ENGINES (gasoline) 4 cylinder - Casting Type E6J E5F Vehicles Express Clio Clio Renault Clio Renault 19 Renault

19 19 Clio Megane Express E7J E7F Cancels and replaces the reference 77 11 091 460 77 11 193 635 APRIL 1997 Spanish edition La Régie Nationale des Usines Renault reserves all copyrights. Reproduction or t ranslation, even partial, of this document and use the numbering system of refer ences for the parts, without the prior written consent of the Regie Nationale de s Usines Renault SA. "The repair methods prescribed by the manufacturer in this document have been es tablished on the basis of technical specifications in force on the date of publi cation of this document. They may be modified, if changes made by the manufactur er in the manufacture of the various bodies and accessories of vehicles of their brand. " C 1997 Renault Index Pages 10 MOTOR ASSEMBLY AND LOW ENGINE - 10-1 Preamble - Overview 10-2 - Identification 10-3 - Section and torques 10-5 - Lubrication circuit diagram 10-8 - Features standard Change 10-20 10-10 - Specialized Tooling indispensable 10-21

- Material must 10-24 - Motor Repair Exploded Exploded engine block cylinder head 10-25 10-25 10-34 MOTOR ASSEMBLY MOTOR AND LOW Preamble USING THE MANUAL 10 You will find in this manual three main chapters: - features, - remove the engin e - engine mounting. For the repair of the vehicle bodies, see MR and NT the veh icle. UNITS OF MEASURE All the dimensions are in millimeters: mm (unless otherwise noted). The torque in decaNewtonmetro (daN.m) (remember: 1 m.kg daN.m = 1.02), respecting the torq ue without tolerance to ± 10% - in degrees, must be respected peers clamping wit hout tolerance ± 3 °. The pressures are given in bars. 10-1 MOTOR ASSEMBLY MOTOR AND LOW Perspective 10 DI1042 10-2 MOTOR ASSEMBLY MOTOR AND LOW ID The identification was done through a plate riveted to the engine block. Content s: In A: the type of motor. 10 In B: the letter of approval of the engine. In D: RENAULT identity. In E: engine index. In F: the number of engine manufacture. G: the engine assembly plant. 92072R A B D E 0000 0 / 00 0000000 F G 10-3

MOTOR ASSEMBLY MOTOR AND LOW ID 10 Displacement (cm 3) Engine Index 710 716 700 704 706 708 730 750 700 701 706 712 713 718 734 738 760 601 62 4 700 706 710 711 716 718 719 720 724 726 728 742 745 754 756 757 764 770 771 77 3 Vehicle B / C / S 572 B 57N B / C / S 3 / 5 B / C / SB / C / SB / C / S 3 / 5 B / C / LB / C 3 / 5 B / C / LB / LB / CB / CBFF 5 B / CBB / C / LB / C / LB / CB / CB / CB / CB / CFFFFB / C / LB / C / LB / CB / CB / CB / J / LFFF 57F 57A / L 57A 57r 57g 57A / R 53W 57S 57J 573 537 536 57B 57B 57B 57p A0T 40 and 40A 53A 5 3A 57B 57T 57B 57T 57B 40V 40U 40U 535 53A 40D 57Y 57J 57J 40U 40S 40S A0E Volumetric ratio of 9.25 / 1 9.25 / 1 9.25 / 1 8.8 / 1 9.5 / 1 9.25 / 1 9.5 / 1 9.5 / 1 9.5 / 1 9.5 / 1 9.5 / 1 9.5 / 1 8.8 / 1 9.5 / 1 8.8 / 1 9.5 / 1 Diameter (mm) Stroke (mm) E5F 75.8 64.9 1171 E7F B/C/L/S537 E6J 75.8 77 1390 E7J 9.5 / 1 10-4 MOTOR ASSEMBLY MOTOR AND LOW Section and torques (in daN.my / o °) 10 5 to 5.5 DI1043 (1) Nut idler distribution: 5 daN.m tighten (2) M6 nuts and bolts, tighten to a

daN.m M8 screw, tightening to 2.2 daN.m (3) pre-tightening to 2 daN . m, then ap ply a torque angle of 68 ° ± 6 ° 10-5 MOTOR ASSEMBLY MOTOR AND LOW Section and torques (in daN.my / o °) 10 2.5 to 3 DI1044 * Pre-tightening of the screws to 2.5 daN.m, then apply an angle of 43 ° ± 6 ° * * See tighten butt 10-6 MOTOR ASSEMBLY MOTOR AND LOW Section and torques (in daN.my / o °) 10 DI1045 10-7 MOTOR ASSEMBLY MOTOR AND LOW lubrication circuit diagram 10 92 130 10-8 MOTOR ASSEMBLY MOTOR AND LOW lubrication circuit diagram 10 92 130 10-9 MOTOR ASSEMBLY MOTOR AND LOW Features STOCK 10 All cylinder head bolts must be replaced routinely after removal. Lubricate thre ads with engine oil and under the screw heads. 90775S METHOD OF TIGHTENING OF THE STOCK A board Preasentamiento tighten two daN.m, then apply a torque angle of 97 ° ± 2 ° in the order recommended: - tighten the screws 1-2 - 3-4-5-6 tightening screw s, - tightening the screws 7-8-9-10. Settlement of the board Wait 3 minutes settling time.

Squeeze - Loosening of the screws 1-2. Retighten the screws daN.m 1-2 to 2, then apply an angle of 97 ° ± 2 °. - Loosening of the screws 3-4-5-6. Retighten the screws to 2 daN.m 3-4-5-6, then apply an angle of 97 ° ± 2 °.€- Loosening of the screws 7-8-9-10. Retighten the screws to 2 daN.m 7-8-9-10, then apply an angle of 97 ° ± 2 °. No readjustment of the stock. Gasket thickness gasket (mm): 1.3 ± 0.06 (value for a junta crushed) 10-10 MOTOR ASSEMBLY MOTOR AND LOW Features VALUES OF THE GAME SETTING VALVES VALVE 10 7 (Mm) Diameter of tail (mm) - Admission - Escape Seat Angle 0.10 0.25 - Admission - Escape 120 ° 90 ° Head height Head diameter (mm) - Admission - Escape 37.5 ± 0.1 33.5 ± 0.1 ATTENTION: during a valve replacement, it is imperative to mount a valve (new) h aving the same reference (1) that the old, in order to prevent the destruction o f the valve / seat. 10032R H = 113 ± 0.05 mm maximum deflection board the plane at 0.05 mm is not authorize d any rectification. Volume of the chamber with valves and spark plugs: 26.25 ± 0.6 cm3 Torque spark plugs: 2.5 to 3 daN.m 10030R The same reference APR may merge several brands, in this case the valves are com pletely interchangeable. Verify that the new valves just marked differently than older ones, are actually assigned to the same reference APR. 10-11 MOTOR ASSEMBLY MOTOR AND LOW Features VALVE SEAT 10 Seat angle α - Admission - Esc pe Se t Width (mm) X - Admission - Esc pe Outer d i meter (mm) D - Admission - Esc pe 120 ° 90 ° 1.7 ± 0.1 1.7 ± 0.1 Position of the guide with respect to the bottom of the v lve spring (without bo ttom pl te) (mm): - Admission: A = 12.34 - Esc pe: E = 12.34 34.5 38.5 91881R 87428R

 

 

 

 

 

 

 

 

VALVE GUIDES Inner di meter (mm) Norm l di meter of the housing in the butt (in mm) Norm l 7 12 Guides int ke nd exh ust re equipped with g skets in line v lve, must be repl ced when removing the v lves. Inclin tion of the guides: - Admissions - Esc pe β = 17 ° β = 17 ° 91 881-1R 10-12 MOTOR ASSEMBLY MOTOR AND LOW Features VALVE SPRINGS 10 1st Mount ( lack) Free length (mm) Length under load (in mm) - 27 daN.m - 53.6 d aN.m - 65 daN.m spirals together (in mm) Wire diameter (mm) internal diameter (m m) 46.64 The 2nd Assem ly (Orange) 44.93 37 27.5 23.63 3.8 21.5 37 4 21.5 27.6 26.01 NOTE: The APR provides only the 2nd spring montage. CAMSHAFT Game length (mm): Num er of support: 0.06 to 0.15 5 10-13 MOTOR ASSEMBLY MOTOR AND LOW Features Distri ution diagram (not verified) E5F 710-716 E7F 700 - 704-706 E6J 700-701 - 706 10 E7F 708-750 730 E7J 624 - 718 - 719 720 712 - 713 - 718-734 738-760 E7J 601 - 700 - 706 710 - 711 - 716-724 726-728 - 74 2-745 754-756 - 757-764 770-771 - 773 -6 43 44 -3 -4 30 40 -6 Opening Delay Admission (RAA) * Admission Delay Close (RCA) Advance Opening Esca pe (EPA) Advance Close Escape (ACE) **

 

   

 

 

 

 

 

 

 

 

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-2 39 48 -7 * To e negative Opening Delayed Admission, the opening of the valve is after TDC. Negative ** Advance As Close Escape, the closing of the valve is in front of PM S. 11953S 1 2 3 4 5 6 7 8 Brand PMS fixed mo ile Brand engine lock flywheel flywheel TDC Mo ile Brand PMI Opening Delayed Admission (RAA) Progress Close Escape (ACE) Delay Closing Admis sion (RCA) Advance Opening Escape (EPA) Direction of rotation of the engine (fly wheel side) 10-14 MOTOR ASSEMBLY MOTOR AND LOW Features PISTONS 10 Piston Metal Leve Foot holder of the olt: the shock link tight and turning in the piston. Mountin g direction: arrow pointing hand wheel. Piston Pins (mm) Length OD Bore 60 Novem er 19 Marking pistons 12617R Sense of piston shaft (1) towards the wheel. The class of the piston is position ed at (2) (stock-piston A - B - C). Brands (3) only uses the supplier. IDENTIFICATION OF THE DIAMETER OF THE PISTONS ON THE DIAMETER OF CYLINDER Piston Identification 12618R Piston Diameter (mm) 75.765 to 75.775 (excluded) from 75.775 to 75.785 (incl.) ( excl.) from 75.785 to 75.795 (inclusive) Cylinder ore (mm) 75.8 to 75.81 (excluded) from 75.81 to 75.82 (incl.) (excl.) 75.82 to 75.83 (included) A B C 10-15 MOTOR ASSEMBLY MOTOR AND LOW Features Measure the diameter of the piston diameter measurement must e at level A = 46 mm. SHIRTS

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10 They are wet type. The oard is the ase ring (J). Shirts Height (mm) internal d iameter (mm) centering (mm) Projection of the oard shirts (mm) Height of the sh irts (mm) Depth of the engine lock (mm) H2 = 130 +0 75.8, 03 0 D = 80.6 X = 0.02 to 0.09 H1 = 91.5 +0.035 +0.005 K1 = 91.5 86 928-4R - 0.015 to 0.055 Segments (thickness in mm) of fire sealing Scraper 1.5 1.75 3 CONNECTING RODS (mm) Game lateral head of rod (mm) 0.310 to 0.572 WARNING: Do not use a stylus for marking, tune to avoid the onset of the cranks. Use a permanent marker 75615R4 10-16 MOTOR ASSEMBLY MOTOR AND LOW Features CRANKSHAFT OIL PUMP 10 1 ar 3 ar Num er of supports ...... 5 54.795 ± 0.01 54.550 ± 0.005 0 to 0.02 0 to 0.02 Burnished towers (mm): - nominal diameter - diameter polished repair pads (mm): - nominal diameter - diameter lateral Repair Kit Minimum oil pressure at 80 ° C: - Idle - 4000 rpm The pump is of the gear pump. 43.73 43.98 Remove the valve cover and oil pump. 0.045 to 0.852 0.045 to 0.252 with wear-wear There are coves of different thicknesses. If correct, the urnishing is to remai n intact over 140 ° in the areas indicated y arrows. These areas are defined in sections (A) and (B) taken as an example. 92313S

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Control of the oil pump Control the game: Juejo A (in mm): - mini - maxi 0.249 0.110 79 260-1G1 80142R1 10-17 MOTOR ASSEMBLY MOTOR AND LOW Features Game B (mm): - mini - maxi 10 0.086 0.020 92362R 10 099-2R1 Fixing the motor on the racket Mot. Stems Mot 792-03. 1132 (Q, S, R) are fixed to the engine lock so as to fit into the holes (12, 27, 7) of the plate. 92668R 10-18 MOTOR ASSEMBLY MOTOR AND LOW Features INGREDIENTS 10 Ref A.P.R. (Sodicaman) Type Amount Body concerned Loctite FRENETANCH (Resin 1-2 drops Fixing screws: the volantemotor, sheet converter drag. Crankshaft Bearing (when fixing screws volantemotor sheet containing no retention). Support face-motor fl ywheel on the crankshaft Carter lower cap, water pump shaft support, closed cran kcase crankshaft. Cleaning the flat aluminum cylinder head gasket 77 01,394,070 Loctite FRENBLOC (resin lock and sealing) Spread 77 01,394,071 Loctite AUTOFORM Spread 77 01,400,309

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RHODORSEAL 5661 Spread 77 01,404,452 Loctite 518 Cord 77 01,421,162 Décapjoint Spread 77 01,405,952 ENGINE CLEANING PRECAUTIONS PARTS REPLACED ONCE A have

- All together. Protect the timing elt and alternator to prevent the screening of water and laundry products on them. Do not get water in the air intake pipe. ADDED PLACEMENT THREAD - Flywheel olts. - Valve guides. - Screw head. - Supports the crankshaft olts. Threaded holes of all the components of the engine can e repaired using threads added. 10-19 MOTOR ASSEMBLY MOTOR AND LOW standard Change USED MOTOR PREPARATION FOR THE RETURN 10 The engine must e cleaned and drained (oil and water). Lay on the engine used o r attach to the shipping case: the oil dipstick and guide, the flywheel or drive plate, disc and the clutch mechanism, the fuel pump, water pump, pulley the cra nkshaft, cylinder head cover, spark plugs, tensioner elt, and the thermal manoc ontacto, the housing distri ution, the oil filter. Do not forget to remove - all hoses water, - or elts (excluding distri ution). The engine used to e fixed in the socket under the same conditions as the new m otor - plastic lids and caps in place, - card oard lid covering it. 10-20 MOTOR ASSEMBLY MOTOR AND LOW indispensa le specialized tooling 10 Figure Reference Methods Reference

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A.P.R. Designation Rou. 15-01 69 306-1S1 00 01,331,601 Bumper protector of the tree, within 16 mm ∅ Mot. 251-01 83812S 00 00,025,101 Support the comparator. Used with Mot. 252-01 Mot. 252-01 83812S1 00 00,025,201 Plate to measure the projection of the shirts. Used with Mot. 251-01. Mot. 330-01 68666S 00 00,033,001 Support stock. Mot. 574-22 00 00,057,422 Tools to replace the piston pins (set in case). Useful for placing ( olt with highlighting), complementing the suitcase Mot. 574-22. Mot. 574-24 10052S 00 00,057,424 Mot. 582-01 99614S 00 00,058,201 Sector to hold the flywheel. Mot. 588 77666S1 00 00,058,800 Flange to hold the shirts. Mot. 591-02 77889S1

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00 00,059,102 Flexi le magnetic torque wrench cylinder head angle. 10-21 MOTOR ASSEMBLY MOTOR AND LOW indispensa le specialized tooling 10 Figure Reference Methods Reference A.P.R. Designation Mot. 591-04 78181S 00 00,059,104 Angular wrench for tightening cylinder head (drag 1 / 2 "). Ele. 1382 10 250 00 00,138,200 Chest with spark plug wrench with torque limited. Mot. 792-03 00 00,079,203 Motor racket for stand Desvil. Game 3 threaded rods for securing the motor Mot. 792-03. Mot. 1132 82919S1 00 00,113,200 Mot. 799-01 80359S1 00 00,079,901 Immo ilizer timing elt sprockets for distri ution. Mot. 1127-2001 97628S 00 00,112,701 Useful to insert the sealing of the camshaft.

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Mot. 1128-2001 80357S 00 00,112,801 Useful for placing the crankshaft seal, side distri ution. Mot. 1129-2001 68658S 00 00,112,901 Useful for placing the seal of the crankshaft, flywheel side. Mot. 1135-2001 92 645-1S1 00 00,113,501 Useful for tightening the distri ution idler. 10-22 MOTOR ASSEMBLY MOTOR AND LOW indispensa le specialized tooling 10 Figure Reference Methods Reference A.P.R. Designation Mot. 1273 96508S1 00 00,127,300 Useful to control elt tension. Mot. 1330 97 160-1S1 00 00,133,000 Cap to remove the oil filter ∅ 66. Mot. 1335 98503S 00 00,133,500 Clamp to remove the seals from the tails of valves. 10-23 MOTOR ASSEMBLY MOTOR AND LOW indispensa le Material

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10 Designation Bushing piston assem ly segments in the shirt (all types). 83391S Briefcase of straw erries for the correction of the valve seat (Example: C108 CE RGYSDIS NEWAY). Lift valves. Boca star, 12. 10-24 MOTOR ASSEMBLY MOTOR AND LOW Motor Repair CUTTING OF CYLINDER HEAD 10 PRO10.1 10-25 MOTOR ASSEMBLY MOTOR AND LOW Motor Repair MOTOR DISASSEMBLY 10 Set the engine on the stand Mot. 792-03 with stems Mot. 1132. Empty: - Engine oi l - coolant from the engine lock (if the engine is equipped with drain plug). Extract: - wiring the engine - the alternator and its elt - the crankshaft pull ey to do so, with the latter immo ilized useful Mot. 582-01, 10020R - The protective casing of the elt. 92073R1 Put the drain plugs. 10-26 MOTOR ASSEMBLY MOTOR AND LOW Motor Repair Start the engine at the point of setting, aligning the marks (L) of the gears of the camshaft and crankshaft with fixed marks (M). Unscrew the nut (O) and loose n the tension pulley, then remove the elt. 10 DI1101R3 (A) Sense of stress tensor. 10-27 MOTOR ASSEMBLY MOTOR AND LOW Motor Repair

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Extract: - the top of the cylinder head - intake manifold - the mouth of hot air - exhaust manifold - Cylinder head screws, except the screw (F) which is unlock ed only (use a mouth Star 12), after the stock swing around knocking on this scr ew (G) having rought a lock of wood, put the clamps Mot liners. 588. 10 92062R Extract: - rocker ramp, marking the location of the screws: • two screws (B) are solid, • the three screws (C) are hollow (oil flow). 92106R1 - The utt. 92064R 10-28 MOTOR ASSEMBLY MOTOR AND LOW Motor Repair - Sealing cap camshaft - flange camshaft, Clean 10 It is very important not to scratch the oard flat aluminum parts. Decapjoint pr oduct use to dissolve the oard has een attached. Apply the product on the clea n up, wait ten minutes and then remove using a wooden spatula. 92078R the camshaft, fuel pump (if equipped), the distri utor with the ignition wires, the support of the thermostat, spark plugs, camshaft sprocket, pinning him to th e Mot. 799-01. 10010S Compress valve springs (Example: useful FACOM U43L). Remove the semi-caps, the t op plate, springs, valves, valve seals using the clamp Mot. 1335 and elow the p lates. It is advisa le to wear gloves during the operation. Do not drop product on the paintings. We call your attention to the care that must e put into this operati on, in order to prevent the introduction of foreign odies in the oil pipelines coming under pressure to camshaft (wiring located oth in the engine lock and t he stock) and the oil return pipe. Failure to o serve this instruction may lead shutter rocker pumps and cause a rapid deterioration of the cams and rocker skid s. 10-29 MOTOR ASSEMBLY MOTOR AND LOW Motor Repair JOINT PLAN CHECK 10 Check with a ruler and a set of ays if there is distortion of the plane togethe r. - 0.05 mm maximum deflection Not authorize any correction of the stock.

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10011S 10-30 MOTOR ASSEMBLY MOTOR AND LOW Motor Repair RECTIFICATION OF THE VALVE SEATS 10 X = 1,7 ± 0.1 α = 90 ° Admission - Se t Width (mm): - Angle: X = 1.7 ± 0.1 α = 120 ° Esc pe - Se t Width (mm): - Angle: The rectific tion of the se t (1) is m de with str wberry n ° 208 31 ° side. Red ucing the width of the se t (2) by No 212 bur 75 ° side to get the width (X). The rectific tion of the se t (1) is m de with str wberry side No 204 46 °. Redu cing the width of the se t (2) by No 273 bur 60 ° side to get the width (X). 91880R2 NOTE: Observe the position of cont ct on the v lve se t. 88 988-1R 10-31 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir MOUNT HEAD 10 Lubric te ll p rts. Pl ce w shers b se (1) of the docks. Pl ce g skets (2) in t he v lve guides (3) using socket wrench 11 mm. WARNING: When repl cing the v l ves, it is imper tive to mount v lve (new) th t h ve the s me m rking (8) th t the old, in order to prevent the destruction of the v lve / se t. The s me refe rence APR m y merge sever l IDs, in this c se the v lves re completely interch nge ble. Verify th t the new v lves just m rked differently th n older ones ctu lly correspond to the s me reference APR.

Mount in the following order: - the new v lves (4), - the springs (5) (identic l to the int ke nd exh ust) - the pl tes (6). Compress the springs. Pl ce the se mi-c ps (7) (identic l for both int ke nd exh ust). 77678R3 10030R1 10-32 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Oil the c msh ft. Inst ll the c msh ft nd its fl nge. Check: - the g me length should be between 0.06 nd 0.015 mm, if not correct, the fl nge or the c msh ft re the c use, 10

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

   

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

     

 

 

 

 

 

 

   

   

- The distributor wiring - fuel pump (if equipped) with new g sket - thermost t br cket, the se ling is chieved with Loctite 518. The cord (H) must h ve wi dth of 0.6 to 1 mm nd should be pplied ccording to the di gr m below, 92102S 92066R - Se ling ring, use the mounting c p Mot. 1127-01, this tool is designed to obt in offsetting the cont ct re of the bo rd)

- The c msh ft sprocket, immobilize it with the h ndy Mot. 799-01 nd tighten th e screw to 4.5 d N.m p ir (gre sing the thre ds nd under the screw he ds. 92 102-1R 10-33 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir CUTTING BLOCK MOTOR 10 PRO10.2 10-34 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Extr ct: - w ter tube nd the rod guide of oil (the tightness of these tubes is chieved with O-rings to be repl ced fter e ch remov l), - the mech nism nd the clutch disc, - the engine flywheel, by immobilizing Mot. 582-01, - the lower c sing, - the cr nksh ft ge r. If needed, use the loc l dummy tree protector c p Rou. 15-01. NOTE: 10 There re two cr nksh ft ge r ssemblies - keyed pinion mounted on the cr nksh f t - integr ted pinion keyed to it. The two ssemblies re not interch nge ble. E xtr ct: - the closing pl te of the cr nksh ft 87069R 92311R A B C D ∅ 12 1.75 Step 1 hole ∅ Febru ry 13 holes ∅ 6.5 ∅ 12 step 1.75 Nut welded - The tension roller, 92171R 10-35 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir - W ter pump, EXTRACTION bolts PISTONS

     

 

   

   

 

 

 

 

 

   

 

 

 

 

 

   

 

 

   

 

 

 

 

 

 

 

 

 

 

 

   

   

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

     

 

 

 

 

10 Pl ce the plunger into the "V" br cket, the bolt ligned with the output port (t wo lines (T) Identific tion of the hole to f cilit te this lignment). With the remov l m ndrel (E), remove the piston pin with the press. 92312R - The three screws th t secure the sprocket to the hub oil pump nd remove the s procket nd ch in set - the oil pump. M ke m rking rods c ps over their bodies. WARNING: Do not use stylus for m rking, in order to prevent the onset of bre k ge of the cr nks. Use perm nent m rker. Extr ct: - the c ps of connecting rod s nd be rings, - the sleeve fl nges (Mot. 588), - be ring "piston-rods-shirts" - the support c ps with be rings (m rk), - the cr nksh ft (recovered coves of l ter l pl y), - the cr nksh ft be rings in the engine block. 76555R 10-36 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir OUTGOING MOTOR ASSEMBLY OF SHIRTS 10 Cle n the engine block, in p rticul r the se t liners with respect to the block. These engines re equipped with O-rings ensure w tertight only. s the b sis for the shirts. These se ls

Prep r tion of the "piston-shirts" The p rts supplied in the collection re p ir ed. Check ll the p rts from A to D, so s to preserve the p iring. The shirt is b sed directly on the engine block nd the projection (X) is represented by the dimensions of m nuf cturing. 80437R Completely dissolve the film nti-rust. Do not scr tch the p rts. 75615R5 10-37 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir The control of the projection (X) should be m de s follows: pl ce the shirt, de void of O-ring (J) on the engine block, check the Mot outgoing supplies. 251-01 nd Mot. 252-01. 10 Once the correct outgoing, tr in sets A, B, C, D then numbered shirts, pistons nd piston pins 1 to 4 (n ° 1 flywheel side) in order to find consistency with th e corresponding cr nk. In c se of projection incorrect, check with set of ne w shirts to see if this is defect in the engine block or the shirts, if not, v erify the theoretic l bounds (see Ch pter "Ch r cteristics"). The s lientet (X) must be between 0.02 to 0.09 mm. INSTALLING THE PISTONS Bolts The piston pins re fitted tightly on rods nd pistons turning. Use the tools Mo

 

 

 

 

 

 

 

 

 

 

 

   

 

   

   

     

 

 

   

 

     

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

   

   

 

 

     

   

t. 574-2 provided in

suitc se th t cont ins: 85404R1

piston socket support (S), remov l m ndrel (M), ton (B), xes (A) ssembly, fitted centering (C).

Put the shirts so th t: - the difference in projections between two neighboring shirts is no more th n 0.05 mm (within toler nce) - le ves degr ded outgoing cyl inder cylinder No 1 to No 4 or vice vers . 92278S 76554R2 10-38 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir PREPARATION FOR THE PREPARATION OF THE CONNECTING RODS PISTONS Bolts 10 Check visu lly: the st te of the rod (torsion-squ red), the support of the c ps on the body of the connecting rods (delete if necess ry with burr grinder to get proper se t). Check th t the bolts pistons slide freely in the corresponding new pistons. Usin g the C13 centering nd mounting posts or A13-01 A13 for piston pins highlighted . Inst ll the piston pin (E) on the mounting sh ft (A), tighten the centering (C ) until it m kes cont ct nd rele se qu rter turn. Use hot pl te of 1500 W of power. Set foot on the cr nk pl te. W tch the entir e surf ce of the foot of the rod is in cont ct with the pl te. On e ch foot of r od drop, s temper ture control, piece of soldering tin utodec p nte ( ), who se melting point is 250 ° C. He t the bottom of the rod to the fusion of self-co ntrol welding flux. DI1038 76716R 12367R 10-39 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir ASSEMBLY "Biel-PISTONS» 10 The pistons re m rked with n rrow over their he ds indic ting the flywheel si de. The cr nk ssembly re me ningless, however, we must pl ce the retention pin s be ring the s me side. To ssemble the piston nd rod, respect the following i nstructions: - put the c p on the st nd B13 nd fix the piston ( rrow pointing u p) on the fork c p, The following oper tions must be c rried out expeditiously so th t the he t loss is minimized. When the piece re ches the solder melting point (ch nge in drop): cle n the weld be d, insert the guide focuses on the piston, put the rod in the piston, insert piston pin quickly until the guide stops socket on the bottom br cket.

 

 

 

       

 

 

 

 

 

   

   

 

 

 

 

 

 

 

 

 

 

 

   

   

 

 

 

   

   

 

 

 

 

 

   

     

 

 

 

 

         

       

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

   

support bushing of the pis

Verify th t the gudgeon pin is pl ced inside the piston di meter for ll positio ns with the piston rod. 92310R - Centering nd lubric te the piston pin with engine oil - piston pin to enter i nto this show to m ke sure it slides freely nd, if necess ry, re-center the pis ton. 10-40 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir ASSEMBLY OF THE RINGS 10 Riding on the piston: - scr per segment (3), - the se ling segment (2), m rked " Top" up - the segment "of fire" (1), m rked "Top" f cing up, When you h ve set t he cut in ll segments, we should not move them. Oil nd medi te segments, cutti ng the segment scr per on fl t re of the thro t. Mount the "cr nk-piston-segments" in their shirts, using the sleeve ssembly. 86 314 92317S Do not forget, before mounting the sets' shirts-piston-rods "in the engine block ,€pl ce the O-ring on e ch shirt, m king sure not twisted 86 307 91 803 Mount the motor on the block, in the order given t of 0.1 mm to p ss freely between the shirts. 91803G1 92316S 10-41 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Freeze shirts with the tool Mot. 588. 10 Fit the cr nksh ft nd the coves of the g me side, spr ying the p ds nd the mot or oil towers, Mount c ps support the cr nksh ft. Apply thin l yer on support RHODORSEAL 5661 No. 1 re (K) nd tighten the screws to 2.5 d N.m then pply torque ngle of 43 ° ± 6 °. Check cr nksh ft end pl y must be between: - 0.045 nd 0.852 mm we r - 0.045 nd 0.252 mm we r. 92062R BEARING ASSEMBLY cr nk be rings re identic l, the cr nksh ft be rings re grooved side engine bl bove nd ensuring th t n inle

 

 

 

   

 

 

   

 

   

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

   

   

 

 

 

 

     

 

 

 

 

 

 

 

 

     

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ock. 92314S The thickness (mm) of the b ys v il ble in the APR re: 2.80, 2.85, 2.90, 2.95. Assemble the connecting rod c ps nd tighten nuts to torque of 4.2 d N.m. Check : - the g me side of the cr nk, - good rot tion of the whole 92315R The upper be ring support No. 5 is specific, is 10-42 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Inst ll: - the oil pump, check for centering c ps nd tighten the two d N.m - the two sprockets nd drive ch in oil pump, tighten the three screws th t re the sprocket on the hub to d N.m, - the top of the nose of the cr nksh the se ling is chieved with Loctite 518. The cord (H) must h ve width of to 1 mm nd should be pplied ccording to the di gr m below. 10 - The cr nksh ft se ling ring (support No. 1), using the tool Mot. 1129-0 which is intended to get se t offsetting the bo rd. Lubric te the lip nd the outsid e of the meeting. 92319R 92067R se ling ring in the nose of the cr nksh ft using the tool Mot. 1128-01, oil the lip nd the outside di meter of the meeting. Turn the t b if the old g sket h s m rked the cont ct re . 92318R 10-43 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Inst ll the lower cr nkc se nd tighten the two 1 d N.m. NOTE: The tightness of the c sing is m de exclu10 Mount the w ter pump, the se ling is done with Loctite 518. The cord (H) must h ve width of 0.6 to 1 mm nd pplied ccording to the di gr m below.

lso slotted.

sively with the O-specific post-s le E7J except for the engine 764 in which the se ling is done by pplying RHODORSEAL 5661. The cord (D) must h ve width of 3 mm. 92068R REPLACEMENT HEAD 99179R1 Remove the fl nges of the shirts Mot. 588. Cle n pl nes together the engine bloc

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

                                 

 

 

 

 

     

 

 

   

 

 

 

 

 

 

 

 

 

 

 

     

2.5 secu ft, 0.6

 

   

 

k nd cylinder he d. Mount the centering c p stock. The new he d g sket. The sto ck (gre se the thre ds nd supports under the screw he ds). All cylinder he d bo lts must be repl ced routinely fter remov l. Do not forget to repl ce the two together, "crescent" in (A) with new ones. Spre d the wheel support f ce on the cr nksh ft with Loctite AUTOFORM. Pl ce the ste ering wheel or the converter pl te, immobilizing the toothed sector Mot. 582-01. Put on one drop of Loctite screws nd tighten to 5 to 5.5 d N.m. FRENETANCH Center the clutch disc nd fix the mech nism. 10-44 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Method for tightening the cylinder he d 10 Mount r mp positioning the br nd rocker (1) from distribution nd screws (A) (B) . 90775S Pre sent miento bo rd: A two d N.m tighten, then pply torque ngle of 97 ° ± 2 ° in the order recommended: - tighten the screws 1-2, - tightening the screws 3-4-5-6 , - tightening the screws 7-8-9-10. Settlement of the bo rd: W it 3 minu tes settling time. Press: - Loosen the screws 1-2. Retighten the screws d N.m 12 to 2, then pply n ngle of 97 ° ± 2 °. - Loosening of the screws 3-4-5-6. Re tighten the screws to 2 d N.m 3-4-5-6, then pply n ngle of 97 ° ± 2 °. - Loos ening of the screws 7-8-9-10. Retighten the screws to 2 d N.m 7-8-9-10, then pp ly n ngle of 97 ° ± 2 °. No re djustment of the stock. 92063R NOTE: There

re two dimensions of screws (A):

M8 nd M8 × 100 × 125. Pl ce: - the fixing screws (2) rocker r mp tightening tor que of 2.3 to d N.my not forget to lubric te the thre ds with engine oil nd und er the he ds - the he d cover loosely to f cilit te the timing of distribution the cr nksh ft ge r. 10-45 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Depth distribution 10 DI1101R4 (A) Sense of stress tensor. 10-46 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir On the b ck of the belt is p inted rrow pointing in the direction of rot tion nd two strokes for setting. Align m rks (N) of the belt with the sprocket (L) nd housings (M). Observe the mounting str p nd position it to st rt t the cr

 

 

   

 

 

 

 

 

   

 

 

     

 

 

 

 

   

 

 

 

   

 

     

 

 

 

   

 

     

 

 

 

   

 

   

 

 

 

   

   

   

 

 

 

 

 

 

 

 

 

 

 

 

 

     

   

 

 

 

   

 

nksh ft ge r. Pl ce the sensor of Mot. 1273. 10 Lock the tensioner, to control, djust the v lue. Cr nksh ft three l ps minimum. Check th t the volt ge is within the volt ge drop toler nce (± 10%), if not, re set. NOTE: Do not re ssemble str p removed. Tighten the nut (O) of the tension roller 5 d N.m. It is imper tive to tighten t he tension pulley nut to the p ir of 5 d N.m to prevent loosening th t m y c use d m ge to the motor. WARNING: Some of the c msh ft sprockets h ve five br nds, only the rect ngul r s h ped m rk on the f ce of tooth represents the TDC. Other tr dem rks re used for the djustment of the rocker. 98708R Turn the knob until it pops Collector (three C "CLIC"). Tighten the belt until t he cquisition on the screen of Mot. 1273 recommended pl cement v lue, using the Mot. 1135-2001. Belt Tension (in units SEEM). 10072S Loc tion: U.S. 30 Only c msh ft sprockets with m rks in the APR will be 10-47 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir SETTING THE ROCKER KIT 10 Method of the exh ust v lve in the opening Bring the cylinder v lve 1 fully open nd regul te the g me of the int ke v lve cylinder No. 3 nd the g me of the ex h ust v lve cylinder No. 4. Proceed in the s me w y for the rest of cylinders, i n the order given in the t ble. Setting v lues (cold) (mm): - Admission - esc pe Motor equipped with CAMSHAFT PINION OF NO MARKS 0.25 0.10 Method c lled "in sc le" Pl ce cylinder v lves concerned in order to esc pe the st rt position 1 3 4 2 dmission rules the g me concerned rocker cylinder 4 2 1 3 Exh ust v lve to open fully. Inlet to org nize. Exh ust v lve to org nize. 78373R 10-48

v il ble from now on.

 

 

 

 

   

 

 

 

 

 

 

 

 

     

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

     

 

 

 

 

   

 

 

 

 

             

     

MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Motor equipped with PIIÑON OF MARKS WITH CAMSHAFT 10 Set the engine to TDC, cylinder No. 1 on. Turn the cr nksh ft in the direction o f the clockwise (viewed side distribution) to re ch the first m rk. RULES: esc pe. An esc pe. 3 dv nce to the second m rk: Rules: dmission. An

dmission. 3

third br nd: RULES: esc pe. 2 esc pe. 4 fourth br nd: RULES: dmission. 2 dmission. 4

10072S 10-49 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Inst ll: - the cylinder he d cover equipped with new bo rd - the w ter pipe n d tube rod with new g sket oil - cr nkc se distribution - the cr nksh ft pulle y tightening the screw to 2 d N.m , then pply torque ngle of 68 ° ± 6 °, - t he int ke m nifolds nd exh ust, tightening the nuts to 2.5 d N.m - the belts or ccessories. 10 Motor volt ge process cold (room temper ture). Fit the new belt. Pl ce the senso r of Mot. 1273. Turn the knob until it pops Collector (three "CLIC"). Tighten the belt until the cquisition on the screen of Mot. 1273 recommended pl cement of the v lue below. Lock the tensioner, to control, djust the v lue. Gi ve three turns of the cr nksh ft. Check th t the volt ge is within toler nce of stress pl cement, if not, reset. NOTE: Do not re ssemble str p removed. 10-50 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir 10 Altern tor Belt Tension (U.S. = Unit SEEM) Corre steering Air Conditioning Belt Corre ir conditioning nd power steering

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

     

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

   

         

3 cloves Estrie stri te. Zoid l Tr pe3 teeth F3 F4 F3 F2 F1 (E7J 764) F5 Tr pezoid l 4 cloves stri ted 4 cloves stri ted 5 cloves stri ted F6 F7 F8 F9 F8 Pl cement 83 ± 7 84 ± 6 84 ± 6 84 ± 5 84 ± 4 90 102 ± 6 103 ± 4 106 110 ± 7 110 Minimum oper ting 70 52 52 46 47 72 55 77 59

 

 

 

     

 

 

 

 

75 59 A B C D E T → Cr nksh ft Altern tor conditioning compressor steering ssist nce pump Roller ro ller furling stress tensor Checkpoint Altern tor Power steering 12310R 12311R 10-51 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Power steering A.A. 10 94103R1 Air conditioning 12308R1 A.A. 92672R 12309R1 10-52 MOTOR ASSEMBLY MOTOR AND LOW Motor Rep ir Air conditioning nd power steering 10 98707R1 Power steering nd ir conditioning 98707R2 10-53