

22 N.m

mounting bolts of themain bearing caps

32 N.m

WARNINGBefore performing the repair operations, checkthe directives concerning safety, hygiene and theprocedures (see 10A , Engine and cylinderblock assembly , Engine: Precautions for therepair , page 10A-1 )





X38, SAMSUNG BRAND

10AII - REMOVAL OF THE PARTS CONCERNED

1 - Removing the crankshaft


- the mounting bolts of the crankshaft main bearingcaps, in the order indicated above,

- the crankshaft main bearing caps,

- the crankshaft lower main bearings.

a Remove the crankshaft ( 1 ) .


- the crankshaft upper main bearings ( 2) ,

- the crankshaft thrust bearing ( 3) .

148313

Note:

Mark the initial location of the main bearing capsusing an oil-base pen.

148314

148315




X38, SAMSUNG BRAND

10A2 - Removing the crankshaft position sensor target


- the mounting bolt of the crankshaft position sensortarget ( 4) ,

- the crankshaft position sensor target ( 5) .

REFITTING


a Replace the mounting bolts of the crankshaft mainbearing caps with new parts.

a Use a CAN OF STRONG CLEANER (part no.: KC1048901070 ) to clean the following parts:

- the crankshaft,

- the crankshaft main bearing caps,

- the contact surface between the crankshaft upperbearings and the cylinder block,

- the contact surface between the crankshaft lowerbearings and the main bearing caps.

a Dry the crankshaft assembly.

a Check the crankshaft (see 10A , Engine and cylin-der block assembly , Crankshaft: Check , page10A-134 ) .

II - REFITTING THE PARTS CONCERNED

1 - Refitting the crankshaft position sensor target

a Refit the crankshaft position sensor target ( 1) andthe positioning pin ( 2 ) on the crankshaft.

a Adjust the target position with the positioning pin.

a Torque tighten the mounting bolts of the crank-shaft position sensor target (22 N.m) .

a Remove the positioning pin.

148316

Note:

The crankshaft position sensor target is removedonly when replacing the crankshaft or the crank-shaft position sensor.

148317




X38, SAMSUNG BRAND

10A2 - Refitting the crankshaft

a Refit the thrust bearings ( 3) , ensuring that the lubri-cation groove is oriented outwards.

a Refit the upper main bearings ( 5) , ensuring that thecylinder block lubrication holes and the bearingholes ( 4) coincide.

a Place the upper main bearings so that the positionon the cylinder block (X1) is as follows:

- Journal no. 1: 1.64 - 2.05 mm ,

- Journal no. 2: 1.25 - 1.65 mm ,

- Journal no. 3: 2.30 - 2.70 mm ,

- Journal no. 4: 1.25 - 1.65 mm ,- Journal no. 5: 1.60 - 2.00 mm .

148318

148319

148320

Note:

Use new engine oil to lubricate the surface of themain bearings in contact with the crankshaft jour-nals.




X38, SAMSUNG BRAND

10A

a Refit the crankshaft ( 6) on the cylinder block.

a Use new engine oil to lubricate the threadings of themain bearing cap mounting bolts and the assemblyparts.

a Refit the lower main bearings ( 7) on the main bea-ring caps in order to obtain a position (X2) as fol-lows:

- Journal no. 1: 1.30 - 1.70 mm ,

- Journal no. 2: 1.30 - 1.70 mm ,

- Journal no. 3: 2.30 - 2.70 mm ,

- Journal no. 4: 1.30 - 1.70 mm ,

- Journal no. 5: 1.30 - 1.70 mm .

a Refit the main bearing caps, taking account of thefront mark ( 8) and the journal number ( 9) .

a Refit the mounting bolts of the main bearing caps.

a Torque tighten in order the mounting bolts of themain bearing caps (32 N.m) .

a Tighten in the order the mounting bolts of the main

bearing caps to the defined angle (60°°°°).

a Check the end float of the crankshaft (see 10A , En-gine and cylinder block assembly , Crankshaft:Check , page 10A-134 ) .

148314

148321

148322

148313




X38, SAMSUNG BRAND



- the piston - con rod (see 10A , Engine and cylin-

der block assembly , Piston - Con rod: Removal- Refitting , page 10A-88 ) ,

- the lower plate of the cylinder block (see 10A , En-gine and cylinder block assembly , Cylinderblock base plate: Removal - Refitting , page 10A-73) ,

















a Refit the engine and transmission assembly (see

Engine - gearbox assembly: Removal - Refitting ).




ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft: Check


10A







Remove the crankshaft (see 10A , Engine and cylin-der block assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) .

Before any checks:

- clean the crankshaft using SURFACE CLEANER(see Vehicle: Parts and consumables for the re-pair ) (04B, Consumables - Products),

- check that the crankshaft does not have any scratch-es, any trace of impact or abnormal wear (if neces-sary, replace the crankshaft).

II - CRANKSHAFT CHECKING OPERATION

1 - Identification

Equipment required

component support

dial gauge support

Dial gauge

external micrometer





WARNING




X95 – X38, JH3

X38, CK1

X95

141317





10A

(1J) Diameter category for journal no. 1,





(1P) Diameter category for crankpin no. 1,(2P) Diameter category for crankpin no. 2,

(3P) Diameter category for crankpin no. 3,

(4P) Diameter category for crankpin no. 4.

Crankshaft journal diameter classes

(1) Crankshaf t crankpin diameterclasses

(2) Timing end crankpin class

(3) Gearbox end crankpin class

(4) Crankshaft journal diameterclasses

(5) Timing end journal class

(6) Gearbox end journal class

X38

147008

(1) Crankshaft journal diameterclasses

(2) Crankshaf t crankpin diameterclasses

Letter indicating thejournal class on thecrankshaft

Diameter of crankshaftjournals (mm)

A 47.978 to 47.979

B 49.977 to 49.978

C 49.976 to 49.977

D 49.975 to 49.976E 47.974 to 47.975

F 47.973 to 47.974

G 47.972 to 47.973

H 47.971 to 47.972

J 47.970 to 47.971

K 47.969 to 47.970

L 47.968 to 47.969

M 47.967 to 47.968

N 47.966 to 47.967

P 47.965 to 47.966

R 47.964 to 47.965

S 47.963 to 47.964

T 47.962 to 47.963

U 47.961 to 47.962

V 47.960 to 47.961

W 47.959 to 47.960







10A2 - Checking engine flywheel bearing face run-out

Fit:



Position the feeler of the Dial gauge on the flywheelface of the crankshaft avoiding the holes of the fly-wheel bolts.

Calibrate the Dial gauge to zero.

Rotate the crankshaft once to measure the engine fly-wheel bearing face run-out, which must not exceed0.02 mm .

3 - Checking the crankshaft journals

a - Checking journal concentricity

Support the crankshaft on two slightly oiled V-blocks.

Fit:

- the dial gauge support ,- the Dial gauge on the mounting.

Support the feeler of Dial gauge on the centre of themating face of the crankshaft journal to check.


Rotate the crankshaft once to check the concentricityof the journal, which must not be greater than 0.01mm .

b - Checking journal diameters

139843

Note:

Rest the crankshaft on two slightly oiled V-groovesto perform the check, if the crankshaft has beenremoved from the cylinder block.

22163

102805





10AUse a external micrometer to measure the diameter(in the centre of the mating face) of each crankshaft

journal to be checked, which must be between 47.959and 47.979 mm .

Compare the value measured with the diameter classmarked on the crankshaft (see Identification of thecrankshaft and Crankshaft journal diameter class-es ).

4 - Checking crankpin diameters

Use a external micrometer to measure the diameter(in the centre of the mating face) of each crankshaftcrankpin to be checked, which must be between43.953 and 43.971 mm .

Use a external micrometer to measure the diameter(in the centre of the mating face) of the crankshaftcrankpin to be checked, which must be between39.951 and 39.971 mm .

Compare the value measured with the diameter classmarked on the crankshaft (see Identification of thecrankshaft and Crankshaft crankpin diameterclasses ).

5 - Checking the crankshaft bearing shells

a - Identification

102806

X95

X38

141315

(7) Upper bearing shell

(8) Lower bearing shell

146987

(9) Cylinder block (10) Upper bearing shell

(11 ) Lower bearing shell

(12) Crankshaft bearing cap





10ACrankshaft bearing shell thickness classes (theupper and lower bearing shells are the samecolour)

Crankshaft bearing shell thickness classes (the upper and lower bearing shells are different colours)

b - Checking radial play

Refit without lubricating (see 10A , Engine and cylin-der block assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) :

- the upper crankshaft bearing shells from the cylinderblock,

- the central crankshaft bearing side shims (grooves atcrankshaft end),

- the crankshaft.

L1 (mm) L2 (mm)

1 1.65 to 2.05 1.30 to 1.70

2 1.25 to 1.65 1.30 to 1.70

3 2.30 to 2.70 2.30 to 2.70

4 1.25 to 1.65 1.30 to 1.70

5 1.65 to 2.05 1.30 to 1.70

Categorynumber Bearing shellthickness(mm)

Identicationcolour

0 1.996 to 1.999 Black

1 1.999 to 2.002 Brown

2 2.002 to 2.005 Green

3 2.005 to 2.008 Yellow

4 2.008 to 2.011 Blue

5 2.011 to 2.014 Pink



Identication colour



12 upper 1.999 to 2.002 Brownlower 2.002 to 2.005 Green





45upper 2.008 to 2.001 Blue

lower 2.011 to 2.014 Pink

Note:

Do not rotate the crankshaft during this check.





10A

Cut pieces of radial play measuring tape .

Position the wire ( 13 ) in the axis of the crankshaft jour-nal avoiding the bearing lubrication holes.


- the lower bearing shells on the crankshaft bearings,

- the « lower bearing shell - crankshaft bearing » as-semblies,

- the old crankshaft bearing bolts.

Remove (see 10A , Engine and cylinder block as-sembly , Crankshaft: Removal - Refitting , page 10A-120 ) :

- the old crankshaft bearing bolts,

- the « lower bearing shell - crankshaft bearing » as-

semblies.

Measure the flattening of the radial play measuringtape which must be between 0.01 and 0.06 mm , usingthe gauge printed on the wire wrapping paper ( 14) .

Measure the flattening of the radial play measuringtape which must be between 0.02 and 0.03 mm , usingthe gauge printed on the wire wrapping paper ( 14) .

Clean off of any remaining parts of the measuring wireon the crankshaft and bearing shells.

c - Determination of the thickness class of thecrankshaft bearing shell

When replacing the crankshaft or crankshaft bearingshells always use the following method to identify thecrankshaft bearing shell thickness class to refit oneach bearing before refitting the crankshaft :

127838 102807

X95

X38

Note:

Any crankshaft journal clearances outside the toler-ances can cause engine damage.







10ATable 2 Crankshaft bearing shell class determination

Crank-shaft jour-

naldiameterclasses

Crankshaft bearing diameter classes on the cylinder block

L M N P R S T U V W

A 1 1 1 12 12 12 2 2 2 23

B 1 1 12 12 12 2 2 2 23 23

C 1 12 12 12 2 2 2 23 23 23

D 12 12 12 2 2 2 23 23 23 3

E 12 12 2 2 2 23 23 23 3 3

F 12 2 2 2 23 23 23 3 3 3

G 2 2 2 23 23 23 3 3 3 34

H 2 2 23 23 23 3 3 3 34 34

J 2 23 23 23 3 3 3 34 34 34

K 23 23 23 3 3 3 34 34 34 4

L 23 23 3 3 3 34 34 34 4 4

M 23 3 3 3 34 34 34 4 4 4

N 3 3 3 34 34 34 4 4 4 45

P 3 3 34 34 34 4 4 4 45 45

R 3 34 34 34 4 4 4 45 45 45

S 34 34 34 4 4 4 45 45 45 5

T 34 34 4 4 4 45 45 45 5 5

U 34 4 4 4 45 45 45 5 5 5

V 4 4 4 45 45 45 5 5 5 5

W 4 4 45 45 45 5 5 5 5 5





10A6 - Checking the crankshaft thrust washer

a - Checking the thickness of the thrust washer

Use a external micrometer to measure the thickness(X3) of each thrust washer, which must be between1.90 and 2.40 mm .

Use a external micrometer to measure the thickness(X3) of each thrust washer, which must be between2.126 and 2.134 mm .

b - Checking the crankshaft lateral clearance


- the upper crankshaft bearing shells from the cylinderblock,

- the central crankshaft bearing side shims (grooves atcrankshaft end),

- the crankshaft,

- the lower bearing shells on the crankshaft bearings,

- the lower bearing shell - crankshaft bearing assem-blies,

- the old crankshaft bearing bolts.

Fit:



Support the feeler of the Dial gauge on the flywheelface of the crankshaft.

Support the crankshaft on the thrust washer by push-ing the crankshaft in the axis towards the timing end.


Support the crankshaft on the other thrust washer bypushing the crankshaft in the axis towards the flywheelend.

Check the crankshaft lateral clearance, which must be

between 0.1 and 0.3 mm .



Refit the crankshaft (see 10A , Engine and cylinderblock assembly , Crankshaft: Removal - Refitting ,page 10A-120 ) .


135057

X95

X38

139719





10A

Connect the manual gearbox to the engine (see Manu-

al gearbox: Removal - Refitting ) (21A, Manual gear-box).



X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A



Put the engine assembly on the engine stand (see10A , Engine and cylinder block assembly , Enginesupport equipment: Use , page 10A-19 ) .


Perform the following:

- clean the crankshaft,

- check for possible scratches or damage caused by animpact on the crankshaft surface.

II - CRANKSHAFT

1 - Marking on the crankshaft

The diameter categories of the main journals ( 1) are in-scribed on the crankshaft.





(5J) Diameter category for journal no. 5.

The diameter categories of the crankpins ( 2) are in-scribed on the crankshaft.



(3P) Diameter category for crankpin no. 3,(4P) Diameter category for crankpin no. 4.

Crankshaft journal diameter classes

Equipment required

dial gauge support

Dial gauge

external micrometer


WARNINGBefore performing the repair operations, check thedirectives concerning safety, hygiene and the pro-cedures (see 10A , Engine and cylinder blockassembly , Engine: Precautions for the repair ,page 10A-1 )

WARNINGWear protective gloves during the operations. 148326



A 47.978 to 47.979

B 49.977 to 49.978

C 49.976 to 49.977

D 49.975 to 49.976




X38, SAMSUNG BRAND

10A

Crankshaft crankpin diameter classes

2 - Crankshaft inspection

a - Crankshaft eccentricity

Place the crankshaft on V blocks.

Fit the following tools:- dial gauge support ,

- Dial gauge (3 ) .

E 47.974 to 47.975

F 47.973 to 47.974

G 47.972 to 47.973

H 47.971 to 47.972

J 47.970 to 47.971

K 47.969 to 47.970

L 47.968 to 47.969

M 47.967 to 47.968

N 47.966 to 47.967

P 47.965 to 47.966

R 47.964 to 47.965

S 47.963 to 47.964

T 47.962 to 47.963

U 47.961 to 47.962

V 47.960 to 47.961

W 47.959 to 47.960

Letter indicating thecrankpin class on thecrankshaft

Diameter of crankshaftcrankpins (mm)

A 39.970 to 39.971

B 39.969 to 39.970

C 39.968 to 39.969

D 39.967 to 39.968

E 39.966 to 39.967

F 39.965 to 39.966

G 39.964 to 39.965

H 39.963 to 39.964

J 39.962 to 39.963



K 39.961 to 39.962

L 39.960 to 39.961

M 39.959 to 39.960

N 39.958 to 39.959

P 39.957 to 39.958

R 39.956 to 39.957

S 39.955 to 39.956

T 39.954 to 39.955

U 39.953 to 39.954

V 39.952 to 39.953

W 39.951 to 39.952

148327

Letter indicating thecrankpin class on thecrankshaft

Diameter of crankshaftcrankpins (mm)




X38, SAMSUNG BRAND

10APlace the dial gauge so that the indicator is at the sur-face of the central journal of the crankshaft.

Adjust the indicator to zero.

Slowly rotate the crankshaft one turn.The crankshaft eccentricity must be less than 0.1 mm .

b - Crankshaft main journal diameter

Measure the diameter of each main journal with the ex-ternal micrometer (4 ) . Compare the measured val-ues with those indicated in the Table of crankshaftmain journal diameter classes .

c - Crankshaft crankpin diameter

Measure the diameter ( X2) of the crankshaft crankpinswith the external micrometer . Compare the valuesmeasured with those indicated in the Table of crank-shaft crankpin diameter classes .

3 - Crankshaft main bearings

Technical specifications of the main bearings

4 - Operating play of the main bearings

Refit the following parts (see 10A , Engine and cylin-der block assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) :

- the thrust bearing,

- the upper main bearing, taking account of the positionof the lubrication hole,

148328

148329

148274

b () Front of engine

(1) Cylinder block

(2) Upper main bearing

(3) Lower main bearing

(4) Main bearing cap

(5) Lubrication hole

L1 (mm) L2 (mm)

1 1.65 to 2.05 1.30 to 1.70

2 1.25 to 1.65 1.30 to 1.70

3 2.30 to 2.70 2.30 to 2.70

4 1.25 to 1.65 1.30 to 1.70

5 1.60 to 2.00 1.30 to 1.70




X38, SAMSUNG BRAND

10A- the crankshaft.

Place a radial play measuring tape (5) in the direc-tion of the journal axis.

Refit the following parts:

- the main bearing cap,

- the mounting bolt of the crankshaft main bearing cap.

Remove the following parts:

- the mounting bolt of the crankshaft main bearing cap,

- the main bearing cap,- the lower main bearing.

Compare the play with the thickness of the graduationsof the play measuring paper ( 6 ) .

Standard value: 0.024 - 0.034 mm .

5 - Method of replacing main bearings

If using a new cylinder block and reusing the cranks-haft:

- a - Check the class of the new cylinder block from theTable of bearing housing diameter classes (see10A , Engine and cylinder block assembly , Cylin-der block: Check , page 10A-168 ) ,

- b - Check the diameter class of each journal from theTable of crankshaft main journal diameter class-es ,

- c - In the Main bearing selection table , check thenumber at the intersection of the column of the cylin-der block main bearing housing bore and the line ofthe crankshaft main journal diameter ,

- D - Check the main bearing thickness that corre-sponds to the main bearing number in the Bearingclass table .

If reusing the cylinder block and a new crankshaft:

- measure the operating play of the main bearings andif the defined value is exceeded, choose the mainbearing according to the prescribed method for usinga new cylinder block while reusing the crankshaft.

148330

102807




X38, SAMSUNG BRAND

10AClasses of cylinder block main bearing housing bores

Classes of cylinder block main bearing housing bores

Crankshaftjournal diam-

eter classes


A B C D E F G H J K

A 0 0 0 0 0 0 0 01 01 01

B 0 0 0 0 0 0 01 01 01 1

C 0 0 0 0 0 01 01 01 1 1

D 0 0 0 0 01 01 01 1 1 1

E 0 0 0 01 01 01 1 1 1 12

F 0 0 01 01 01 1 1 1 12 12

G 0 01 01 01 1 1 1 12 12 12

H 01 01 01 1 1 1 12 12 12 2

J 01 01 1 1 1 12 12 12 2 2

K 01 1 1 1 12 12 12 2 2 2

L 1 1 1 12 12 12 2 2 2 23

M 1 1 12 12 12 2 2 2 23 23

N 1 12 12 12 2 2 2 23 23 23

P 12 12 12 2 2 2 23 23 23 3

R 12 12 2 2 2 23 23 23 3 3

S 12 2 2 2 23 23 23 3 3 3

T 2 2 2 23 23 23 3 3 3 34

U 2 2 23 23 23 3 3 3 34 34

V 2 23 23 23 3 3 3 34 34 34

W 23 23 23 3 3 3 34 34 34 4

Crank-shaft jour-naldiameterclasses


L M N P R S T U V W

A 1 1 1 12 12 12 2 2 2 23

B 1 1 12 12 12 2 2 2 23 23

C 1 12 12 12 2 2 2 23 23 23




X38, SAMSUNG BRAND

10A

Crankshaft bearing shell thickness classes (theupper and lower bearing shells are the samecolour)

D 12 12 12 2 2 2 23 23 23 3

E 12 12 2 2 2 23 23 23 3 3

F 12 2 2 2 23 23 23 3 3 3

G 2 2 2 23 23 23 3 3 3 34

H 2 2 23 23 23 3 3 3 34 34

J 2 23 23 23 3 3 3 34 34 34

K 23 23 23 3 3 3 34 34 34 4

L 23 23 3 3 3 34 34 34 4 4

M 23 3 3 3 34 34 34 4 4 4

N 3 3 3 34 34 34 4 4 4 45

P 3 3 34 34 34 4 4 4 45 45

R 3 34 34 34 4 4 4 45 45 45

S 34 34 34 4 4 4 45 45 45 5

T 34 34 4 4 4 45 45 45 5 5

U 34 4 4 4 45 45 45 5 5 5

V 4 4 4 45 45 45 5 5 5 5

W 4 4 45 45 45 5 5 5 5 5

Crank-shaft jour-naldiameterclasses


L M N P R S T U V W

Categorynumber


Identicationcolour

0 1.996 to 1.999 Black

1 1.999 to 2.002 Brown

2 2.002 to 2.005 Green

3 2.005 to 2.008 Yellow

4 2.008 to 2.011 Blue

5 2.011 to 2.014 Pink






X38, SAMSUNG BRAND

10ARemove the crankshaft (see 10A , Engine and cylin-der block assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) .

IV - FINAL OPERATIONSRefit the crankshaft (see 10A , Engine and cylinderblock assembly , Crankshaft: Removal - Refitting ,page 10A-120 ) .





ENGINE AND CYLINDER BLOCK ASSEMBLYCylinder block: Removal - Refitting


10AREMOVAL


a









Mot. 923 Engine lifting ring.

Equipment required

component support

standard vice grip

workshop hoist

load balancer


oil splash plate bolts (iftted)

10 N.m

accessories belt xedroller support bolts

25 N.m

coolant drain plug 10 N.m

crankshaft position sen-sor bolt

7 N.m

coolant pump bolts 25 N.m

oil pressure switch 21 N.m

pinking sensor bolt 26 N.m

bolts of the coolantpump inlet pipe support

17 N.m


8 N.m

IMPORTANT




WARNING




X95 – X38, JH3

X38, CK1





10A




a Remove:




a Check that the inlet camshaft dephaser marks ( 4)and the exhaust camshaft sprocket marks ( 5) arepositioned exactly as shown in the illustration.


139484

X38

141016

141017





10A


a Remove:



shaft seal on timing end: Removal - Refitting ) ,- the timing chain (see Timing chain: Removal -Refitting ) ,



a Remove:



a Remove:














a Remove the piston base cooling jets (see 10A , En-

gine and cylinder block assembly , Piston basecooling jet: Removal - Refitting , page 10A-172 ) .

141008

X95

X95







10A

a Remove:

- the bolts ( 11 ) of the coolant pump inlet pipe sup-port,

- the coolant pump inlet pipe ( 12 ) .

a Remove the thermostat - rubber washer assembly(13) .

a Remove:

- the pinking sensor bolt ( 14 ) ,

- the pinking sensor ( 15) ,

- the oil pressure switch ( 16 ) .

a Remove:

- the coolant pump bolts ( 17) ,

- the coolant pump ( 18 ) ,

- the coolant pump seal.

147000

147001

147002

146998





10A

a Remove:

- the bolt ( 19 ) from the crankshaft position sensor,

- the crankshaft position sensor ( 20 ) ,

- the crankshaft position sensor O-ring,

- the coolant drain plug ( 21) .

REFITTING


a Position the (Mot. 923) (22 ) on the cylinder block.

a Remove the cylinder block from the component

support , using a workshop hoist and a load bal-ancer (see 10A , Engine and cylinder block as-sembly , Engine support equipment: Use , page10A-19 ) .


a Refit the cylinder block on the component supportusing a workshop hoist and a load balancer (see10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .


If replacing the cylinder block

a

X38

147004

116868

Note:

The Parts Department supplies the new cylinderblock:

- without the timing chain jet,

- without the oil pump chain tensioner pin,

- tted with a crankshaft, a « piston - con rod »assembly, a cylinder block base plate and asump.





10A

a Refit:

- an oil pump chain tensioner pin ( 23 ) ,

- a new timing chain jet ( 24 ) by positioning the flatsurface ( 25 ) horizontally.

II - CYLINDER BLOCK REFITTING OPERATION

a Refit the oil splash plate (if fitted).

a Torque tighten the oil splash plate bolts (if fitted)(10 N.m) .

a Refit:

- the accessories belt fixed roller support,

- the dipstick guide.

a Torque tighten the accessories belt fixed rollersupport bolts (25 N.m) .

a Apply SILICONE ADHESIVE to the coolant drainplug (see Vehicle: Parts and consumables for the

repair ) (04B, Consumables - Products).a Refit the coolant drain plug.

a Torque tighten the coolant drain plug (10 N.m) .

a Refit:

- a new crankshaft position sensor O-ring,

- the crankshaft position sensor,

- the crankshaft position sensor bolt.a Torque tighten the crankshaft position sensor

bolt (7 N.m) .

a Refit:

- a new coolant pump seal,

- the coolant pump,

- the coolant pump bolts.

a Torque tighten the coolant pump bolts (25 N.m) .

a Apply SILICONE ADHESIVE to the oil pressureswitch (see Vehicle: Parts and consumables forthe repair ) (04B, Consumables - Products).

a Refit the oil pressure switch.

a Torque tighten the oil pressure switch (21 N.m) .

a Refit:


- the pinking sensor bolt.

a Torque tighten the pinking sensor bolt (26 N.m) .

a Refit:

- the new rubber washer ( A) on the thermostat,

- the thermostat with the automatic discharge valve(B ) facing upwards,

141098

X95

X38

147009





10A- the water pump inlet pipe.

- the bolts of the coolant pump inlet pipe support.

a Torque tighten the bolts of the coolant pump inlet

pipe support (17 N.m) .

a Refit:

- a new dipstick guide O-ring,

- the dipstick guide.


a If reusing the cylinder block, refit the piston basecooling jets (see 10A , Engine and cylinder blockassembly , Piston base cooling jet: Removal - Re-fitting , page 10A-172 ) .

a If reusing the cylinder block, refit:- the crankshaft (see 10A , Engine and cylinderblock assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) ,



- the sump (see Lower cover: Removal - Refitting ).

a Refit:









a Refit:



a Refit:








a Refit:





a Torque tighten the bolts on the coolant pump pul-

ley (8 N.m) locking the coolant pump pulley using ascrewdriver.


X38

X95

X95

X38





10Aa Remove the engine from component support (see

10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .




X95 – X38, JH3

X38, CK1




X38, SAMSUNG BRAND

10A

REMOVAL


a
























coolant drain plug 10 N.m

crankshaft position sen-sor mounting bolt

7 N.m

coolant pump mountingbolts

25 N.m

oil pressure sensor 21 N.m

pinking sensor mountingbolt

26 N.m

bolts of the coolant

pump inlet pipe support17 N.m

WARNINGBefore performing the repair operations, checkthe directives concerning safety, hygiene and the

procedures (see 10A , Engine and cylinderblock assembly , Engine: Precautions for therepair , page 10A-1 ) .





X38, SAMSUNG BRAND

10AII - REMOVAL OF THE PARTS CONCERNED


- the dipstick guide ( 2) from its mounting clip ( 1) ,

- the dipstick guide O-ring.


- the bolts of the coolant pump inlet pipe support ( 3) ,

- the coolant pump inlet pipe ( 4) .

a Remove the thermostat ( 5 ) and its rubber washer to-gether.


- the pinking sensor mounting bolt ( 6) ,

- the pinking sensor ( 7) .

a Remove the oil pressure switch ( 8 ) .

148351

148352

148353

148354

148355




X38, SAMSUNG BRAND

10A


- the coolant pump mounting bolt ( 9) ,

- the coolant pump ( 10 ) ,



- the crankshaft position sensor mounting bolt ( 11 ) ,- the crankshaft position sensor ( 12 ) ,

- the crankshaft position sensor O-ring.

a Remove the coolant drain plug ( 13 ) .

REFITTING


a Replace the following parts with new parts:- the crankshaft position sensor O-ring,

- the rubber washer for the thermostat,

- the dipstick guide O-ring,


a Remove the cylinder block from the engine stand(see 10A , Engine and cylinder block assembly ,Engine support equipment: Use , page 10A-19 ) .


a Refit the cylinder block onto the engine stand (see10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .

148356

148357

148358




X38, SAMSUNG BRAND

10AII - REFITTING THE PARTS CONCERNED

a Apply SILICONE ADHESIVE (part no. :KC111TB1217G ) to the threading of the coolantdrain plug.

a Refit the coolant drain plug.

a Torque tighten the coolant drain plug (10 N.m) .


- a new crankshaft position sensor O-ring,

- the crankshaft position sensor,

- the crankshaft position sensor mounting bolt.

a Torque tighten the crankshaft position sensormounting bolt (7 N.m) .

aRefit the following parts:- a new coolant pump seal,

- the coolant pump,

- the coolant pump mounting bolts.

a Tighten to torque the coolant pump mountingbolts (25 N.m) .

a Coat the threading of the oil pressure sensor usingSILICONE ADHESIVE (part no.: KC111TB1217G ).

a Refit the oil pressure sensor.

a Torque tighten the oil pressure sensor (21 N.m) .a Refit the following parts:


- the mounting bolt of the pinking sensor.

a Torque tighten the pinking sensor mounting bolt(26 N.m) .

a Fit the new rubber washer ( A) on the thermostat.


- the thermostat with the automatic discharge valve(B) facing upwards,

- the coolant pump inlet pipe,

- the bolts of the coolant pump inlet pipe support.a Torque tighten the bolts of the coolant pump inlet

pipe support (17 N.m) .


- the new dipstick guide O-ring,

- the dipstick guide on its mounting clip.

148359




X38, SAMSUNG BRAND



- the crankshaft (see 10A , Engine and cylinder



- the lower plate of the cylinder block (see 10A , En-gine and cylinder block assembly , Cylinderblock base plate: Removal - Refitting , page 10A-73) ,
















a Remove the engine assembly from the engine stand(see 10A , Engine and cylinder block assembly ,

Engine support equipment: Use , page 10A-19 ) .a Refit the engine and transmission assembly (see

Engine - gearbox assembly: Removal - Refitting ).




ENGINE AND CYLINDER BLOCK ASSEMBLYCylinder block: Cleaning

X95 – X38

10AI - CLEANING PREPARATION OPERATION

a

a Remove the engine - gearbox assembly (see En-gine - gearbox assembly: Removal - Refitting ) .

a Place the engine on the component support (see10A , Engine and cylinder block assembly , En-gine support equipment: Use , page 10A-19 ) .

aRemove the cylinder block (see 10A , Engine andcylinder block assembly , Cylinder block: Re-moval - Refitting , page 10A-153 ) .

II - CLEANING THE ENGINE PERIPHERALS

a Clean the gasket surfaces of the cylinder block withSUPER CLEANING AGENT FOR JOINT FACES(see Vehicle: Parts and consumables for the re-pair ) .

a Remove the residue using a wooden spatula

a Finish cleaning the parts using a GREY ABRASIVEPAD , part number 77 01 405 943 .

a Wash the cylinder block using a cleaning fountain ora heated cleaning bath.

III - FINAL OPERATION.

a Refit the cylinder block (see 10A , Engine and cylin-der block assembly , Cylinder block: Removal -Refitting , page 10A-153 ) .

a Refit the engine - gearbox assembly (see Engine -

gearbox assembly: Removal - Refitting ) .



IMPORTANTWear leaktight gloves (Nitrile type) for this opera-tion.

WARNINGDo not allow this product to drip onto the paint-work.

Clean the cylinder head carefully to avoid anyforeign bodies entering the oil return and supplypipes.

Failure to follow this advice could lead to theblocking of the various oil inlet galleries, whichwould quickly result in engine damage.

113592

113553



ENGINE AND CYLINDER BLOCK ASSEMBLYCylinder block: Check

X95 – X38

10A







Remove the cylinder block (see 10A , Engine and cyl-inder block assembly , Cylinder block: Removal -Refitting , page 10A-153 ) .

Before any checks:

- clean the cylinder block (see 10A , Engine and cylin-der block assembly , Cylinder block: Cleaning ,page 10A-167 ) ,

- check that the cylinder block does not have anyscratches, any trace of impact or abnormal wear onthe cylinders, the joint faces and the mating faces ofthe crankshaft bearing shell.

II - CYLINDER BLOCK CHECKING OPERATION

1 - Identification

Equipment required

component support

cylinder head rule


internal micrometer

IMPORTANT




WARNING




X95 – X38, JH3

X38, CK1

139717

(1) Crankshaft bearing diameterclasses




X95 – X38

10A

Crankshaft bearing diameter classes

2 - Checking the cylinder block joint face

Check the joint face deformation using a cylinderhead rule and a set of feeler gauges .

Maximum deformation: 0.1 mm for 100 mm length .

3 - Checking the diameter of the crankshaftbearings

Refit (see 10A , Engine and cylinder block assem-bly , Crankshaft: Removal - Refitting , page 10A-120 )the crankshaft bearing caps, placing cap no. 1 on thetiming end.

Using a internal micrometer , measure the diameter(X1) of the crankshaft bearings, which must be be-

tween 51.997 and 52.017 mm .Compare the value measured with the diameter classmarked on the cylinder block (see Class of crankshaftbearing diameters table).

(2) Timing end bearing no. 1 cate-gory

(3) Gearbox end bearing no. 5 cate-gory

Letter indicating theclass of the crankshaftbearings on the cylin-der block

Cylinder block crank-shaft bearing diame-ter (mm)

A 51.997 to 51.998

B 51.998 to 51.999

C 51.999 to 52D 52 to 52.001

E 52.001 to 52.002

F 52.002 to 52.003

G 52.003 to 52.004

H 52.004 to 52.005

J 52.005 to 52.006

K 52.006 to 52.007

L 52.007 to 52.008

M 52.008 to 52.009

N 52.009 to 52.010

P 52.010 to 52.011

R 52.011 to 52.012

S 52.012 to 52.013

T 52.013 to 52.014

U 52.014 to 52.015

V 52.015 to 52.016

W 52.016 to 52.017

117919

139716






X95 – X38

10A

Connect the manual gearbox to the engine (see Manu-

al gearbox: Removal - Refitting ) (21A, Manual gear-box).



X95 – X38, JH3

X38, CK1



ENGINE AND CYLINDER BLOCK ASSEMBLYPiston base cooling jet: Removal - Refitting

X95

10A

REMOVAL


a


a Separate the gearbox from the engine (see Manualgearbox: Removal - Refitting ) (21A, Manual gear-

box).a Position the engine on the component support




a Remove:






Equipment required

component support


piston base cooling jetbolts

23 N.m

coolant pump pulleybolts

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and ope-ration recommendations before carrying out any

repair:- (see 10A , Engine and cylinder block assem-bly , Engine: Precautions for the repair , page10A-1 ) ,


WARNING

It is strictly forbidden to apply any pressure to the

engine oil sump. Damage to the sump will irrepa-rably damage the engine by:



139484





ENGINE AND CYLINDER BLOCK ASSEMBLYPiston base cooling jet: Removal - Refitting

X95

10A- the flywheel (see Flywheel: Removal - Refitting ) ,





- the crankshaft (see 10A , Engine and cylinderblock assembly , Crankshaft: Removal - Refit-ting , page 10A-120 ) .

II - OPERATION FOR REMOVING THE PISTONBASE COOLING JETS

aRemove:- the bolts ( 7 ) from the piston base cooling jets,

- the piston base cooling jets

REFITTING

I - OPERATION FOR REFITTING THE PISTON BASECOOLING JETS

a Refit the piston base cooling jets.

a Torque tighten the piston base cooling jet bolts(23 N.m) .

II - FINAL OPERATION

a Refit:

- the crankshaft (see 10 A , Engine and cylinder






















139286



Documents

Renault Technical note 6044A