Renault Technical note 6044A

Technical Note6044A X38, H4M - X95, H4J H4J - H4M engines

Edition 4

NOVEMBER 2010 "The repair procedures given by the manufacturer in this document are based on the technical specifications current when it was prepared. The procedures may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are constructed".

EDITION ANGLAISE

All rights reserved by Renault. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

© Renault s.a.s 2010

H4J - H4M engines

H4J - H4M enginesContentsPages

Contents Pages

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY

10A

Engine: Precautions for the repair

10A-1

Engine: Specifications

10A-5

Engine: New replacement

10A-8

Engine: Repair

10A-10

Engine support equipment: Use

10A-19

Camshaft: Check

10A-25

Valve: Removal - Refitting

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 - Refitting

10A-73

Piston - Con rod: Removal Refitting

10A-88

Piston - Con rod: Check

10A-105

Crankshaft: Removal Refitting

10A-120

Crankshaft: Check

10A-134

Cylinder block: Removal Refitting

10A-153

Cylinder block: Cleaning

10A-167

ENGINE AND CYLINDER BLOCK ASSEMBLY Cylinder block: Check

10A-168

Piston base cooling jet: Removal - Refitting

10A-172

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Precautions for the repair

10A

X95 – X38, RENAULT BRAND I - SAFETY WARNING

General information

Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).

All information contained in these manuals is intended exclusively for automotive industry professionals. The documentation is intended to cover all vehicles in the RENAULT range throughout the world, but may not cover equipment designed for use in specific countries. The procedures and fault finding procedures recommended and described in this manual have been designed by automotive industry repair professionals. a - General recommendations

b - Special tooling - ease of use The repair procedures have been designed using special tools; they must therefore be carried out using these tools to ensure a high degree of working safety and quality of repair. The equipment we have approved has undergone careful research and testing, and must be used and maintained with care.

Observe basic principles of vehicle repair. The quality of repair depends first and foremost on the care exercised by the person in carrying it out.

c - Safety

To ensure good repair: - use recommended professional products and original parts, - observe the tightening torques, - observe the recommendations for parts that should always be replaced after removal, refitting or replacement operations, - clean and degrease the sections to be bonded, to ensure they bond correctly.

WARNING

Certain devices and parts must be handled with particular attention to safety and cleanliness and, above all, with due care. The safety symbol used in this manual indicates that special attention must be paid to the procedure or the tightening 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 performing heavy work or raising loads,

To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).

- check that the working area is clean and tidy during the operation, - use personal protection (gloves, goggles, work shoes, masks, skin protection, etc.),

WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.

- always follow the safety instructions associated with the operation to be performed, - do not smoke when working on vehicles,

The design quality of the vehicles demands that nothing be left to chance during repair. Consequently, parts or components must be refitted in their original positions (for example: heat shields, wiring routing, pipe routing). Use professional products and apply them with care. For example, do not apply too much sealant to joint faces, in order to avoid plugging engine oil or coolant pipes.

- 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.).

10A-1

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Precautions for the repair X95 – X38, RENAULT BRAND d - Conclusion The procedures contained in this document merit your attention. Please read them carefully in order to reduce the risk of injury, and avoid using incorrect procedures that could damage the vehicle or make it dangerous in use. Following the recommended procedures will help you to provide a quality of service which will ensure the vehicles achieve the highest levels of performance and reliability. Maintenance and repair operations must be carried out under the proper conditions to ensure that our vehicles run safely and reliably. II - CLEANLINESS Risks relating to contamination Protective bags Use hermetically-resealable plastic bags, using adhesive tape, for example, to store components which will be refitted and reused. Stored parts will therefore be less subject to the risk of contamination. These are single-use bags: after use they must be discarded.

10A-2

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Precautions for the repair

10A

X38, SAMSUNG BRAND I - SAFETY

5 - Safety

1 - General information

Safety and hygiene are the basic criteria for the maintenance of equipment and parts.

All the information provided in this workshop manual is intended for use by professional mechanics. Except for some vehicles, the information provided herein apply to most Renault Samsung Motors vehicles. This manual describes the procedures recommended by professionals regarding fault finding and fault detection.

Information in bold type in the manual indicate the procedures that require special care or indicate tightening torque values.

Note: Do not use flammable products to clean parts. For safety during operations:

Learn the basic principles of automobile maintenance.

- use tools that are most suited to the task (avoid using as much as possible multi-use tools, such as adjustable pliers),

The mechanic must focus his full attention and concentration in order to provide top quality maintenance operations.

- when handling heavy objects, install them correctly on their supports and adopt the correct working position,

To provide top quality maintenance:

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

2 - General recommendations

- use original Renault Samsung Motors parts and the accessories recommended, - check the tightening torques,

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

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

- follow the safety instructions for the maintenance work to be performed,

- clean the contact surfaces and check their condition.

- do not smoke during maintenance operations,

Ensure that no parts are left over or missing after maintenance operations. This point must always be taken into account when refitting spare parts (e.g.: heat-resistant plates, routing of wiring harnesses, pipe routing).

- do not handle dangerous products in a closed area,

Make sure that products such as sealants are used appropriately. Do not spread too much sealant on the contact surface.

- no chemicals must be swallowed or come into contact with the skin (brake fluid, antifreeze fluid, etc.). To protect the environment: - sort waste, - do not burn waste (tyres, etc.).

3 - Special tools

6 - Conclusion

It is requested that special tools be used to perform maintenance procedures. For top quality maintenance and in order to ensure safety during operations, special tools must be used.

Bodily injury must be limited as much as possible by following the work procedures set out in this manual and by avoiding procedures that might damage the vehicle or create dangerous situations.

Special Renault Samsung Motors tools have been designed based on studies and tests. Special care must be taken when using these tools. The tools must also be regularly maintained.

By following the abovementioned procedures, it will be possible to ensure that top quality maintenance, top vehicle performance and reliability are all obtained. II - CLEANLINESS

4 - Reliability The technical specifications of the parts are continuously being improved and developed. It is therefore necessary to regularly check for updated information on new spare parts in the technical bulletins.

1 - Cleaning the engine Cover adjacent parts to protect them from water and cleaning products.

10A-3

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Precautions for the repair X38, SAMSUNG BRAND Make sure that air inlet parts do not come into contact with water. 2 - Cleaning engine parts

WARNING When cleaning the parts, never tap a mounting component such as the contact surface of parts, as this could damage the parts and change their dimensions which could consequently damage the engine.

3 - Repairing threads The threading holes of the engine assembly (excluding the rocker cover) may be repaired using the thread repair kit.

10A-4

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Specifications

10A

X95 – X38, RENAULT BRAND I - ENGINE IDENTIFICATION

Detail of the marking (A):

X95

135515

(1)

the engine type

(2)

the engine approval letter

(3)

the engine suffix

(4)

the engine production number

Detail of the marking (B): 139836

140017

139835

Engine identification is located: - on the cylinder block, by an engraving (A) , between the starter and the flywheel, - on the timing cover, by a label (B) .

10A-5

(5)

the engine type

(6)

the engine approval letter

(7)

the engine suffix

(8)

the assembled engine part number

(9)

the fabrication number

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Specifications

10A

X95 – X38, RENAULT BRAND The engine identification is engraved on the cylinder block at (C) .

X38

II - TABLE OF ENGINE SPECIFICATIONS X95

146979

Engine type

H4J

Engine suffix

700

Cubic capacity

Bore

Stroke

Compression

(cc)

(mm)

(mm)

ratio

1397

78

73.1

9.2 / 1

X38

Engine type

Engine suffix

Cubic capacity

Bore

Stroke

Compression

(cc)

(mm)

(mm)

ratio

1598

78

83.6

10.7:1

720 H4M 721

10A-6

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Specifications

10A

X38, SAMSUNG BRAND The engine serial number is engraved at (1) on the cylinder block.

147908

Engine type

H4M

Cubic capacity

Bore

Stroke

Compression

(cc)

(mm)

(mm)

ratio

1598

78

83.6

10.7:1

10A-7

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: New replacement

10A

X95 – X38 - the cylinder head right-hand suspended mounting.

NEW REPLACEMENT ENGINE 1 - Preparing the old engine to be returned to the engine renovation plant

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

a Clean the engine.

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

a Drain:

- the cooling system hose assembly,

- the engine oil (see Engine oil: Draining - Refilling) ,

- the oil pressure sensor, - the pinking sensor,

- the coolant (see Cooling system: Draining - Refilling) .

- the inlet distributor,

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

- the exhaust manifold, - the exhaust manifold heat shield,

- fit the plastic plug welds and covers,

- the exhaust manifold heat shields,

- fit the cardboard cover over the whole assembly.

- the starter, - the alternator,

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

- the water pump pulley,

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

- the air conditioning compressor , - the multifunction support,

- dipstick guide ,

- the clutch,

- the oil filter,

- the flywheel.

- the coolant - oil heat exchanger, - the oil level sensor, - the rocker cover, - the coolant pump,

X95 a Parts to be removed from the old engine and fitted on the new engine:

- the « injector rail - injector » assembly,

- the catalytic converter,

- the spark plugs,

- the turbocharger,

- the timing chain,

- the turbocharger oil pipes, - the turbocharger coolant pipes.

- the timing chain tensioner, - the timing chain guides, - the crankshaft sprocket, - the exhaust camshaft sprocket,

4 - Parts always to be replaced

- the inlet camshaft dephaser,

a Parts always to be replaced:

- the timing cover,

- the inlet distributor seal,

- the crankshaft accessories pulley,

- the exhaust manifold gasket,

- the water chamber,

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

- the thermostat support,

- the exhaust manifold nuts,

- the thermostat,

- the flywheel bolts,

- the lifting rings,

- the oil pressure sensor seal,

- the camshaft position sensor,

- the accessories belt,

- the coolant temperature sensor,

- the accessories belt tensioning roller,

10A-8

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: New replacement X95 – X38 - the bolt for the accessories belt tensioning roller, - the cooling circuit hoses (if damaged). X95 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 the new engine.

10A-9

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X95 – X38, RENAULT BRAND Special tooling required X38, CK1 Mot. 1431

Flywheel locking tool.

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

Equipment required component support

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

Tightening torquesm bolts on the coolant pump pulley

8 N.m

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

REMOVAL II - UPPER ENGINE REMOVAL OPERATION I - ENGINE REPAIR PREPARATION OPERATION a IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: - (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 the engine oil sump. Damage to the sump will irreparably damage the engine by:

139484

- blocking the strainer,

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

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

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

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

X38 a Remove the inlet distributor (see Inlet distributor: Removal - Refitting) .

X95 – X38, JH3 a Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

a Remove: - the coils (see Coils: Removal - Refitting) , - the rocker cover (see Rocker cover: Removal Refitting) .

10A-10

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X95 – X38, RENAULT BRAND

141016

a Turn the crankshaft clockwise until the mark (2) (not painted) on the crankshaft accessories pulley is aligned with the mark (3) on the timing cover.

141008

a Fit the flywheel locking tool (Mot. 1431) (6) . a Remove: - the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting) , - the crankshaft seal on the timing side (see Crankshaft 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 - Refitting) . X95 a Remove: - the catalytic converter (see Catalytic converter: Removal - Refitting) , - the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting) .

141017

a Check that the marks (4) of the camshaft dephaser and the marks (5) of the exhaust camshaft sprocket are in the same position as shown in the illustration.

a Remove:

a If they are not, turn the crankshaft an additional turn until the unpainted mark on the crankshaft accessories pulley is aligned with the mark on the timing cover.

10A-11

- the spark plugs (see Plugs: Removal - Refitting) , - the camshaft dephaser solenoid valve (see Camshaft dephaser solenoid valve: Removal - Refitting) , - the cylinder head (see Cylinder head: Removal Refitting) .

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X95 – X38, RENAULT BRAND III - UPPER ENGINE REPAIR OPERATION

IV - LOWER ENGINE REMOVAL OPERATION a Remove:

X95

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

a Remove:

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

- the turbocharger (see Turbocharger: Removal Refitting) ,

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

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

- the flywheel (see Flywheel: Removal - Refitting) , - the crankshaft seal on the gearbox side (see Crankshaft seal, gearbox end: Removal - Refitting) ,

a Remove: - the exhaust manifold (see Exhaust manifold: Removal - Refitting) ,

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

- the valves (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting, page 10A32) ,

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

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

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

- the water chamber (see Water chamber: Removal - Refitting) ,

- the crankshaft (see 10A, Engine and cylinder block assembly, Crankshaft: Removal - Refitting, page 10A-120) .

- the camshaft position sensor (see Camshaft position sensor: Removal - Refitting) , - the « injector rail - injector » assembly (see Injector rail - Injectors: Removal - Refitting) . a Strip the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Stripping Rebuilding, page 10A-57) . a Clean the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Cleaning, page 10A-64) .

X95 a Remove the piston base cooling jets (see 10A, Engine and cylinder block assembly, Piston base cooling jet: Removal - Refitting, page 10A-172) .

a Remove: - the alternator (see Alternator: Removal - Refitting) ,

a Check: - the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Check, page 10A-67) , - the camshafts (see 10A, Engine and cylinder block assembly, Camshaft: Check, page 10A25) , - the valves and the valve springs (see 10A, Engine and cylinder block assembly, Valve: Check, page 10A-46) .

- the multifunction support (see Multifunction support: Removal - Refitting) , - the coolant pump (see Coolant pump: Removal Refitting) , - the thermostat (see Thermostat: Removal - Refitting) , - the pinking sensor (see Pinking sensor: Removal - Refitting) , - the oil pressure sensor (see Oil pressure sensor: Removal - Refitting) ,

Note:

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

Replace the parts whose values are outside the permitted tolerance values.

10A-12

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X95 – X38, RENAULT BRAND V - LOWER ENGINE REPAIR OPERATION

- the oil pump chain,

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

- the oil pump chain tensioning roller. X95

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

a Part always to be replaced: - the accessories belt fixed roller, - the turbocharger nuts,

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

- the turbocharger studs (if removed), - the catalytic converter nuts.

- the crankshaft (see 10A, Engine and cylinder block assembly, Crankshaft: Check, page 10A134) . a Note:

WARNING

Replace the parts whose values are outside the permitted tolerance values.

The gasket faces must be clean, dry and free from grease (avoid finger marks)

REFITTING

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).

I - REFITTING PREPARATION OPERATION a Parts always to be replaced: - all seals, - the cooling circuit hoses if they are damaged,

Note:

- the accessories belt,

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

- 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,

a When replacing the crankshaft or the crankshaft bearing shells, it is essential to determine the thickness class for each bearing shell to be refitted on each crankshaft bearing to ensure that the journal clearance is within the tolerances (see 10A, Engine and cylinder block assembly, Cylinder block: Check, page 10A-168) and (see 10A, Engine and cylinder block assembly, Crankshaft: Check, page 10A-134) .

- the exhaust manifold nuts, - the exhaust manifold studs (if removed),

Note:

- the oil filter,

Any clearances of the crankshaft crankpin outside the tolerances can cause engine damage.

- the flywheel bolts, - the con rod cap bolts, - the crankshaft bearing cap bolts, - the crankshaft bearing shells, - the con rod bearing shells,

a When replacing the crankshaft, the « piston - con rod » assembly or the big end bearing shells, always determine the bearing shell thickness class to refit to each big end to ensure that the crankpin clearance is within the tolerances (see 10A, Engine and cylinder block assembly, Crankshaft: Check, page

10A-13

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X95 – X38, RENAULT BRAND 10A-134) and (see 1 0 A , Engine and cylinder block assembly, Piston - Con rod: Check, page 10A-105) .

X95 a Refit the piston base cooling jets (see 10A, Engine and cylinder block assembly, Piston base cooling jet: Removal - Refitting, page 10A-172) .

If replacing the cylinder block base plate

X95 a Remove the coolant-oil heat exchanger from the old cylinder block base plate (see Oil-coolant heat exchanger: Removal - Refitting) .

a Refit: - the crankshaft (see 10A, Engine and cylinder block assembly, Crankshaft: Removal - Refitting, page 10A-120) , - the « piston - con rod » assembly (see 10A, Engine and cylinder block assembly, Piston - Con rod: Removal - Refitting, page 10A-88) ,

a Remove the oil level sensor from the old cylinder block base plate (see Oil level sensor: Removal Refitting) .

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

a Refit the oil level sensor on the new cylinder block base plate (see Oil level sensor: Removal - Refitting) .

- the sump (see Lower cover: Removal - Refitting) , - the crankshaft seal on the gearbox side (see Crankshaft seal, gearbox end: Removal - Refitting) ,

X95 a Refit the coolant-oil heat exchanger on the new cylinder block base plate (see Oil-coolant heat exchanger: Removal - Refitting) .

- the flywheel (see Flywheel: Removal - Refitting) , - 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 - Refitting) (62A, Air conditioning).

II - LOWER ENGINE REFITTING OPERATION a Refit: - the cylinder block (see 10A, Engine and cylinder block assembly, Cylinder block: Removal - Refitting, page 10A-153) , - the oil pressure sensor (see Oil pressure sensor: Removal - Refitting) ,

III - UPPER ENGINE REFITTING OPERATION a Rebuild the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Stripping - Rebuilding, page 10A-57) . a Refit:

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

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

- the thermostat (see Thermostat: Removal - Refitting) ,

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

- the coolant pump (see Coolant pump: Removal Refitting) , - the multifunction support (see Multifunction support: Removal - Refitting) , - the alternator (see Alternator: Removal - Refitting) .

10A-14

- the water chamber (see Water chamber: 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 10A32) ,

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X95 – X38, RENAULT BRAND - the exhaust manifold (see Exhaust manifold: Removal - Refitting) .

X38 a Refit the inlet distributor (see Inlet distributor: Removal - Refitting) .

X95 a Refit: - the inlet distributor (see Inlet distributor: Removal - Refitting) , - the turbocharger (see Turbocharger: Removal Refitting) .

a Refit: - the cylinder head (see Cylinder head: Removal Refitting) , - the camshaft dephaser solenoid valve (see Camshaft dephaser solenoid valve: Removal - Refitting) ,

a Refit the accessories belt (see Accessories belt: Removal - Refitting) . a Torque tighten the bolts on the coolant pump pulley (8 N.m) locking the coolant pump pulley using a screwdriver. IV - FINAL OPERATION a Fill up the engine oil (see Engine oil: Draining - Refilling) . a Remove the engine from component support (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-19) .

- the spark plugs (see Plugs: Removal - Refitting) . X95 – X38, JH3 X95 a Refit: - the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting) ,

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

- the catalytic converter (see Catalytic converter: Removal - Refitting) . X38, CK1 a Connect the automatic gearbox to the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic gearbox).

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

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

- the timing chain (see Timing chain: Removal Refitting) , - the crankshaft seal on the timing side (see Crankshaft seal on timing end: Removal - Refitting) . a Position the (Mot. 1431). a Refit the crankshaft accessories pulley (see Crankshaft 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) .

10A-15

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X38, SAMSUNG BRAND

REMOVAL

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

I - PREPARING TO REMOVE THE ENGINE

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

a

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

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 10A, Engine and cylinder block assembly, Engine: Precautions for the repair, page 10A-1) .

- the valves (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting, page 10A32) , - the valve stem seals (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting, page 10A-32) .

WARNING III - CYLINDER HEAD MAINTENANCE

Wear protective gloves during the operations. a Drain the engine oil (see Engine oil: Draining - Refilling) . a Remove the engine and transmission assembly (see Engine - gearbox assembly: Removal - Refitting) .

a Clean the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Cleaning, page 10A-64) . a Service the following parts: - the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Check, page 10A-67) ,

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

- the camshaft (see 10A, Engine and cylinder block assembly, Camshaft: Check, page 10A25) ,

II - CYLINDER HEAD REMOVAL a Remove or disconnect the following parts:

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

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

Note:

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

All parts that have exceeded their wear limit must be replaced.

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

IV - REMOVING THE CYLINDER BLOCK

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

a Remove or disconnect the following parts:

- the injector rail - injectors assembly (see Injector rail - Injectors: Removal - Refitting) , - the rocker cover (see Rocker cover: Removal Refitting) , - the timing cover (see Timing chain: Removal Refitting) , - the front oil seal (see Timing chain: Removal Refitting) , - the timing chain (see Timing chain: Removal Refitting) , - the oil pump chain (see Timing chain: Removal Refitting) ,

10A-16

- the rear oil seal (see 10A, Engine and cylinder block assembly, Cylinder block base plate: Removal - Refitting, page 10A-73) , - the lower plate of the cylinder block (see 10A, Engine and cylinder block assembly, Cylinder block base plate: Removal - Refitting, page 10A73) , - the piston - con rod (see 10A, Engine and cylinder block assembly, Piston - Con rod: Removal - Refitting, page 10A-88) , - the crankshaft (see 10A, Engine and cylinder block assembly, Crankshaft: Removal - Refitting, page 10A-120) ,

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair

10A

X38, SAMSUNG BRAND - the coolant pump seal,

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

- the exhaust manifold seal, - the inlet manifold seal A, B,

V - CYLINDER BLOCK MAINTENANCE

- the cylinder head gasket,

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

- the rocker cover seal,

a Service the following parts:

- the drain plug washer,

- the oil filter,

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

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

- the camshaft sensor O-ring, - the valve stem seal,

- the crankshaft (see 10A, Engine and cylinder block assembly, Crankshaft: Check, page 10A134) , - the piston - con rod (see 10A, Engine and cylinder block assembly, Piston - Con rod: Check, page 10A-105) .

- the cylinder head mounting bolts. II - REFITTING THE CYLINDER BLOCK a Refit the following parts: - the cylinder block (see 10A, Engine and cylinder block assembly, Cylinder block: Removal - Refitting, page 10A-153) ,

Note: All parts that have exceeded their wear limit must be replaced.

- the crankshaft (see 10A, Engine and cylinder block assembly, Crankshaft: Removal - Refitting, page 10A-120) ,

REFITTING

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

I - PREPARATION FOR REFITTING

- the lower plate of the cylinder block (see 10A, Engine and cylinder block assembly, Cylinder block base plate: Removal - Refitting, page 10A73) ,

a Replace the following parts with new parts: - the accessories belt, - the loose pulley,

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

- the oil pump chain, - the oil pump chain tensioner, - the timing chain, - the timing chain tensioning roller, - the guide shoe of the timing chain,

III - REFITTING OF THE CYLINDER HEAD a Refit the following parts: - the valve stem seals (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting, page 10A-32) ,

- the timing chain tensioner pad, - the front oil seal,

- the valves (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting, page 10A32) ,

- the crankshaft main bearing cap mounting bolt, - the con rod cap mounting bolt, - the front oil seal,

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

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

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

- the crankshaft position sensor O-ring, - the coolant inlet rubber washer,

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

- the dipstick tube O-ring,

10A-17

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine: Repair X38, SAMSUNG BRAND - the oil pump chain (see Timing chain: Removal Refitting) , - the timing chain (see Timing chain: Removal Refitting) , - the front oil seal (see Timing chain: Removal Refitting) , - the timing cover (see Timing chain: Removal Refitting) , - the rocker cover (see Rocker cover: Removal Refitting) , - the injector rail - injectors assembly (see Injector rail - Injectors: Removal - Refitting) , - the injector rail protector (see Rocker cover: Removal - Refitting) , - the ignition coils (see Coils: Removal - Refitting) , - the exhaust manifold (see Exhaust manifold: Removal - Refitting) , - the inlet manifold (see Inlet distributor: Removal - 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 (see Engine - gearbox assembly: Removal - Refitting) . a Refill the engine oil (see Engine oil: Draining - Refilling) .

10A-18

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine support equipment: Use

10A

X95 – X38, RENAULT BRAND

Equipment required

X95 – X38, JH3 a Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

component support workshop hoist load balancer I - PREPARATION OPERATION FOR FITTING THE ENGINE ON THE COMPONENT SUPPORT

X38, CK1 a Disconnect the automatic gearbox from the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic transmission).

X95

117508

a IMPORTANT To work in complete safety, it is essential to use a component stand.

WARNING

141090

a Fit the studs (1) of component support on the cylinder block on the flywheel end.

It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. a Remove the « engine and gearbox » assembly (see Engine - gearbox assembly: Removal - Refitting) .

10A-19

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine support equipment: Use

10A

X95 – X38, RENAULT BRAND II - FITTING THE ENGINE ON THE COMPONENT SUPPORT

X38

135620 146980

a Fit the studs (1) of component support on the cylinder block on the flywheel end.

a Fit the "engine - studs - support bars" assembly on the component support using a workshop hoist and a load balancer.

141088

a Tighten the support bar bolts (4) on the component support. 141089

a Remove the load balancer.

a Fit the support bars (2) on the studs of component support. a Fit the support bar nuts (3) , without tightening them.

10A-20

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine support equipment: Use X95 – X38, RENAULT BRAND III - OPERATION FOR REMOVING THE ENGINE FROM COMPONENT SUPPORT a Support the "engine - studs - support bars" assembly on the component support using a workshop hoist and a load balancer. a Remove the support bar bolts on the component support. a Separate the "engine - studs - support bars" assembly from the component support using a workshop hoist and a load balancer. IV - FINAL OPERATION a Remove: - the support bar nuts, - the support bars, - the studs. X95 – X38, JH3 a Connect the manual gearbox to the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

X38, CK1 a Connect the automatic gearbox to the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic gearbox).

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

10A-21

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine support equipment: Use

10A

X38, SAMSUNG BRAND

Equipment required

CK1 a Disconnect the automatic gearbox from the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic transmission).

engine stand workshop hoist

Tightening torquesm mounting bolts of the body of the special tool (RSM 9000)

196 N.m

mounting bolt of the arms on the body of the special tool (RSM 9000)

160 N.m

mounting bolt of the arms on the tubes of the special tool (RSM 9000)

95 N.m

mounting nuts of the arms on the tubes of the special tool (RSM 9000)

95 N.m

I - PREPARATIONS BEFORE THE OPERATION a WARNING

147909

a

For the safety of the operation, use the appropriate engine stand for the engine.

WARNING

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

When using the engine stand, it is advisable to install at least 4 sets of engine mounting equipment in order to guarantee safety.

Wear protective gloves during the operation. a Remove the « engine and gearbox » assembly (see Engine - gearbox assembly: Removal - Refitting) .

a Pretighten the following parts: - mounting nuts (1) of the tubes (3) and arm (4) of the special tool (RSM 9000), - mounting bolt (2) of the tubes (3) and arm (4) of the special tool (RSM 9000).

JH3 a Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

II - POSITIONING THE ENGINE a Using the workshop hoist, place the engine assembly in the centre of the engine stand.

10A-22

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine support equipment: Use

10A

X38, SAMSUNG BRAND 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 torques defined: - mounting bolt of the arms on the body of the special tool (RSM 9000) (160 N.m), - mounting bolt of the arms on the tubes of the special tool (RSM 9000) (95 N.m), - mounting nuts of the arms on the tubes of the special tool (RSM 9000) (95 N.m).

147910

147912

a WARNING For your safety, gently remove the workshop hoist from the engine stand. a Remove the workshop hoist (10) . 147911

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

III - REMOVING FROM THE ENGINE

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

a Connect the workshop hoist.

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

a Remove the following parts:

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

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

a Pretighten the bolts of the following parts on the engine stand (5) :

- mounting bolt on the tubes and arm of the special tool (RSM 9000), - tube of the special tool (RSM 9000).

- arm (7) of the special tool (RSM 9000), - mounting bolt of the arms (9) of the special tool (RSM 9000).

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

10A-23

ENGINE AND CYLINDER BLOCK ASSEMBLY Engine support equipment: Use X38, SAMSUNG BRAND a Remove the following parts: - mounting bolt on the body of the special tool (RSM 9000), - arm of the special tool (RSM 9000), - mounting bolt of the body of the special tool (RSM 9000), - body of the special tool (RSM 9000). IV - FINAL OPERATIONS JH3 a Refit the manual gearbox to the engine (see Manual gearbox: Removal - Refitting) .

CK1 a Refit the automatic gearbox to the engine (see Automatic gearbox: Removal - Refitting) .

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

10A-24

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check

10A

X95 – X38, RENAULT BRAND

Equipment required

X38, CK1

component support

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

dial gauge support Dial gauge external micrometer radial play measuring tape

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

I - PREPARATION OPERATION FOR CHECK Remove the camshafts (see Camshaft: Removal Refitting) . IMPORTANT Before any checks: To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair:

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

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

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

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

II - CAMSHAFT CHECKING OPERATION

1 - Identification of the camshafts

WARNING It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. Remove the « engine and gearbox » assembly (see Engine - gearbox assembly: Removal - Refitting) . X95 – X38, JH3 Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

115892

(1)

Exhaust camshaft

(2)

Inlet camshaft

(3)

Camshaft position sensor target

(4)

Camshaft dephaser supply openings

There are 5 camshaft bearings.

10A-25

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check

10A

X95 – X38, RENAULT BRAND 3 - Checking the diameter of the camshaft journals

2 - Checking the concentricity of the camshaft journals

102772

X95 Use a external micrometer to measure the diameter (X1) of each camshaft journal which should be between: 103148

- bearing No.1: 27.04 and 27.06 mm, - bearings No.2, 3, 4 and 5: 24.95 and 24.97 mm.

Place the camshaft on two slightly oiled v-blocks (5) . Fit: - the dial gauge support (6) ,

X38 - the Dial gauge (7) . Fit the sensor of the Dial gauge against the centre of the camshaft journal mating face.

Use a external micrometer to measure the diameter (X1) of each camshaft journal which should be between: - bearing No.1: 27.94 and 27.96 mm,

Calibrate the Dial gauge to zero.

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

X95 Rotate the camshaft one turn while avoiding the lubrication holes to check the journal concentricity, which should be a maximum of 0.05 mm.

X38 Rotate the camshaft one turn while avoiding the lubrication holes to check the journal concentricity, which should be a maximum of 0.02 mm.

10A-26

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check

10A

X95 – X38, RENAULT BRAND 4 - Checking the height of the cam lobes

- exhaust cam: 40.18 and 40.37 mm.

5 - Checking the camshaft radial play Remove any oil that may be on the camshaft bearings and on the camshaft bearing caps.

103149 141041

Cut 10 pieces of radial play measuring tape the width of the camshaft journal mating face. Place each piece of wire in line with the camshaft on the camshaft journal mating faces on the cylinder head at (8) and (9) .

Note: Do not allow the camshaft to rotate during the operation in order to avoid distorting the measurement. Refit (see Camshaft: Removal - Refitting) : 102771

Place the camshaft on two slightly oiled v-blocks. X95 Use a external micrometer to measure the height of the cams (H) which should be between:

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

- inlet cam: 39.58 and 39.77 mm,

- the camshaft bearing caps,

- exhaust cam: 40.92 and 42 mm.

- the camshafts.

X38 Use a external micrometer to measure the height of the cams (H) which should be between: - inlet cam: 41.71 and 41.90 mm,

10A-27

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check

10A

X95 – X38, RENAULT BRAND - the Dial gauge (12) . Position the dial gauge sensor against the end of the camshaft. Move the camshaft towards the dial gauge until it hits a stop. Calibrate the dial gauge to zero. Move the camshaft towards the side opposite the dial gauge until it hits the other stop. Check the longitudinal play, which should be between 0.08 and 0.16 mm. III - FINAL OPERATION Refit the camshafts (see Camshaft: Removal - Refitting) . Remove the engine from component support (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-19) . 102807

Measure the flatness of the radial play measuring tape using the gauge (10) printed on the wrapping paper of the measuring tape, which should be between: - bearing No.1: 0.04 to 0.08 mm,

X95 – X38, JH3 Connect the manual gearbox to the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

- bearings No.2, 3, 4 and 5: 0.03 and 0.07 mm. 6 - Checking the camshaft longitudinal play Refit the camshafts on the cylinder head (see Camshaft: Removal - Refitting) .

X38, CK1 Connect the automatic gearbox to the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic gearbox).

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

139706

Fit: - the dial gauge support (11) ,

10A-28

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check

10A

X38, SAMSUNG BRAND II - CHECKING THE CAMSHAFT Equipment required 1 - Camshaft end float

Dial gauge external micrometer I - PREPARATION FOR THE CHECK

Note: Before performing the repair operations, check the directives concerning safety, hygiene and the procedures (see 10A, Engine and cylinder block assembly , Engine: Precautions for the repair, page 10A-1) .

WARNING Wear protective gloves during the operations. Remove the engine and transmission assembly (see Engine - gearbox assembly: Removal - Refitting) . 147956

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

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

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

The normal value of the end float of the camshaft is between 0.075 and 0.153 mm.

Before performing the check: - clean the camshaft, - Check for possible scratches or damage caused by an impact on the surface of the camshaft.

147957

If the end float of the camshaft is not within the normal values, check the following lengths: - A: camshaft support bearing no.1 4.000 - 4.030 mm.

10A-29

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check

10A

X38, SAMSUNG BRAND 3 - Camshaft eccentricity Note: The position of camshaft journal no. 1 is located on the side of the timing chain. 2 - Operating play of the camshaft journals Perfectly clean the journals and the camshaft support.

147961

The camshaft eccentricity must not exceed 0.02 mm. 4 - Normal values for the camshaft bearings

Bearing no.

Internal diameter of the camshaft support (mm)

Camshaft journal diameter (mm)

No. 1

28.000 - 28.021

27.935 - 27.955

25.000 - 25.021

24.950 - 24.970

147960

(A)

Measuring tape

(B)

Measurement sheet of operating clearances

No. 2 No. 3

Note: No. 4

For the accuracy of the measurements, do not rotate the camshaft during measurement.

No. 5

The operating clearances of the camshaft journals must 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.

10A-30

ENGINE AND CYLINDER BLOCK ASSEMBLY Camshaft: Check X38, SAMSUNG BRAND 5 - Cam height

147962

Measure the cam height using the external micrometer.

Cam height

Inlet (mm)

Exhaust (mm)

41.705 - 41.895

40.175 - 40.365

III - FINAL OPERATIONS Refit the camshaft (see Camshaft: Removal - Refitting) . Remove the engine assembly from the engine stand (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-19) . Refit the engine and transmission assembly (see Engine - gearbox assembly: Removal - Refitting) .

10A-31

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND

REMOVAL

Special tooling required Mot. 1431

Flywheel locking tool.

I - REMOVAL PREPARATION OPERATION

Mot. 1573

Cylinder head support

a

Mot. 1502

Tool for removing the pins from valve stems.

Mot. 1849

Slide hammer valve lifter.

Mot. 1511

Tool for fitting valve stem seals.

Mot. 1335

Pliers for removing valve stem seals.

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: - (see 10A, Engine and cylinder block assembly, Engine: Precautions for the repair, page 10A-1) , - (see V ehicle: Precautions for the repair) (01D, Mechanical introduction).

Equipment required component support indelible pencil

WARNING

tweezers

It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: Tightening torquesm

bolts on the coolant pump pulley

- blocking the strainer, 8 N.m

- raising the oil level above maximum, with a risk of engine racing. a Remove the « engine and gearbox » assembly (see Engine - gearbox assembly: Removal - Refitting) . X95 – X38, JH3 a Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

X38, CK1 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 - Refilling) .

10A-32

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND

139484

141016

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

a Turn the crankshaft clockwise until the mark (2) (not painted) on the crankshaft accessories pulley is aligned with the mark (3) on the timing cover.

a Remove the accessories belt (see Accessories belt: Removal - Refitting) . X38 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) .

141017

a Check that the marks (4) of the camshaft dephaser and the marks (5) of the exhaust camshaft sprocket are in the same position as shown in the illustration. a If they are not, turn the crankshaft an additional turn until the unpainted crankshaft accessories pulley mark and the timing cover mark are aligned.

10A-33

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND

139838

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

X95

141008

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

a Remove:

a Remove:

- the turbocharger (see Turbocharger: Removal Refitting) ,

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

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

- the crankshaft seal on the timing side (see Crankshaft seal on timing end: Removal - Refitting) , - the timing chain (see Timing chain: Removal Refitting) , - the camshaft dephaser (see Camshaft dephaser: Removal - Refitting) ,

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

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

II - VALVE REMOVAL OPERATION

X95 a Remove: - the catalytic converter (see Catalytic converter: Removal - Refitting) , - the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting) .

a Remove: - the spark plugs (see Plugs: Removal - Refitting) , - the camshaft dephaser solenoid valve (see Camshaft dephaser solenoid valve: Removal - Refitting) , - the cylinder head (see Cylinder head: Removal Refitting) .

139705

a Mark the position of the valve tappets using a indelible pencil. a Remove the valve tappets.

10A-34

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND

116011

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

15738

a Note: Before removing the valve stem seals, always take the dimension (H) of the old seals on the inlet side and then on the exhaust side using the tool (Mot. 1511).

X38 a Normal value (H) : 13.2 -13.8 mm.

116012

a Remove: - the collets (8) using a tweezers (9) , - the (Mot. 1502) or (Mot. 1849), - the valve spring cups (10) , - the valve springs.

10A-35

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND

15738-1

15738-3

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

a Note: The internal diameter of the pushrod must be identical to that of the valve. In addition, the bottom of the pushrod must cover the metal upper section of the valve stem seal.

a Lock the sleeve using tumblewheel (14) . a Remove the « pushrod - guide tube - sleeve » assembly, taking care not to loosen the wheel.

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

a Repeat the operation for the other valves.

116002 15738-2

a Remove:

a Fit the guide tube (12) of the tool (Mot. 1511) over the pushrod until the guide tube comes into contact with the cylinder head.

10A-36

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

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND - the lower washers of the valve spring.

REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Valve stem seal a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean: - the valves, - the valve springs, - the valve spring cups, - the valve collets, - the valve guides. II - VALVE REFITTING OPERATION 15739-1

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

15739

a Refit: - the lower valve spring washer, - the valve.

15739-2

a Keep the valve pressed against its seat. a Fit a new valve stem seal (not lubricated) on the protector. a Push the valve stem seal until it protrudes from the protector.

10A-37

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND

15739-3

a Remove the fitting protector.

15739-4

a Fit the « pushrod - guide tube - sleeve » assembly which was previously adjusted on the valve stem seal. a Push the valve stem seal down by tapping the sleeve of the tool (Mot. 1511) with the palm of your hand until the guide tube comes into contact with the cylinder 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 respective positions.

10A-38

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X95 – X38, RENAULT BRAND III - FINAL OPERATION X95 X95

a Fit the (Mot. 1431). a Refit the crankshaft accessories pulley (see Crankshaft accessories pulley: Removal - Refitting) .

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

a Remove the tool (Mot. 1431).

- the turbocharger (see Turbocharger: Removal Refitting) . a Refit: - the rocker cover (see Rocker cover: Removal Refitting) , 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:

- the coils (see Coils: Removal - Refitting) . X38 a Refit the inlet distributor (see Inlet distributor: Removal - Refitting) .

- the cylinder head (see Cylinder head: Removal Refitting) , - the camshaft dephaser solenoid valve (see Camshaft dephaser solenoid valve: Removal - Refitting) , - the spark plugs (see Plugs: Removal - Refitting) .

a Refit the accessories belt (see Accessories belt: Removal - Refitting) . a Torque tighten the bolts on the coolant pump pulley (8 N.m) locking the coolant pump pulley using a screwdriver. a Fill up the engine oil (see Engine oil: Draining - Refilling) .

X95 a Refit: - the turbocharger oil pipes (see Turbocharger oil pipe: Removal - Refitting) , - the catalytic converter (see Catalytic converter: Removal - Refitting) .

a Remove the engine from component support (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-19) . X95 – X38, JH3 a Connect the manual gearbox to the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

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

X38, CK1 a Connect the automatic gearbox to the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic gearbox).

- the timing chain (see Timing chain: Removal Refitting) , - the crankshaft seal on the timing side (see Crankshaft seal on timing end: Removal - Refitting) .

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

10A-39

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X38, SAMSUNG BRAND

REMOVAL

- camshaft (see Camshaft: Removal - Refitting) ,

I - REMOVAL PREPARATION OPERATION

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

a

II - REMOVAL OF THE PARTS CONCERNED WARNING Before performing the repair operations, check the directives concerning safety, hygiene and the procedures (see 10A, Engine and cylinder block assembly, Engine: Precautions for the repair, page 10A-1) .

WARNING Wear protective gloves during the operations. a Drain the engine oil (see Engine oil: Draining - Refilling) . a Remove the engine and transmission assembly (see Engine - gearbox assembly: Removal - Refitting) . a Fit the engine assembly on the engine mount (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-19) . a Remove the following parts:

148064

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

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

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

- special tool (RSM 9139) (1) on the mounting hole of the spark plug, - Special tool (RSM 9007) (2) on the upper section of the valve spring cup.

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

Note:

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

If the operation is performed without removing the cylinder head, connect the air pipe adapter so that the valves do not enter the cylinders, then replace the valve stem seals.

- the rocker cover (see Rocker cover: Removal Refitting) , - the accessories belt (see Accessories belt: Removal - Refitting) , - crankshaft seal on the timing side (see Crankshaft seal on timing end: Removal - Refitting) , - timing cover (see Timing chain: Removal - Refitting) , - the timing chain (see Timing chain: Removal Refitting) , - the camshaft sprocket (see Camshaft dephaser: Removal - Refitting) ,

10A-40

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X38, SAMSUNG BRAND

148065

148066

a Compress the valve springs using the special tool (RSM 9139). a Remove the following parts: - valve cotters, - valve spring cups

(A)

cylinder head

(B)

valve guide

(C)

valve stem seal

a Note:

- valve springs.

Before removing the valve stem seal for replacement, measure its current exact height (H) using the special tool (not yet attached) and record the data. The heights of the inlet and exhaust valve stem seals may differ.

Note: Remove the valve cotters using a magnetic strut.

Normal values (H) : 13.2 - 13.8 mm

10A-41

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X38, SAMSUNG BRAND

148067

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

116002

a Remove the following parts: - valve stem seal using the tool (RSM 9189) (6) , - valve.

REFITTING I - PREPARATION FOR REFITTING a Replace the valve stem seal with a new one. a Clean the following parts using a CAN OF STRONG CLEANER (part no.: KC1048901070): - valves, - valve springs, - the valve spring cups, - valve cotters, - valve guides. II - REFITTING THE PARTS CONCERNED 148068

a Insert the sleeve guide (4) of the special tool (RSM 9203) until it is in contact with the cylinder head.

a Grease the internal section of the new valve guides with new engine oil.

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

10A-42

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X38, SAMSUNG BRAND

148070

148071

a Refit the following parts: - valves (1) , - seal insertion guide (2) . Note:

(A)

cylinder head

(B)

valve guide

(C)

valve stem seal

a Note:

Technical specifications of valve seats and guides (see 10A, Engine and cylinder block assembly, Valve: Check, page 10A-46) .

Before removing the valve stem seal for replacement, measure its current exact height (H) using the special tool (not yet attached) and record the data. The heights of the inlet and exhaust valve stem seals may differ. Normal values (H) : 13.2 - 13.8 mm

10A-43

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting

10A

X38, SAMSUNG BRAND a Remove the seal insertion guide. a Refit the following parts: - valve springs, - valve spring cups.

148072

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

148074

a Compress the valve springs using the special tool (RSM 9139). a Refit the valve cotters. III - FINAL OPERATIONS a Refit the following parts: - cylinder head (see Cylinder head: Removal - Refitting) , - camshaft (see Camshaft: Removal - Refitting) , - the camshaft sprocket (see Camshaft dephaser: Removal - Refitting) , - the timing chain (see Timing chain: Removal Refitting) , 148073

a

- timing cover (see Timing chain: Removal - Refitting) , - crankshaft seal on the timing side (see Crankshaft seal on timing end: Removal - Refitting) ,

Note: When fitting the valve stem seal, do not use tools such as a hammer. This could damage the cylinder head and the valve.

- the accessories belt (see Accessories belt: Removal - Refitting) ,

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

10A-44

- the rocker cover (see Rocker cover: Removal Refitting) , - the injector rail - injectors assembly (see Injector rail - Injectors: Removal - Refitting) ,

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Removal - Refitting X38, SAMSUNG BRAND - the injector rail protector (see Rocker cover: Removal - Refitting) , - ignition coils (see Coils: Removal - Refitting) , - the exhaust manifold (see Exhaust manifold: Removal - Refitting) , - the inlet manifold (see Inlet distributor: Removal - Refitting) , - throttle valve (see Throttle valve: 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 (see Engine - gearbox assembly: Removal - Refitting) . a Fill the engine oil (see Engine oil: Draining - Refilling) .

10A-45

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X95 – X38, RENAULT BRAND

Equipment required

X38, CK1

component support

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

compressed air nozzle external micrometer dial gauge support

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

Dial gauge internal micrometer set of feeler gauges

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

I - PREPARATION OPERATION FOR CHECK Before any checks: - clean the parts to be checked with SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) and dry them using a compressed air nozzle,

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair:

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

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

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

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

II - VALVE CHECK OPERATION 1 - Valve identification

WARNING It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irreparably damage the engine by: - blocking the strainer, - raising the oil level above maximum, with a risk of engine racing. Remove the « engine and gearbox » assembly (see Engine - gearbox assembly: Removal - Refitting) .

X95 – X38, JH3 Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

139709

10A-46

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X95 – X38, RENAULT BRAND Measure using a external micrometer : - the diameter (d) of the valve stem,

X95

- the valve length (L) . Inlet valve (A) ±

Diameter (D) of the valve face

29.6 mm

Thickness (e) of the valve head

0.98 mm

0.15

Exhaust valve (B)

X95

25.45 ± 0.15 mm

Inlet valve

0.98 mm

±

0.01

Exhaust valve 5.46 ± mm

Diameter (d) of the valve stem

4.97 mm

0.01

Length (L) of the valve

101.32 mm

102.49 mm

Inlet valve

Exhaust valve

X38 X38 Inlet valve (A)

Exhaust valve (B)

Diameter (D) of the valve face

31.15 ± 0.15 mm

25.45 ± 0.15 mm

Thickness (e) of the valve head

1.00 mm

1.00 mm

±

Diameter (d) of the valve stem

4.97 mm

0.01

Length (L) of the valve

101.65 mm

4.96 ± mm

0.01

102.46 mm

3 - Clearance check between the valve and the valve guide

2 - Checking the valve size

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

102777

139709

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

10A-47

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X95 – X38, RENAULT BRAND Fit:

III - VALVE SPRING CHECK OPERATION

- the dial gauge support, 1 - Valve spring identification

- the Dial gauge on the mounting. Position the dial gauge feeler against the valve head at a 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 dial gauge. Note the value displayed on the dial gauge. Calculate the actual clearance between the valve and the valve guide by dividing the value measured on the dial gauge by two.

104720

X95

102782

Or measure: - the internal diameter (1) of the valve guide using a internal micrometer, - using a external micrometer the diameter (X1) of the valve stem. Calculate the actual clearance = internal diameter of the valve guide (X1) - the diameter of the valve stem (1) . The clearance between the valve and the valve guide must be between: - 0.02 and 0.05 mm for the inlet valve, - 0.03 to 0.06 mm for the exhaust valve.

10A-48

Mark on the outer diameter of the spring Internal diameter (X2)

Inlet spring

Exhaust spring

Yellow

White or Green

17.8 ± 0.2 mm

Wire diameter (X3)

2.7 ± 0.02 mm

2.75 ± mm

Outer diameter (X4)

23.2 ± 0.2 mm

23.3 ± 0.2 mm

Free (X5)

46.73 mm

54.3 mm

length

0.02

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X95 – X38, RENAULT BRAND

X38

X38

Inlet spring

Free (X5)

length

Use a dynamometer to check the wear of the inlet spring and the exhaust spring by measuring the length (X6) , which must be 32.4 mm under a load of 145 ± 9 N.

Exhaust spring

42.26 mm

3 - Checking valve spring perpendicularity 2 - Checking valve spring wear

102774

On the body jig bench, place: - the valve spring (2) , - the bracket (3) . Use a set of feeler gauges to check that the clearance (X7) is less than 1.8 mm. 102776

IV - STAGE FOR CHECKING VALVE CLEARANCE

X95 Use a dynamometer to check spring wear by measuring the spring's length (X6) , which must be: - inlet: 32.4 mm under a load of 145 ± 9 N and 23.96 mm under a load of 257 ± 15 N, - exhaust: 32.4 mm under a load of 201 ± 10 N and 26.10 mm under a load of 285 ± 13 N.

118423

Turn the camshafts until the valve cam to be checked is facing upwards.

10A-49

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X95 – X38, RENAULT BRAND Use a set of feeler gauges to measure the valve clearance which should be (when cold):

Tappet class

Tappet thickness (mm)

- Inlet: 0.26 to 0.34 mm,

322

3.22

- Exhaust: 0.29 to 0.37 mm.

324

3.24

Compare the values noted with the specified values.

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

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

139837

10A-50

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check X95 – X38, RENAULT BRAND Replace the tappets if they are not within the tolerances. - measure the thickness of the tappet using a external micrometer and carry out the operation again for the tappets with valve clearances outside the permitted tolerances, - to select the different thicknesses of tappets, see the SPARE PARTS CATALOGUE for the vehicle concerned. V - FINAL OPERATION Refit the valves (see 10A, Engine and cylinder block assembly, Valve: Removal - Refitting, page 10A-32) . Remove the engine from component support (see 10A, Engine and cylinder block assembly, Engine support equipment: Use, page 10A-19) . X95 – X38, JH3 Connect the manual gearbox to the engine (see Manual gearbox: Removal - Refitting) (21A, Manual gearbox).

X38, CK1 Connect the automatic gearbox to the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic gearbox).

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

10A-51

10A

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X38, SAMSUNG BRAND The exterior diameter of the valve tappet must be between 29.977 and 29.987 mm.

Equipment required internal micrometer

2 - Cylinder head valve tappet housing bore

I - PREPARATION FOR THE CHECK

WARNING Before performing the repair operations, check the directives concerning safety, hygiene and the procedures (see 10A, Engine and cylinder block assembly , Engine: Precautions for the repair, page 10A-1) .

WARNING Wear protective gloves during the operations.

148076

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

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

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

The standard value is between 30.000 and 30.021 mm.

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

3 - Play between the cylinder head valve tappets and their housings

Carry out the following:

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

- Clean the valves and the valve tappets, - Check for possible scratches or damage caused by an impact on the surface of the valve tappets.

4 - Checking the valve tappets

II - CHECKING THE VALVE TAPPETS 1 - Outer diameter of the valve tappets

148075

10A-52

148077

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X38, SAMSUNG BRAND Check the status of the valve tappets (wear or cracks on the coating). 5 - Adjusting valve clearances

148079

Valve tappet thickness (T) (mm)

Identification (S)

3.00

300

3.02

302

3.04

304

The play of the inlet valves must be between 0.304 and 0.416 mm when hot.

3.06

306

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

3.08

308

3.10

310

3.12

312

3.14

314

3.16

316

3.18

318

3.20

320

3.22

322

3.24

324

3.26

326

3.28

328

3.30

330

3.32

332

148078

Turn the camshaft until the valve cam to be checked is facing outwards. The play of the inlet valves must be between 0.260 and 0.340 mm when cold.

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

10A-53

code

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X38, SAMSUNG BRAND Valve tappet thickness (T) (mm)

Identification code (S)

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

7 - Perpendicularity of the valve spring

6 - Valve springs 148081

The limit value of perpendicularity of the spring (H) not to be exceeded is 1,8 mm. The valve spring is to be replaced in the case of the limit value being exceeded.

Note: It is not necessary to dismantle the valve spring seat. 8 - Valves

148080

Inlet valve spring (mm)

Exhaust valve spring (mm)

No load length

42.26

Length with load (136 - 154 NS)

32.40

148082

10A-54

ENGINE AND CYLINDER BLOCK ASSEMBLY Valve: Check

10A

X38, SAMSUNG BRAND

Inlet valve

Exhaust valve

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 the valve (˚)

45° 15°