General: Specifications Lifting Towing Lubricants and Consumables Oil Change and Engine Oil Refilling Values and Settings

General
SPECIFICATIONS LIFTING TOWING LUBRICANTS AND CONSUMABLES OIL CHANGE AND ENGINE OIL REFILLING VALUES AND SETTINGS
BG0A - BG0B - BG0D - BG0G - KG0A - KG0B - KG0D - KG04

77 11 297 322 NOVEMBER 2000
All copyrights reserved by Renault. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.
EDITION ANGLAISE
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. 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."
RENAULT
General
Contents
Page
01 SPECIFICATIONS
Engine - Clutch - Gearbox Vehicle identification 01-1 01-2
02 LIFTING
Trolley jack - Axle stands Underbody lifts 02-1 02-2
03 TOWING
All types 03-1
04 LUBRICANTS AND CONSUMABLES

Packaging 04-1
05 OIL CHANGE AND ENGINE OIL

REFILLING
Engine Gearbox Power-assisted steering 05-1 05-3 05-5
07 VALUES AND SETTINGS

Capacities - Grades Dimensions Accessories belt tension Procedure for tensioning the timing belt Tightening the cylinder head Tyres and wheels Brakes Underbody height Front axle angle values Rear axle angle values 07-1 07-2 07-4 07-6 07-41 07-44 07-45 07-46 07-48 07-67
The LAGUNA Workshop Repair Manual has been prepared by specialists in repair methods and diagnostics. The document covers the methods and the diagnostic operations required in order to carry out high quality repairs on this vehicle. However, if a removal - refitting operation involves no particular features, difficulties or special tools, the method is not described in this manual, being considered very simple for a vehicle repair specialist. The labour times are the result of time and motion studies carried out in our workshops, even though certain methods have not been described in the Workshop Repair Manual.
UNITS OF MEASUREMENT
G G G G G
All dimensions are given in millimetres ( mm) except where stated otherwise. Tightening torques are expressed in decaNewtonmetres ( daNm.) Pressures are expressed in bar (rappel: 1 bar = 100 000 Pa). Electrical resistance is expressed in ohms ( ). Voltages are expressed in volts (V ).
TOLERANCES Tightening torques given without a tolerance must be accurate to within:

G G
In degrees: 3. In daNm: 10%.
MATERIALS AND TOOLS The repair methods described for the vehicles in the RENAULT range require special materials and tools in certain cases. There is a wide choice in the catalogue of special materials and tools.
SPECIFICATIONS 101 Engine - Clutch - Gearbox

Engine Vehicle type Type XG0A XG0B XG0G XG0D XG0A XG0B K4M F4P F9Q L7X K4M F4P Capacity (cm 3) 1598 1783 1870 2946 1598 1783 Clutch type Gearbox type
01
JH3 JR5 PK6 SU1 DP0
215 CPOE 3500 215 CPOE 4400 228-7900 -
VEHICLE IDENTIFICATION Example: BG0A B G : Body type (five-door) : Project code
0A : Engine suffix
01-1
SPECIFICATIONS Vehicle identification

LOCATION OF VEHICLE IDENTIFICATION PLATE
01
1 2 3 4 5
Vehicle type and chassis number This information is repeated in the marking (B). MGVW (Maximum Gross Vehicle Weight) GTW (Gross Train Weight - loaded vehicle with trailer) Front axle MGVW Rear axle MGVW
6 7 8 9 10 11 12 13
Technical specifications of the vehicle Vehicle paint reference Equipment level Vehicle type Trim code Additional equipment details Fabrication number Interior trim code
01-2
LIFTING 102 Trolley jack - Axle stands

Safety symbol (special precautions to be taken when carrying out operations).. ESSENTIAL SPECIAL TOOLS Cha. 280 -02 Adaptor cup for trolley jack Cha. 408-01 or Adaptor socket for trolley jack Cha. 408 -02
02
If a trolley jack is used, appropriate axle stands must always be used. The vehicle must not be raised by placing the jack beneath the front suspension arm or under the rear axle. Depending on the type of trolley jack, use sockets Cha. 408-01 or Cha. 408-02 for accommodating the cup Cha. 280-02. To lift at the front or the rear of the vehicle, position the jack beneath the side jacking points.
AXLE STANDS When the vehicle is to be placed on axle stands, these must be positioned: either beneath the reinforcements provided for raising the vehicle with the tool kit jack, or beneath the studs located behind the reinforcements. Axle stands are positioned at the rear by raising the vehicle at the sides.
TROLLEY JACK AT THE SIDE Use cup Cha. 280-02. Position the jack beneath the valance at the level of the front door. Position the flange correctly in the groove of the cup.
02-1
LIFTING Underbody lifts

SAFETY ADVICE Various cases have to be considered: FRONT
02
1 - REMOVING COMPONENTS As a general rule, never use a two-post lift whenever a four-post lift can be used. If this is not possible, place the lifting pads beneath the underbody flange by the tool kit jack supports.
REAR
02-2

2 - REMOVING AND REFITTING HEAVY COMPONENTS WARNING: always use a safety harness if using a two-post lift to remove heavy components. For your safety, take care to ensure that the vehicle is balanced when placed on a two-post lift. This is because removing heavy components (such as the engine and transmission assembly, rear axle or fuel tank, etc.), depending on: the vehicle load, its length, the position of the lifting pads, may cause the vehicle to become unbalanced. It is therefore essential to put a strap around or inside the bodywork and fix it to the arms of the lift between the pads. TOOLING REQUIRED Straps: 10 metres long, 25 mm wide.
02
Straps are available from SODICAM under Part No.: 77 11 172 554.
This type of strap should only be used to immobilise a vehicle on a two-post lift (for safety reasons, they should not be used for any other purpose). Use straps that are in good condition and clean (so as not to dirty the interior or the bodywork). Avoid damaging the vehicle by pulling the strap too tight (the sill panels can be protected at the point where the strap passes over them).
02-3

FITTING THE SAFETY STRAPS Fastening the vehicle with straps allows work to be carried out beneath the vehicle free from obstruction. The strap must be placed at the front and/or rear of the vehicle during any operation involving the transfer of weight. Check the strap before each use. The lift pads are placed under the vehicle by the tool kit jack support. Lift the vehicle a few centimetres. Protect the vehicle interior (seats, etc....). Place the strap through under the arms of the lift and pass twice around the vehicle, placing the strap protectors correctly so as not to damage the bodywork or upholstery. Do not pull too tight. The following example shows a vehicle secured at the front.
02
02-4
103
TOWING All types
03
OBSERVE THE TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN. NEVER USE THE DRIVESHAFTS AS AN A TTACHMENT POINT. The towing points may only be used for towing the vehicle on the road. They should never be used for removing the vehicle from a ditch or to lift the vehicle, either directly or indirectly.
FRONT
REAR
03-1
LUBRICANT 104 CONSUMABLES Packaging

DESCRIPTION PACKAGING
04
PART NUMBER 77 01 421 145
LUBRICANTS
G
MOLYKOTE "BR2" for main bearing journal faces, thrust pad guide tubes, clutch fork pads, lower suspension arm bearings, torsion bar splines, steering box, driveshaft splines. MOLYKOTE "33 Mdium" bushes on tubular rear axle, anti-roll bar rings. ANTI-SEIZE (high temperature grease) turbocharger etc. "MOBIL CVJ" 825 Black star or MOBIL EXF57C for driveshaft joints. MULTIPURPOSE GREASE wheel sensor.
1 kg tin
100 g tube 80 ml tube 180 g sachet
77 01 028 179 77 01 422 307 77 01 366 100
Aerosol
77 01 422 308
MECHANICAL SEALANTS
G
Mastic for sealing exhaust pipe unions. RHODORSEAL 5661 HARDENER KIT (RHODORSEAL 5661) for bearing cap lateral seals AUTO blue seal sealing paste.
1.5 kg tin 100 g tube Collection 100 g tube
77 01 421 161 77 01 421 042 77 01 404 452 77 01 421 080 77 01 396 227
VARNISHES
G
"CIRCUIT PLUS" varnish for repairing heated screens
Bottle
77 01 421 135
BRAKES
G
Brake fluid
0.5 l bottle DOT4
77 11 172 381
04-1
LUBRICANT CONSUMABLES Packaging

DESCRIPTION PACKAGING
04
PART NUMBER 77 01 422 750 77 01 421 162 77 11 143 071
MECHANICAL SEALANTS
G
AUTO grey seal sealing paste. LOCTITE 518 for sealing the gearbox housing Leak detector.
100 g tube 24 ml syringe Aerosol
ADHESIVES
G
"LOCTITE-FRENETANCH" stops bolts loosening and allows them to be released. "LOCTITE-FRENBLOC" locks bolts. "LOCTITE SCELBLOC" for bonding bearings. "LOCTITE AUTOFORM" for bonding the flywheel to the crankshaft.
24 cc bottle 24 cc bottle 24 cc bottle 50 cc bottle
77 01 394 070 77 01 394 071 77 01 394 072 77 01 400 309
LUBRICANT CLEANING AGENTS

G
"NETELEC" unseizes, lubricates. Carburettor cleaner. Injector cleaner Super-concentrated unseizing agent. "DECAPJOINT" (FRAMET) for cleaning the gasket faces of aluminium cylinder heads. Brake cleaner.
Aerosol 300 ml aerosol 355 ml can 500 ml aerosol Aerosol 400 ml aerosol
77 11 171 287 77 11 171 437 77 01 423 189 77 01 408 466 77 01 405 952 77 11 170 801
G G G G
04-2
FLUID CHANGE AND FLUID 105 REFILLING Engine

TOOLING REQUIRED Engine drain plug spanner
05
DRAINING : plug (1)
FILLING: plug (2)
K4M and F4P ENGINES
F9Q engine
05-1
FLUID CHANGE AND FLUID REFILLING Engine

DRAINING : plug (1) FILLING: plug (2)
05
L7X Engine
05-2
FLUID CHANGE AND FLUID REFILLING Gearbox

DRAINING : plug (1) FILLING: plug (2)
05
K4M and F4P ENGINES Manual gearbox
K4M and F4P ENGINES Automatic gearbox
K4M and F4P ENGINES Automatic gearbox
F9Q engine
05-3
FLUID CHANGE AND FLUID REFILLING Gearbox

FLUID CHANGE AND FLUID REFILLING: plug (1)
05
L7X Engine
05-4
FLUID CHANGE AND FLUID REFILLING Power assisted steering

CHECKING THE LEVEL POWER ASSISTED STEERING PUMP LEVEL For topping up or filling, use ELF RENAULTMATIC D2 or MOBIL ATF 220 fluid. The level, when correct, should be visible between the MIN and MAX marks on the reservoir (1).
05
ENGINES OF ALL TYPES
39
05-5
VALUES AND 107 SETTINGS Capacities - Grades

Average capacity* in litres Components After an oil change, adjust using a dipstick Diesel engine (oil) F9Q 4.65 Petrol engine (oil) K4M F4P L7X 4.7 4.95 5.1 Manual gearbox JR5 JH3 PK6 Automatic gearbox DP0 SU1 * Adjust using a dipstick/ Note: never exceed the the maximum mark on the dipstick. 6 7.6 2.5 2.8 2.2 4.85 5.1 5.4 4.8 Following replacement of the oil filter
07
Components Brake circuit
Capacity in litres Standard: 0.7 ABS: 1
Grade SAE J 1703 and DOT 4
Brake fluids must be approved by the Technical Department
Components Fuel tank Power assisted steering Coolant circuit K4M-F4P F9Q L7X
Capacity in litres Approximately 70 Separate reservoir 1.1 6.5 7 7.2
Grade Unleaded petrol Diesel ELF RENAULT MATIC D2 or MOBIL ATF 220 GLACEOL RX (type D) Add only coolant
07-1
Saloon
VALUES AND SETTINGS Dimensions
07
Dimensions in metres
* Unladen
07-2
Estate
VALUES AND SETTINGS Dimensions
07
Dimensions in metres
18210
* Unladen
07-3
VALUES AND SETTINGS Accessories belt tensioning

REMOVAL Put the vehicle on a 2 post lift. Disconnect the battery. Remove: the right front mudguard and side protector the power steering reservoir mounting. Turn the belt's automatic pulley tensioner in the direction indicated below using a 16 mm wrench. F9Q engine F4P engine
07
07-4
VALUES AND SETTINGS Accessories belt tensioning

K4M engine Swivel the automatic belt tensioner in the direction indicated below using a 13 mm offset ring spanner. Tighten the tension wheel using a 6 mm Allen key (1). L7X Engine
07
Tighten the tension wheel using a 9.53 mm square.
Remove the accessories belt. REFITTING NOTE: never refit a belt once removed, but replace it. Refitting is the reverse of removal.
07-5
F9Q engine
VALUES AND SETTINGS Procedure for tensioning the timing belt
07
SPECIAL TOOLING REQUIRED Mot. 1505 Mot. 1543 Tool for checking belt tension Tool for pretensioning a belt
TENSIONING PROCEDURE Engine cold (ambient temperature) Check that the tensioner is securely positioned on the pin (1).
The crankshaft groove (4) should be located at the centre of the two ribs (2) on the crankshaft closure cover, mark (3) on the crankshaft timing sprocket should be offset one tooth to the left of the vertical axis of the engine.
16153-1R
16187R
Check that pin Mot. 1054 is in place.
07-6
F9Q engine

Fit the new timing belt by aligning the belt markings with those of the camshaft and crankshaft sprockets. Place the tensioner against the belt by tightening bolt (2) on the tensioner support.
07
07-7
F9Q engine

Remove pin Mot. 1054. Fit the crankshaft accessories pulley bolt fitted with the washer numbered 4 included in the tool kit Mot. 1543. NOTE: Do not forget to remove it again when fitting the crankshaft pulley.
07
16351R
16563R
07-8
F9Q engine
07
Fit Mot. 1543 and the cover numbered 1 on the crankshaft accessories pulley bolt.
16351-2R1
Apply pretension between the crankshaft timing sprocket and the tensioner using the tool Mot. 1543 and the cover 1 , adjusting the torque wrench to a torque of 1.1 daNm .
16351-1S
07-9
F9Q engine

Connect the sensor of Mot. 1505. Tighten the belt until you reach the recommended fitting value of 88 3Hz by tightening the bolt (2). Tighten the tensioner to a torque of 1 daNm.
07
16151-5R1
Turn the crankshaft two revolutions.
07-10
F9Q engine

Refit the pin Mot. 1054 and set the timing at its setting point, (begin to press on the pin a half-tooth before alignment of the mark on the camshaft pulley and that made by the operator on the inner timing housing, to prevent it falling into a crankshaft balance hole). Remove the pin Mot. 1054. Apply pretension between the crankshaft timing sprocket and the tensioner using the tool Mot. 1543 and the cover 1, adjusting the torque wrench to a torque of 1.1 daNm. Connect the sensor of Mot. 1505. Check that the tension value is 85 3Hz, readjust it if necessary. Tighten the tension wheel nut to a torque of 5 daNm. NOTE: it is vital that you tighten the tensioner nut to torque to avoid any loosening which may cause damage to the engine. WARNING: remove the washer numbered 4 included in the tool kit Mot 1543 before fitting the crankshaft pulley.
07
07-11
K4M engine

SPECIAL TOOLING REQUIRED Mot. Mot. Mot. Mot. Mot. Mot. 799 01 1368 1453 1489 1490 1496 Tool for immobilising pinions on the toothed timing belt Timing pulley tightening tool Engine support tool Top Dead Centre pin Tool for locking the camshaft pulleys Tool for setting the camshaft
07
ESSENTIAL SPECIAL TOOLING Angular tightening wrench
There are two distinct procedures for setting the timing. 1 st PROCEDURE The first procedure is used when replacing all timing components not requiring one or more of the camshaft pulleys to be undone.
Adjusting the timing WARNING: it is essential to degrease the end of the crankshaft, the bore of the crankshaft pinion and the bearing faces of the crankshaft pulley to prevent any slip between the timing and the crankshaft which would risk destroying the engine. Position the grooves of the camshafts using tool Mot. 799-01 as shown in the diagram below.
14490S
07-12
K4M engine
07
Mount tool Mot. 1496, on the end of the camshafts.
Fitting the belt Check that the crankshaft is resting on the Top Dead Centre pin Mot. 1489 (crankshaft groove (5) upwards). The tension wheel and the timing pulley must be replaced when the timing belt is replaced. Ensure when fitting the tension wheel that the lug of the wheel is correctly positioned in the groove (A).
07-13
K4M engine
07
Refit: the timing belt, the pulley by tightening the mounting bolt using Mot. 1368 (to a torque of 4.5 daNm for information only).
Pre-tighten the tension wheel nut to a torque of 0.7 daNm. Fit the crankshaft accessories pulley by moving the bolt away from the pulley (2 to 3 mm clearance between the bolt and the pulley). NOTE: the crankshaft accessories pulley bolt can be reused if the length under its head does not exceed 49.1 mm (otherwise replace it), do not oil the new bolt. However, bolts must be oiled if they are being reused. Tighten the crankshaft pulley bolt to a torque of 2 daNm then angle tighten to 135 15 (crankshaft resting on the Top Dead Centre pin ). Remove tool Mot. 1496 for clamping the camshaft and Mot. 1489 Top Dead Centre pin. Turn the crankshaft clockwise twice (timing end), and before the end of the second turn, tighten the pin Mot. 1489 in the cylinder block and move the crankshaft slowly and smoothly to rest on the pin. Remove the Top Dead Centre pin.
Belt tension Shift the adjustable tension wheel index (A') by 7 to 8 mm beyond the fixed index (7), using a 6 mm Allen key (in B). NOTE: position (A) corresponds to the adjustable index at rest.
Slacken the tension wheel nut by a maximum of one turn, holding it with a 6 mm Allen key. Align the adjustable index with the fixed index and tighten the nut fully to a torque of 2.7 daNm.
07-14
K4M engine
07
Checking the tension and the timing. Checking the tension Turn the crankshaft clockwise twice (timing end), and before the end of the second turn, tighten the pin Mot. 1489 in the cylinder block and move the crankshaft slowly and smoothly to rest on the pin. Remove the Top Dead Centre pin. Check that the pulley indices are aligned, otherwise continue with the tensioning procedure. Checking the timing Ensure that the tension wheel indices are in the correct position before checking the setting of the timing. Tighten the pin Mot. 1489 in the cylinder block and move the crankshaft slowly and smoothly to rest on the pin. Fit (without forcing) tool Mot. 1496 for setting the camshaft (the camshaft grooves must be horizontal). The timing setting and tensioning operation must be repeated if the tool does not engage.
07-15
K4M engine
07
2 nd PROCEDURE The second procedure is used for the replacement of all components requiring the slackening of one or more of the camshaft pulleys. All the camshaft nuts must be replaced during this operation. Adjusting the timing WARNING: it is essential to degrease the following: the end of the crankshaft (timing side), the bore of the timing pinion, the bearing faces of the accessories belt as well as the ends of the camshafts (timing side) and the bores of the camshaft pulleys, to prevent there being any slip between the timing, crankshaft and camshaft pulleys which would risk destroying the engine. Position the camshaft grooves, as illustrated below, by tightening the two old camshaft pinion nuts on the studs at the end of the camshafts.
Fit tool Mot. 1496, on the end of the camshafts.
Position the camshaft pulleys pretightening the new nuts (without locking the nuts, clearance between the nut and pulley of 0.5 - 1 mm). Check that the crankshaft is resting on the Top Dead Centre pin (crankshaft groove (5) upwards).
07-16
K4M engine
07
The tension wheel and the timing pulley must be replaced when the timing belt is replaced. Ensure that the tension wheel lug is correctly positioned in the groove (A).
Fit the pulley, tightening the mounting bolt using Mot. 1368 (to a torque of 4.5 daNm for information only).
Position the RENAULT badge engraved on the camshaft pulley spokes (A) vertically upwards, fit the timing belt on the camshaft pulleys then fit the camshaft pulley locking tool Mot. 1490 (use the timing cover fasteners to fix Mot. 1490 ).
07-17
K4M engine
07
Fit the crankshaft accessories pulley by pretightening the bolt (without locking the bolt, clearance of 2 to 3 mm between the bolt and the pulley). Belt tension Check that there is still a clearance of 0.5 to 1 mm between the nuts and camshaft pulleys. Shift the tension wheel adjustable index (A') by 7 to 8 mm beyond the fixed index (7), using a 6 mm Allen key (in B). NOTE: position (A) corresponds to the adjustable index at rest.
Remove camshaft pulley locking tool Mot. 1490. Rotate the timing system through six revolutions in a clockwise direction (timing side) using the exhaust cam pulley and Mot. 799-01. Slacken the tension wheel nut by a maximum of one turn, holding it with a 6 mm Allen key. Align the adjustable index (A') with the fixed index (7) and tighten the nut finally to a torque of 2.7 daNm. Remove the crankshaft pulley in order to fit the lower timing cover (without the mounting bolts), then refit the crankshaft pulley. NOTE: the crankshaft accessories pulley bolt can be reused if the length under its head does not exceed 49.1 mm (otherwise replace it), do not oil the new bolt. However, bolts must be oiled if they are being reused. Fit the camshaft pulley locking tool Mot. 1490 using Mot. 799-01 if necessary.
Pre-tighten the tension wheel nut to a torque of 0.7 daNm.
07-18
K4M engine

Checking the timing and the tension Checking the tension
07
Check that the crankshaft is resting on pin Mot. 1489.
Turn the crankshaft clockwise twice (timing end) and before the end of the second turn, tighten the pin Mot. 1489 in the cylinder block and move the crankshaft slowly and smoothly to rest on the pin. Remove the Top Dead Centre pin. Check that the pulley indices are aligned, otherwise continue with the tensioning procedure. Slacken the tension wheel nut by a maximum of one turn, holding it with a 6 mm Allen key. Align the adjustable index with the fixed index and tighten the nut to a torque of 2.7 daNm.
Checking the timing Ensure that the tension wheel indices are in the correct position before checking the setting of the timing. Tighten the pin Mot. 1489 in the cylinder block then position and hold the crankshaft resting on the pin. Fit (without forcing) tool Mot. 1496 for setting the camshaft pulleys (the camshaft grooves must be horizontal). The timing setting and tensioning operation must be repeated if the tool does not engage.
Tighten the crankshaft pulley bolt to a torque of 2 daNm, then angle tighten to 135 15 (crankshaft resting on the Top Dead Centre pin). Tighten the exhaust camshaft pulley to a torque of 3 daNm then turn through an angle of 84 . Remove camshaft timing tool Mot. 1496 camshaft pulley locking tool Mot. 1490 and Top Dead Centre pin tool Mot. 1489.
07-19
F4P engine
07
SPECIAL TOOLING REQUIRED Mot. 799-01 Mot. 1054 Mot. 1453 Mot. 1496 Mot. 1509 Tool for immobilising pinions for the toothed timing belt Top Dead Centre pin Engine support tool Tool for setting the camshafts Tool for locking the camshaft pulleys
Mot. 1509-01 Addition to Mot. 1509 Mot. 1517 Tool for fitting inlet camshaft seals
ESSENTIAL SPECIAL TOOLING Angular tightening wrench
There are two distinct procedures for setting the timing.
1 st PROCEDURE The first procedure is used for replacing all components which require the exhaust camshaft pulley and the inlet camshaft dephaser to be undone. The following components must be replaced in this operation: the nut of the exhaust camshaft pulley, the bolt of the inlet camshaft dephaser, the seal of the camshaft dephaser, the seal of the dephaser blanking plate.
07-20
F4P engine
07
Method for undoing the exhaust camshaft pulley and the inlet camshaft dephaser. The operation is performed using tools Mot. 1509 and Mot. 1509-01.
Remove the upper toothed pinion from the bracket.
07-21
F4P engine
07
Fit: the spacer (1) of tool Mot. 1509-01 on the stud (2),
the upper bolt (3) whilst positioning the spacer (4) of tool Mot. 1509-01 between the tool and the camshaft bearing cap housing (do not lock the bolt).
tool Mot. 1509 as shown in the diagram below, the shouldered nut (5) of tool Mot. 1509-01.
07-22
F4P engine
07
Tighten the shouldered nut (6) and the bolt (7), then bring the pinions of tool Mot. 1509 into contact with the camshaft pulleys by tightening the nuts (8) to a torque of 8 daNm. Remove: the blanking plate of the inlet camshaft dephaser using a 14 mm Allen key,
Replacing the inlet camshaft dephaser seal Fit the seal of the inlet camshaft dephaser using tool Mot. 1517 and the old bolt (2).
NOTE: to use tool Mot. 1517, it is necessary to modify the hole to a diameter of 13 mm.
16019-4R2
the nut of the exhaust camshaft pulley, the bolt of the inlet camshaft dephaser.
07-23
F4P engine

Adjusting the timing WARNING: it is essential to degrease the end of the crankshaft (timing end), the bore and the bearing faces of the timing pinion, the bearing faces of the accessories pulley and the ends of the camshafts (timing side), the bores and the bearing faces of the exhaust camshaft pulley and the inlet camshaft dephaser; to prevent there being any slip between the timing, the crankshaft, the exhaust camshaft pulleys and the inlet dephaser, which would risk destroying the engine. NOTE: to make it easier to position the grooves horizontally, position the pulley and dephaser, then tighten the old nut of the pulley and the old bolt of the dephaser to a torque of 1.5 daNm MAXIMUM. Check that the pistons are positioned at mid-stroke (to prevent any contact between the valves and the pistons). Position the grooves of the camshafts horizontally as shown in the diagram below (rotating the camshafts using tool Mot. 799-01 if necessary).
07
07-24
F4P engine

Check that the ring of the camshaft dephaser is correctly locked (no rotation of the ring to the left or to the right).
07
07-25
F4P engine

Incorrect position
07
Fit tool Mot. 1496 , on the ends of the camshafts.
Remove the old nut from the pulley, the old bolt from the dephaser and replace them with a new nut and bolt (leave a clearance of 0.5 - 1 mm between the nut or the bolt and the camshaft pulleys). Check that the crankshaft is resting on the Top Dead Centre pin and not in the balancing hole (crankshaft groove (5) upwards).
Pinned crankshaft
07-26
F4P engine
07
The tension wheel and the pulley must be replaced when the timing belt is replaced. Ensure that the lug (1) of the tension wheel is correctly positioned in the groove (2).
Refit: the timing belt, the pulley (3) tightening the mounting bolt to a torque of 4.5 daNm ,
the crankshaft accessories pulley, pretightening the bolt (without locking the bolt, clearance of 2 to 3 mm between the bolt and the pulley). NOTE: the crankshaft accessories pulley bolt can be reused if the length under its head does not exceed 49.1 mm (otherwise replace it), do not oil the new bolt. However, the bolt must be oiled on the threads and under the head if it is being reused.
07-27
F4P engine

Belt tension Check that there is still a clearance of 0.5 - 1 mm between the nut, the bolt and the camshaft pulleys. NOTE: do not turn the tension wheel in an anticlockwise direction. Align the marks (6) and (7) of the tension wheel, using a 6 mm Allen key in (B).
07
Pre-tighten the tension wheel nut to a torque of 0.7 daNm. Rotate the timing through six revolutions in a clockwise direction (timing end) using the exhaust camshaft pulley using tool Mot. 799-01. NOTE: check that the nut and the bolt of the camshaft pulleys are not touching their respective pulleys. To do this, from time to time, push the camshaft pulleys against the camshafts. Align the marks (6) and (7) if necessary, undoing the tension wheel nut by a maximum of one turn whilst holding it with a 6 mm Allen key. Then tighten the nut finally to a torque of 2.8 daNm . Tighten the crankshaft accessories pulley bolt to a torque of 2 daNm (Top Dead Centre pin still positioned in the crankshaft) .
07-28
F4P engine

Mark a reference (C) using a pencil between the camshaft pulleys and the camshaft bearing cap housing.
07
REMOVE THE TOP DEAD CENTRE PIN.
07-29
F4P engine

Incorrect position
07
Lock the flywheel using a large screwdriver, then turn the bolt of the crankshaft accessories pulley though an angle of 115 15.
Fit the camshaft pulley locking tool Mot. 1509 fitted with the additional tool Mot. 1509-01. Pin the crankshaft using the marks made previously between the camshaft pulleys and the camshaft bearing cap housing. These marks must be aligned, which will ensure that the pin is in the pinning hole and not in the crankshaft balancing hole.
Follow the same procedure as when removing.
Correct position
07-30
F4P engine

Pinned crankshaft
07
Tighten the new bolt of the inlet camshaft dephaser to a torque of 10 daNm . Tighten the exhaust camshaft pulley nut to a torque of 3 daNm. then turn through an angle of 86 16. Remove tool Mot. 1496 for setting the camshafts, tool Mot. 1509 for locking the camshaft pulleys and tool Mot. 1054 , the Top Dead Centre pin.
Checking the timing and the tension Checking the tension: Rotate the crankshaft twice in a clockwise direction (timing end) and before the end of the second turn (in other words, before the marks made previously are aligned) , insert the crankshaft Top Dead Centre pin (so as to be between the balancing hole and the pinning hole) then move the timing to its setting point. Before pinning Remove the Top Dead Centre pin. Check that the tension wheel marks are correctly aligned, otherwise repeat the tensioning procedure. Slacken the tension wheel nut by a maximum of one turn, holding it with a 6 mm Allen key. Align the tension wheel marks and tighten the nut finally to a torque of 2.8 daNm.
07-31
F4P engine
07
Checking the timing Ensure that the tension wheel marks are in the correct position before checking the timing. Fit the Top Dead Centre pin (check that the marks made previously on the camshaft pulleys are aligned). Fit (without forcing) tool Mot. 1496 for setting the camshafts (the camshaft grooves must be horizontal and offset towards the bottom). The timing setting and tensioning procedure must be repeated if the tool does not engage.
Refit the blanking plate (1) (fitted with a new seal) of the dephaser tightening it to a torque of 2.5 daNm.
07-32
F4P engine
07
2 nd PROCEDURE The second procedure is used for replacing all components located on the front of the timing which do not require the exhaust camshaft pulley and the inlet camshaft dephaser to be undone. Adjusting the timing WARNING: it is essential to degrease the end of the crankshaft, the bore of the crankshaft pinion and the bearing faces of the crankshaft pulley to prevent any slip between the timing and the crankshaft which would risk destroying the engine. Position the grooves of the camshafts using tool Mot. 799-01 as shown in the diagram opposite.
Fit tool Mot. 1496 , on the ends of the camshafts.
07-33
F4P engine

Pinned crankshaft
07
Check that the crankshaft is pinned on the Top Dead Centre pin and not in the balancing hole (crankshaft groove (5) upwards).
Incorrect position
07-34
F4P engine

Check that the ring of the camshaft dephaser is correctly locked (no rotation of the ring to the left or to the right).
07
07-35
F4P engine
07
The tension wheel rollers and timing pulley must be replaced when the timing belt is replaced. Ensure that the lug (1) of the tension wheel is correctly positioned in the groove (2).
Refit: the timing belt, the pulley (3) tightening the bolt to a torque of 4.5 daNm ,
the crankshaft accessories pulley, pre-tightening the bolt (without locking the bolt, clearance of 2 mm to 3 mm between the bolt and the pulley). NOTE: the crankshaft accessories pulley bolt can be reused if the length under its head does not exceed 49.1 mm (otherwise replace it), do not oil the new bolt. However, the bolt must be oiled on the threads and under the head if it is being reused.
07-36
F4P engine

NOTE: do not rotate the tension wheel in an anticlockwise direction. Align the marks (6) and (7) of the tension wheel, using a 6 mm Allen key in (B).
07
Pre-tighten the tension wheel nut to a torque of 0.7 daNm. Tighten the bolt of the accessories crankshaft pulley to a torque of 2 daNm (Top Dead Centre pin Mot. 1054 still positioned in the crankshaft).
07-37
F4P engine
07
Mark a reference (C) on the ring of the inlet camshaft dephaser and the exhaust pulley in relation to the camshaft bearing cap housing.
Remove the camshaft setting tool Mot. 1496 for as well as the Top Dead Centre pin, tool Mot. 1054. Tighten the crankshaft pulley bolt to an angle of 115 15 locking the flywheel using a large screwdriver.
07-38
F4P engine

Incorrect position
07
Checking the timing and the tension Checking the tension: Rotate the crankshaft through two revolutions in a clockwise direction (timing side). Before the end of the two revolutions (in other words, half a tooth before the marks previously made are aligned), insert the crankshaft Top Dead Centre pin (so as to be between the balancing hole and the pinning hole) then move the timing to its setting point.
Remove the Top Dead Centre pin Mot. 1054. Check that the tension wheel marks are correctly aligned, otherwise repeat the tensioning procedure. To do this, slacken the nut of the tensioning roller by a maximum of one turn whilst holding it with a 6 mm Allen key. Align the tension wheel marks and tighten the nut finally to a torque of 2.8 daNm. Correct position
07-39
F4P engine
07
Checking the timing: Ensure that the tension wheel marks are in the correct position before checking the setting of the timing. Fit the Top Dead Centre pin (check that the marks made previously on the camshaft pulleys are aligned). Fit (without forcing) the camshaft setting tool Mot. 1496 (the camshaft grooves must be horizontal and offset towards the bottom). If the tool cannot be inserted, the timing setting and tensioning procedure must be repeated.
07-40
F4P-K4M ENGINES
VALUES AND SETTINGS Tightening the cylinder head
07
CYLINDER HEAD TIGHTENING PROCEDURE The bolts can be reused if the length under the head does not exceed 118.5 mm (F4P engine) or 117.7 mm (K4M engine) otherwise replace all the bolts. REMINDER: Use a syringe to remove any oil which may have entered the cylinder head fastening bolt holes to ensure correct tightening of the bolts. Do not oil the new bolts. However, the bolts must be oiled if they are being reused. Tighten all the bolts to 2 daNm in the order recommended below.
Check that all the bolts are correctly tightened to 2 daNm then angle tighten (bolt by bolt) by 165 6 (F4P engine) or 240 6 (K4M engine). Do not retighten the cylinder head bolts after applying this procedure.
07-41
F9Q engine
07
METHOD FOR TIGHTENING THE CYLINDER HEAD REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to ensure correct tightening of the bolts. All cylinder head bolts must always be changed after removal. There is no cylinder head retightening operation.
Preseating the gasket Tighten all the bolts to 3 daNm, then angle tighten to 100 4 in the order shown below.
Wait 3 minutes settling time. Tightening the cylinder head: Cylinder head tightening is carried out in stages, and the following procedure is applied successively to bolts 1-2 then 3-4, 5-6, 7-8 and 9-10, undo bolts 1-2 until they are completely free, tighten bolts 1-2 to 2.5 daNm, then angle tighten to 213 7, repeat the undoing and tightening operations for bolts 3-4, 5-6, 7-8 and 9-10. There is no cylinder head retightening operation.
07-42
L7X Engine

METHOD FOR TIGHTENING THE CYLINDER HEAD REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to ensure correct tightening of the bolts. Pretighten bolt by bolt to 2 daNm in the recommended order. Undo completely by proceeding from bolt to bolt. Pretighten bolt by bolt to 1.5 daNm then angle tighten by 225 following the order of tightening:
07
07-43
VALUES AND SETTINGS Tyres and wheels
07
Pressure (bar ) cold Front Rear 2.2 2.2 2.3 2.5
Type BG0A BG0B BG0R BG0G BG0A BG0B BG0R BG0G KG0A KG0B KG0R KG0G BG0D KG0D KG0A KG0B KG0R KG0G
Rim
Tyres
6.5J15 6.5J16(1) 6.5J16(1) 6.5J16* 7J17*
195/65R15H 205/55R16V(1) 205/55R16V 205/55R16 225/45R17V 205/60R16V
2.3
2.2
6.5 J 16
205/55R16V
2.3
2.2
6.5J16* 7J17*
205/55R16V 205/60R16V 225/45R17V
2.7
2.2
The tyre pressures are values for motorway use. * Alluminium wheel rim (1) Surmount For vehicles with automatic transmission, increase the pressure by 0.1 bar on the front wheels (except SU1) Tightening torque of the wheel nuts: 10.5 daNm Wheel rim run-out: Steel wheel rim = 1 mm Aluminium wheel rim = 0.3 mm
07-44
VALUES AND SETTINGS Brakes

Disc thickness (in mm) Type Normal BG0A BG0B BG0R BG0R KG0R KG0A KG0B BG0A(1) BG0B(1) BG0R(1) 26 BG0A* BG0B* BG0R* BG0D KG0D (1) Tyre surmount * Aluminium wheel Lining thicknesses (in mm) (including backing) Type New BG0A BG0B BG0R BG0A KG0A BG0B KG0B BG0R KG0R BG0G KG0G BG0D KG0D 17 Front Min. 7.5 New 16 Rear Min. 7 28 25.5 11 8.5 23.5 11 8.5 24 Front Min. 21.5 Normal 11 Disc thickness (in mm) Rear Max. 8.8
07
Max. disc runout (in mm)
0.2
26
23.5
11
8.5
0.2
0.2
0.2
Brake fluid
SAE J1703 DOT 4
17.5
7.5
16
SAE J1703 DOT 4
07-45
VALUES AND SETTINGS Underbody height

at the front H1-H2 =...mm At the rear H4-H5 =...mm
07
Dimension (X) (in mm) LH and RH
VEHICLE BG0A KG0A BG0B KG0B BG0D KG0D BG0G KG0G BG0R KG0R Tolerence: 3.5 mm
122.5
105
The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not exceed 5 mm, the driver's side always being higher.
07-46
VALUES AND SETTINGS Underbody height

MEASUREMENT POINTS
07
18209
Dimension H2 is measured under the bolt at mounting point A of the austral arm.
Dimension H5 is taken under the rear axle bracket.
07-47
BG0A with 15 tyres
VALUES AND SETTINGS Front axle angle checking values

ANGLES VALUES POSITION OF FRONT AXLE
07
ADJUSTMENT
CASTOR 346 416 446 30 H5 - H2 = 28 mm H5 - H2 = 8 mm H5 - H2 = -12 mm
Max. right/left difference = 1
NOT ADJUSTABLE
CAMBER -005 -012 30 -020 Max. right/left difference = 1 H1 - H2 = 126 mm H1 - H2 = 137 mm H1 - H2 = 148 mm
NOT ADJUSTABLE
PIVOT 1212 1230 1252 30 H1 - H2 = 126 mm H1 - H2 = 137 mm H1 - H2 = 148 mm
NOT ADJUSTABLE
PARALLELISM (for 2 wheels) Toe-out +0 10 +0 mm 1 mm UNLADEN Adjustable by rotating track rod sleeves 1 turn= 30 (3 mm)
POSITION FOR TIGHTENING RUBBER BUSHES
UNLADEN
07-48
BG0B with 15 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
UNLADEN
07-49
BG0R with 15 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
POSITION FOR TIGHTENING RUBBER BUSHES UNLADEN
07-50
BG0A with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
UNLADEN
07-51
BG0B with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-52
BG0R, BG0G with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-53
BG0D with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-54
BG0A, BG0B with 17 tyres

07
ADJUSTMENT
CASTOR 335 405 435 30 H5 - H2 = 42 mm H5 - H2 = 22 mm H5 - H2 = 2 mm
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-55
BG0G with 17 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-56
BG0R with 17 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-57
BG0D with 17 tyres

POSITION OF FRONT AXLE
07
ADJUSTMENT
ANGLES CASTOR
VALUES
326 356 426
30
H5 - H2 = 39 mm H5 - H2 = 19 mm H5 - H2 = -1 mm
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-58
KG0A with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-59
KG0B with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-60
KG0R, KG0G with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-61
KG0D with 16 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-62
KG0A, KG0B with 17 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-63
KG0G with 17 tyres

07
ADJUSTMENT
CASTOR 337 407 437 30 H5 - H2 = 43 mm xH5 - H2 = 23 mm H5 - H2 = 3 mm
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
PARALLELISM (for 2 wheels) Toe-out UNLADEN +0 10 +0 mm 1 mm Adjustable by rotating track rod sleeves 1 turn= 30 (3 mm)
07-64
KG0R with 17 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-65
KG0D with 17 tyres

07
ADJUSTMENT
NOT ADJUSTABLE
NOT ADJUSTABLE
NOT ADJUSTABLE
07-66
VALUES AND SETTINGS Rear axle angles checking values

ANGLES CAMBER VALUES POSITION OF FRONT AXLE
07
ADJUSTMENT
-040' 10'
UNLADEN
NOT ADJUSTABLE
PARALLELISM (for 2 wheels) Toe-in -32 10 -3,2 mm 1 mm UNLADEN NOT ADJUSTABLE
07-67

General: Specifications Lifting Towing Lubricants and Consumables Oil Change and Engine Oil Refilling Values and Settings

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General: Specifications Lifting Towing Lubricants and Consumables Oil Change and Engine Oil Refilling Values and Settings

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General

BG0A - BG0B - BG0D - BG0G - KG0A - KG0B - KG0D - KG04

04 LUBRICANTS AND CONSUMABLES

05 OIL CHANGE AND ENGINE OIL

07 VALUES AND SETTINGS

TOLERANCES Tightening torques given without a tolerance must be accurate to within:

In degrees: 3. In daNm: 10%.

SPECIFICATIONS 101 Engine - Clutch - Gearbox

215 CPOE 3500 215 CPOE 4400 228-7900 -

VEHICLE IDENTIFICATION Example: BG0A B G : Body type (five-door) : Project code

SPECIFICATIONS Vehicle identification

LIFTING 102 Trolley jack - Axle stands

LIFTING Underbody lifts

LIFTING Underbody lifts

LIFTING Underbody lifts

TOWING All types

LUBRICANT 104 CONSUMABLES Packaging

100 g tube 80 ml tube 180 g sachet

77 01 028 179 77 01 422 307 77 01 366 100

1.5 kg tin 100 g tube Collection 100 g tube

"CIRCUIT PLUS" varnish for repairing heated screens

0.5 l bottle DOT4

LUBRICANT CONSUMABLES Packaging

100 g tube 24 ml syringe Aerosol

24 cc bottle 24 cc bottle 24 cc bottle 50 cc bottle

77 01 394 070 77 01 394 071 77 01 394 072 77 01 400 309

LUBRICANT CLEANING AGENTS

FLUID CHANGE AND FLUID 105 REFILLING Engine

DRAINING : plug (1)

FILLING: plug (2)

K4M and F4P ENGINES

FLUID CHANGE AND FLUID REFILLING Engine

FLUID CHANGE AND FLUID REFILLING Gearbox

K4M and F4P ENGINES Manual gearbox

K4M and F4P ENGINES Automatic gearbox

K4M and F4P ENGINES Automatic gearbox

FLUID CHANGE AND FLUID REFILLING Gearbox

FLUID CHANGE AND FLUID REFILLING Power assisted steering

ENGINES OF ALL TYPES

VALUES AND 107 SETTINGS Capacities - Grades

Components Brake circuit

Capacity in litres Standard: 0.7 ABS: 1

Grade SAE J 1703 and DOT 4

Brake fluids must be approved by the Technical Department

Capacity in litres Approximately 70 Separate reservoir 1.1 6.5 7 7.2

VALUES AND SETTINGS Dimensions

VALUES AND SETTINGS Dimensions

VALUES AND SETTINGS Accessories belt tensioning

VALUES AND SETTINGS Accessories belt tensioning

Tighten the tension wheel using a 9.53 mm square.

VALUES AND SETTINGS Procedure for tensioning the timing belt

Check that pin Mot. 1054 is in place.

VALUES AND SETTINGS Procedure for tensioning the timing belt

VALUES AND SETTINGS Procedure for tensioning the timing belt

VALUES AND SETTINGS Procedure for tensioning the timing belt

VALUES AND SETTINGS Procedure for tensioning the timing belt

Turn the crankshaft two revolutions.

VALUES AND SETTINGS Procedure for tensioning the timing belt

VALUES AND SETTINGS Procedure for tensioning the timing belt

ESSENTIAL SPECIAL TOOLING Angular tightening wrench

VALUES AND SETTINGS Procedure for tensioning the timing belt

Mount tool Mot. 1496, on the end of the camshafts.

VALUES AND SETTINGS Procedure for tensioning the timing belt