Renault J8S manuale d’uso

Workshop repair manual ENGINE (Diesel) Indirect injection Aluminium, 4 cylinders Types Vehicles 852 J8S Renault 18 Fuego Renault 20 Renault 21 Renault 25 Renault 30 Safrane Espace Trafic Master Jeep Cancels and replaces note dated JULY 1991 77 11 293 322 "The repair methods given by the manufacturer in this document are based on the technical [...]

Contents Page 10 ENGINE AND PERIPHERALS Foreword Diagram Engine identification Tightening torques (in daNm) Lubrication circuit diagram Specifications Standard replacement Special tooling required Essential equipment Cylinder head exploded drawing Overhauling the engine Removing top engine Stripping the cylinder head Cleaning Checking the gasket fa[...]

ENGINE AND PERIPHERALS Foreword 10 110 ENGINE AND PERIPHERALS Foreword USING THE MANUAL There are two main sections in this manual: – technical specifications, – overhauling the engine. T o repair the component on the vehicle, refer to the Workshop Repair Manual and Technical Notes for the vehicle. UNITS OF MEASUREMENT – All dimensions are gi[...]

ENGINE AND PERIPHERALS Diagram 10 10-2 Diagram J8S TURBO ENGINE[...]

ENGINE AND PERIPHERALS Diagram 10 10-3 J8S AND 852 ENGINES[...]

ENGINE AND PERIPHERALS Engine identification 10 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[...]

ENGINE AND PERIPHERALS Engine identification 10 10-5 Engine Index Type Compression ratio Bore (in mm) Stroke (mm) Capacity (in cm 3 ) 852 700 710 720 750 1276 1344, 2354, 1354 Pxx3 Txx3 Vxx3 J8S 240 330 600 604 620 622 704 708 714 738 742 746 758 774 786 788 J115, S115 Rxx3 X480 X48A PxxF TxxK X486 B290 X488 B29W X488 X486, X48W TxxF J114 X487 X48P[...]

ENGINE AND PERIPHERALS Engine identification 10 10-6 Engine Index Type Compression ratio Bore (in mm) Stroke (in mm) Capacity (in cm 3 ) J8S 610 612 702 706 711 712 736 740 760 772 776 778 J63D, S63D J63E 1270 B296 1344 TA, 1354TA 1346, 1356, 1366 B296 X48, 6, V, V 4x4 B546 J635, S635 J634 J633 21.5/1 86 89 2068 J8S 784 800 814 X480 CJ XJ 21.5/1 86[...]

ENGINE AND PERIPHERALS Tightening torques (in daNm) 10 Tightening torques (in daNm) A 0.5 to 0,9 B 2.5 to 3 C 1.3 to 1.8 D 2 E 6 to 6.5 F 13 G 2.5 H 1.3 J 5 K 1.25 10-7[...]

ENGINE AND PERIPHERALS Tightening torques (in daNm) 10 10-8 CYLINDER BLOCK * Preheating shunt nut connector: 0.25 daNm ** Aluminium sump : 1.4 to 1.7 daNm Metal sump : 1.25 daNm A 2 B 2 C 2.5[...]

ENGINE AND PERIPHERALS Tightening torques (in daNm) 10 10-9 * Turbo: IHI : 4.5 daNm Garrett : 2.6 daNm A 3.2 to 3.9 B 2 C 1.3 D 1.4[...]

ENGINE AND PERIPHERALS Tightening torques (in daNm) 10 10-10 * Turbo: IHI : 4.5 daNm Garrett : 2.6 daNm A 5 B 5 C 2.25 to 2.75 D 5 E 13 F 2.5 G 1.3[...]

ENGINE AND PERIPHERALS Tightening torques (in daNm) 10 10-11 A 2 B 4 C 5 to 5.5[...]

ENGINE AND PERIPHERALS Tightening torques (in daNm) 10 * Spark plug M12 tighten to 2 daNm Spark plug M10 tighten to 1.6 daNm ** 1 st model: – coolant pipe : 0.8 to 1 daNm – coolant rail : 2 to 2.5 daNm 2 nd model: – cooling jets only : 1.2 to 1.4 daNm *** Seethe cylinder head tightening procedure page 10-16 10-12 A 7 B 2.3 C 6.5 ± 0.25 D 8.7[...]

ENGINE AND PERIPHERALS Tightening torques (in daNm) 10 10-13 * Turbo: IHI : 4.5 daNm Garrett : 2.6 daNm A 3.2 to 3.9 B 8.75 to 9.75 C 2.5 to 3 D 3 E 2.3[...]

ENGINE AND PERIPHERALS Lubrication circuit diagram 10 10-14 Lubrication circuit diagram Key: All types Turbo with radiator Turbo with heat exchanger 1 returning cooling jets 2 integrated cooling jets 1 st fitting 3 integrated cooling jets 2 nd fitting[...]

ENGINE AND PERIPHERALS Lubrication circuit diagram 10 10-15[...]

ENGINE AND PERIPHERALS Specifications 10 10-16 Specifications CYLINDER HEAD Tightening procedure All the cylinder head bolts must always be changed after removal (including the mounting studs). Lubricate the threads and under the bolt heads with engine oil. REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting [...]

ENGINE AND PERIPHERALS Specifications 10 10-17 J8S longitudinal engine Carry out the following in the order prescribed: 1 st tightening : 3 daNm 2 nd tightening: 5 daNm Wait 3 minutes settling time. Unscrew bolt 1 until it is completely free, and then carry out: 1 st retightening 2 daNm 2 nd retightening (angle) according to the table: Repeat the o[...]

ENGINE AND PERIPHERALS Specifications 10 10-18 Thickness of the cylinder head gasket There are several dif ferent thicknesses of cylinder head gasket as replacements. When the 1 model (A) gaskets have been used up, the Parts Store will only deliver 2 nd model (B, C or D) gaskets. 1 st model On engines fitted with a 1 st model cylinder head gasket ([...]

ENGINE AND PERIPHERALS Specifications 10 10-19 Cylinder head cover gasket All types except J8S 736 1 st model: This gasket is not symmetrical. Cylinder side graphitised surface. 2 nd model: This gasket has a an area intended to prevent confusion; it is located opposite the timing end. 3 rd model: same position as the 2 nd model . 93779-1R 93780R[...]

ENGINE AND PERIPHERALS Specifications 10 10-20 Height of the cylinder head (in mm) H = 104.5 ± 0.04 NO REDRESSING IS PERMITTED T est the cylinder head for cracks. (refer to the mating face checking section in the Engine overhaul section ). Maximum mating face deformation 0.05 mm Prechamber Assembled prechamber This is fitted in the cylinder head. [...]

ENGINE AND PERIPHERALS Specifications 10 10-21 Bare prechamber Half-prechamber Valves See the "Overhauling the engine" section for how to redress the valve seats. 92448-1S Stem diameter (in mm) Inlet: 7.991 + 0 - 0.02 Exhaust: 7.978 + 0 - 0.02 Setting angle 90 ˚ Head diameter (in mm) Inlet: Exhaust: 40.32 ± 0.12 33.32 ± 0.12 Maximum va[...]

ENGINE AND PERIPHERALS Specifications 10 10-22 Valve guides The inlet and exhaust guides have valve stem seals which must be changed every time the valves are removed. The valve stem seals must be fitted using tool Mot. 1511 or with the FACOM tool, part number DM6J4 for example. NOTE: do not lubricate the valve stem seals before fitting them. Mot. [...]

ENGINE AND PERIPHERALS Specifications 10 10-23 Valve springs The inlet and exhaust valve springs are identical. Rocker arm rail When performing operations on faults that cause metallic particles to become suspended in the lubricating oil, e.g.: – damaged con rod bearing shells or crankshaft, – parts grating, it is essential to replace: – the [...]

ENGINE AND PERIPHERALS Specifications 10 10-24 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 16576-1R 16576-2R 16576-3R[...]

ENGINE AND PERIPHERALS Specifications 10 10-25 The paint mark that indicates diameter class is also present on the piston. 1 Height between the gudgeon pin and the top of the piston (see table below). 2 Modification index, for supplier's use only. 3 For supplier's use only. 4 Dater, for supplier's use only. 5 Diameter class mark, pai[...]

ENGINE AND PERIPHERALS Specifications 10 10-26 Rings Three rings (thickness in mm ) FITTING THE RINGS Rings set to their original adjustment must be free within their channels. Ensure the fitting direction is observed. Fit the rings so that the gaps are equally spaced around the piston. Normally aspirated engine – Compression – Sealing – Scra[...]

ENGINE AND PERIPHERALS Specifications 10 10-27 CON RODS The small end has a bush. N.B.: the small end bushes cannot be replaced or re- drilled. WARNING: do not use a sharp point to mark the bearing caps in relation to their con rods as this could start a crack in the rods. Use an indelible marker pen. Normally aspirated engine The big end and the h[...]

ENGINE AND PERIPHERALS Specifications 10 10-28 Direction for fitting the circlips on the piston Fit the circlips on the piston as shown below. CRANKSHAFT Number of bearings 5 Burnishing ● normally aspirated engine with ● turbo engine 1 st fitting without ● turbo engine 2 nd fitting with N.B.: non-burnished crankshafts fitted on turbo engines [...]

ENGINE AND PERIPHERALS Specifications 10 10-29 Burnished crankshaft In case of correction, the burnishing must remain intact on 140 ˚ in the areas indicated by the arrows. These zones are defined in sections (A) and (B), used as examples. Identification of crankshafts: Normally aspirated engine ● eight counterweights, ● Burnished bushings and [...]

ENGINE AND PERIPHERALS Specifications 10 10-30 RELAY SHAFT Longitudinal play (in mm) 0.05 to 0.15 PISTON BASE COOLING RAIL Never remove the mounting bolts (H) if the sump is not removed. CLUTCH SHAFT CENTERING BEARINGS Gearbox: – with bearing in the clutch housing: short clutch shaft (A) . – without bearing in the clutch housing: long clutch sh[...]

ENGINE AND PERIPHERALS Specifications 10 10-31 CYLINDER LINER Assembling cylinder liners - cylinder block in mm Internal diameter 86 Diameter of the base centering (D) 93.6 Protrusion of cylinder liner without gasket (X) 0.07 to 0.13 Base seal (J) O ring. Shaft seal (F) barrel shape in mm Height (H) of the cylinder liner 93.035 to 93.065 Depth (K) [...]

ENGINE AND PERIPHERALS Specifications 10 10-32 Identification of liners Normally aspirated engine 1 st model 2 nd model[...]

ENGINE AND PERIPHERALS Specifications 10 10-33 Turbo engine 1 st model Cylinder liner with two notches and piston fitted cooling oil jets. 2 nd model Cylinder liner with four notches and integral piston cooling oil jets. 3 rd model Cylinder liner with no notches and tube piston cooling oil jets. 4 th model Special Parts store cylinder liner with fo[...]

ENGINE AND PERIPHERALS Specifications 10 10-34 OIL PUMP Removal Remove: – the oil pump cover, – the discharge valve and its spring. Checking clearances Clearance (A) – minimum (in mm) 0.05 – maximum (in mm) 0.12 Clearance (B) – minimum (in mm) 0.02 – maximum (in mm) 0.10 Refit: – the oil pump cover by tightening the bolts to a torque [...]

ENGINE AND PERIPHERALS Specifications 10 10-35 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). Turbo engine Remove: – the supply and oil return pipes (D), – the strut (B), – [...]

ENGINE AND PERIPHERALS Specifications 10 10-36 FITTING THE ENGINE T O 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. SAFETY PRECAUTIONS Turbocharger engine After pe[...]

ENGINE AND PERIPHERALS Specifications 10 10-37 CONSUMABLES PRECAUTIONS WASHING THE ENGINE Do not let the alternator come into contact with water or cleaning products. Do not let water run into the air intake pipes. FITTING THREAD INSERTS Threaded holes on all engine component parts can be repaired by using thread inserts. PARTS TO BE REPLACED WHEN [...]

ENGINE AND PERIPHERALS Standard exchange 10 10-38 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, – the cylinder head cover, – the heater plugs, – the timing belt tensioner, – the timi[...]

ENGINE AND PERIPHERALS Essential special tooling 10 Essential special tooling Illustration Tool number Parts Department number Description Mot. 11 00 01 072 500 Crankshaft spigot bush extractor. Mot. 251-01 00 00 025 101 Dial gauge support. Used with Mot. 252-01 . Mot. 252-01 00 00 025 201 Dial gauge support thrust plate. Used with Mot. 251-01 . Mo[...]

ENGINE AND PERIPHERALS Essential special tooling 10 10-40 Illustration Tool number Parts Department number Description Mot. 591-02 00 00 059 102 Magnetised flexible shaft for cylinder head angular wrench. Mot. 591-04 00 00 059 104 Cylinder head angular wrench, 1/2" drive with gauge. Mot. 647 00 00 064 700 Tappet adjuster. Mot. 720 00 00 072 00[...]

ENGINE AND PERIPHERALS Essential special tooling 10 10-41 Illustration Tool number Parts Department number Description Mot. 855 00 00 085 500 Timing gear locking strap. Mot. 856 00 00 085 600 BOSCH diesel injection pump timing gauge support. Mot. 861 00 00 086 100 TDC setting rod. Mot. 997-01 00 00 099 701 Diesel injector removal/refitting wrench. [...]

ENGINE AND PERIPHERALS Essential special tooling 10 10-42 Illustration Tool number Parts Department number Description Mot. 1079-02 00 00 107 902 Dial gauge for Mot. 1079-01 timing gauge kit for Roto-Diesel pumps. Mot. 1281-01 00 00 128 101 Oil filter removing tool 96 mm diameter . Mot. 1297 00 00 129 700 Crankshaft oil seal fitting tool (flywheel [...]

ENGINE AND PERIPHERALS Essential special tooling 10 10-43 Illustration Tool number Parts Department number Description 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. 1573 00 00 157 300 Cylinder head support.[...]

ENGINE AND PERIPHERALS Essential equipment 10 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, – FACOM , part number DM360 for example. Tooling[...]

ENGINE AND PERIPHERALS Cylinder head exploded drawing 10 Cylinder head exploded drawing 10-45[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-46 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 lockin[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-47 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) [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-48 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 p[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-49 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. 1383 , – the cold start coolant pipe, – the injection pump rear mou[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-50 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[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-51 – the thermostatic unit, – the camshaft pulley using Mot. 799-01 (take care with the key) , – the gasket. 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 h[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-52 Remove: – the camshaft, – the prechambers (11) and, if necessary, gently tap with tool B. Vi. 31-01 inserted in the injector housing. Some prechambers may be free; be careful not to let them fall out. Compress the valve springs. Remove the half rings, the upper and lower cups and the spring[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-53 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. Insert sleeve (1) in the guide [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-54 CLEANING It is very important not to scratch the mating faces of any aluminium components. Use the Décapjoint product to dissolve any part of the gasket which remains attached. Apply the product to the parts to be cleaned; wait about ten minutes, then remove it using a wooden spatula. W ear gl[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-55 REDRESSING THE VALVE SEATS INLET Width of mating faces X (in mm) 1.75 ± 0.2 Angle ( α ) 90 ˚ The mating face is corrected (1) using burr N 208 46 ˚. Reduce the width of this mating face at (2) using burr N 213 15 ˚ until width X is obtained. EXHAUST Width of mating faces X (in mm) 1.75 ± [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-56 ASSESSMENT AND REPAIR OF ROCKER ARM RAILS The filter (24) located in the rocker arm rail (17) must be replaced in all operations on faults that cause metallic particles to become suspended in the lubricating oil. In this case, the engine oil and oil filter on the main pipe must also be replaced[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-57 The rocker arm shaft is oriented using a full dog point screw. The shaft bearing greasing holes are directed towards the camshaft (the oil passes through the rocker arm shaft bearings). Rocker arms The inlet and exhaust rocker arms are identical and both have an oil way to lubricate the cams on[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-58 The valve stem seals must be fitted using tool Mot. 1511 or with the FACOM tool, part number DM6J4. NOTE: do not lubricate the valve stem seals before fitting them. Fitting new valve stem seals. Locate the valve in the cylinder head. Place the barrel of the Mot. 151 1 tool over the valve stem ([...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-59 Push the valve stem seal past the tool barrel, then withdraw the barrel. Place the pushrod over the valve stem seal. 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 upper section of the valve stem [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-60 Place the guide tube and sleeve assembly, adjusted at removal, over the pushrod. Push the valve stem seal down by tapping the top of the sleeve with the palm of your hand until the guide tube touches the cylinder head. Repeat the above sequence of operations for all the valves. 15738-4S 15739-6[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-61 Fit: – the spring collar rings (7), – the springs (8) (inlet and exhaust springs are identical), – the cups (9). Compress the springs. Fit the half rings (10) (inlet and exhaust valve half rings are identical). Check the amount by which the valve is retracted from the cylinder head gasket[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-62 Turbo engine Mark X : a drill stamp. Normally aspirated engine Mark X : none. Engines J8S 736 and 740 Diameter (D) in mm: – Original dimension 1 = 35.5 – Original dimension 2 = 35.7 It is essential to take a note of the diameter (D) of the prechamber housing in the cylinder head and to refi[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-63 Refit the heater plugs (12) and their electrical wiring. Place new heat flange welds (27) on a cylinder head being re-used. T ake a note of the dimensions of the removed flame- shields and replace them with new ones of the same diameter. Diameter (D) in mm: – original dimension 1 = 15.5 – o[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-64 Engines J8S 736 and 740 Injector holders - special features The cylinder head has been modified to accept BOSCH "KCA" threaded injector holders. 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 i[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-65 CYLINDER BLOCK EXPLODED DRAWING[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-66 REMOVING THE BOTTOM ENGINE Fit the flywheel locking tool Mot. 582 and remove the clutch and the flywheel. Unscrew the three mounting bolts on the injection pump support to remove the unit comprising the pump, the support and the injection pump pulley. Remove the vacuum pump then remove the pini[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-67 – the tension wheel, – the relay shaft pinion, use immobiliser Mot. 855 , – the key, – the relay shaft cover, – the seal using a lever, – the relay shaft retainer, – the relay shaft (2), – the crankshaft timing sprocket using a two handle extractor, – the key. 16532-2S 16532-1[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-68 Remove the sump. 1 st model Three types of bolt marked A, B and C. 2 nd model Two types of bolt marked as follows: – 13 bolts (M7 x 100-40), – 8 bolts (M7 x 100-52). Remove: – the crankshaft seals, – the oil filter using Mot. 1281-01 . Position the pistons at mid-stroke. Disconnect the [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-69 For engine sump with reinforcing plate Remove: – the oil pump strainer, bolt (A), keeping the pump pinions, – the two bolts on the oil pump body, – the oil pump body, – the oil level sensor, – the plate mounting bolts (then remove all the marked bolts). 91576R[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-70 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[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-71 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. Remove the bearing caps and shells.[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-72 Extract the cylinder liners and pistons (mark them). Mark the crankshaft bearing caps according to their housing and then remove them. NOTE: Extracting crankshaft bearings 1 and 5 T o extract the silicone injected crankshaft bearings 1 and 5 use a locally manufactured metal tool of an approxima[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-73 Remove the filter holder. Replacing the bearing NOTE: if the gearbox is fitted with a short shaft (A) , it does not need a bearing in the crankshaft. If the gearbox is fitted with a long shaft (B) the crankshaft must be fitted with a bearing. Remove the bearing using tool Mot. 11 . Refitting th[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-74 EXTRACTING THE CON RODS - PIST ONS Remove: – the rings using ring pliers, – the circlips (E) retaining the gudgeon pin, – the gudgeon pin (F). CLEANING Remove the threaded plugs in the lubricating pipes to clean the cylinder block. It is very important not to scratch the mating faces of a[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-75 Clean the cylinder head mounting holes, especially in the oil outlet duct (C). This is necessary in order to obtain the correct tightening of the bolts. Also pass a wire through the crankshaft pipes. REFITTING THE BOTTOM ENGINE Replace the lubrication channel plugs, tightening them to: ● 8 da[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-76 When fitting the dipstick guide tube, fit the collar to butt against the cylinder block. If necessary, wind a cloth around the external diameter of the tube to make fitting easier and coat it with Loctite SCELBLOC . Fit the various mounting studs. The water pump, cylinder block and timing belt [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-77 For engines fitted with a piston base cooling rail, the oil gallery mounting bolts (H) need a drop of Loctite FRENETANCH . Do not add more, as too much increases the risk of blocking the oil circulation around the mounting bolt. Engines 852 before n ˚ 42 253 Check that seals (D) are present be[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-78 Fitting the crankshaft bearing shells Identification Only grooved and pierced crankshaft bearing shells are supplied as spares, whatever the crankshaft lubrication configuration. Fit the shells on to the bearings and the cylinder block and oil them. Fit the side shims for crankshaft n ˚ 2 (gro[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-79 T emporarily fit bearing n ˚ 1 with no lateral seals in order to fit the magnetic holder. Checking end play ( in mm ): Fitting the crankshaft bearings There are two ways to ensure that bearings 1 and 5 are properly sealed: 1 - Fit butyl rubber seals. 2 - Inject with silicone. 1 - Fitting butyl[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-80 Apply a thin coating of RHODORSEAL 5661 to the supports on bearings 1 and 5 without blocking the oil return on the sump seals. Screw the ∅ 12 mm centering studs (G) ( span 1.50 ) in to the cylinder block. Fit the bearings. Oil the two seals. Use two steel shims placed either side of the beari[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-81 Thoroughly clean the cylinder block and the bearing cap surfaces (A). Degrease using a cloth soaked in diluted cleaning agent. Allow to dry. NOTE: older engines have grooves (B) in their cylinder blocks. Do not obstruct these oil grooves when applying RHODORSEAL 5661 . NOTE: New fitting (J engi[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-82 Lightly coat the inner surfaces of the cylinder block in (B) with RHODORSEAL 5661 without obstructing the oil grooves. Fit the caps and tighten them to a torque of 8.75 to 9.75 daNm . Mix 45 ml of RHODORSEAL 5661 (approximately half a 100 g tube ) with half the tube of hardener. Stir with the s[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-83 Use a cloth to wipe up any excess paste, both inside and outside the cylinder block, and at (A). Pass a thin wire through the lubricating channels to check that they have not been blocked (this can also be done using a compressed air gun). Allow to dry for a few moments and cut the excess off t[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-84 REFITTING AND ASSEMBLING PISTON CON RODS Go to the cylinder liner-piston replacement 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. Completely dissolve the non-stick [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-85 FITTING THE PIST ON RINGS Rings set to their original adjustment must be free in their channels. Ensure the rings are fitted in the correct orientation. Fit the rings such that the gaps are equally spaced around the piston. CHECKING CYLINDER LINER PROTRUSION This engine is fitted with cylinder [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-86 Therefore, the protrusion ( X ) should be checked in the following way: – place the cylinder liner not fitted with seals , in the cylinder block, – check protrusion ( X ) using tools Mot. 251-01 and Mot. 252-01 . It should be between 0.07 and 0.13 mm . Position the cylinder liners so that: [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-87 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 liners-pistons-con rods assemblies in the cylinder block, making [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-88 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.[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-89 CHECKING PIST ON PROTRUSION Clean the piston heads. Turn the crankshaft once clockwise at the timing end to bring piston n˚ 1 near to top dead centre. Place tool Mot. 252-01 on the piston . Place tool Mot. 251-01 fitted with a gauge on the thrust plate Mot. 252-01 , the dial gauge measuring pi[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-90 Assessment and repair of the oil pump Removing the valve Checking the oil pump Check the clearances: Clearance A – minimum (in mm) 0.05 – maximum (in mm) 0.12 Clearance B – minimum (mm) 0.02 – maximum (mm) 0.10 80142R 86303-1R[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-91 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[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-92 Refitting the relay shaft Refit the vacuum pump. On APG pumps, the pinion (A) is force fitted. On the BARMAG pumps, the pinion (B) is not fixed to the pump. Refit the relay shaft before refitting the pinion (B). Oil and fit the relay shaft, tightening the clamp bolts to a torque of 1 daNm . 165[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-93 Refitting the oil filter holder Replace the O-rings (G) when refitting. Fitting the relay shaft seal Push the seal in until tool Mot. 1299 butts up against the holder. Fitting the crankshaft seals – flywheel side, Mot. 1297 . – timing side, Mot. 1298 . If the seal lip marks the crankshaft m[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-94 Refitting the sump Metal sump 1 st model: Fit a cork or rubber gasket. A 1 st model B 2 nd model 2 nd model: Only fit a rubber gasket. Aluminium sump Fit a rubber gasket. The alignment of the cylinder block and the sump must be respected (flywheel side) to prevent the clutch housing from being [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-95 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. Put a blob of RHODORSEAL 5661 wher[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-96 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 b[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-97 Fitting the flywheel Use Loctite AUTOFORM to coat the flywheel bearing face on the crankshaft Fit the flywheel. Place a drop of Loctite FRENETANCH on the new bolts. Replace the flywheel bolt stop if there is one fitted. Lock off the flywheel using locking tool Mot. 582 and tighten the bolts to [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-98 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). Fit the cylinder head gasket. Refit t[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-99 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. A foot dimensi[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 100 Value of the piston-cylinder head clearances Form this dimension (piston - valve), subtract the valve clearance value measured earlier; the result (piston - cylinder head clearance) should be more than 0.6 mm . Example of completed measurement, cylinder head removed from the engine: 1) Piston[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 101 Fitting the camshaft seal (timing side) Fit the seal (18) to the mounting bush Mot. 1300 . Oil the external diameter of the seal. Fit the assembly on to the camshaft (16). If the seal lip marks the crankshaft mating face a 1.5 mm thick washer (fitting the tool) must be placed between the seal[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 102 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 b[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 103 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. Fit TDC setting rod Mot. 861 or Mot. 1054 . Bring the camshaft sproc[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 104 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. Check that the timing [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 105 Remove TDC setting rod Mot. 861 or Mot. 1054 and replace the cap. Engine fitted with an automatic tension wheel Undo the tension wheel fasteners half a turn and it will automatically shift under the action of its spring and come into contact with the belt. Redo the fasteners. T urn the cranks[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 106 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. Either sensor, (a) or (b[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 107 The two sensors must not both be facing the belt at the same time during measurement. T ake the measurement by vibrating the belt with your finger. A bleep sounds to confirm the measurement. 16168S 16169S 16166S 16167S[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 108 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), – bring the tension wheel again[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 109 – 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,[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 1 10 Injection pump setting Remove the injector pump rear cap and fit dial gauge support Mot. 856 and a dial gauge fitted with an adapter. 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 i[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10-111 Read the piston lift on the dial gauge, which should be: MANUFACTURER TYPE Top dead centre setting (rod in the crankshaft) Piston lift ( mm ) Pin lift ( mm ) BOSCH VE.. R452 VE.. R452-1 VE.. R452-2 0.75 - BOSCH VE.. R158 0.70 - ROTO DIESEL DPC R 8443 B403C - dimension "X" on pump BOS[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 1 12 If this is not the case, correct the setting. IMPORTANT : the following operations must be carried out in this order. Remove TDC setting rod Mot. 861 or Mot. 1054 . Turn the injection pump to obtain the desired setting value (see above table). Tighten the injection pump mounting bolts. Turn [...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 1 13 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, – the multifunction support, t[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 1 14 NOTES ON FITTING ACCESSORIES BEL TS V BEL T 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. Turn the crankshaft over thr[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 1 15 ENGINE TYPE BELT FUNCTION FITTING TENSION IN SEEM UNITS MINIMUM OPERATING TENSION IN SEEM UNITS FITTING TENSION IN HERTZ DIA- GRAM J8S - 852 Alternator Water pump (V-belt) 106 ± 4 68 158 ± 5 1 J8S Power steering (V-belt) 101 ± 4 74 222 ± 7 2 J8S Air conditioning (four ribs) 85 ± 5 60 88[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 1 16[...]

ENGINE AND PERIPHERALS Overhauling the engine 10 10- 1 17 A Crankshaft B Alternator C Power assisted steering pump D Air conditioning compressor E Water pump T T ension wheel → T ension 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[...]