Page 1 Copying or translating, in part or in full, of this document or use of the service part The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault. in the production of the various component units and accessories from which his vehicles are constructed."...
Page 2: Table Of Contents
Contents Page ENGINE AND PERIPHERALS 10-1 Foreword 10-2 Diagram 10-4 Engine identification 10-7 Tightening torques (in daNm) 10-14 Lubrication circuit diagram 10-16 Specifications 10-38 Standard replacement 10-39 Special tooling required 10-44 Essential equipment 10-45 Cylinder head exploded drawing Overhauling the engine 10-46 Removing top engine 10-51...
Page 3: Foreword
ENGINE AND PERIPHERALS ENGINE AND PERIPHERALS Foreword Foreword USING THE MANUAL There are two main sections in this manual: – technical specifications, – overhauling the engine. To repair the component on the vehicle, refer to the Workshop Repair Manual and Technical Notes for the vehicle.
Page 4: Diagram
ENGINE AND PERIPHERALS Diagram Diagram J8S TURBO ENGINE 10-2...
Page 5 ENGINE AND PERIPHERALS Diagram J8S AND 852 ENGINES 10-3...
Page 6: Engine Identification
ENGINE AND PERIPHERALS Engine identification Engine identification The engine is identified by a plate riveted onto the cylinder block. It includes: A: the engine type B: the engine approval letter C: the manufacturer code D: the engine index E: the engine fabrication number F: the engine assembly works 10-4...
Page 7 ENGINE AND PERIPHERALS Engine identification Compression Bore Stroke Capacity Engine Index Type ratio (in mm) (mm) (in cm 1276 1344, 2354, 1354 Pxx3 Txx3 Vxx3 J115, S115 Rxx3 X480 X48A PxxF TxxK X486 B290 21/1 2068 X488 B29W X488 X486, X48W TxxF J114 X487...
Page 8 ENGINE AND PERIPHERALS Engine identification Compression Bore Stroke Capacity Engine Index Type ratio (in mm) (in mm) (in cm J63D, S63D J63E 1270 B296 1344 TA, 1354TA 21.5/1 2068 1346, 1356, 1366 B296 X48, 6, V, V 4x4 B546 J635, S635 J634 J633 X480...
Page 9: Tightening Torques (In Danm)
ENGINE AND PERIPHERALS Tightening torques (in daNm) Tightening torques (in daNm) 0.5 to 0,9 2.5 to 3 1.3 to 1.8 6 to 6.5 1.25 10-7...
Page 10 ENGINE AND PERIPHERALS Tightening torques (in daNm) CYLINDER BLOCK Preheating shunt nut connector: 0.25 daNm Aluminium sump : 1.4 to 1.7 daNm Metal sump 1.25 daNm 10-8...
Page 11 ENGINE AND PERIPHERALS Tightening torques (in daNm) 3.2 to 3.9 Turbo: : 4.5 daNm Garrett : 2.6 daNm 10-9...
Page 12 ENGINE AND PERIPHERALS Tightening torques (in daNm) 2.25 to 2.75 Turbo: : 4.5 daNm Garrett : 2.6 daNm 10-10...
Page 13 ENGINE AND PERIPHERALS Tightening torques (in daNm) 5 to 5.5 10-11...
Page 14 ENGINE AND PERIPHERALS Tightening torques (in daNm) 6.5±0.25 8.75 to 9.75 4 to 4.5 Spark plug M12 tighten to 2 daNm Spark plug M10 tighten to 1.6 daNm model: – coolant pipe 0.8 to 1 daNm – coolant rail 2 to 2.5 daNm model: –...
Page 15 ENGINE AND PERIPHERALS Tightening torques (in daNm) 3.2 to 3.9 8.75 to 9.75 2.5 to 3 Turbo: : 4.5 daNm Garrett : 2.6 daNm 10-13...
Page 16: Lubrication Circuit Diagram
ENGINE AND PERIPHERALS Lubrication circuit diagram Lubrication circuit diagram Key: All types Turbo with radiator Turbo with heat exchanger returning cooling jets integrated cooling jets fitting integrated cooling jets fitting 10-14...
Page 17 ENGINE AND PERIPHERALS Lubrication circuit diagram 10-15...
Page 18: Specifications
ENGINE AND PERIPHERALS Specifications Specifications CYLINDER HEAD Unscrew bolt 1 until it is completely free, and then carry out: Tightening procedure retightening 2 daNm All the cylinder head bolts must always be changed after removal (including the mounting retightening (angle) according to the table: studs).
Page 19 ENGINE AND PERIPHERALS Specifications J8S longitudinal engine Unscrew bolt 1 until it is completely free, and then carry out: Carry out the following in the order prescribed: retightening 2 daNm tightening : 3 daNm retightening (angle) according to the table: tightening: 5 daNm Angle...
Page 20 ENGINE AND PERIPHERALS Specifications Thickness of the cylinder head gasket model There are several different thicknesses of cylinder On engines fitted with a 2 model cylinder head head gasket as replacements. When the 1 model (A) gasket, the label showing the gasket thickness can be gaskets have been used up, the Parts Store will only seen from the outside.
Page 21 ENGINE AND PERIPHERALS Specifications Cylinder head cover gasket model: same position as the 2 model. All types except J8S 736 model: This gasket is not symmetrical. Cylinder side graphitised surface. 93780R model: This gasket has a an area intended to prevent confusion;...
Page 22 ENGINE AND PERIPHERALS Specifications Height of the cylinder head (in mm) Engine type H = 104.5 ± 0.04 Normally Turbo aspirated Channel angle 35˚ 31˚ (α) A drill Mark (X) None. stamp Diameter (D) of the housing in the cylinder head (in mm) –...
Page 23 ENGINE AND PERIPHERALS Specifications Bare prechamber Valve seats Half-prechamber α Seat angles ( Inlet and exhaust: 90˚ Mating surface width X (in mm) 1.75 ± 0.2 Inlet and exhaust: External diameter D (in mm) + 0.13 Inlet: + 0.11 + 0.03 Exhaust: 34.6 + 0.01...
Page 24 ENGINE AND PERIPHERALS Specifications Valve guides Position of the inlet and exhaust valve guides Position of guides in relation to the cylinder head Internal diameter (in mm) mating face (in mm): External diameter (in mm): D = 32.5 – Normal 13.10 –...
Page 25 ENGINE AND PERIPHERALS Specifications Valve springs Rocker arm rail The inlet and exhaust valve springs are identical. When performing operations on faults that cause metallic particles to become suspended in the lubricating oil, e.g.: Free length (in mm): 45.2 – damaged con rod bearing shells or crankshaft, –...
Page 26 ENGINE AND PERIPHERALS Specifications PISTONS These engines are fitted with Floquet Monopole pistons. The gudgeon pin is free in the con rod and in the piston. Piston marking 16576R 16576-2R 16576-1R 16576-3R 10-24...
Page 27 Piston measuring Engine type point (A) (in mm) Height between the gudgeon pin and the top of the piston (see table below). J8S 852 24.35 Modification index, for supplier's use only. normally aspirated For supplier's use only. Dater, for supplier's use only.
Page 28 ENGINE AND PERIPHERALS Specifications Rings FITTING THE RINGS Three rings (thickness in mm) Rings set to their original adjustment must be free within their channels. Normally aspirated engine Ensure the fitting direction is observed. – Compression – Sealing (tapered) – Scraper (rounded) Turbo engine –...
Page 29 Ensure that the piston and con rod are fitted the right Small end diameter way around (follow the arrows): + 0.021 without ring Engines 852 J8S all types except turbo + 0.01 with ring + 0.003 The small end has a bush.
Page 30 ENGINE AND PERIPHERALS Specifications Direction for fitting the circlips on the piston CRANKSHAFT Fit the circlips on the piston as shown below. Number of bearings Burnishing normally aspirated engine with turbo engine 1 fitting without turbo engine 2 fitting with in mm Longitudinal play normally aspirated engine...
Page 31 ENGINE AND PERIPHERALS Specifications Burnished crankshaft Identification of crankshafts: In case of correction, the burnishing must remain intact Normally aspirated engine on 140˚ in the areas indicated by the arrows. eight counterweights, Burnished bushings and crankpins. 88007S Turbocharged engine These zones are defined in sections (A) and (B), used four counterweights, as examples.
Page 32 ENGINE AND PERIPHERALS Specifications RELAY SHAFT CLUTCH SHAFT CENTERING BEARINGS Longitudinal play (in mm) 0.05 to 0.15 Gearbox: – with bearing in the clutch housing: short clutch shaft (A). – without bearing in the clutch housing: long clutch PISTON BASE COOLING RAIL shaft (B).
Page 33 ENGINE AND PERIPHERALS Specifications CYLINDER LINER Assembling cylinder liners - cylinder block in mm in mm 93.035 Internal diameter Height (H) of the cylinder liner 93.065 Diameter of the base centering (D) 93.6 92.945 Depth (K) of cylinder block Protrusion of cylinder liner without 0.07 to 0.13 92.985 gasket (X)
Page 34 ENGINE AND PERIPHERALS Specifications Identification of liners Normally aspirated engine model model 10-32...
Page 35 ENGINE AND PERIPHERALS Specifications Turbo engine model model Cylinder liner with two notches and piston fitted cooling Cylinder liner with no notches and tube piston cooling oil jets. oil jets. model model Cylinder liner with four notches and integral piston Special Parts store cylinder liner with four notches.
Page 36 ENGINE AND PERIPHERALS Specifications OIL PUMP Clearance (B) – minimum (in mm) 0.02 Removal – maximum (in mm) 0.10 Remove: – the oil pump cover, – the discharge valve and its spring. 86303-1R Refit: – the oil pump cover by tightening the bolts to a torque Checking clearances of 1 daNm, –...
Page 37 ENGINE AND PERIPHERALS Specifications PREPARING THE ENGINE TO BE SET ON THE STAND Before fitting the engine to support plate Mot. 792-03, remove the engine electrical wiring harness and drain the engine oil and the coolant by removing the drain plug (A).
Page 38 ENGINE AND PERIPHERALS Specifications FITTING THE ENGINE TO SUPPORT Mot. 792-03 AND THE THREE RODS A, B AND C Engines of all types Remove the intake and exhaust manifolds, The rods (A), (B) and (C) are mounted on the cylinder block so that they fit into the holes (1, 8, 17) on the plate.
Page 39 ENGINE AND PERIPHERALS Specifications CONSUMABLES Type Quantity Component concerned Part no. RAVITOL S 56 Cleaning parts 77 01 421 513 DECAPJOINT Coat Cleaning gasket faces 77 01 405 952 RHODORSEAL 5661 Coat Crankshaft bearing cap 77 01 404 452 Loctite 518 Coat Crankshaft cover, coolant pump 77 01 421 162...
Page 40 ENGINE AND PERIPHERALS Standard exchange Standard exchange PREPARING THE USED ENGINE FOR RETURN The engine should be cleaned and drained (oil and water). Leave on the used engine or include in the return box: – the dipstick, – the water pump, –...
Page 41 ENGINE AND PERIPHERALS Essential special tooling Essential special tooling Parts Department Illustration Tool number Description number Mot. 11 00 01 072 500 Crankshaft spigot bush extractor. Dial gauge support. Used with Mot. 251-01 00 00 025 101 Mot. 252-01. Dial gauge support thrust plate. Used Mot.
Page 42 ENGINE AND PERIPHERALS Essential special tooling Parts Department Illustration Tool number Description number Magnetised flexible shaft for cylinder Mot. 591-02 00 00 059 102 head angular wrench. Cylinder head angular wrench, 1/2" Mot. 591-04 00 00 059 104 drive with gauge. Mot.
Page 43 ENGINE AND PERIPHERALS Essential special tooling Parts Department Illustration Tool number Description number Mot. 855 00 00 085 500 Timing gear locking strap. BOSCH diesel injection pump timing Mot. 856 00 00 085 600 gauge support. Mot. 861 00 00 086 100 TDC setting rod.
Page 44 ENGINE AND PERIPHERALS Essential special tooling Parts Department Illustration Tool number Description number Dial gauge for Mot. 1079-01 timing Mot. 1079-02 00 00 107 902 gauge kit for Roto-Diesel pumps. Mot. 1281-01 00 00 128 101 Oil filter removing tool 96 mm diameter. Crankshaft oil seal fitting tool (flywheel Mot.
Page 45 ENGINE AND PERIPHERALS Essential special tooling Parts Department Illustration Tool number Description number Mot. 1384 00 00 138 400 Belt tensioner adjusting tool. Mot. 1505 00 00 150 500 Belt tension setting tool. Mot. 1511 00 00 151 100 Valve stem seal tool. Mot.
Page 46: Essential Equipment
ENGINE AND PERIPHERALS Essential equipment Essential equipment Description Ring for fitting piston with rings into the liner. Grinding kit for redressing the valve seat, for example CERGYDIS C 108 NEWAY. Valve lifter. Angular tightening tool: – STAHLWILLE, part number 540 100 03 for example, –...
Page 47: Cylinder Head Exploded Drawing
ENGINE AND PERIPHERALS Cylinder head exploded drawing Cylinder head exploded drawing 10-45...
Page 48: Overhauling The Engine
ENGINE AND PERIPHERALS Overhauling the engine Overhauling the engine REMOVING THE TOP ENGINE Remove: – the accessories belt, – the air conditioning compressor (if fitted), – the power assisted steering pump, – the alternator, – the multifunction mounting, – the engine lifting bracket on the flywheel end. Fit the flywheel locking tool Mot.
Page 49 ENGINE AND PERIPHERALS Overhauling the engine Adjusting the timing Fit the TDC setting rod on Mot. 861 or Mot. 1054, then turn the engine (clockwise from the timing end) to bring the camshaft sprocket and injection pump marks in line with the valve timing cover marks (start to pull on the rod one half-tooth before the marks are aligned), in...
Page 50 ENGINE AND PERIPHERALS Overhauling the engine Check the timing on the camshaft sprocket and injection pump (marks on the valve timing cover must be aligned with pulley marks). Remove the timing cover. Check the marks on the crankshaft timing sprocket (see diagram). Make a fixed mark on the cylinder head cover and another on the injection pump where they are...
Page 51 ENGINE AND PERIPHERALS Overhauling the engine Remove the TDC setting rod Mot. 861 or Mot. 1054. Slacken and then re-tighten the tensioner in order to remove the timing belt. Remove: – the fuel return pipes, – the high pressure pipes on the injection pump using Mot.
Page 52 ENGINE AND PERIPHERALS Overhauling the engine Remove the camshaft lateral shim (pulley end). Undo the rocker arm adjusting bolts. Remove the rocker arm rail. Remove the cylinder head bolts and fastening nuts. Insert a wooden shim and strike the side of the cylinder head to unstick it from the sealing face within the clearance limit between the cylinder head and...
Page 53: Stripping The Cylinder Head
ENGINE AND PERIPHERALS Overhauling the engine STRIPPING THE CYLINDER HEAD Place the cylinder head on the cylinder head support Mot. 1573. Remove: – the heater plugs and their electrical wiring, – the injectors and injector holders with seals, – the flame-shield washers between the cylinder head and the injector holder, –...
Page 54 ENGINE AND PERIPHERALS Overhauling the engine Remove: NOTE: before removing the valves and the valve – the camshaft, stem seals, it is vital that you measure position H – the prechambers (11) and, if necessary, gently tap of one of the old seals in relation to the cylinder with tool B.
Page 55 ENGINE AND PERIPHERALS Overhauling the engine NOTE: the internal diameter of the pushrod must be identical to that of the valve. Moreover, the pushrod must contact the metallic upper section of the valve stem seal. Fit the guide tube from above the pushrod until it comes into contact with the cylinder head.
Page 56: Cleaning
ENGINE AND PERIPHERALS Overhauling the engine CLEANING CHECKING THE GASKET FACE It is very important not to scratch the mating faces Check for gasket face bow using a straight edge and a of any aluminium components. set of shims. Use the Décapjoint product to dissolve any part of the Maximum bow 0.05 mm gasket which remains attached.
Page 57: Redressing The Valve Seats
ENGINE AND PERIPHERALS Overhauling the engine REDRESSING THE VALVE SEATS INLET EXHAUST Width of mating faces X (in mm) Width of mating faces X (in mm) 1.75± 0.2 1.75± 0.2 Angle (α) 90˚ Angle (α) 90˚ The mating face is corrected (1) using burr N 208 46˚. The mating face is corrected (1) using burr N 204 46˚.
Page 58: Assessment And Repair Of Rocker Arm Rails
ENGINE AND PERIPHERALS Overhauling the engine ASSESSMENT AND REPAIR OF ROCKER ARM They comprise: RAILS – a greasing hole (G) for corresponding camshaft bearings, The filter (24) located in the rocker arm rail (17) must – an offset (F) directed towards the flywheel. be replaced in all operations on faults that cause metallic particles to become suspended in the lubricating oil.
Page 59: Rebuilding The Cylinder Head
ENGINE AND PERIPHERALS Overhauling the engine The rocker arm shaft is oriented using a full dog point Refitting screw. Place the bearing (E) on the shaft and fix it so that the The shaft bearing greasing holes are directed towards greasing holes point towards the bearing plate.
Page 60 ENGINE AND PERIPHERALS Overhauling the engine The valve stem seals must be fitted using tool Place the barrel of the Mot. 1511 tool over the valve Mot. 1511 or with the FACOM tool, part stem (the internal diameter of the barrel must be number DM6J4.
Page 61 ENGINE AND PERIPHERALS Overhauling the engine Push the valve stem seal past the tool barrel, then withdraw the barrel. 15739-5S NOTE: the internal diameter of the pushrod must be identical to the diameter of the valve stem. Moreover, the pushrod must be in contact with the Place the pushrod over the valve stem seal.
Page 62 ENGINE AND PERIPHERALS Overhauling the engine Place the guide tube and sleeve assembly, adjusted at Push the valve stem seal down by tapping the top of removal, over the pushrod. the sleeve with the palm of your hand until the guide tube touches the cylinder head.
Page 63 ENGINE AND PERIPHERALS Overhauling the engine Fit: Check the amount by which the valve is retracted from – the spring collar rings (7), the cylinder head gasket face using tools Mot. 251-01 – the springs (8) (inlet and exhaust springs are and Mot.
Page 64 ENGINE AND PERIPHERALS Overhauling the engine Turbo engine Fit the prechambers (11) then use tools Mot. 251-01 and Mot. 252-01 to check their protrusion. Mark X: a drill stamp. It should be between 0.01 and 0.04 mm. Normally aspirated engine Mark X: none.
Page 65 ENGINE AND PERIPHERALS Overhauling the engine Refit the heater plugs (12) and their electrical wiring. All engine types except J8S 736 and 740 Place new heat flange welds (27) on a cylinder head being re-used. Take a note of the dimensions of the removed flame- shields and replace them with new ones of the same diameter.
Page 66 ENGINE AND PERIPHERALS Overhauling the engine Engines J8S 736 and 740 Injector holders - special features The cylinder head has been modified to accept BOSCH "KCA" threaded injector holders. 92448-2R 1 Flame-shield 2 Flame-shield washer 3 Seal Fit a new seal and a new flame-shield washer (oriented as shown in the diagram) every time the injector holder is refitted.
Page 67: Cylinder Block Exploded Drawing
ENGINE AND PERIPHERALS Overhauling the engine CYLINDER BLOCK EXPLODED DRAWING 10-65...
Page 68: Removing Bottom Engine
ENGINE AND PERIPHERALS Overhauling the engine REMOVING THE BOTTOM ENGINE Fit the cylinder liner clamp Mot. 521-01. Fit the flywheel locking tool Mot. 582 and remove the clutch and the flywheel. 16558R Remove: – the water pump. 16531R Unscrew the three mounting bolts on the injection pump support to remove the unit comprising the pump, the support and the injection pump pulley.
Page 69 ENGINE AND PERIPHERALS Overhauling the engine – the tension wheel, – the relay shaft cover, – the seal using a lever, 16532-2S 16532S – the relay shaft pinion, use immobiliser Mot. 855, – the relay shaft retainer, – the key, –...
Page 70 ENGINE AND PERIPHERALS Overhauling the engine Remove the sump. Remove: – the crankshaft seals, model – the oil filter using Mot. 1281-01. Three types of bolt marked A, B and C. Position the pistons at mid-stroke. Disconnect the connection tube between the oil pump and the lubricating gallery (if fitted).
Page 71 ENGINE AND PERIPHERALS Overhauling the engine For engine sump with reinforcing plate Remove: – the oil pump strainer, bolt (A), keeping the pump pinions, 91576R – the two bolts on the oil pump body, – the oil pump body, – the oil level sensor, –...
Page 72 ENGINE AND PERIPHERALS Overhauling the engine Marking of the mounting bolts on the cylinder block plate and on the sump on the plate. 4 types of bolt marked as follows: : 17 bolts (M7 x 100-50). : 21 bolts (M6x100-16), : 1 bolt (M10x150-40), : 9 bolts (M10x150-75), : bolt not used...
Page 73 ENGINE AND PERIPHERALS Overhauling the engine Mark the bearing caps according to their con rods: – n˚ 1 flywheel end, – relay shaft end. WARNING: do not use a sharp point for marking as this could start a crack in the rods. Use an indelible marker pen.
Page 74 ENGINE AND PERIPHERALS Overhauling the engine Extract the cylinder liners and pistons (mark them). Remove: – the crankshaft, Mark the crankshaft bearing caps according to their – the lateral play stops, housing and then remove them. – the crankshaft bearing shells, –...
Page 75 ENGINE AND PERIPHERALS Overhauling the engine Remove the filter holder. Remove the bearing using tool Mot. 11. 77443R Replacing the bearing NOTE: if the gearbox is fitted with a short shaft (A), it does not need a bearing in the crankshaft. Refitting the bearing If the gearbox is fitted with a long shaft (B) the Cement the bearing with loctite FRENBLOC for...
Page 76: Extracting The Con Rod -Pistons
ENGINE AND PERIPHERALS Overhauling the engine EXTRACTING THE CON RODS - PISTONS It is very important not to scratch the mating faces of any aluminium components. Remove: – the rings using ring pliers, Use the Décapjoint product to dissolve any part of the –...
Page 77: Refitting Bottom Engine
ENGINE AND PERIPHERALS Overhauling the engine Clean the cylinder head mounting holes, especially in REFITTING THE BOTTOM ENGINE the oil outlet duct (C). Replace the lubrication channel plugs, tightening them 8 daNm for the plugs (A), 2 daNm for the plugs (B) for bearing n˚ 1, 4 daNm for the other plugs.
Page 78 ENGINE AND PERIPHERALS Overhauling the engine When fitting the dipstick guide tube, fit the collar to butt Replace the piston base cooling jets incorporated in against the cylinder block. the cylinder block and tighten to a torque of 1.2 to 1.4 daNm.
Page 79 ENGINE AND PERIPHERALS Overhauling the engine For engines fitted with a piston base cooling rail, the oil Engines 852 before n˚ 42 253 gallery mounting bolts (H) need a drop of Loctite FRENETANCH. Do not add more, as too much...
Page 80 ENGINE AND PERIPHERALS Overhauling the engine Fitting the crankshaft bearing shells Grease the crankpins and bushings with engine oil. Identification Refit: – the crankshaft, Only grooved and pierced crankshaft bearing shells – the crankshaft bearing caps except caps 1 and 5. are supplied as spares, whatever the crankshaft lubrication configuration.
Page 81 ENGINE AND PERIPHERALS Overhauling the engine Temporarily fit bearing n˚ 1 with no lateral seals in Fitting the crankshaft bearings order to fit the magnetic holder. There are two ways to ensure that bearings 1 and 5 are properly sealed: 1 - Fit butyl rubber seals.
Page 82 ENGINE AND PERIPHERALS Overhauling the engine Apply a thin coating of RHODORSEAL 5661 to the Remove the shims and the studs. supports on bearings 1 and 5 without blocking the oil return on the sump seals. Cut the side seals so that they protrude 0.5 to 0.7 mm in relation to the sump gasket face.
Page 83 ENGINE AND PERIPHERALS Overhauling the engine Thoroughly clean the cylinder block and the bearing NOTE: New fitting (J engine) cap surfaces (A). Degrease using a cloth soaked in diluted cleaning agent. The bearing caps have watertight grooves (C). Allow to dry. Following modifications to the bearing caps: –...
Page 84 ENGINE AND PERIPHERALS Overhauling the engine Lightly coat the inner surfaces of the cylinder block in Insert the mixture into the syringe and inject it into the (B) with RHODORSEAL 5661 without obstructing the grooves of the crankshaft bearing cap. oil grooves.
Page 85 ENGINE AND PERIPHERALS Overhauling the engine Use a cloth to wipe up any excess paste, both inside Allow to dry for a few moments and cut the excess off and outside the cylinder block, and at (A). the gasket face. 89199S 89197R Pass a thin wire through the lubricating channels to...
Page 86 ENGINE AND PERIPHERALS Overhauling the engine REFITTING AND ASSEMBLING PISTON CON Turbo engine RODS Go to the cylinder liner-pistonreplacement section. The parts in the cylinder liner-piston section are identical to those used for this operation. Mark the parts in each box from A to D to ensure they remain identical.
Page 87: Fitting The Rings
ENGINE AND PERIPHERALS Overhauling the engine FITTING THE PISTON RINGS CHECKING CYLINDER LINER PROTRUSION Rings set to their original adjustment must be free in This engine is fitted with cylinder liner base O-rings (J) their channels. and cylinder liner shaft seals (F). Ensure the rings are fitted in the correct orientation.
Page 88: Refitting Cylinder Liner - Pistons - Con Rods
ENGINE AND PERIPHERALS Overhauling the engine Therefore, the protrusion (X) should be checked in the NOTE: the parts supplied in the cylinder liner-piston following way: operation kit are identical to those used for this operation. Mark the parts in each box from A to D to –...
Page 89 ENGINE AND PERIPHERALS Overhauling the engine Before fitting the cylinder liners-pistons-con rods assemblies in the cylinder blocks, don't forget to place an O-ring on each cylinder liner, making sure that it is not twisted, as well as a shaft seal.. Fit the cylinder liner retaining flange Mot.
Page 90 ENGINE AND PERIPHERALS Overhauling the engine Fit the con rod bearings caps with their shells, observing the pairing with the con rods. Fit and tighten the new con rod bearing bolts to a torque of 6.5 daNm. Check that the mobile assembly can rotate freely. 10-88...
Page 91: Checking Piston Protrusion
ENGINE AND PERIPHERALS Overhauling the engine CHECKING PISTON PROTRUSION Example: Protrusion in position 2: 1.09 mm. Clean the piston heads. Turn the crankshaft once clockwise at the timing end to bring piston n˚ 1 near to top dead centre. Position 2 Place tool Mot.
Page 92 ENGINE AND PERIPHERALS Overhauling the engine Assessment and repair of the oil pump Checking the oil pump Removing the valve Check the clearances: Clearance A – minimum (in mm) 0.05 – maximum (in mm) 0.12 80142R Clearance B – minimum (mm) 0.02 –...
Page 93 ENGINE AND PERIPHERALS Overhauling the engine Refitting the oil pump Refit the oil pump control shaft, circlip on the oil pump side. Check for the presence of the two centring pins (A). Refit the oil pump and tighten to a torque of 4 daNm. 16562S 10-91...
Page 94 ENGINE AND PERIPHERALS Overhauling the engine Refitting the relay shaft Oil and fit the relay shaft, tightening the clamp bolts to a torque of 1 daNm. Refit the vacuum pump. On APG pumps, the pinion (A) is force fitted. 16557S 16548R On the BARMAG pumps, the pinion (B) is not fixed to the pump.
Page 95 ENGINE AND PERIPHERALS Overhauling the engine Refitting the oil filter holder Fitting the crankshaft seals Replace the O-rings (G) when refitting. – flywheel side, Mot. 1297. 83334R – timing side, Mot. 1298. Fitting the relay shaft seal Push the seal in until tool Mot. 1299 butts up against the holder.
Page 96 ENGINE AND PERIPHERALS Overhauling the engine Refitting the sump Aluminium sump Metal sump Fit a rubber gasket. The alignment of the cylinder block and the sump must be respected (flywheel side) to model: prevent the clutch housing from being damaged when the gearbox is fitted to the engine.
Page 97 ENGINE AND PERIPHERALS Overhauling the engine For engine sump with reinforcing plate Refitting Remove all traces of grease from the cylinder block and the reinforcing plate with brake cleaner (for example). Fit two threaded rods (T) ∅ 7 length 30 mm and cut a groove at the end of one rod with a hacksaw.
Page 98 ENGINE AND PERIPHERALS Overhauling the engine Marking of the bolts fitting the plate to the cylinder block plate and the sump to the plate. NOTE: the plate gasket is fitted dry. Four types of bolt marked as follows: : 17 bolts (M7 x 100-50), tightening torque: 1.2 to 1.8 daNm : 21 bolts (M6x100-16), tightening torque: 0.7 to 1.1 daNm : 1 bolt (M10x150-40), tightening torque: 3.2 to 4.8 daNm : 9 bolts (M10x150-75), tightening torque: 3.2 to 4.8 daNm...
Page 99 ENGINE AND PERIPHERALS Overhauling the engine Fitting the flywheel Close the stop, if there is one fitted on the flywheel. Use Loctite AUTOFORM to coat the flywheel bearing Refit: face on the crankshaft – the clutch, tightening it to a torque of 2 daNm. –...
Page 100: Refitting Top Engine
ENGINE AND PERIPHERALS Overhauling the engine REFITTING THE TOP ENGINE Position the pistons in mid-stroke and remove tool Mot. 521-01. Positioning the cylinder head gasket It is necessary to use tool Mot. 720 placed in the hole (A) on the cylinder block. Check for the presence of the centring pin (B).
Page 101 ENGINE AND PERIPHERALS Overhauling the engine Checking the piston-cylinder head clearances Checking the piston-valve clearances Using a locally manufactured tool (formerly tool Rou. 541) fixed to a camshaft bearing mounting, place the dial gauge on the stem of the valve retained for measuring the valve clearance dimensions.
Page 102 ENGINE AND PERIPHERALS Overhauling the engine Value of the piston-cylinder head clearances Valve clearance (measurement B) Form this dimension (piston - valve), subtract the valve On the inlet and exhaust valves of the 4 cylinder: clearance value measured earlier; the result (piston - cylinder head clearance) should be more than 0.6 mm.
Page 103 ENGINE AND PERIPHERALS Overhauling the engine Fitting the camshaft seal (timing side) Refit: – the camshaft sprocket and tighten to a torque of Fit the seal (18) to the mounting bush Mot. 1300. Oil 5 daNm, the external diameter of the seal. Fit the assembly on –...
Page 104 ENGINE AND PERIPHERALS Overhauling the engine Adjusting the rocker arms Bring the exhaust valve of cylinder n° 1 to the fully open position, then adjust the inlet valve clearance for cylinder n° 3 and the exhaust valve clearance for cylinder n° 4. Use the same method for the other cylinders following the order given in the table below.
Page 105 ENGINE AND PERIPHERALS Overhauling the engine Setting the timing Check the existing clearance between the tension wheel support in locked position and the setting bolt (A); a 0.1 mm feeler gauge should fit between the support and the bolt, and then tighten the lock nut. 16535-1R Information: –...
Page 106 ENGINE AND PERIPHERALS Overhauling the engine NOTE: fit the air conditioning compressor belt (if fitted) before replacing the timing belt. Fit the timing belt starting from the crankshaft and working towards the relay shaft. Line up the markings of the timing belt with those of the pulleys and crankshaft sprockets.
Page 107 ENGINE AND PERIPHERALS Overhauling the engine Remove TDC setting rod Mot. 861 or Mot. 1054 and Turn the crankshaft four times and re-position the replace the cap. timing at setting point. Undo the tension wheel fasteners half a turn again and it will automatically shift under the action of its spring and come into contact with the belt.
Page 108 ENGINE AND PERIPHERALS Overhauling the engine NOTE: Using device Mot. 1505 Switch on the device and bring the read head (A) up to the belt wire for measuring. Hold the read head between approximately 5 and 10 mm from the belt (distance X). The measurement can be read on side (1) or (2) of the belt as appropriate.
Page 109 ENGINE AND PERIPHERALS Overhauling the engine The two sensors must not both be facing the belt at the Take the measurement by vibrating the belt with your same time during measurement. finger. A bleep sounds to confirm the measurement. 16168S 16166S 16169S 16167S...
Page 110: Tensioning Procedure
ENGINE AND PERIPHERALS Overhauling the engine TENSIONING PROCEDURE 852 - J8S engines (without pretensioning) It is very important to follow these instructions for tightening the belt: – engine cold (ambient temperature), – fit the new belt; the timing should be at the setting point (top dead centre), –...
Page 111 ENGINE AND PERIPHERALS Overhauling the engine – tighten the tension wheel, – turn the crankshaft four times and re-position the timing at setting point, – Position the read head of Mot. 1505 and take the measurement. Check to see if it is within in the fitting tension tolerance, and if not, adjust it using the tension setting tool, –...
Page 112 ENGINE AND PERIPHERALS Overhauling the engine Injection pump setting Remove the injector pump rear cap and fit dial gauge support Mot. 856 and a dial gauge fitted with an adapter. 16541R1 Turn the engine over once and calibrate the dial gauge on the bottom dead centre of the injection pump piston (check that the dial gauge pin can move freely in the pump body).
Page 113 ENGINE AND PERIPHERALS Overhauling the engine Read the piston lift on the dial gauge, which should be: Top dead centre setting (rod in the crankshaft) MANUFACTURER TYPE Piston lift (mm) Pin lift (mm) VE.. R452 BOSCH VE.. R452-1 0.75 VE.. R452-2 BOSCH VE..
Page 114 ENGINE AND PERIPHERALS Overhauling the engine Top dead centre setting (rod in the crankshaft) MANUFACTURER TYPE Piston lift (mm) Pin lift (mm) VE.. R484 BOSCH 0.75 VE.. R484-1 DPC R8443 B142B dimension "X" on ROTO DIESEL pump DPC R8443 B143B DPC R8443 A400 A to A409 A (A) DPC R8443 A401 B to...
Page 115 ENGINE AND PERIPHERALS Overhauling the engine Refit: – the timing cover, – the high pressure pipes on the injection pump using Mot. 1383, – the inlet and exhaust manifolds, by tightening the nuts to a torque of 2.8 daNm, – the lifting bracket at the flywheel end and the fuel pipe support plate, –...
Page 116: Notes On Fitting Accessory Belts
ENGINE AND PERIPHERALS Overhauling the engine NOTES ON FITTING ACCESSORIES BELTS V BELT Tensioning procedure for new belts Engine cold, ambient temperature. Fit the new belt. Bring the tension wheel into contact with the belt and tighten to obtain the recommended fitting tension. Tighten the tension wheel.
Page 117 TENSION TYPE GRAM SEEM UNITS UNITS IN HERTZ Alternator 106 ± 4 158 ± 5 J8S - 852 Water pump (V-belt) 101 ± 4 222 ± 7 Power steering (V-belt) Air conditioning 85 ± 5 88 ± 4 (four ribs) Alternator 98 ±...
Page 118 ENGINE AND PERIPHERALS Overhauling the engine 10-116...
Page 119 ENGINE AND PERIPHERALS Overhauling the engine Crankshaft Alternator Power assisted steering pump Air conditioning compressor Water pump Tension wheel → Tension test point Refit the engine wiring harness. Remove the engine from the DESVIL support. Refit: – the metal oil vapour rebreather pipe tubes for the bottom engine.

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