Workshop Repair Manual PDF

Workshop repair manual
Petrol engine
4 cylinders
Engine type
Vehicle
Vehicle type
D4D 700
Clio II
XB06
D4F 702 - 704
Twingo
X06C - X06D
D4F 712
Clio II
XB0W
77 11 296 742
FEBRUARY 2001
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
EDITION ANGLAISE
All copyrights reserved by Renault.
The methods may be modified as a result of changes introduced by the manufacturer

in the production of the various component units and accessories from which his
vehicles are constructed."
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.
RENAULT 2001
Contents
Page
10 ENGINE AND PERIPHERALS

Introduction
Engine identification
Tightening torques (in daNm or degrees)
Specifications
Cylinder head
Camshaft
Pistons
Cylinder block barrel sizes
Piston rings
Con rods
Crankshaft
Bearing shells
Preparing the engine to be set on the support
Consumables
Standard exchange
Essential special tooling
Essential equipment
Overhauling the engine
Removing the upper engine
Stripping the cylinder head
Cleaning
Checking the mating surfaces
Checking the camshaft end play
Rebuilding the cylinder head
Assessment and repair of rocker arm rails
Removing the lower engine
Extracting the gudgeon pins
Fitting the con rod bearing shells
Assembling the con rods - pistons
Fitting the piston rings
Refitting the lower engine
Replacing the oil filter
Refitting the upper engine
Tensioning the accessories belts
10-1
10-2
10-3
10-5
10-11
10-12
10-13
10-14
10-15
10-16
10-16
10-18
10-20
10-21
10-22
10-25
10-26
10-29
10-33
10-33
10-33
10-34
10-38
10-44
10-49
10-49
10-52
10-55
10-56
10-62
10-63
10-69
ENGINE AND PERIPHERALS

110
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
vehicle Workshop Repair Manual and Technical
Notes.
UNITS OF MEASUREMENT
All dimensions are given in millimetres (mm) (unless
stated otherwise).
Tightening torques are expressed in decaNewton
metres (daNm)
Reminder: 1 daNm = 1.02 m.kg.
Pressures in bar
Reminder: 1 bar = 100 000 Pa.
TOLERANCES
Tightening torques given without a tolerance must be
accurate to within:
in Degrees ( 3).
in daNm ( 10 %).
10-1
10

Engine identification
10
The engine identification is stamped on the cylinder

block.
It displays:
A : the engine type
B : the engine approval letter
D : the Renault identification number
E : the engine suffix
F : the engine production number
G : the engine factory number
Engine
Index
Compression
ratio
Bore
(mm)
Stroke
(mm)
Capacity
(cm 3)
D4D
700
9.8/1
69
66.8
999
D4F
702
704
712
9.8/1
69
76.8
1149
10-2

UPPER ENGINE
Description
Tightening torques
Cylinder head bolts
Coolant temperature sensor
1.5
Cylinder head coolant output unit
0.9
Rocker arm rail
**
Timing gear tension wheel
2.4
Camshaft pulley
3 plus an angle of 456
Spark plugs
2.4
Cylinder head cover
1.2
Lower and intermediate timing covers
1.2
Upper timing cover
3.3
Exhaust manifold
2.5
Exhaust manifold heat shield
1.5
Ignition coil
0.7
Inlet manifold
***
Air filter unit bolt
*
See the procedure for tightening the cylinder head
** See the procedure for tightening the rocker arm rails
*** See the procedure for tightening the inlet manifold.
10-3
10

LOWER ENGINE
Description
Tightening torques
Pinking sensor
Oil level sensor
3.8
2 plus an angle of 76 6
Crankshaft bearing bolts
1.4 plus an angle of 39 6
Con rod cap bolts

Oil pump
0.9
Coolant pump
0.9
Crankshaft closure housing (flywheel side)
0.9
Strainer
0.9
Sump
Flywheel
1.8 plus an angle of 1106
Clutch
Accessories crankshaft pulley
4 plus an angle of 70 6
Alternator mounting
Air conditioning compressor mounting
Power steering pump mounting
2.5
Air conditioning compressor
Alternator
Upper bolt
2.5
Lower bolt
Power steering pump
2.2
Oil filter
10-4
10

Specifications
CYLINDER HEAD
Cylinder head tightening procedure
REMINDER: in order to tighten the bolts correctly, use
a syringe to remove any oil which may have entered
the cylinder head mounting bolt holes.
All cylinder head bolts must always be changed
after removal. Do not oil the new bolts.
Tighten all the bolts to 2 daNm0.2 daNm.
Check that all the bolts are tightened to 2 daNm, then

angle tighten (bolt by bolt) by 2306.
Do not retighten the cylinder head bolts after
performing this procedure.
10-5
10

Specifications
Thickness of the cylinder head gasket
Cylinder head height
The thickness of the cylinder head gasket is measured

at (A):
thickness of the gasket when tightened:
0.49 0.04 mm.
H = 99 mm
10
Firing order:
1-3-4-2
Gasket face bow (mm):
0.05
No corrections are permitted

Test the cylinder head to detect possible cracks using
the cylinder head test tools (a container and a kit for
the particular cylinder head, plug, sealing plate,
blanking plate). The approval number of the cylinder
head test container is 664 000.
Spark plug tightening torque
2 to 2.7 daNm
Chamber volume with valves and spark plugs:

26.775 1.01 cm3
10-6

Specifications
Valve seats
Valves
Seat angle ()
Stem diameter (in mm)

Inlet:
5.48
0
- 0.015
Exhaust:
5.47
0
- 0.015
Inlet and exhaust:
89 30'
Mating surface width X (in mm)

Inlet:
Exhaust:
Mating surface angle

Inlet and exhaust:
10
0.994 0.403
1.136 0.377
90
External seat diameter (D) (in mm)
Head diameter (in mm)

Inlet:
Exhaust:
Inlet:
Exhaust:
26 0.12
22.1 0.12
Valve length (in mm)

Inlet:
Exhaust:
110.54 to 110.99
112.27 to 112.72
Max. valve lift (in mm)

Inlet:
Exhaust:
8.849
8.850
Valve clearance settings (in mm)

Inlet:
Exhaust:
0.05 to 0.12
0.15 to 0.22
10-7
27.995 to 28.005
23.995 to 24.005

Specifications
Valve guides
The valve stem seals must be fitted using tool

Mot. 1511 or the FACOM tool part number DMJ4,
for example.
Length (in mm)

Inlet and exhaust:
10
40.15 0.15
Guide external diameter (in mm)

Inlet and exhaust:
11
+ 0.068
+ 0.05
+ 0.075
0
5.5
+ 0.018
0
Guide internal diameter (in mm)

Inlet and exhaust
Non machined:
Machined*:
* This dimension is measured with the guide fitted in

the cylinder head.
Diameter of the guide housing in the cylinder head

(in mm)
Inlet and exhaust:
110.01
The inlet and exhaust guides have valve stem seals

which also act as a lower bearing washer for the valve
spring. The seals must be changed every time the
valves are removed.
NOTE: do not lubricate the valve stem seals before

fitting them.
10-8

Specifications
Angle of the inlet and exhaust guides (in degrees)
Inlet:
Exhaust:
A = 27
E = 21
Position of the inlet and exhaust valve guides (in mm)

B = 10.3 0.15
Inlet and exhaust:
10-9
10

Specifications
Valve springs
The valve has a conical spring.
Unloaded length (in mm):
40.20
Loaded length (in mm):

14.5 daN8
42.8 daN20
34
25.15
Meeting spires (in mm):
23.50
Diameter of wire (in mm):
3.100.03
Internal diameter (in mm):

Upper
Lower
14.100.2
16.800.2
External diameter (in mm):

Upper
Lower
20.300.2
230.2
10-10
10

Specifications
10
Camshaft
End play (in mm):
0.08 to 0.178
Number of bearings:
Diameter of the cylinder head camshaft bearings

(in mm)
Flywheel side
1
2
25.050.01
3
4
28.050.01
Timing side
1
2
3
4
5
6
7
8
Diameter of the camshaft bearings (in mm)

Flywheel side
1
2
24.980.01
3
4
27.980.01
Timing side
Graph showing timing with a calculated clearance

of zero (cannot be checked)
Inlet opening delay*
Inlet closing delay
Exhaust opening advance
Exhaust closing advance**
- 10
31
25
- 8
If the inlet opening delay is negative, the valve

opening can be found after top dead centre.
**
If the exhaust closing advance is negative, the

valve opening can be found before top dead
centre.
10-11
Cylinder block top dead centre fixed mark.

Flywheel top dead centre mobile mark.
Flywheel bottom dead centre mobile mark.
Inlet opening delay.
Exhaust closing advance.
Inlet closing delay.
Exhaust opening advance.
Engine operating direction (flywheel end).

Specifications
10
D4D engine
PISTONS
Fitting the gudgeon pin in the con rod and in the
piston.
These engines are fitted with Mahle pistons.
Piston marking
D4F engine
1
2
3
4
5
6
7
10-12
Direction of fitting of piston, flywheel side

Piston diameter grade (A - B)
Used by the supplier only
Used by the supplier only
Piston symmetry axis
Gudgeon pin hole axis
Offset between the pin hole (6) and the piston
symmetry axis (5) is 0.8 mm

Specifications
10
Measuring the piston diameter

The piston diameter is measured at these heights
(in mm).
D4D engine
D4F engine
10
Piston diameter marking in relation to cylinder

block diameter
D4D engine
Position
of holes
T on the
cylinder
block
Grade
marking on
the pistons
Piston
diameter
(mm)
Barrel
diameter
(mm)
CYLINDER BLOCK BARREL SIZES
1 = 5 mm
68.9560.006
69 0.015
IMPORTANT: the diameters of the pistons and the

barrels must be matched on the cylinder block.
Thus,
2 = 9 mm
68.9640.006 69.0150.015
D4F engine
the position of the holes T, in relation to the gasket

face of the cylinder block, is used to identify the
original nominal dimension of the barrel and
consequently the diameters of the corresponding
pistons.
10-13
Position
of holes
T on the
cylinder
block
Grade
marking on
the pistons
Piston
diameter
(mm)
Barrel
diameter
(mm)
1 = 5 mm
68.9760.006
69 0.015
2 = 9 mm
68.9840.006 69.0150.015

Specifications
10
PISTON RINGS
Fitting the rings
Thickness of piston rings
Rings set to their original adjustment must be able to

move freely in their channels.
Three rings (thickness in mm)

compression ring
1.175 to 1.19
Ensure the rings are fitted the correct way round with
the TOP pointing upwards.
sealing ring
1.475 to 1.49
Oil and the piston rings and divide into three.
oil scraper ring

which consists of three parts:
two steel rails (1),
a spring ring (2).
2.31 to 2.46
Piston ring brake clearance
10-14
Rings
Clearance at the break

(in mm)
Compression
0.20 to 0.35
Sealing
0.35 to 0.50
Scraper
0.2 to 0.9

Specifications
Gudgeon pin (in mm)
10
CON RODS
The gudgeon pin is fitted with an inner collar (1).
Lateral clearance of the big end

(in mm)
0.21 to 0.453
Radial clearance of the big end

(in mm)
0.025 to 0.064
Centre distance between the big

end and little end (in mm)
Diameter of the big end (in mm)
Diameter of the little end (in mm)
1220.03
43.639
17.5
+ 0.11
0
- 0.021
- 0.039
NOTE: the small end does not have a ring.
Length:
External diameter (A):
54
WARNING: do not use a sharp point to mark the

bearing caps in relation to their con rods to avoid
starting a crack in the rod.
0
- 0.2
17.495 to 17.499
Use a permanent marker pen.
Internal diameter (B):
10.5
+ 0.1
- 0.2
Collar inner diameter (C) :
9.660.2
Inner collar length (D) :
8.20.15
The gudgeon pins (E) are fitted with ring B19, centre
tool C19 and fitting shaft A19 (Mot. 574-25).
The maximum weight difference for the con rod, piston

and gudgeon pin assemblies for the same engine must
be 11 grams.
10-15

Specifications
Direction of fitting of the con rod in relation to the
piston
10
BEARING SHELLS
Crankshaft bearing shells
Point the V (1) on the piston downwards and the

index (2) of the con rod as shown in the diagram
below.
The engine is fitted with bearing shells without a

locator notch.
The crankshaft bearing shells are fitted on the cylinder

block and on the bearings using Mot. 1493-02.
CRANKSHAFT
Number of bearings
Burnished bushings: (in mm)

nominal diameter
44 0.01
Burnished crankpins: (in mm)

nominal diameter
40
0
- 0.016
lateral play of the crankshaft (in mm)

0.045 to 0.235
radial play of the crankshaft (in mm)
0.02 to 0.046
The crankshaft stroke is:
Crankshaft stroke
(mm)
D4D engine
D4F engine
66.80.05
76.80.05
The lateral shims are located on bearing no. 3.
10-16

Specifications
Direction of fitting:
on the cylinder block, fit the grooved shells on all
the bearings. The shell fitted with flange stops
goes on bearing 3,
10
Con rod bearing shells

The engine is fitted with bearing shells without a
locator notch.
The bearing shells are fitted using Mot. 1492 and
Mot. 1492-04.
on the bearing caps, fit non grooved bearing shells.
10-17

Specifications
10
the alternator belt by unscrewing the two bolts (3),
PREPARING THE ENGINE TO BE SET ON THE

SUPPORT
Change the engine oil before fitting the engine to
support Mot. 792-03.
Remove:
the air conditioning compressor belt, by unscrewing
the bolts (1) and turning the hexagon nut (2)
clockwise,
the air conditioning compressor and the alternator,
10-18

Specifications
10
Place the rods (G), (H), (W1) and the plate (H1)
Mot. 1360-01 (including rod W1 and plate H1), on the
cylinder block so that they fit into the holes (18, 8, 4)
on the plate (Mot. 792-03).
the accessories multifunction supports.
NOTE: before fitting the rods to the cylinder block,

you need to alter rod W1 by making a chamfer of
the following dimensions:
X = 10 mm
Y = 15 mm
10-19

Specifications
10
CONSUMABLES
Type
Cleaner
Quantity
Part no.
Cleaning parts
77 01 421 513
Coat
Cleaning gasket faces
77 01 405 952
Coat
Coolant pump, oil pump, crankshaft closing

panel
77 01 404 452
Tube of
RHODORSEAL 5661
Bead
Coolant pump, oil pump, crankshaft closing

panel
77 01 421 042
Loctite FRENETANCH
1 - 2 drops
Exhaust manifold studs
77 01 394 070
DECAPJOINT
RHODORSEAL 5661
Component concerned
WARNING
PARTS TO BE REPLACED AFTER REMOVAL:
all the gaskets,
flywheel bolts,
crankshaft bearing bolts,
con rod cap bolt,
belts,
timing gear tension wheel,
cylinder head bolts
FITTING THREAD INSERTS

Threaded holes on all engine component parts can be repaired by using thread inserts.
10-20

Standard replacement
PREPARING THE USED ENGINE FOR RETURN
The engine should be cleaned and drained (oil and
water).
Leave on the used engine or include in the return box:
the dipstick and its guide,
the flywheel,
the clutch mechanism and plate,
the water pump,
the cylinder head cover,
the oil pressure switch,
the valve timing cover,
the oil filter.
Remember to remove:
all coolant flexible hoses,
the inlet and exhaust manifolds,
the alternator,
the air conditioning compressor,
the multifunction supports,
the oil level sensor,
the cylinder head coolant output unit.
The used engine should be secured to the base under

the same conditions as the overhauled engine:
plastic plugs and covers fitted,
cardboard cover over the assembly.
WARNING: never place the engine on the sump
(risk of destroying the oil pump strainer).
10-21
10

Illustration
10
Part number
Part Stores
Number
Mot. 574-25
00 00 057 425
Gudgeon pin fitting tool (centre tool C19, shaft

A19, and ring B19)
Mot. 582-01
00 00 058 201
Flywheel locking tool
Mot. 591-02
00 00 059 102
Magnetized pointer arm
Mot. 591-04
00 00 059 104
Cylinder head bolt tightening gauge (angular

measuring type)
Mot. 799-01
00 00 079 901
Timing gear tension wheel immobiliser
Mot. 1054
00 00 105 400
TDC setting pin
Mot. 1330
00 00 133 000
Oil filter removing tool
Mot. 1335
00 00 133 500
Tool for removing valve stem seals
10-22
Description

Illustration
10
Part number
Part Stores
Number
Description
Mot. 1354
00 00 135 400
Crankshaft seal gasket fitting tool (flywheel side)
Mot. 1355
00 00 135 500
Oil pump seal gasket fitting tool
Mot. 1360-01
00 00 136 001
Additional to Mot. 792-03 containing rod W1 and

plate H1
Mot. 1374
00 00 137 400
Oil pump seal gasket removal tool
Mot. 1377
00 00 137 700
Crankshaft seal gasket removal tool

(flywheel side)
Mot. 1381
00 00 138 100
Camshaft seal gasket removal tool
El. 1382-01
00 00 138 201
Spark plug key
Mot. 1492
00 00 149 200
Tool for fitting con rod bearing shells
10-23

Illustration
10
Part number
Part Stores
Number
Description
Mot. 1492-04
00 00 149 204
Adaptation kit for fitting the con rod bearing shells
Mot. 1493-02
00 00 149 302
Tool for fitting crankshaft bearing shells
Mot. 1502
00 00 150 200
Valve spring compressor tool
Mot. 1505
00 00 150 500
Belt tension setting tool
Mot. 1511
00 00 151 100
Tool for fitting valve stem seals
Mot. 1573
00 00 157 300
Cylinder head support
Mot. 1587
00 00 158 700
Tool for fitting inlet camshaft seals
Mot. 1605
00 00 160 500
Tool for fitting cylinder head adjuster
10-24

Essential equipment
10
Description
Ring for fitting piston with ring in the cylinder block.
Standard 22 mm long socket 1/2" (12.7 mm squared) for removing the oil
pressure gauge.
Tooling for testing the cylinder head, including: a tray and the various kits suited
for each model of cylinder head (plug, sealing plate, blanking plate). The approval
number of the cylinder head test container is 664000.
Standard 1/2" 12 female torx socket (12.7 mm squared).
Angular tightening tool from:

STAHLWILLE part number 540 100 03 for example,
FACOM part number DM360 for example,
SAM part number 1 SA for example.
FACOM tool for fitting the valve stem seals, part number DM6J4 for example.
Gun for using tube of RHODORSEAL 5661.
FACOM spark plug key, part number B.J 14 BH2.
Angled tweezers (pliers) from:

SAM, part number 366.1 for example,
FACOM, part number 151 for example.
10-25

the lower timing cover (4).
REMOVING THE UPPER ENGINE

Fit the flywheel block Mot. 582-01.
Remove the flywheel block Mot. 582-01.
Remove:
the upper timing housing (1),
the crankshaft accessories pulley (2),
the intermediate timing cover (3),
10-26
10

10
Check that the mark (7) on the camshaft pulley is on

the vertical shaft of the engine.
Adjusting the timing

Turn the crankshaft clockwise (timing side) until it is
one half-tooth from alignment with the mark (5) on the
crankshaft sprocket and the fixed mark (6) on the oil
pump body.
Unscrew the nut (8) on the timing gear tension wheel,

then remove the timing belt.
Insert the TDC setting pin Mot. 1054, then turn the
crankshaft until it is pinned.
10-27

10
Disengage the electric wiring harness from the inlet

manifold.
Remove:
the ignition coil and the spark plug wires,
the four upper bolts (1) on the inlet manifold (do not
pull the section of the wiring harness labelled (2) as
it is held between the cylinder head cover and the
manifold),
the eight lower bolts (3) on the inlet manifold.
Remove:
the cylinder head cover,
the cylinder head bolts,

the cylinder head.
10-28

10
the camshaft pulley,

the timing gear tension wheel,
STRIPPING THE CYLINDER HEAD

Place the cylinder head on cylinder head support
Mot. 1573.
Remove:
the exhaust heat shield,
the camshaft seal gasket by screwing the puller tool

Mot. 1381 into the seal gasket.
the exhaust manifold,

the fuel pipe retaining brackets (1),
10-29

10
Remove the seal gasket by screwing the bolt (1) on

tool Mot. 1381.
the rocker arm rails by removing the bolts (2).
Remove:
the lifting rings,
the cylinder head coolant output unit,
the camshaft adjuster,
Mark the camshaft bearing caps with a permanent

marker pen.
10-30

Remove:
the camshaft bearing caps,
the valve springs using tool Mot. 1502.
the camshaft,
10-31
10

10
To compress the valve springs correctly, the piston (1)

of the Mot. 1502 tool must be centred on the valve
stem. The spring upper retaining cup must fit into the
cavity (2) of the socket (3) on tool Mot. 1502.
Remove:
the pins,
the upper cups,
the springs,
the valves,
the valve guide seal gaskets using the Mot. 1335
pliers.
10-32

CLEANING
CHECKING THE CAMSHAFT END PLAY
It is very important not to scratch the mating

surfaces of any aluminium components.
Refit:
the camshaft,
the camshaft bearing caps,
the rocker arm shafts.
Wear gloves whilst carrying out this operation.

Use the Dcapjoint product to dissolve any part of the
gasket which remains attached.
Tighten bolts (1) and (2) to a torque of 0.9 daNm.

Pretighten bolts (3), (4), (5), (7), (8), (9), (10), (11) and
(12) in the recommended order to a torque of
0.5 daNm.
Apply the product to the parts to be cleaned; wait

about ten minutes, then remove it using a wooden
spatula.
Unscrew bolt (3) until it is free, then tighten bolt (3) to

a torque of 0.7 daNm plus an angle of 506.
Do not allow this agent to drip on to the paintwork.

Great care should be taken when performing this
operation, to prevent foreign objects entering the
pipes taking oil under pressure to the camshafts
(pipes in both the cylinder head and its cover) and
the oil return pipes.
CHECKING THE MATING SURFACE

Check for mating surface bow using a ruler and a set
of shims.
Maximum bow
10
0.05 mm
CORRECTION OF THE CYLINDER HEAD IS NOT

AUTHORISED
Test the cylinder head to detect possible cracks
using the cylinder head test tools (comprising a tray
and a kit suited to the cylinder head, plug, sealing
plate, blanking plate). The approval number of the
cylinder head test container is 664000.
10-33
Repeat the process for bolts (4), (5), (6), (7), (8), (9),
(10), (11) and (12).

Check the end play, which must be between 0.08 and
0.178 mm.
10
REBUILDING THE CYLINDER HEAD

Lubricate the inside of the valve guide.
The valve stem seals must be fitted using tool
Mot. 1511 or the FACOM tool, part number DMJ4.
Remove the rocker arm shafts, the camshaft bearing

caps and the camshaft.
NOTE: do not lubricate the valve stem seals before

fitting them.
10-34

10
Fitting new valve stem seals
Keep the valve pressed against its seat.
Place the valve in the cylinder head.
Place the valve stem seal (not lubricated) over the tool
barrel.
Place the barrel of the Mot. 1511 tool over the valve
stem (the internal diameter of the barrel must be
identical to the diameter of the valve stem).
Push the valve stem seal past the tool barrel, then
withdraw the barrel.
10-35

10
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.
Place the pushrod (1) over the valve stem seal.
NOTE: the internal diameter of the pushrod must

be identical to the diameter of the valve stem.
Moreover, the lower part of the pushrod must be in
contact with the upper section of the valve stem
seal.
Repeat these operations for all the valves.
10-36

Fit:
the springs,
the upper cups,
To compress the valve springs correctly, the piston (1)
of the Mot. 1502 tool must be centred on the valve
stem. The spring upper retaining cup must fit into the
cavity (2) of the socket (3) on tool Mot. 1502.
Refit the keys using tweezers.
10-37
10

ASSESSMENT AND REPAIR OF
ROCKER ARM RAILS
Mark the position of the rocker arms
in relation to the rails, then remove
the rocker arm rails.
Examine the condition of the bearing
surfaces and the rocker arm bolts.
Check that the cam/tappet
lubricating holes are not blocked up.
Replace worn parts.
Refit the rocker arm rails, placing the
rails in the correct position in relation
to the tappets:
for the inlet rocker arm rail, put the
mark (1) on the timing side,
for the exhaust rocker arm rail, put
the mark (2) on the flywheel side.
10-38
10

10
Grease the camshaft bearings with engine oil.

Refit the camshaft.
Refit:
the camshaft bearing caps by tightening the bolts (1)
and (2) to a torque of 0.9 daNm.
Apply:
two lines (3) of Rhodorseal 5661, 2 mm wide, on
cylinder head bearing 5,
two beads (4) of Rhodorseal 5661 on cylinder head
bearing 1.
10-39

the rocker arm rails by placing them in the correct
position and tightening the bolts in the recommended
order to a torque of 0.5 daNm. Then unscrew bolt (3)
until it is free, then tighten bolt (3) to a torque of
0.7 daNm plus an angle of 506.
Repeat the process for the other bolts.
10-40
10
Refit:
the engine lifting bracket,
the cylinder head coolant output unit fitted with a new
seal by tightening the bolts to a torque of 0.9 daNm,
the camshaft adjuster using tool Mot. 1605.

10
Screw the threaded rod (3) from tool Mot. 1587 into
the camshaft.
Fitting the camshaft seal gasket.

IMPORTANT: this type of seal gasket is extremely
FRAGILE. Only touch the protector part (1) when
handling the gasket. It is strictly forbidden to
touch the seal (2). This is to ensure that there will
be no oil leaks once the gasket is fitted on the
engine.
Fit the seal gasket using tool Mot. 1587.
Fit the seal gasket and protector on the camshaft. Be

careful not to touch the seal.
10-41

10
Fit the canister (4) and the collar nut (5) from
Mot. 1587.
Remove the nut, the canister, the protector and the

threaded rod.
Screw the collar nut until the canister touches the
cylinder head.
10-42

10
Refit:
the camshaft pulley by tightening the bolts to a torque
of 3 daNm plus an angle of 456,
Refit:
the inlet manifold fitted with a new seal by tightening
the nuts to a torque of 2.5 daNm in the
recommended order,
the tension wheel by positioning it correctly.
the exhaust heat shield by tightening the bolts to a

torque of 1.5 daNm.
Fit the tension wheel notch (5) into the cylinder wheel
rib (6).
10-43

10
Setting the valve clearances

Valve clearance setting values (in mm)
inlet
exhaust
0.05 to 0.12
0.15 to 0.22
Open exhaust valve method

Bring the exhaust valve of cylinder no. 1 to the fully open position, then adjust the inlet valve clearance for cylinder
no 3 and the exhaust valve clearance for cylinder no 4.
Follow the same method for the other cylinders, in the order shown by the table below.
Exhaust valve to be fully

opened.
Inlet valve to be adjusted.
10-44
Exhaust valve to be adjusted.

10
the sump,
REMOVING THE LOWER ENGINE

Fit flywheel block Mot. 582-01.
Remove:
the clutch,
the crankshaft seal gasket on the flywheel side by

screwing puller tool Mot. 1377 into the seal gasket.
the flywheel,
10-45

10
Remove the seal by screwing the bolt (1) of tool

Mot. 1377.
the oil pump seal gasket by screwing puller tool

Mot. 1374 into the seal gasket.
Remove:
the crankshaft seal supporting ring,
Remove the seal gasket by screwing the bolt (2) of tool

Mot. 1374.
10-46

10
Remove:
the strainer and its seal,
the oil pump (the oil pump cannot be repaired),
the oil pressure supply seal.
the coolant pump,
WARNING: do not use a sharp point to mark the

big end caps in relation to their con rods, to
prevent starting a crack in the rod.
Use a permanent marker pen.
10-47

Remove:
the bearing caps and the con rod/piston assemblies.
the crankshaft bearing shells,
the crankshaft bearing caps,
Clean:
the cylinder block,
the oil pump,
the coolant pump,
the crankshaft,
the seal supporting ring,
10-48
10

10
EXTRACTING THE GUDGEON PINS
FITTING THE CON ROD SHELLS
Remove the piston rings.
The con rod bearing shells are fitted using Mot. 1492
and Mot. 1492-04.
Place the piston on the V of the support, the shaft

aligned with the removal hole.
On the con rod body
Drive out the gudgeon pin on the press with the

extraction mandrel (E).
Remove the pin (1) from Mot. 1492 (using a jaw vice),
and replace it with the pin (2) from Mot. 1492-04.
10-49

10
Slide the shell support (3) from Mot. 1492-04 into the
groove (4) on the base of Mot. 1492, then place the
rail (5) from Mot. 1492-04 on the base (as shown in
the diagram).
Push the shell support in the direction of the arrow (as

shown in the diagram) as far as it can go into the con
rod body.
Lay the body of the con rod on the base of the tool (as
shown in the diagram). Ensure that the lower part (6)
of the small end of the con rod is in contact with the
centring pin. Then place the shell (7) on the shell
support.
Remove the con rod body support and repeat the

operation for the remaining con rod bodies.
10-50

10
Push the shell support in the direction of the arrow (as

shown in the diagram) as far as it can go into the con
rod cap.
On the con rod cap

Fit the bar (8) and the con rod cap as shown in the
diagram.
Push the rail (in the direction of the arrow) until the con
rod cap touches the bar. Then place the shell (9) on
the shell support.
10-51
Remove the con rod cap support and repeat the

operation for the remaining con rod caps.

10
ASSEMBLING THE CON RODS - PISTONS
Fitting the gudgeon pins
Preparing the piston/gudgeon pins assembly
The gudgeon pins are tightened in the con rods and

able to rotate in the pistons before they are fitted. Use
tooling Mot. 574-25 (to be ordered from the
Replacement Parts Store to complete Mot. 574-22).
The parts supplied in the set are identical.

Mark the parts in each box from A to D to ensure they
remain identical.
A : fitting pins with centrers (C).
Completely dissolve the non-stick film without

scratching the parts.
B : piston supporting rings,

M : extraction mandrel,
S : piston support base,
10-52

10
Preparing the con rods
Preparing the gudgeon pins
Visually inspect the condition of the con rod (piercings/

level),
Check that the gudgeon pins rotate properly in the

corresponding new pistons.
Use a 1500 W heating plate.
Use tool Mot. 574-25 containing centre tool C19 and

pin fitter A19.
Place the small ends on the heating plate.

Place the gudgeon pin (E) on the pin fitter (A), screw
the centre tool (C) until it touches, and then
unscrew one quarter of a turn.
Ensure that all the small end surfaces are in contact

with the plate.
To test the temperature, place a solder on each small
end at (a) where the fusion point is
approximately 250 C.
Heat each small end until the test solder welds.
10-53

10
Follow these instructions when assembling the piston

and con rod:
Assembling the con rods/pistons

The piston heads are stamped with an arrow pointing
to the flywheel side.
Position the (1) engraved on the piston head to point

downwards and at thesame side as the boss (2) of the
small end (as shown in the diagram) (or the dipstick
side on the cylinder block).
Fit ring B19 on the support and place the piston

(arrow pointing downwards) on the ring, securing it
with the pin.
Grease the centre tool and the gudgeon pin with

engine oil.
Drive the gudgeon pin into the assembly to check
that it can move freely and re-centre the piston if
necessary.
10-54

The following operations should be performed as
quickly as possible to keep heat loss at a minimum.
FITTING THE RINGS

Rings set to their original adjustment must be able to
move freely within their channels.
When the solder reaches welding point (becomes

liquid):
10
Ensure that the rings are fitted the correct way round
as shown in the diagram.
wipe off the solder,

engage the centring guide in the piston,
fit the con rod in the piston,
quickly drive in the gudgeon pin until the guide
reaches the bottom of the support base.
Ensure that the gudgeon pin remains set back from

the piston diameter for all the positions of the con rod
in the piston .
10-55

REFITTING THE LOWER ENGINE
Fitting the bearing shells on the bearings.
Fitting the bearing shells in the cylinder block.
Position Mot. 1493-02 on the bearing.
10
Position tool Mot. 1493-02 on the cylinder block.
Fit the non-grooved bearing shell in Mot. 1493-02,

then press at (3) until the bearing shell is touching
Mot. 1493-02 at (4).
Fit the grooved bearing shell in Mot. 1493-02, then

press at (1) until the bearing shell is touching
Mot. 1493-02 at (2).2
10-56

10
Refit the crankshaft.
Check that the crankshaft rotates freely.
Grease the crankpins and bushings with engine oil.
Refit the con rod/piston assemblies using the fitting

ring.
Fit the crankshaft bearing caps (so that the arrows (1)
engraved on the bearings are pointing to the flywheel
side), then tighten the bolts to a torque of 2 daNm
plus an angle of 766.
Fit the con rod caps, ensuring that they are correctly
matched (use the marks made on removal).
Check the crankshaft clearance which should be

between 0.045 and 0.235 mm.
10-57

Refit the con rod caps by tightening the bolts to a
torque of 1.4 daNm plus an angle of 396.
10
NOTE: the crankshaft closure panel is sealed with

RHODORSEAL 5661. The band (1) must be 1.3 mm
wide and be applied as shown in the diagram
below.
Check the lateral clearance of the big end which

should be between 0.21 and 0.453 mm.
Tighten the crankshaft closure panel bolts on the
flywheel side to a torque of 0.9 daNm in the
recommended order.
10-58

NOTE: the coolant pump is sealed with
below.
10
Systematically replace the oil pressure supply seal (3).
IMPORTANT: the oil pump is driven by two studs

located on the crankshaft.
Tighten the coolant pump bolts to a torque of
0.9 daNm in the recommended order.
NOTE: the oil pump is sealed with

below.
18646R ]
10-59

10
Tighten the oil pump bolts to a torque of 0.9 daNm in

the recommended order.
oil pump side, use tool Mot. 1355.
Fitting the crankshaft seal gaskets
Replace the strainer fitted with a new O-ring by

tightening the bolts to a torque of 0.9 daNm.
flywheel side, use tool Mot. 1354.
10-60

10
the flywheel by tightening the new bolts to a torque of

1.8 daNm, then turning to an angle of 1106
(blocking the flywheel with Mot. 582-01).
NOTE: the sump must only be sealed with a

special After Sales seal. Place the flat surface on
the cylinder block side.
Refit:
the sump, tightening the bolts to a torque of 1 daNm
in the recommended order.
the clutch, tightening the bolts to a torque of 2 daNm.
Remove flywheel block Mot. 582-01.
10-61

10
Replacing the oil filter

The two seal gaskets (2) must be replaced when the
oil filter (1) is replaced.
Refit the oil filter by tightening it to a torque of 2 daNm

to prevent any leaks.
NOTE: the coolant pipe is sealed with
below.
Hold the filter upside down and tap it on a piece of

wood to remove the filter element.
Tighten the coolant pipe bolts to a torque of 0.9 daNm.
10-62

10
REFITTING THE UPPER ENGINE

Refitting the cylinder head
Position the pistons at mid-stroke.
Fit the cylinder head gasket using the centring sockets
of the cylinder block.
Tighten the cylinder head (see the section on
cylinder head specifications).
Paste lines (1) of Rhodorseal 5661 around the cylinder
head cover mounting bolts and on camshaft bearings
1 and 5 as shown in the diagrams below.
Replace the cylinder head cover seal.

Refit the cylinder head cover, tightening the bolts to a
torque of 1.2 daNm in the recommended order.
10-63

10
Replace the inlet manifold seals and the oil vapour

seal.
Refit the spark plug well seals using a socket with an

external diameter of 41 mm (32 mm socket for
example).
Position the inlet manifold.

Place a drop of Loctite FRENETANCH on the inlet
manifold bolts.
Tighten the eight bolts by hand, then pretighten bolts
(4) and (5) to a torque of 0.6 daNm.
Loosen bolts (4) and (5) until they are completely free.
Tighten the eight bolts to a torque of 1 daNm in the
recommended order.
Check that the wiring harness is correctly positioned at

(1) and (2) before refitting the inlet manifold.
10-64

10
Tighten the four upper bolts in a cross on the inlet

manifold to a torque of 1 daNm.
that the TDC pin Mot. 1054 is in place,
Adjusting the timing
that the crankshaft timing sprocket mark (7) is facing

the oil pump body mark (8).
Check:
that the tension wheel notch (5) is correctly
positioned in the cylinder wheel rib (6).
10-65

10
Remove the TDC setting pin Mot. 1054.
that the camshaft pulley mark (9) is facing the

cylinder head cover mark (10).
Turn the tension wheel eccentric ring anti-clockwise

using a 6 mm Allen key to bring the tension wheel
mobile index (A) into the position shown below.
Tighten the crankshaft accessories pulley bolt fitted

with its washer to a torque of 1.5 daNm, to hold the
timing sprocket in place.
Tighten the tension wheel nut to a torque of 2.4 daNm.
Fit the timing belt by aligning the belt markings with
those on the camshaft and crankshaft sprockets.
Rotate the crankshaft through six revolutions in a

clockwise direction (timing side).
Refit the TDC pin Mot. 1054 and position the timing at
setting point (check that the camshaft and crankshaft
sprocket marks are correctly aligned with the fixed
marks).
Remove the TDC setting pin Mot. 1054.
10-66

Unscrew the tension wheel nut no more than one turn
with a 6 mm Allen key, then turn the mobile index (11)
in a clockwise direction until it is in the middle of the
timing window (12). Then tighten the timing gear
tension wheel nut to a torque of 2.4 daNm.
10
Fit the flywheel block Mot. 582-01.
Remove the accessory crankshaft pulley bolt.

Refit:
the lower timing cover,
NOTE: it is vital that you tighten the tension wheel
nut to torque to avoid any loosening which may
cause damage to the engine.
10-67

10
the timing intermediate housing (3), tightening the

bolts to a torque of 1 daNm ,
the timing upper housing (1), tightening the bolts to a
torque of 3.3 daNm,
the accessories crankshaft pulley (2), tightening the
bolts to a torque of 4 daNm plus an angle of 706.
Refit:
the alternator support, tightening the bolts to a torque
of 5 daN.m,
the coolant pipe fitted with a new seal,
the air conditioning compressor mounting, tightening
the bolts to a torque of 5 daNm,
Remove the flywheel block Mot. 582-01.
the power assisted steering pump support (for

engines fitted with air conditioning and power
assisted steering), tightening the bolts to a torque of
2.5 daNm,
the air conditioning compressor, tightening the bolts
to a torque of 5 daNm,
the power assisted steering pump by tightening the
bolts to a torque of 2.2 daNm,
the alternator by tightening the upper bolt to a torque
of 2.5 daNm and the lower bolt to a torque of
5 daNm,
the accessories belts.
Remove the engine from support Mot. 792-03.
10-68

Tensioning the accessory belts
measure the tension of the accessory belts with tool
Mot. 1505.
Alternator belt
Power assisted steering belt
Air conditioning and power assisted steering belt
Air conditioning belt
A
B
C
D
G
T
Crankshaft
Alternator
Power assisted steering pump
Air conditioning compressor
Tension
Wheel
Point for checking belt tension
10-69
10

10
Table of fitting tension values
TENSION
(Hertz)
Fitting tension
Alternator belt
Power assisted
steering belt
Air conditioning belt
Air conditioning and

power assisted
steering belt
260 5
210 5
210 5
210 5
10-70

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Workshop repair manual

D4F 702 - 704

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The methods may be modified as a result of changes introduced by the manufacturer

10 ENGINE AND PERIPHERALS

ENGINE AND PERIPHERALS

ENGINE AND PERIPHERALS

The engine identification is stamped on the cylinder

ENGINE AND PERIPHERALS

Cylinder head bolts

Coolant temperature sensor

Cylinder head coolant output unit

Rocker arm rail

Timing gear tension wheel

3 plus an angle of 456

Cylinder head cover

Lower and intermediate timing covers

Upper timing cover

Exhaust manifold heat shield

Air filter unit bolt

ENGINE AND PERIPHERALS

Oil level sensor

Crankshaft bearing bolts

1.4 plus an angle of 39 6

Con rod cap bolts

Crankshaft closure housing (flywheel side)

1.8 plus an angle of 1106

Accessories crankshaft pulley

Air conditioning compressor mounting

Power steering pump mounting

Air conditioning compressor

Power steering pump

ENGINE AND PERIPHERALS

Check that all the bolts are tightened to 2 daNm, then

ENGINE AND PERIPHERALS

Cylinder head height

The thickness of the cylinder head gasket is measured

No corrections are permitted

Chamber volume with valves and spark plugs:

ENGINE AND PERIPHERALS

Stem diameter (in mm)

Inlet and exhaust:

Mating surface width X (in mm)

Mating surface angle

Head diameter (in mm)

Valve length (in mm)

Max. valve lift (in mm)

Valve clearance settings (in mm)

ENGINE AND PERIPHERALS

The valve stem seals must be fitted using tool

Length (in mm)

Guide external diameter (in mm)

Guide internal diameter (in mm)

* This dimension is measured with the guide fitted in

Diameter of the guide housing in the cylinder head

The inlet and exhaust guides have valve stem seals

NOTE: do not lubricate the valve stem seals before

ENGINE AND PERIPHERALS

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

Inlet and exhaust:

ENGINE AND PERIPHERALS

Unloaded length (in mm):

Loaded length (in mm):