Workshop Repair Manual

Workshop Repair Manual High Pressure Common Rail Diesel Engine 4 Cast Iron Cylinders

Vehicle

Type

Engine

Clio

XB07 XB08 XB09

K9K 700 and 704 K9K 702 K9K 710

Kangoo

KC07 KC09

K9K 700 K9K 710

77 11 298 922

JULY 2001

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared.

EDITION ANGLAISE All copyrights reserved by Renault.

The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

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

© RENAULT 2001

Contents Page

10 ENGINE AND PERIPHERALS Cleanness & Safety Foreword Engine identification Tightening torques (in daNm or degrees) Technical specifications Standard exchange Essential special tooling Essential equipment Engine overhaul

10-1 10-7 10-8 10-10 10-12 10-31 10-32 10-36 10-37

K9 ALL TYPES

ENGINE 110 Cleanness & Safety

10

CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM Risks relating to contamination The system is very sensitive to contamination. The risks caused by the introduction of contamination are: – damage to or destruction of the high pressure injection system, – seizing or leaking of a component. All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) must be allowed to enter the system during dismantling or into the circuits via the fuel unions. The cleanliness principle must be applied from the filter to the injectors.

WHAT ARE THE SOURCES OF CONTAMINATION? Contamination is caused by: – metal or plastic chips, – paint, – fibres, ● of cardboard, ● brushes, ● paper, ● clothing, ● cloths. – foreign bodies such as hairs, – ambient air, – etc. IMPORTANT: it is forbidden to clean the engine using a high pressure washer because of the risk of damaging connections. Also the moisture may collect in the connectors and cause electrical connection problems.

10-1

K9 ALL TYPES

ENGINE Cleanness & Safety

10

INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM ●

Ensure that you have the plugs for the unions to be opened (bag of plugs sold by the Parts Stores - Part no.: 77 01 206 804). Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be thrown away.

●

Ensure that you have the resealable plastic bags for storing removed parts. There is less risk of parts stored in this way being exposed to contamination. The bags must be used only once, and after use they must be thrown away.

●

Make sure that lint-free cleaning cloths are available (cleaning cloths part number 77 11 211 707). The use of conventional cloth or paper is prohibited. These are not lint-free and may contaminate the fuel circuit of the system. Each lint-free cloth should only be used once.

CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE CARRYING OUT ANY WORK ON THE FUEL SYSTEM ●

For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.

●

For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).

●

Use a brush and thinners to clean the connections to be opened.

●

Blow compressed air over the cleaned parts (tools, bench and parts, connections and injection system zone). Check that no bristles remain adhered.

●

Wash your hands before and during the operation if necessary.

●

When wearing leather protective gloves, cover these with latex gloves.

10-2

K9 ALL TYPES

ENGINE Cleanness & Safety

10

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION ●

As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores (part number 77 01 206 804). They must not, under any circumstances, be reused .

●

Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries contamination.

●

All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once the plugs have been inserted.

●

The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened. In fact, these items are likely to result in impurities entering the system.

●

A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.

10-3

K9 ALL TYPES

ENGINE Cleanness & Safety

INSTRUCTIONS FOR FITTING THE PLUGS (part number 77 01 206 804)

10-4

10

K9 ALL TYPES

ENGINE Cleanness & Safety

10

IMPORTANT ●

The engine must not run with: – diesel containing more than 10% diester, – petrol, even in very small amounts.

●

The system can inject the diesel into the engine at a pressure of up to 1400 bars. Before carrying out any work, check that the injector rail is no longer pressurised and that the fuel temperature is not too high.

●

You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system.

●

Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the diesel temperature sensor and the venturi may be changed on the pump.

●

For safety reasons, it is strictly forbidden to undo a high pressure pipe union when the engine is running.

●

It is forbidden to remove the pressure sensor from the fuel rail because this may cause contamination problems. If the pressure sensor develops a fault, the pressure sensor, fuel rail and the five high pressure pipes must be replaced.

●

It is strictly forbidden to remove any high pressure pump pulley bearing the part no. 070 575. The pulley must be replaced when the high pressure pump is replaced.

●

It is forbidden to repair the wiring connecting the accelerometer and the engine speed sensor. If the wiring should fail, it has to be replaced with new wiring.

●

Applying 12 volts directly to any component in the system is prohibited.

●

Ultrasonic decoking and cleaning are prohibited.

●

Never start the engine if the battery is not connected correctly.

●

Disconnect the injection system computer when carrying out any welding work on the vehicle.

●

All disconnected plastic air inlet hoses must be replaced.

10-5

K9 ALL TYPES

ENGINE Cleanness & Safety

10

A 16 character code called C2I (Individual Injector Corrector) is marked on the injectors. This code, specific to each injector, takes into account any manufacturing variations and specifies the flow injected by each injector. The code of the new injector must be programmed into the computer when injector is replaced. The code of the four injectors must be programmed into the computer when the computer is replaced.

There are two possibilities: ●

If it is possible to communicate with the computer: – Upload the data from the computer into the diagnostic tool, – change the computer, – download the data from the diagnostic tool to the computer. – Using the diagnostic tool, ensure that the computer has not detected faults relating to the injector codes and check that the instrument panel warning light is off.

●

If it is not possible to communicate with the computer: – Change the computer, – read the data on the injectors, – store the data in the computer using the diagnostic tool. – Using the diagnostic tool, ensure that the computer has not detected faults relating to the injector codes and check that the instrument panel warning light is off.

10-6

ENGINE Foreword

K9 ALL TYPES

USING THE MANUAL There are two main sections in this manual: – technical specifications, – overhauling the engine. To repair a component on the vehicle, refer to the vehicle's Workshop Repair Manual and Technical Notes.

UNITS OF MEASUREMENT – All dimensions are expressed in millimetres mm (unless otherwise stated). – Tightening torques are expressed in decanewtonmetres daNm (reminder: 1 daNm = 1.02 kgm). – Pressures are expressed in bar (reminder: 1 bar = 100 000 Pa).

TOLERANCES Tightening torques given without a tolerance must be accurate to within: – in degrees (± 3º). – in daNm (± 10 %).

10-7

10

K9 ALL TYPES

ENGINE Engine identification

Identification is by means of an engraved plate on the cylinder block which carries: – A: engine type, – B: engine type approval letter, – D: Renault code, – E: engine suffix, – F: engine fabrication number, – G: engine assembly plant.

10-8

10

ENGINE Engine identification

K9 ALL TYPES

10

Engine

Suffix

Compression ratio

Bore (mm)

Stroke (mm)

Cubic capacity (cc)

K9K

700 - 702 704 - 710

18.25/1

76

80.5

1461

10-9

K9 ALL TYPES

ENGINE Tightening torques (in daNm or degrees)

UPPER ENGINE Description

Tightening torques * 1 3 + 84° 2.1 1 2.6 2.1 1.5 2.1 2.8 2.8 3.8 1 2.6 0.9 2.3 2.5 2 2.1

Cylinder head Camshaft bearings Camshaft pulley Vacuum pump Cylinder head coolant outlet unit Exhaust manifold Exhaust gas recirculation valve Pre-heater plugs High pressure pump Injector flanges High pressure rail High pressure pipe Cylinder head cover Turbo - manifold mounting Turbo oil return pipe Turbo oil delivery pipe Timing tension wheel Top dead centre cap Cylinder head suspended mounting support * See tightening procedure.

10-10

10

K9 ALL TYPES

ENGINE Tightening torques (in daNm or degrees)

10

BOTTOM ENGINE: Description

Tightening torques 4.5 4.5 2.7 + 47° ± 5° 2 + 45° ± 6° 2 2.2 2.5 * 1.1 5 - 5.5 0.8 2 + 130° ± 15° 2 4 2.1 2.1 2.1

Heat exchanger connector Oil filter unit bracket Crankshaft bearing caps Con rods Pinking sensor Oil level sensor Oil pump Engine oil sump Water pump Flywheel Clutch mechanism Crankshaft accessories pulley Water pump inlet pipe Multifunction support Alternator Power steering pump Air conditioning compressor * See tightening procedure.

10-11

K9 ALL TYPES

ENGINE Specifications

10

CYLINDER HEAD

Thickness of the cylinder head gasket

Cylinder head tightening procedure

The thickness of the cylinder head gasket is measured at (A): – thickness of the gasket when tightened: 0.78 ± 0.3 mm.

REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to achieve correct tightening of the bolts. All bolts must always be changed after removal. Do not oil the new bolts. Tighten all the bolts to a torque of 2.5 daN.m.

Check that all the bolts are correctly tightened to 2.5 daN.m then tighten to an angle, bolt by bolt, of 255° ± 10°. Do not retighten the cylinder head bolts after performing this procedure.

10-12

K9 ALL TYPES

ENGINE Specifications Checking piston protrusion Clean the piston heads in order to eliminate any traces of deposits. Turn the crankshaft one turn in its operating direction to bring piston no.1 close to Top Dead Centre. Fit tool Mot. 251-01 equipped with a gauge on its base plate Mot. 252-01, and find top dead centre of the piston. N.B.: All measurements must be carried out along the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston. WARNING: the gauge follower must not be in the valve clearance.

Measure the piston protrusion. The protrusion must be: 0.192 ± 0.093 mm.

10-13

10

K9 ALL TYPES

ENGINE Specifications

Height of the cylinder head (in mm)

Valves

H = 127

Stem diameter (in mm) Inlet Exhaust

10 5.977 ± 0.008 5.963 ± 0.008

Face angle Inlet and exhaust:

90º

Head diameter (in mm) Inlet Exhaust

33.5 ± 0.12 29 ± 0.12

Valve length (in mm) Inlet Exhaust

100.95 ± 0.22 100.75 ± 0.22

Max. valve lift (in mm) Inlet Exhaust: Gasket face bow (in mm): Cylinder head Cylinder block

8.015 8.595

Protrusion of valves in relation to the cylinder head gasket face (in mm)

0.05 0.03

Inlet and exhaust

NO REGRINDING IS AUTHORISED Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit suited to the cylinder head, plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664 000.

10-14

0 ± 0.07

ENGINE Specifications

K9 ALL TYPES

Valve seats

Valve guides

Seat angle (α)

Length (in mm)

Inlet and exhaust:

Inlet and exhaust:

89º 30'

Mating surface width (X) (in mm) Inlet and exhaust:

10 40.5 ± 0.15

Guide external diameter (in mm) 1.8

Normal:

Seat external diameter (D) (in mm)

11

+0.062 +0.044

+0.12 0

Guide internal diameter (in mm)

Inlet

34.542 ± 0.008

Inlet and exhaust

Exhaust

30.042 ± 0.008

Not machined

5.5

Machined*

6.009 ± 0.009

* This dimension is measured with the guide fitted in the cylinder head. Diameter of the housing in the cylinder head (in mm) Normal

11 ± 0.0075

The inlet and exhaust guides have valve stem seals which must be changed each time the valves are removed.

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

34.459 ± 0.015

Exhaust

29.97 ± 0.015

10-15

K9 ALL TYPES

ENGINE Specifications

10

Angle of the inlet and exhaust guides (in degrees)

It is imperative to fit the valve stem seals using tool Mot. 1511-01 or other suitable equipment.

α = 90

Inlet and exhaust:

19675

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

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

10-16

A = 14 A = 14.2

ENGINE Specifications

K9 ALL TYPES

10

Valve springs

Pistons

The valve springs are tapered (ensure the correct direction of fitting).

Piston external diameter (in mm) 34.975 ± 0.01 Diameter of the housing in the cylinder head (in mm) 35.02 ± 0.02 Checking the valve clearance Place the valves of the cylinder concerned at the "end of exhaust - beginning of inlet" position and check the clearance (X). NOTE: dimension (Y) corresponds to the tappet thickness class (there are 25 classes at the Parts Store).

Free length (in mm)

43.31

Length under a load of (in mm) 23 daN 50 daN

33.80 24.80

Joined spires (in mm):

23.40

Wire diameter (in mm)

3.45

Internal diameter (in mm) Bottom Top

18.80 ± 0.2 14.10 ± 0.2

External diameter (in mm): Bottom Top

25.70 ± 0.2 21 ± 0.2

1

4

3

2

4

1

2

3

Compare the values recorded with the values specified, then replace the tappets which are not within tolerance.

WARNING: THIS ENGINE DOES NOT HAVE ANY VALVE SPRING LOWER WASHERS.

Clearance (in mm), when the engine is cold:

10-17

Inlet

0.20

+ 0.05 -0.075

Exhaust:

0.40

+ 0.05 -0.075

K9 ALL TYPES

ENGINE Specifications

The camshaft must be removed to replace the tappets. Determining dimension "Y".

10

Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance. Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s) . The Parts Stores supplies 25 classes of single-piece tappets.

Set up the following assembly using Mot. 252-01 and Mot. 856-02, then calibrate the gauge.

Camshaft End play (in mm)

0.08 to 0.178

Number of bearings

6

Diameter of the camshaft bearings (in mm) – on the camshaft: ● bearings 1, 2, 3, 4, 5 ● bearing 6

24.989 ± 0.01 27.989 ± 0.01

– on the cylinder head: ● bearings 1, 2, 3, 4, 5 ● bearing 6

25.05 ± 0.01 28.05 ± 0.01

Timing diagram

Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly), then slide in the tappet to be measured.

– – – –

Inlet opening retard * Inlet closing retard Exhaust opening advance Exhaust closing advance **

-9 20 27 -7

* As the inlet opening retard is negative, the valve is opened after Top Dead Centre. ** As the exhaust closing advance is negative, the valve is closed before Top Dead Centre.

10-18

K9 ALL TYPES

ENGINE Specifications

10

PISTONS Fitting the gudgeon pin in the con rod and in the piston. The gudgeon pin is retained by circlips. These engines are fitted with FEDERAL MOGUL pistons. Piston marking

1 2 3 4 5 6 7 8

Cylinder block top dead centre fixed mark Flywheel top dead centre moving mark Flywheel bottom dead centre moving mark Inlet Opening Retard Exhaust Closing Advance Inlet Closing Retard Exhaust Opening Advance Direction of engine rotation (flywheel end).

1 Direction of fitting of the piston Λ towards the flywheel 2 Height between the gudgeon pin and the top of the piston (see table below). 3 Used by the supplier only 4 Used by the supplier only 5 Used by the supplier only 6 Piston axis of symmetry 7 Gudgeon pin hole axis 8 Offset between the hole axis (7) and the piston's axis of symmetry (6) is 0.3 mm

10-19

ENGINE Specifications

K9 ALL TYPES

10

Measuring the piston diameter

Table of gudgeon pin heights * Mark on piston

Pin height (mm)

K

41.667

L

41.709

M

41.751

N

41.793

P

41.835

The piston diameter must be measured at height A = 56 mm. Piston diameter (in mm): 75.94± 0.007

The tolerance on the pin heights is ± 0.02 mm. * The different gudgeon pin heights are exclusively reserved for the engine assembly plant. The Parts Stores will only supply piston classes (height) L, M, N. NOTE: ● if the engine is fitted with a K class piston, an L class piston must be fitted as a replacement. ● if the engine is fitted with a P class piston, an N class piston must be fitted as a replacement,

Gudgeon pin (in mm)

10-20

Length

59.7 - 60.3

External diameter

24.8 - 25.2

Internal diameter:

13.55 - 13.95

ENGINE Specifications

K9 ALL TYPES

Rings

10

Clearance at the gap

Three rings (thickness in mm): Compression

2

-0.01 -0.03

Sealing

2

-0.01 -0.03

Scraper

2.5

-0.01 -0.03

The rings are supplied ready adjusted.

T = Top

10-21

Rings

Clearance at the gap (in mm)

Compression

0.2 to 0.35

Sealing

0.7 to 0.9

Scraper

0.25 to 0.5

K9 ALL TYPES

ENGINE Specifications

10 47.619 ± 0.009

CON RODS

Diameter of the big end (in mm)

The connecting rods are of the "DETACHABLE CAP" type.

Diameter of the small end (in mm) (without ring) 27.25 ± 0.010 (with ring)

25.019 ± 0.006

NOTE: the con rod small end rings cannot be replaced. The maximum weight difference for the con rod, piston and gudgeon pin assemblies for the same engine must be 25 grams. WARNING: do not use a sharp point to mark the big end caps in relation to their con rod, to avoid initiating a crack in the rod. Use a permanent marker pen.

WARNING: ● The bolts must be coated with engine oil under the heads and on the threads when the con rods are fitted in the engine. ● The big end caps are positioned on the con rod by irregularities on the parting line. ● The occurrence of impacts or a foreign body between the body - cap mating surfaces will lead to rapid rupture of the con rod.

Lateral big end play (in mm)

0.205 to 0.467

Diametrical big end play (in mm)

0.035 to 0.045

Centre distance between the big end and small end (in mm) 133.75

10-22

K9 ALL TYPES

ENGINE Specifications

10

CRANKSHAFT

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

Number of main journals Point the "Λ" (1) engraved on the top of the piston downwards and the machined flat (2) of the big end as shown on the diagram below.

5

Crankshaft lateral clearance (in mm): – without wear on lateral shims: 0.045 - 0.252 – with wear on the lateral shims: 0.045 - 0.852 Crankshaft diametrical clearance (in mm): – journals 0.027 - 0.054 – crankpins 0.035 - 0.045 Journal diameter (in mm):

Crankpin diameter (in mm):

48 ± 0.01 43.97 ± 0.01

The lateral shims are located on bearing Nº 3. NO RECTIFICATIONS ARE ALLOWED.

Direction for fitting the circlips on the piston Position the opening (3) of the spring rings opposite the removal and fitting channel (4).

10-23

ENGINE Specifications

K9 ALL TYPES

Working out the class of crankshaft bearing shells (Original fitment) Marking (5) on the crankshaft

Detail of the marking (5): Number of journals 1*

2

3

4

5

B

B

C

C

B

Classes of journal diameters A = D1 B = D2 C = D3

* Flywheel end.

10-24

10

Table of journal diameter classes Journal class mark on the crankshaft

Journal diameter (in mm)

A = D1

47.990 to 47.996

B = D2

47.997 to 48.003

C = D3

48.004 to 48.010

K9 ALL TYPES

ENGINE Specifications

CYLINDER BLOCK

10

Table of cylinder block bearing diameters

The diameters of the bearings (6) of the cylinder block are marked by a hole on the block (7) located above the oil filter.

Hole position (7)

Class reference

Cylinder block bearing diameter (in mm)

A = 33 mm

1 or blue

51.936 - 51.942 exclusive

B = 43 mm

2 or red

51.942 inclusive 51.949

NOTE: the marking zone includes: – A - B gives the diameter class of bearings 1 or 2. Matching the crankshaft bearing shells Journal diameter class

1*

2*

D1

D2

D3

C1

C2

C3

1.949 to 1.955

1.946 to 1.952

1.943 to 1.949

yellow

blue

black

C4

C1

C2

1.953 to 1.959

1.949 to 1.955

1.946 to 1.952

red

yellow

blue

Bearing shell thickness and class

* Cylinder block crankshaft bearing diameter class. NOTE: the parts stores will only supply class C2 (blue).

10-25

K9 ALL TYPES

ENGINE Specifications

BEARING SHELLS

10

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

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

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

The crankshaft bearing shells are fitted on the cylinder block and on the bearings using Mot. 1493-01.

10-26

K9 ALL TYPES

ENGINE Specifications

The bearing shells are fitted using Mot. 1492 and Mot. 1492-03.

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

NOTE: the upper and lower con rod bearing shells are not the same width. Bearing shell width (in mm): – upper – lower

10

20.625 17.625

10-27

K9 ALL TYPES

ENGINE Specifications

10

– the alternator, – the air conditioning compressor or the powerassisted steering pump,

PREPARING THE ENGINE TO BE SET ON THE STAND Before the engine is mounted on the stand Mot. 792-03, the engine's electrical harness must be removed and the engine oil drained. Remove: – the accessories belt,

– the multifunction support,

10-28

K9 ALL TYPES

ENGINE Specifications – the coolant inlet pipe on the water pump.

Place the rods (A), (X), (Y) of Mot. 1378 on the cylinder block so that they fit into the holes (20, 32, 33) on the plate of Mot. 792-03.

10-29

10

ENGINE Specifications

K9 ALL TYPES

10

CONSUMABLES Type Cleaner DECAPJOINT

Quantity Coat

Component concerned

Part no.

Cleaning parts

77 01 421 513

Cleaning gasket faces

77 01 405 952

Crankshaft bearing cap Sealing paste

Bead

Camshaft bearings

-

Crankshaft closure plate Loctite FRENETANCH

1 - 2 drops

RHODORSEAL 5661

Coat

Water pump bolts

77 01 394 070

Top Dead Centre pin plug

77 00 404 452

FITTING THREAD INSERTS

WARNING

Threaded holes on all engine component parts can be repaired by using thread inserts.

WARNING: when working on the fuel supply system, the cleanliness rules described in this document must be strictly complied with. PARTS TO BE REPLACED AFTER REMOVAL: – All gaskets, – Flywheel bolts, – Crankshaft bearing bolts, – Camshaft pulley bolt, – Crankshaft pulley bolts, – Big end cap bolts, – Injector holder copper washers, – High pressure injection pipes, – Pipe plugs, – Belts, – Timing belt tension wheel, – Piston base cooling jets, – Turbo plastic pipes.

10-30

K9 ALL TYPES

ENGINE Standard replacement PREPARING THE USED ENGINE FOR RETURN The engine should be cleaned and drained (oil and water). Leave on the used engine or include in the return box: – the oil filter, – the oil pressure switch, – the water pump, – the high pressure pump, – the rail, – the injectors – the heater plugs, – the dipstick, – the vacuum pump, – the flywheel, – the clutch Remember to remove: – all coolant pipes, – the exhaust manifold, – the alternator, – the power-assisted steering pump, – the air conditioning compressor, – the multifunction support, – the oil level sensor, – the cylinder head coolant outlet unit. The used engine should be secured to the base under the same conditions as the overhauled engine: – plastic plugs and covers fitted, – cardboard cover over the assembly.

10-31

10

K9 ALL TYPES

Illustration

ENGINE Essential special tooling

10

Method part number

Parts stores number

Emb. 880

00 00 088 000

Inertia extractor

Mot. 11

00 01 072 500

Crankshaft bearing extractor

Mot. 251-01

00 00 025 101

Gauge stand used with Mot. 252-01

Mot. 252-01

00 00 025 201

Thrust plate for measuring the protrusion of cylinder liners used with Mot. 251-01.

Mot. 445

00 00 044 500

Oil filter wrench

Mot. 582-01

00 00 058 201

Flywheel immobilising tool.

Mot. 588

00 00 058 800

Liner retaining strap

Mot. 591-02

00 00 059 102

Magnetic flexible shaft for angular wrench for tightening cylinder head.

Mot. 591-04

00 00 059 104

Angular wrench for tightening cylinder head, 1/2" drive with index

10-32

Description

K9 ALL TYPES

Illustration

ENGINE Essential special tooling

10

Method part number

Parts stores number

Mot. 792-03

00 00 079 203

Engine mounting plate for Desvil stand

Mot. 799-01

00 00 079 901

Tool for locking sprockets for toothed timing belt

Mot. 1329

00 00 132 900

Oil filter cap

Mot. 1335

00 00 113 500

Tool for removing valve stem seals

Mot. 1378

00 00 137 800

X and Y engine pins

Mot. 1430

00 00 143 000

Set of top dead centre pins

Mot. 1485-01

00 00 0148 501

Tool for removing the piston bottom cooling jets

Mot. 1489

00 00 148 900

TDC setting pin

Mot. 1492

00 00 149 200

Tool for fitting con rod bearing shells

10-33

Description

K9 ALL TYPES

Illustration

ENGINE Essential special tooling

10

Method part number

Parts stores number

Mot. 1492-03

00 00 149 203

Adaptation kit for fitting the detachable cap con rod bearing shells

Mot. 1493-01

00 00 149 301

Tool for fitting crankshaft bearing shells

Mot. 1494

00 00 149 400

Tool for removing the piston bottom jets

Mot. 1505

00 00 150 500

Belt tension setting tool

Mot. 1511-01

00 00 151 101

Tool for fitting valve stem seals

Mot. 1566

00 00 156 600

Spanner for fitting and removing high pressure pipes

Mot. 1567

00 00 156 700

Pliers for exhaust gas recycling pipe clips

Mot. 1573

00 00 157 300

Cylinder head support

Mot. 1585

00 00 158 500

Tool for fitting crankshaft seals, flywheel end

10-34

Description

K9 ALL TYPES

Illustration

ENGINE Essential special tooling

10

Method part number

Parts stores number

Mot. 1586

00 00 158 600

Tool for fitting crankshaft seals, timing end

Mot. 1632

00 00 163 200

Tool for fitting inlet camshaft seals

Mot. 1638

00 00 163 800

Tool for tensioning accessories belt for engines with a mechanical tension wheel

Rou. 15-01

00 00 001 501

Internal shaft protector ∅ 16 mm

10-35

Description

K9 ALL TYPES

ENGINE Essential equipment

10

Description Ring for fitting pistons in the cylinder block Standard 22 mm long 1/2" (12.7 mm) square drive socket for removing the oil pressure checking gauge

Tooling for testing the cylinder head, including: a tray and the various kits suited for each model of cylinder head (plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664000

Standard 1/2" (12.7 mm) square drive 8/12 /14 female torx socket . Angular tightening tool from: – e.g. STAHL WILLE part number 540 100 03, – e.g. FACOM part number DM360, – e.g. SAM part number 1 SA.

Tool for fitting valve stem seals, e.g. FACOM part number DM6J4.

Angled nippers

Wrench for removing high pressure pipes, e.g. FACOM part number DM 19

Crowfoot adapter for tightening high pressure pipe

Articulated wrench for removing and refitting the heater plugs, e.g. FACOM part number B10R10A.

Wrench for removing crankshaft bearings, e.g. FACOM U49 A D5

Valve spring compressor

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ENGINE Overhauling the engine

Removing the upper engine Remove: – the upper timing cover by unclipping the two tabs (1),

– the lower timing cover by unclipping the three tabs (2) and pulling out the plastic bolt (3),

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– the cylinder head suspended mounting support,

– the TDC pin cap.

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Turn the engine clockwise (timing side) until the crankshaft touches the TDC pin Mot. 1489.

Positioning the belt at the timing point Position the hole (4) of the camshaft pulley almost opposite the hole (5) of the cylinder head.

The pin Mot. 1430 must engage in the camshaft pulley and cylinder head holes. Screw in the TDC pin Mot. 1489.

Remove Mot. 1430 and Mot. 1489.

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Fit flywheel block Mot. 582-01.

Remove the crankshaft accessories pulley.

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Slacken the timing belt by loosening the bolt (6) of the tension wheel, then remove the timing belt.

Remove: – the timing belt tension wheel, – the inner timing cover,

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– the air filter unit, by removing the clamp (1) and the bolt (2),

– the clamp (3), – the oil vapour rebreathing pipe, – the turbo oil supply pipe on the cylinder head side,

10

the turbo oil supply pipe on the turbo side, the nuts (4) of the turbo flange, the bolts (5) of the catalytic converter bracket, the turbo oil return pipe (6).

Unclip the fuel return pipe from the cylinder head cover at (7), then remove the cylinder head cover.

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Remove: – the dipstick guide, – the cylinder head.

10

STRIPPING THE CYLINDER HEAD Place the cylinder head on cylinder head support Mot. 1573.

Pay strict attention to the rules regarding cleanliness (see start of document). WARNING: when undoing the high pressure pipes, it is essential to secure the intermediate union (10) of the injector.

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– the injectors (by marking them in relation to their cylinder), – the pre-heater plugs using an angled spanner, – the ring for lifting the engine (flywheel end),

Remove: – the high pressure pipes using Mot. 1566 or a pipe wrench, fit the protective blanking plugs to the high pressure pump, the rail and the injectors.

– the vacuum pump, – the cylinder head coolant outlet unit, – the high pressure pump, – the rail,

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– – – – –

ENGINE Overhauling the engine

10

– the camshaft bearings,

the ring for lifting the engine (timing end), the exhaust gas recirculation pipe, the inlet pipe, the exhaust gas recirculation valve, the exhaust manifold,

20064-2

– the tappets, noting their position.

– the camshaft pulley using Mot. 799-01,

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Compress the valve springs using the valve lifter.

10

N.B.: before removing the valves and the valve stem seals, it is vital to measure position H of one of the old seals in relation to the cylinder head using Mot. 1511 -01 or other suitable equipment.

Remove: – the keys, – the upper cups, – the springs,

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Fit the guide tube (2) over the pushrod until the guide tube comes into contact with the cylinder head, locking the pushrod with the knurled wheel.

Fit the pushrod (1) of Mot. 1511-01 on the valve stem seal.

NOTE: the internal diameter of the pushrod must be identical to that of the valve. In addition, the bottom of the pushrod must come into contact with the metal upper section of the valve stem seal.

Remove the guide tube assembly plus pushrod, being careful not to loosen the knurled wheel. Remove: – the valves, – the valve guide seals using the Mot. 1335 pliers.

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CLEANING

CHECKING THE GASKET FACE

It is very important not to scratch the gasket faces of any aluminium components.

Check for mating surface bow using a ruler and a set of shims.

Use DECAPJOINT to dissolve any part of the seal which remains stuck to the metal surface.

Maximum bow

0.05 mm

Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit suited to the cylinder head, plug, sealing plate, blanking plate). The approval number of the cylinder head test container is 664000

Apply the product to the part to be cleaned, wait approximately 10 minutes, then remove it using a wooden spatula. Wear gloves whilst carrying out this operation. Do not allow this product to drip on to the paintwork. Great care should be taken when performing this operation, to prevent foreign objects entering the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover) and the oil return pipes. Failure to follow this instruction could lead to the blocking of the oilways, resulting in rapid and serious damage to the engine.

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CHECKING THE CAMSHAFT END PLAY

REBUILDING THE CYLINDER HEAD

NOTE: to attach the magnetic gauge to the cylinder head, clamp Mot. 588 must be used and secured using the oil filler attachment bolt (1) of the cylinder head cover and a spacer with the following dimensions: – external diameter 18 mm, – diameter of bolt (1) hole 9 mm, – height 15 mm.

Fit new valves, grind them gently into their respective seats. Clean all the parts thoroughly, mark them for identification purposes, then carry out the refitting operation. Lubricate the inside of the valve guide. It is imperative to fit the valve stem seals using tool Mot. 1511-01 or other suitable equipment.

Refit: – the camshaft, – the camshaft bearings (positioning them correctly with bearing 1 on the flywheel end), then tighten the bolts to a torque of 1 daN.m.

NOTE: do not lubricate the valve stem seals before fitting them. Fitting new valve stem seals Place the valve in the cylinder head.

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

Remove the camshaft bearings and the camshaft.

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

Place the barrel of tool Mot. 1511-01 over the valve stem (the internal diameter of the barrel must be identical to the diameter of the valve stem).

Keep the valve pressed against its seat. Place the valve stem seal (not lubricated) over the tool barrel.

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Place the guide tube plus pushrod assembly on the valve stem seal.

Fit: – the springs, – the upper cups,

Push the valve stem seal down by tapping the top of the sleeve with the palm of your hand until the guide tube touches the cylinder head.

Compress the springs. Refit the keys using tweezers.

Check the valve protrusion which should be 0 ± 0.07 mm.

Repeat these operations for all the valves.

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Remove: – the camshaft bearings, – the camshaft, – the tappet(s) not within tolerance.

CHECKING AND ADJUSTING THE VALVE CLEARANCE Refit: – the tappets, – the camshaft, – the camshaft bearings, tightening the bolts to a torque of 1 daN.m.

Determining dimension Y. Set up the following assembly using Mot. 252-01 and Mot. 856-02, then calibrate the gauge.

Place the valves of the cylinder concerned at the "end of exhaust - beginning of inlet" position and check the clearance (X). NOTE: dimension (Y) corresponds to the tappet thickness class (there are 25 classes at the Parts Store).

1

4

3

2

4

1

2

3

Compare the values recorded with the values specified, then replace the tappets which are not within tolerance. Clearance, when the engine is cold, in mm: Inlet

0.20

+ 0.05 -0.075

Exhaust:

0.40

+ 0.05 -0.075

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Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly), then slide in the tappet to be measured.

10

Grease the underside of the tappets and the camshaft bearings. Degrease the gasket faces (of the cylinder head and bearings numbers 1 and 6). They should be clean, dry and free from grease (in particular, remove finger marks). Lay four beads (3) of Loctite 5181 with a width of 1 mm on bearings 1 and 6 of the cylinder head.

14678-1S

Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance. Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s) . Check the valve clearance again. Remove: – the camshaft bearings, – the camshaft, – the tappet(s) not within tolerance.

10-53

Refit: – the camshaft, – the camshaft bearings (these are numbered from 1 to 6 and bearing (1) should be positioned on the flywheel end) tightening the bolts to a torque of 1 daN.m.

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The new rubber seal has a flat sealing lip (4) and a protector (5) which also assists in fitting the seal to the engine.

Fitting the camshaft seal This engine can be fitted with two different types of seal. Old and new seals are easily recognised. The old rubber seal is fitted with a spring (2) and has a "V"-shaped sealing lip (3).

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Screw the shouldered rod (6) of Mot. 1632 onto the stud of the camshaft.

For the new seal, put the protector with the seal on the camshaft, taking care not to touch the seal.

Fit the old seal on the camshaft.

Fit the cover (7) and the collar nut (8) of Mot. 1632.

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

10

Remove the nut, the cover, the protector and the shouldered rod. Refit the camshaft pulley, tightening the new nut to a torque of 3 daN.m plus an angle of 84°.

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Refit: – the vacuum pump fitted with a new seal, tightening the bolts to a torque of 2.1 daNm, – the cylinder head coolant outlet unit fitted with a new seal, tightening the bolts to a torque of 1 daNm,

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– the exhaust manifold fitted with new seals, tightening the bolts to a torque of 2.6 daNm in the recommended order, – the exhaust gas recycling valve and the exhaust gas recycling pipe fitted with new clips. Tighten the mounting bolts of the valve to a torque of 2.1 daN.m, then tighten the clips of the pipe using pliers Mot. 1567, – the inlet pipe fitted with a new seal, – the ring for lifting the engine (timing end).

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– the high pressure pump, tightening the bolts to a torque of 2.1 daNm, – the high pressure rail without locking its mounting nuts.

Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the wipes recommended for this purpose, part no. 77 11 211 707) dipped in clean solvent. Dry off using a different new wipe. Replace the compression washer with a new washer. Refit: – the injectors (using the marks made during removal), tightening the mounting flanges to a torque of 2.8 daN.m, – the pre-heater plugs, tightening them to a torque of 1.5 daNm, – the ring for lifting the engine (flywheel end),

Method for refitting the injector pipes WARNING: all removed high pressure pipes must be systematically replaced. Before fitting the new high pressure pipes, lubricate the threads of the nuts with the applicator supplied with the kit of new parts.

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– remove the protective plugs from the rail high pressure rail outlet and the injector high pressure inlet. – insert the olive of the high pressure pipe into the taper of the injector high pressure inlet. – insert the olive of the high pressure pipe into the taper of the rail high pressure outlet. – put the high pressure pipe nuts in position by hand beginning with the one located on the injector side.

Fit the rail-high pressure pump pipe: – remove the protective plugs from the pump high pressure outlet and the rail high pressure inlet. – insert the olive of the high pressure pipe into the taper of the pump high pressure outlet. – insert the olive of the high pressure pipe into the taper of the rail high pressure inlet. – put the high pressure pipe nuts in position by hand beginning with the one located on the rail side.

Fit the remaining high pressure pipes as before. Fit the injector-high pressure rail pipe: Fit the clips supplied with the new pipes onto the high pressure pipes: – Insert the first half of the clip using adjustable pliers, – Insert the second half of the clip using adjustable pliers.

WARNING: when tightening the high pressure pipes, it is essential to secure the intermediate union (10) of the injector.

IMPORTANT: Pay attention to the direction of fitting of the second half of the clip. The tabs located in the centre of the clip will only fit together in one position.

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Tighten the rail nuts to a torque of 2.8 daNm.

10

Tighten the nuts of the injector-rail high pressure pipes using the recommended tool: – tighten the nut on the injector side to a torque of 3.8 daN.m, – tighten the nut on the rail side to a torque of 3.8 daN.m,

IMPORTANT: do not touch the pipes with the wrench when torque tightening. WARNING: the correct order and tightening torque must be used for the high pressure pipes.

NOTE: Tighten one pipe fully before moving on to the next pipe.

Tighten the nuts of the pump-rail high pressure pipe using the recommended tool: – tighten the nut on the rail side to a torque of 3.8 daN.m, – tighten the nut on the pump side to a torque of 3.8 daN.m,

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ENGINE Overhauling the engine – the sump,

REMOVING THE BOTTOM ENGINE Fit flywheel block Mot. 582-01.

– the anti-emulsion plate,

Remove: – the clutch mechanism, – the flywheel,

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– the oil level sensor, – the oil pump,

WARNING: do not use a sharp point to mark the bearing caps in relation to their con rods to avoid starting a crack in the rod. Use a permanent marker pen.

– the crankshaft closure plate, – the water pump,

Remove the big end cap bolts and the connecting rod/ piston assemblies.

– the oil pump chain, – the oil pump drive sprocket.

NOTE: It is essential to mark the position of the crankshaft shells, as the category may be different for each bearing. Remove: – the crankshaft bearing caps, – the crankshaft.

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Remove: – the oil pressure sensor, – the pinking sensor, – the bolt of the oil filter unit bracket.

10

Replacement of the piston base cooling jets REMOVAL To remove the piston base cooling jets (1), they must be drilled with a 7 mm diameter drill. This is necessary in order to remove the spring stop (2) and the spring (3).

– the heat exchanger connector.

NOTE: do not remove the ball (4) to prevent swarf entering the cooling circuit.

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– the inertia extractor Emb. 880 onto Mot. 1485-01 and remove the jet.

Remove the swarf using a brush.

Screw: – tool Mot. 1485-01 in the drilled out jets using a 6 mm Allen key which must slide into the tool,

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Fit the pushrod instead and in place of the guide rod, then insert the jet into the pushrod.

Fitting piston base cooling jets The jets must be fitted using tool Mot. 1494.

NOTE: check that the jet is correctly oriented with the end of the jet (4) directed towards the centre of the cylinder.

Fitting the jets for cylinders 1 and 3 Fit plate (3) of tool Mot. 1494 onto the cylinder block (as shown on the diagram below) without tightening the two bolts (1).

With a hammer, tap the pushrod until the shoulder (5) of the pushrod comes into contact with the plate (3). Position the guide rod (2) in the plate (3) and the end of the guide rod in the hole of the jet to centre the plate (3). Tighten the two bolts (1). Remove the guide rod.

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Position the pushrod instead and in place of the guide rod, then insert the jet into the pushrod.

Fitting the jets for cylinders 2 and 4 Fit plate (3) of tool Mot. 1494 onto the cylinder block (as shown on the diagram below) without tightening the two bolts (1).

NOTE: check that the jet is correctly oriented with the end of the jet (4) directed towards the centre of the cylinder.

Position the guide rod (2) in the plate (3) and the end of the guide rod in the hole of the jet to centre the plate (3).

With a hammer, tap the pushrod until the shoulder (5) of the pushrod comes into contact with the plate (3).

Tighten the two bolts (1). Remove the guide rod.

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Orientation of the piston cooling jets (see diagram below).

10

Method for refitting the heat exchanger Remove the cylinder block from engine stand Mot. 792-03. Replace the seal (1) of the exchanger, positioning the lip (2) of the seal behind the lugs (3) of the exchanger.

A: Orientation of the jets of cylinders 2 and 4 B: Orientation of the jets of cylinders 1 and 3 Clean: – the cylinder block, – the crankshaft by passing a wire through the lubrication channels.

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Proceed as follows to ensure the exchanger is correctly refitted.

10

Remove the water pump inlet pipe. Refit the cylinder block on engine stand Mot. 792-03.

Refit the inlet pipe of the water pump, securing using the bolt (4). Fit the exchanger (with its coolant pipes) on the cylinder block using the connector (5) without locking the connector. Insert the two coolant hoses (6) onto the ends of the coolant pipe. Hold the exchanger by hand whilst tightening the connector (5) to a torque of 4.5 daN.m.

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Fit the oil filter support (complete with a new seal (7)), positioning the lug (8) in the hole (9) of the exchanger. Then tighten the bolt (10) fitted with new seals, to a torque of 4.5 daN.m.

EXTRACTING THE GUDGEON PINS N.B.: it is imperative to mark the connecting rod to match it to its piston, because the piston height classes in the same engine may be different (see Technical Specifications section). To extract the gudgeon pin, remove the spring ring using a screwdriver, then release the pin.

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FITTING THE CON ROD BEARING SHELLS

On the con rod body

The bearing shells are fitted using Mot. 1492 and Mot. 1492-03.

Slide the bearing shell support (1) of Mot. 1492-03 (positioning the engraved mark (3) "A" as shown on the diagram below) into the groove (2) of the base of Mot. 1492.

Fit the guide (4) of Mot. 1492-03 onto the base (as shown in the diagram).

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Lay the body of the con rod on the base of the tool (as shown in the diagram). Check that the lower part (5) of the small end is touching the centring pin and push the guide (7) in the direction of the arrow.

10

Bring the shell support up against the base of the con rod body.

Remove the con rod body support and repeat the operation for the remaining con rod bodies. Lay the bearing shell (with a width of 20.625 mm) (6) on the bearing shell support, then push it in the direction of the arrow (as shown on the diagram).

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On the con rod cap Position the bearing shell support either on: – the engraved mark (3) "A" if the width of the bearing shell is equal to 20.625 mm, – the engraved mark (4) "B" if the width of the bearing shell is equal to 17.625 mm,

10

Push the guide (in the direction of the arrow) until the con rod cap is in contact with the pins (9) on the base of the tool.

Fit the shell (8) on the shell support, then push it in the direction of the arrow (as shown in the diagram).

Fit the con rod cap as shown in the diagram.

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Bring the shell support up against the base of the con rod cap.

10

REFITTING THE BOTTOM ENGINE Fitting the crankshaft bearing shells Direction of fitting. Position the grooved bearing shells on the cylinder block.

Remove the con rod cap support and repeat the operation for the remaining con rod caps. Fit the smooth bearing shells on the bearings.

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On the cylinder block

On the bearings

Position tool Mot. 1493-01 on the cylinder block.

Position Mot. 1493-01 on the bearing.

Fit the bearing shell in Mot. 1493-01, then press at (A) until the bearing shell is touching at (B) with Mot. 1493-01.

Fit the bearing shell in Mot. 1493-01, then press at (A) until the bearing shell is touching at (B) with Mot. 1493-01.

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Oil the crankshaft bearing shells. Refit: – the crankshaft, – the lateral shims on bearing no.3, putting the grooves on the crankshaft side, – the crankshaft bearing caps on bearing cap no.1 (these are numbered from 1 - 5 and these numbers should be positioned opposite the water pump). Then tighten the bolts to a torque of 2.7 daN.m plus an angle of 47° ± 5°.

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10

Check the lateral clearance of the crankshaft (in mm) which should be: – without wear on lateral shims: 0.045 - 0.252 – with wear on the lateral shims: 0.045 - 0.852

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ENGINE Overhauling the engine Fitting bearing number 1 Degrease the gasket faces (of the cylinder block and bearing number 1). They should be clean, dry and free from grease (in particular, remove finger marks). Lay two beads (3) of Threebond silicon with a width of 1 mm on bearing no.1 of the cylinder block.

Tighten the bolts of bearing cap no. 1 to a torque of 2.7 daN.m plus an angle of 47° ± 5°.

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10

"CON RODS / PISTON" ASSEMBLY

Direction for fitting the circlips on the piston

The pistons have a "Λ" mark engraved on their heads indicating the flywheel side.

Position the opening (3) of the spring rings opposite the removal and fitting channel (4).

Oil the gudgeon pin. Check that the gudgeon pins rotate correctly in the new piston and in the matching connecting rod. Direction of fitting of the con rod in relation to the piston Point the "Λ" (1) engraved on the top of the piston downwards and the flat (2) of the big end as shown on the diagram below.

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FITTING THE RINGS

Oil the pistons.

Rings set to their original adjustment must be free within their channels.

Fit the con rod/piston assemblies into the cylinder block using the ring (e.g.: FACOM 750 TB), being careful to fit them the right way round ("Λ" towards the flywheel).

Ensure the rings are fitted the correct way round with the word TOP pointing upwards. Orientation of the rings in the piston

Fit the con rods onto the oiled crankpins of the crankshaft.

Ensure the break in each ring is correctly oriented as shown in the diagram below.

Fit the con rod caps, ensuring they are correctly matched. Tighten the big end cap bolts to a torque of 2 daNm, plus an angle of 45° ± 6°. Check that the big ends have the correct lateral clearance of 0.205 to 0.467 mm.

T = Top

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Checking piston protrusion Clean the piston head. Turn the crankshaft one turn in its operating direction to bring piston no.1 close to Top Dead Centre. Fit tool Mot. 252-01 on the piston. Fit tool Mot. 251-01 equipped with a gauge on support plate Mot. 252-01, and find top dead centre. N.B.: All measurements must be carried out along the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston. WARNING: the gauge follower must not be in the valve clearance.

Check the piston protrusion which must be 0.192 ± 0.093 mm. Refit: – the pinking sensor to a torque of 2 daN.m, – the oil pressure sensor to a torque of 2.2 daN.m, – the oil pump sprocket and chain to a torque of 2.5 daN.m.

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NOTE: the gasket faces (cylinder block, crankshaft closure plate and water pump) must be clean, dry and free from grease (in particular, remove finger marks). The crankshaft closure plate is sealed with THREEBOND silicon. The bead (A) must be 1.5 2 mm wide and be applied in accordance with the diagram below.

10

Refit: – the crankshaft closure plate by: ● pre-tightening bolts 1 and 6 to a torque of 0.8 daN.m, ● tightening bolts 2, 3, 4 and 5 to a torque of 1.2 daN.m, ● tightening bolts 1 and 6 to a torque of 1.2 daN.m,

– the water pump fitted with a new seal. Put a drop of LOCTITE FRENETANCH on the bolts, then tighten them to a torque of 1.1 daN.m in the recommended order.

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NOTE: the gasket faces (cylinder block and crankshaft closure plate) must be clean, dry and free from grease (in particular, remove finger marks). Apply: – four beads (B) of THREEBOND silicon, with a diameter of 5 mm, – two drops (C) of THREEBOND silicon, with a diameter of 7 mm at the intersection of the crankshaft closure plate and the cylinder block.

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Refit: – the anti-emulsion plate, – the oil sump, tightening the bolts as follows: ● pretighten the bolts in the recommended order of 1, 2, 3, 4, 5, 6, 7, 8 to a torque of 0.8 daN.m, ● tighten the bolts in the recommended order of 1, 2, 3, 4, 5, 6, 7, 8 to a torque of 1.5 daN.m, ● pretighten the bolts in the recommended order of 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 1, 2 to a torque of 0.8 daN.m, ● tighten the bolts in the recommended order of 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 1, 2 to a torque of 1.5 daN.m,

When refitting the oil sump, ensure that: – the tabs (D) of the anti-emulsion plate are correctly positioned in the slots (E), – the cylinder block and the oil sump are correctly aligned on the flywheel side, to prevent the clutch housing from being damaged when fitting the gearbox.

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10

Fit the protector complete with the seal onto the spacer, taking care not to touch the seal.

Fitting the crankshaft seal gaskets Crankshaft elastomer seal, timing side. Screw the threaded rod (13) of Mot. 1586 into the crankshaft.

Fit the cover (15) and the nut (16) (putting the threaded part (17) of the nut on the side away from the engine) of tool Mot. 1586. Position the spacer (14) of tool Mot. 1586 on the crankshaft.

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Tighten the nut until the cover touches the spacer.

10

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

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Crankshaft elastomer seal, flywheel side.

10

Fit the cover (19) and nut (20) (putting the threaded part (21) of the nut on the side away from the engine) of Mot. 1585.

Fit tool Mot. 1585 on the crankshaft, securing it with bolts (18).

Put the protector complete with the seal on tool Mot. 1585, being careful not to touch the seal.

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Tighten the nut until the cover touches the cylinder block.

10

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

Refit: – the flywheel, tightening the new bolts to a torque of 5 - 5.5 daN.m (blocking the flywheel using Mot. 582-01),

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– the clutch and mechanism, tightening the bolts to a torque of 0.8 daN.m.

10

REFITTING THE UPPER ENGINE Refitting the cylinder head Position the pistons at mid-stroke. Fit the cylinder head gasket using the centring dowels of the cylinder block. Tighten the cylinder head (see the section "Cylinder head specifications"). NOTE: the gasket faces (cylinder head and cylinder head cover) must be clean, dry and free from grease (in particular, remove finger marks). Lay four beads (B) of THREEBOND silicon, with a diameter of 2 mm.

Remove flywheel block Mot. 582-01.

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Tighten: – the bolts of the turbo oil return pipe to a torque of 0.9 daN.m, – the nut and the bolt of the turbo oil supply pipe to a torque of 2.3 daN.m.

Refit: – the cylinder head, tightening the bolts to a torque of 1 daN.m in the recommended order,

Refit: – the oil vapour rebreathing pipe, – the new turbo air ducts,

– the turbo oil return pipe fitted with new seals, – the turbo, tightening the nuts to a torque of 2.6 daN.m, – the catalytic converter bracket, – the turbo oil supply pipe,

– the air filter unit.

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ENGINE Overhauling the engine Refit: – the inner timing cover, – the timing tension wheel.

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Timing adjustment IMPORTANT: it is essential to degrease the end of the crankshaft, the bore of the crankshaft sprocket and the bearing faces of the accessories pulley to prevent any slip between the timing and the crankshaft which would risk destroying the engine. Ensure that the peg (7) of the tension wheel is correctly positioned in the groove (8). Insert pin Mot. 1430 in the camshaft and cylinder head pulley holes. Check that: – the mark on the high pressure pump pulley (9) is opposite the bolt head (10), – the crankshaft is touching the Top Dead Centre pin Mot. 1489 (the crankshaft groove (11) must be facing upwards).

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Tighten the tension wheel bolts to a torque of 2.5 daNm.

Fit the timing belt, aligning the marks on the belt with those on the camshaft and high pressure pump sprockets (19 teeth spaces on the belt between the marks on the camshaft and pump sprockets).

Refit the crankshaft accessories pulley, tightening the bolt to a torque of 2 daNm, then angle tighten to 130° ± 15° (crankshaft touching the Top Dead Centre pin). Remove the Top Dead Centre pin Mot. 1489 and the camshaft pulley timing pin Mot. 1430. Turn the crankshaft two full turns in a clockwise direction (timing side). Just before the hole (4) of the camshaft pulley is opposite the cylinder head hole (5), screw pin Mot. 1489 into the cylinder block. Then move the crankshaft slowly and without jolting it until it is resting on the pin.

Using a 6 mm Allen key, move the movable index (1) of the tension wheel into the position shown below, by turning the key anticlockwise.

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Check that pin Mot. 1430 is correctly inserted in the holes of the camshaft and cylinder head pulleys and that there are 19 teeth spaces between the marks on the camshaft (3) and the high pressure pump (4) sprockets.

Undo the tension wheel bolt by a maximum of one turn while holding it using a 6 mm Allen key, then gradually bring the movable index (1) (by turning the key clockwise) to the centre of the timing window (2) and tighten the nut to a torque of 2.5 daNm.

Remove the Top Dead Centre pin Mot. 1489 and the camshaft pulley timing pin Mot. 1430.

Refit the cap of the Top Dead Centre pin, applying RHODORSEAL 5661 to the thread and tightening to a torque of 2 daNm.

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Refit: – the cylinder head suspended mounting, tightening the bolts to a torque of 2.1 daNm,

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– the lower timing cover by positioning the tab (1) into the hole (2) on the inner timing cover,

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– the upper timing cover.

Remove the engine from the engine stand Mot. 792-03. Refit: – the coolant pipe, tightening the bolt to a torque of 2.2 daN.m, – the two heat exchanger pipes,

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– the accessories belt.

– the multifunction support, tightening the bolts to a torque of 4 daN.m,

NOTE: the accessories belt has five teeth as opposed to the pulleys which have six. It is therefore essential to ensure that tooth "E" remains free when fitting the belt.

Version with air conditioning. – the alternator, tightening the bolts to a torque of 2.1 daNm, – the air conditioning compressor, tightening the bolts to a torque of 2.1 daN.m, – the power-assisted steering pump or the washer which replaces the pulley (if the engine has one), tightening the bolts to a torque of 2.1 daN.m,

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NOTE: the engine must be turned through two revolutions in order to position the belt correctly.

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ENGINE Overhauling the engine A: B: C: T: →:

Version without air conditioning. The belt is tensioned using tool Mot. 1638 (with the two mounting bolts of the tensioner undone). The tension value is 233 ± 5 Hz.

10

Crankshaft: Power-assisted steering pump Alternator Tension wheel: Tension checking point

NOTE: the engine must be turned through two revolutions in order to position the belt correctly.

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