Workshop Repair Manual: Engine Fitted On The: - Megane: DA03 F5R 740 EA03

Workshop Repair Manual
PETROL DIRECT INJECTION ENGINE
4 cylinders - F5R
Engine fitted on the:

- MEGANE: DA03
F5R 740
EA03
77 11 292 042 OCTOBER 1999 EDITION ANGLAISE
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
RENAULT 1999
Contents
Pages
10 ENGINE AND PERIPHERALS
- Cleanliness / Safety 10-1
- Foreword 10-4
- Engine identification 10-5
- Tightening torques (in daN.m or in degrees) 10-6
- Specifications 10-8
- Standard replacement 10-32
- Essential special tooling 10-33
- Essential equipment 10-37
- Overhauling the engine 10-38

ENGINE AND110
PERIPHERALS
Cleanliness / Safety 10
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE
DIRECT INJECTION SYSTEM
RISKS LINKED TO POLLUTION
The petrol direct injection system is very sensitive to pollution. The risks caused by the introduction of pollution are:
damage to or destruction of the high pressure injection system,
seizing or incorrect sealing of a component,
destruction of the engine (by continuously injecting into the cylinder).
All after-sales operations must be performed under very good cleanliness conditions. This means that no impurities
(particle of several microns in size) must enter the high pressure injection system whilst dismantling or the circuits
through the fuel connectors.
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE THE POLLUTING ELEMENTS?
The elements which pollute are:

metal or plastic swarf,
paint,
fibres:
! of cardboard,
! of brushes,
! of paper,
! of clothing,
! of cloths.
foreign bodies such as hair,
ambient air,
etc.
WARNING: cleaning the engine with a high pressure jet may damage the connections. In addition, moisture may
collect in the connectors and create electrical connection problems.
Water may also build up in the injector and plug wells which open out directly into the cylinder.
10-1
ENGINE AND PERIPHERALS
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY REPAIRS ON THE INJECTION SYSTEM
! Ensure that you have the blanks for the connectors which are to be opened (bags of blanks sold from the Parts
Stores). Blanks are to be used once only. They must be disposed of after use. It is not sufficient to clean them in
order to reuse them.
! Ensure that you have the resealable plastic bags for storing removed parts. Stored parts will therefore be less
subject to the risk of impurities. Bags are to be used once only and should be disposed of after use.
! Ensure that you have lint free cleaning cloths (supplied by SODICAM). The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint free and may pollute the fuel circuit of the system. Each lint
free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
! For each operation, use new thinner (used thinner contains impurities). Pour it into a clean container.
! For each operation, use a clean brush which is in good condition (the brush must not lose its hairs).
! Using a brush and thinner, clean the parts to be dismantled, the tools which are to be used and the part of the bench
used.
! Wash your hands before and during the operation if necessary.
! When wearing protective gloves, cover leather gloves with latex gloves (available from SODICAM).
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
! As soon as the circuit is open, all openings must be blanked to prevent pollution from penetrating the circuit. The
blanks to be used are available from the Parts Stores. They must not be reused under any circumstances.
! Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries pollution.
! All components of the injection system must, after having been blanked, be stored in a hermetically sealed plastic
bag.
! After opening the circuit, the use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden. These
items may effectively allow impurities to enter the system.
! When replacing a component with a new one, do not remove it from its packaging until it is to be fitted to the vehicle.
! When cleaning a gasket face, use lint free absorbent paper. Start from the centre of the part and progressively
clean towards the outside so as to move the impurities outwards.
10-2
10-3
Foreword 10
USING THE MANUAL
There are two main sections in this manual:
technical specifications,
overhauling the engine.
To repair a component on the vehicle, refer to the

Workshop Repair Manual or Technical Notes for the
vehicle.
UNITS OF MEASUREMENT
All dimensions are given in millimetres (mm) (except

where stated otherwise).
Tightening torques are expressed in deca-Newton

metres (daN.m)
Reminder: 1 daN.m = 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 daN.m ( 10 %).
10-4
Engine identification 10
ENGINE IDENTIFICATION It contains:
The engine is identified by a plate riveted onto the A: the engine type
cylinder block. B: the engine approval letter
C: the Renault identification
D: the engine suffix
E: the engine assembly factory
F: the engine fabrication number
Capacity Bore Stroke Compression

Engine Suffix
(cm 3 ) (mm) (mm) ratio
F5R 740 1998 82.7 93 11.5/1
10-5
Tightening torques (in daN.m or in degrees) 10
Top of engine:
Description Tightening torque

Air filter unit mounting bolt 0.9
Oil separator bolt (refer to tightening order) *** 1.3
Camshaft bearing cap housing bolts (refer to tightening order) **
Camshaft pulley nuts 3 plus an angle of 90
Cylinder head bolts *
Cylinder head suspension mounting nuts and bolts:
- M10 nuts and bolts 3.5
- M8 bolts 2.5
Intermediate timing housing bolts 1
Spark plugs 2.5 to 3
Assisted steering pump bolts 2.1
Alternator bolts 2.1
Air conditioning compressor bolts 2.1

Alternator support and air conditioning compressor bolts 4.4
Assisted steering pump support bolts 2.1
Accessories belt tensioning roller bolts (air conditioning version) 2.1
Accessories belt fixed roller bolts (air conditioning version) 2.1
Exhaust manifold nuts (refer to tightening order) 1.8
Exhaust manifold upper and lower heat shield bolts 1
Oxygen sensor (see assembly recommendation) 4.5
Exhaust manifold stay mounting:
- Bolts 1
- Nuts 1.8
Petrol rail mounting bolts 1.5
Petrol HP pump bolts 1.2
Ignition rail 1
Coil support mounting nut 2.5
Inlet manifold M8 nuts and bolts 2.5
Inlet manifold M6 bolts 1
EGR valve support bolts 1
Additional air actuator valve bolts 1
Throttle body bolts 1
Lifting lug bolts 0.9
Thermostat housing cover bolts 1
Coolant temperature sensor on cylinder head coolant outlet housing 3.8
* Refer to tightening procedure on page 10-8.

** Refer to tightening order on pages 10-56 and 10-87.
*** WARNING: Self tapping bolts must be tightened to the correct torque using a torque wrench.
10-6
Tightening torques (in daN.m or in degrees) 10
Engine peripherals:
Description Tightening torque

Sump bolts (refer to tightening order) 1.2 to 1.5
Crankshaft pulley bolts 2 plus an angle of 115 15
Crankshaft closure panel 1.5
Flywheel bolts 5 to 5.5
Clutch bolts 2
Oil pump bolts 2.2 to 2.7
Big end bolts 2 plus an angle of 40 6
Crankshaft bearing cap bolts 6 to 6.7
Water pump bolts 1.7
Water pump pulley bolts 2
Timing fixed roller bolts:
- M10 bolts 5
- M8 bolts 2.5
Timing tensioning roller nut 2.8
Water pump inlet pipe bolts 3.6
Pinking sensor 2
Multifunction support bolts 4.4
10-7
Specifications 10
CYLINDER HEAD
The bolts can be reused if the length under the head does not exceed 137.7 mm (otherwise replace all the
bolts).
Cylinder head tightening procedure
REMINDER: in order to obtain the correct tightening of the bolts, use a syringe to remove any oil which may have
entered the cylinder head mounting bolt holes.
Do not oil new bolts. However, when reusing bolts, they must be oiled with engine oil.
Tighten all bolts to 2 daN.m in the order recommended below.
Check that all the bolts are tightened to 2 daN.m, then perform angular tightening (bolt by bolt) of 200 6.
Do not retighten the cylinder head bolts after applying this procedure.
10-8
Specifications 10
Thickness of the cylinder head gasket Cylinder head height
The thickness of the cylinder head gasket is measured H = 138.4 mm.

at (A):
thickness of the
compressed gasket: 0.65 0.02 mm.
R
R
Gasket face bow: 0.05 mm.

Firing order
1 - 3 - 4 - 2. No rectifications are allowed.
Test the cylinder head to detect any cracks.
Spark plug tightening torque: 2.5 to 3 daN.m.
10-9
Specifications 10
Hydraulic tappets Setting angle
This engine is fitted with hydraulic stops (A) and roller

Inlet and exhaust: 90
tappets (B).
Valve length (in mm)
Inlet: 113.55 0.20

Exhaust: 113.97 0.20
VALVE SEATS
Seat angle
Inlet and exhaust: 89
Bearing width X (in mm)
Inlet: 1.8 0.1

15658R1 Exhaust: 1.8 0.1
VALVES External diameter D (in mm)
Valve lift (in mm)

Inlet: 32.53 0.008
+ 0.006
Inlet : 9.687 Exhaust: 28.43 0.007
Exhaust: 9
Stem diameter (in mm)
Inlet: 5.485 0.011

Exhaust: 5.445 0.011
Head diameter (in mm)
Inlet: 31.5 0.12

Exhaust: 27.46 0.12
10-10
Specifications 10
VALVE GUIDES Fitting valve stem seals
Length (in mm) Position the valve in the cylinder head.
Inlet and exhaust: 40.5 0.15
Guide external diameter (in mm)
+ 0.068
Inlet and exhaust: 11 + 0.05
Guide internal diameter (in mm)
Inlet and exhaust
+ 0.075
Non machined: 5 0
+ 0.018
Machined*: 5.5 0
* This dimension is measured with the guide fitted

in the cylinder head. 15771S
The inlet and exhaust guides have valve stem seals

Put the plug of tool Mot. 1511 on the valve stem (the
which also act as a lower bearing washer for the valve
internal diameter of the plug must be the same as that
spring.
of the valve stem).
The valve stem seals must be fitted using tool
Mot. 1511 or with the FACOM tool, part number
DM6J4 for example.
15771-1S
NOTE: do not oil the valve stem seals before

fitting.
10-11
Specifications 10
Keep the valve pressing against its seat. Fit the pushrod (1) on the valve stem seal.
Fit the valve stem seal (non oiled) onto the plug.
15771-5R
15771-2S
NOTE: the internal diameter of the pushrod must
be the same as that of the valve stem. In addition,
Push on the valve stem seal until its goes past the plug the bottom of the pushrod must press against the
then remove the plug. part of the valve stem seal which acts as the lower
bearing washer for the valve spring.
15771-3S
10-12
Specifications 10
Press the valve stem seal down by tapping with the Angle of the inlet and exhaust guides (in degrees)
palm of your hand on the top of the pushrod, until
the valve stem seal touches the cylinder head.
Inlet: 63
15771-6S 15646S
Exhaust: 61
15770S
10-13
Specifications 10
Position of the inlet and exhaust valve guides CAMSHAFT
(in mm)
The camshaft can be identified with a marking (A).
Inlet: A = 9.5 0.15
Exhaust: A = 9.5 0.15
Detail of the marking (A):

the reference (B) is used by the supplier only,
the reference (C) is used for identifying the
camshafts:
A = Inlet
E = Exhaust
the reference (D) gives the engine type
Valve springs (in mm)
Example:
Free length: 43.42
Length under load:

22.5 daN 34.50
52.5 daN 24.50
Number of coils: 23
Internal diameter: 15.80
External diameter: 23.12
Oval type wire cross section.
10-14
Specifications 10
Longitudinal clearance (in mm) Timing diagram (cannot be checked)
Between 0.08 and 0.178.

Inlet Exhaust
camshaft camshaft
Number of bearings: 6
Cam 1 Cam 2 Cam 1 Cam 2
Inlet opening
- 11 - 15 - -
Diameter of the cylinder head camshaft bearings delay*
(in mm)
Inlet closing
41 45 - -
delay
Flywheel side
Exhaust
1 opening - - 27 31
advance
2
Exhaust
+ 0.061 closing - - -4 -8
3 25 + 0.04 advance**
4
* As the Inlet Opening Delay is negative, the
5 valves open after TDC.
+ 0.061 ** As the Exhaust Closing Advance is negative,
6 28 + 0.04
the valves close before TDC.
Timing side
Diameter of the camshaft bearings (in mm)
Flywheel side
2
0
3 25 0.021
4 R
5
A) A4 - 1 = Inlet of cylinder 4 and cam n 1.
0
6 28 0.021 or
E4 - 1 = Exhaust of cylinder 4 and cam n 1.
Timing side
B) A4 - 2 = Inlet of cylinder 4 and cam n 2.
or
E4 - 2 = Exhaust of cylinder 4 and cam n 2.
10-15
Specifications 10
PISTONS
MAHLE piston
The pin is free in the con rod and in the piston.
Piston marking
1 Cylinder block TDC fixed reference

2 Flywheel TDC moving reference
3 Flywheel BDC moving reference
4 Inlet Opening Delay
5 Exhaust Opening Advance
6 Inlet Closing Delay
7 Exhaust Opening Advance
R
1 Piston direction flywheel side

2 Piston class (2 - 3 )
3 Used by the supplier only
4 Used by the supplier only
5 Piston axis of symmetry
6 Gudgeon pin hole axis
7 The offset between the hole of the pin (6) and the
axis of symmetry of the piston (5) is 0.8 mm
Reference of piston diameter in relation to cylinder

block diameter
Piston Piston Cylinder

reference diameter (mm) diameter (mm)
82.710 inclusive
2 or B 82.680 0.007 to
82.720
exclusive
82.720 inclusive
3 or C 82.690 0.007 to
82.730 inclusive
10-16
Specifications 10
Class of cylinder block barrels
WARNING: the diameters of the pistons and the

barrels must be matched on the cylinder block and
to do this:
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.
NOTE: some cylinder blocks do not have a

matching hole which means that the cylinder
heads are fitted with class B or 2 pistons.
Position of the holes T Reference of the class Barrel diameter Piston diameter
on the cylinder block on the piston (mm) (mm)
82.710 inclusive
T = 13 mm 2 or B to 82.680 0.007
82.720 exclusive
82.720 inclusive
T = 19 mm 3 or C to 82.690 0.007
82.730 inclusive
10-17
Specifications 10
Measuring the piston diameter RINGS
The diameter must be measured at the point:

Three rings (thickness in mm)
E = 12 mm.
0.01
Compression: 1.2
0.03
0.01
Sealing: 1.5
0.03
Scraper which consists of three

parts: 2
! two steel rails (1),

! a spring ring (2).
Clearance at the break
Clearance at the break

Rings
(in mm)
Compression 0.2 to 0.35
Sealing 0.4 to 0.6
Scraper 0.2 to 0.9
10-18
Specifications 10
Fitting the rings
Gudgeon pin (in mm)
Length: 58.7 to 59 Rings set to their original adjustment must be free

within their channels.
External diameter: E = 20.995 to 21
Ensure the rings are fitted in the correct direction.
Internal diameter: C = 17 0.2
+ 0.1
I = 12.5 0.2
NOTE: the pin contains a double taper to reduce

the weight of moving parts.
15650S
CON RODS
Lateral clearance of the big end (in mm)
0.22 to 0.402
Diametrical clearance of the big end (in mm)
0.020 to 0.071
Centre distance between the big end and little end

(in mm)
144 0.035
Diameter of the big end (in mm)

0
51.587 0.019
Diameter of the little end (in mm)
23 (without ring)
21 (with ring)
10-19
Specifications 10
WARNING: do not use a punch
to reference the con rod caps in
relation to their body to prevent
creating a fracture line in the
con rod.
Use an indelible pen.
The maximum difference in weight

for the same engine must be
6 grams.
15183S
10-20
Specifications 10
Direction of fitting of the con rod in relation to the CRANKSHAFT
piston
Number of bearings: 5
Position the "" (1) engraved on the top of the piston
downwards and the lubrication hole (2) of the little end
in line with the vertical axis (as shown on the diagram Burnished main bearing journals:
below).
nominal diameter (in mm) 54.795 0.010
Burnished big end journals:

nominal diameter (in mm) 0
48 0.02
Crankshaft lateral clearance

0.07 to 0.23
(in mm):
Crankshaft diametrical clearance

(in mm):
0.04 to 0.075
The lateral shims are located on bearing n 2.
BEARING SHELLS
R
Crankshaft bearing shells
NOTE: put the break in the spring ring of the The engine is fitted with bearing shells without a
gudgeon pin at the top at 45 to the vertical axis foolproofing device.
of the piston.
15197S
16082S
10-21
Specifications 10
Direction of fitting
on the cylinder block, fit grooved bearing shells on all the bearings,
on the bearing cap, fit non grooved bearing shells on all the bearing caps.
15181S
Cylinder block Fit the bearing shell in tool Mot. 1493, then press at
(A) until the bearing shell is touching tool Mot. 1493 at
Fit tool Mot. 1493 on the cylinder block. (B).
R 15469-1R
10-22
Specifications 10
Bearings
Fit tool Mot. 1493 on the bearing.
Fit the bearing shell in tool Mot. 1493, then press at

(A) until the bearing shell is touching tool Mot. 1493 at
(B).
10-23
Specifications 10
CON ROD BEARING SHELLS Fitting the bearing shell in the con rod body
The engine is fitted with bearing shells without a Select the bearing shell support (1) corresponding to
foolproofing device. the engine (engine type (2) marked on the support).
Slide the bearing shell support into the groove (3) of

the base.
15655S
The bearing shells are fitted using tool Mot. 1492.

R
Place the con rod on the base (as shown in the

diagram below). Check that the lower part (4) of the
little end is touching the centring pin.
15743R1
10-24
Specifications 10
Place the bearing shell (5) on the bearing shell support Fitting the bearing shell on the con rod cap
as shown on the diagram below.
Place the con rod cap against the pins (6) of the base,
then position the bearing shell (7) on the bearing shell
support.
15744-1R
Push the bearing shell support (in the direction of the

arrow) until the bearing shell support comes into R
contact with the bottom of the con rod body.
Push the bearing shell support (in the direction of the
arrow) until the bearing shell support comes into
contact with the bottom of the con rod cap.
15745S
Then release the support from the con rod body and
proceed in the same manner for the other con rods. 15747S
10-25
Specifications 10
OIL PUMP
The pump is a gear pump.
Dismantling
Remove the five bolts (1), lift off the cover and remove:
the clip (2),
the end stop (3),
the spring (4),
the valve (5).
R 10024
10-26
Specifications 10
Checking the oil pump clearances
Clearance (A) (in mm):
min 0.110
max 0.249
Clearance (B) (in mm):
min 0.020
max 0.086
10-27
Specifications 10
Reassembling
Refit:
the valve (5),
the spring (4),
the end stop (3),
the clip (2) by fitting it in the same direction as shown on the diagram
below,
the pump cover (bolts 1).
R 10024
10-28
Specifications 10
Before mounting the engine on the
stand Mot. 792-03, the engine's
electrical harness must be
removed and the engine oil
drained.
Remove:
the exhaust heat shield,
16079S1
Remove:
the EGR valve / hose assembly,
the oxygen sensor using tool
Mot. 1495.
16080S
10-29
Specifications 10
the exhaust manifold.
15619S
Mounting the engine on the

stand Mot. 792-03 and the rods
Mot. 995.
The rods (B), (N) and (P), Mot. 995

are mounted on the cylinder block
so that they fit into the holes (12,
25, 26) on the plate.
15619-2R
10-30
Specifications 10
CONSUMABLES
Type Quantity Component concerned Part number
Cleaner - Cleaning parts. 77 01 421 513
DECAPJOINT Coat Cleaning gasket faces. 77 01 405 952
RHODORSEAL 5661 Coat Crankshaft bearing cap. 77 01 404 452
Loctite 518 Coat Camshaft bearing cap housing 77 01 421 162
Loctite FRENETANCH 1 - 2 drops Cylinder head stud 77 01 394 070
Tube of RHODORSEAL 5661 Bead Crankshaft closure plate 77 01 421 042
WARNING PARTS TO BE REPLACED WHEN THEY HAVE

BEEN REMOVED
WARNING: when working on the fuel supply
All the gaskets.
system, the cleanliness rules described in this
document must be strictly complied with.
Flywheel bolts.
Crankshaft bearing bolts.

FITTING THREAD INSERTS
Camshaft pulley nuts.
Threaded holes on all engine component parts can be
repaired by using thread inserts except on the Con rod cap nuts.
camshaft bearing cap housing.
Belts.
Timing tensioning roller.
Timing fixed rollers.
Petrol high pressure pump shim.
Exhaust camshaft sealing plug.
Injector clips.
10-31
Standard replacement 10
PREPARING THE USED ENGINE FOR RETURN
The engine should be cleaned and drained (oil and

water).
Leave on the used engine or include in the return box:

the dipstick,
the flywheel,
the clutch mechanism and plate,
the water pump,
the crankshaft pulley,
the spark plugs,
the belt tensioner,
the pressure switch and temperature switch,
the timing covers.
Remember to remove:
all coolant flexible hoses,
the belt or belts (except the timing belt).
The used engine should be secured to the base under

the same conditions as the overhauled engine:
plastic blanks and covers fitted,
cardboard cover over the assembly.
10-32
Essential special tooling 10
Method Part
Illustration Description
Reference Number
Emb. 880 00 00 088 000 Pin extractor.
Mot. 445 00 00 044 500 Oil filter wrench.
69716S1
Mot. 582-01 00 00 058 201 Tool for immobilising flywheel.
Mot. 588 00 00 058 800 Liner retaining strap.
Magnetised flexible shaft for angular wrench for

Mot. 591-02 00 00 059 102
tightening cylinder head.
Angular wrench for tightening cylinder head,

Mot. 591-04 00 00 059 104
1/2" drive with index.
Mot. 792-03 00 00 079 203 Engine support plate.
Tool for immobilising pinions for toothed timing

Mot. 799-01 00 00 079 901
belt.
80359S
10-33
Method Part
Reference Number
Mot. 990-03 00 00 099 003 Tool for fitting crankshaft seal, timing side.
96897S
Mot. 991-01 00 00 099 101 Tool for fitting crankshaft seal, flywheel side.
96898S
Mot. 995 00 00 099 500 Set of 2 rods (used with engine plate Mot. 793-03).
84900S1
Mot. 1054 00 00 105 400 Top dead centre pin
Mot. 1329 00 00 132 900 Oil filter spanner.
97160-1S1
Mot. 1335 00 00 133 500 Pliers for removing valve steam seals.
17 mm pipe wrench for removing high pressure

Mot. 1383 00 00 138 300
pipes
10578S1
Tool for removing silicon coated crankshaft

Mot. 1423 00 00 142 300
bearings.
12875S1
10-34
Method Part
Reference Number
Mot. 1485 00 00 148 500

Tool for removing piston coolers.
Mot. 1485-01 00 00 148 501
15868S1
Mot. 1488 00 00 148 800 Tool for refitting exhaust camshaft covers.
Mot. 1492 00 00 149 200 Tool for fitting con rod bearing shells.
15867S1
Mot. 1493 00 00 149 300 Tool for fitting crankshaft bearing shells.
15866S1
Mot. 1495 00 00 149 500 Socket for removing and refitting oxygen sensor.
Mot. 1502 00 00 150 200 Valve spring compressor.
Mot. 1511 00 00 151 100 Tool for fitting valve stem seals.
15737S1
Mot. 1512 00 00 151 200 Tool for fitting camshaft seals.
10-35
Method Part
Reference Number
Mot. 1516 00 00 151 600 Tool for fitting piston coolers orientated at 5.
15863S1
Plate for refitting piston coolers orientated at 3

Mot. 1516-01 00 00 151 601
(addition to Mot. 1516).
Mot. 1526 00 00 152 600 Tool for setting camshaft.
Mot. 1530 00 00 153 000 Tool for extracting petrol injectors.
Mot. 1532 00 00 153 200 Tool for removing petrol injection rail.
Mot. 1533 00 00 153 300 Tool for fitting injector Teflon seals.
Mot. 1535 00 00 153 500 Tool for immobilising camshaft pulleys.
10-36
Essential equipment 10
Description
Ring for fitting piston with rings into the liner.
Standard 1/2" 22 mm long socket (12.7 mm square) for removing oil pressure
gauge.
Tooling for testing the cylinder head including : a container and the various kits
suited to each cylinder head model (plug, sealing plate, blank). The approval
number of the cylinder head test container is 664 000
Standard 1/2" 8/12/14 female torx socket (12.7 mm square).
Angular tightening tool from:

STAHL WILLE, part number 540 100 03 for example,
FACOM, part number DM 360 for example.
Tool for fitting valve stem seals from FACOM, part number DM 6J4 for example.
Angled nippers (pliers) from:

SAM, part number 366.1 for example,
FACOM, part number Series 151 for example.
Nozzle for using tube of RHODORSEAL 5661.
10-37
Overhauling the engine 10
Removing the engine the inlet manifold,
Remove:
the air expansion chamber,
15616S
the EGR paper seal,

the seal at the end of the exhaust camshaft,
Pay strict attention to the rules regarding

cleanliness (see start of document).
15618S
the high pressure fuel pipe using the Mot. 1383 tool,
the high pressure fuel pump.
the coil and the ignition harness,
15617R3
15615S
Fit the protective blanking covers to the fuel pump,

the high pressure pipe and the fuel injector gallery.
10-38
Remove: the Top Dead Centre setting pin cap,
the accessories drive belt by turning the spanner to
the right to slacken the belt.
Lock the roller using a 6 mm Allen key (1),
15102-1R
the upper timing cover.
15578-3S
10-39
Positioning the belt at the timing
point
Method
Position the exhaust camshaft
pulley mark (1) one tooth before the
exhaust camshaft sensor mounting
(2). The camshaft grooves must be
below and almost horizontal as
shown in the following
illustration.
15740-1R
15614-1S
10-40
Then insert the Top Dead Centre setting pin Correct position (crankshaft locked)
Mot. 1054, so that it is between the balancing hole
and the crankshaft locking slot.
15163-1S
15163-2S
NOTE: this is to prevent locking of the crankshaft

through the pin entering a balancing hole.
Incorrect position
15163S
10-41
Turn the engine clockwise (from
timing side), until the timing point is
reached.
The camshaft grooves must be
horizontal and off-centred
downwards as shown in the
illustration. Also, the camshaft
pulley mark must be opposite the
sensor mounting.
15614S
15740S 15163-1S
10-42
Fit the flywheel lock Mot. 582-01,
and remove the Top Dead Centre
pin (otherwise, there is a risk of
breaking the crankshaft).
Remove:
the middle timing cover,
15578-5S
10-43
the lower timing cover,
15578-2S
the crankshaft accessories

pulley.
15578-1S
10-44
Slacken the tension wheel securing
nut (3).
Remove:
the pulley (4),
15578R1
the timing belt taking care not to let the crankshaft

timing pinion fall out,
the camshaft pulleys using the Mot. 1535 tool
(locate the middle timing cover bolt in the hole (5) to
immobilise the Mot. 1535 tool),
16078R3
10-45
the power steering pump pulley, the power steering pump mounting bolts (2) and nut
(3),
15576-2S
15575R1
the power steering pump securing bolts (1),

the alternator,
15576-4R
15576-3S
10-46
the air conditioning compressor, the rear timing protection strip by removing the bolt
(1),
15576-1S
15574R1
the multifunction mounting,

the engine lifting rings.
15576R1
10-47
the harness securing bolts.
NOTE: the injectors are attached

to the injection gallery by
retaining clips. It is not
necessary to remove them to
extract the gallery.
15613R3
The gallery is extracted using the Mot. 1532 tool. Screw the sockets (1) to the gallery in place of the
gallery securing bolts.
Locate the bolts (2) in the sockets (1), then extract the
gallery by progressively tightening the bolts (2).
16126R1
Fit the protective blanking pieces to the gallery.
10-48
Remove the injector clips. Fit the Mot. 1530 tool to the injector, then rotate it to
break the oil-carbon deposit on the head of the
Fit the protective blanking pieces over the injector injector.
inlet holes.
The injectors are extracted using the Mot. 1530 tool.
16635S
Fit the protective blanking pieces on the injector

R heads.
Remove:
the oil filler orifice,
15612S
10-49
the EGR valve mounting,
15612-3R
the camshaft bearing cap bolts.
15612-2S
10-50
Vertically loosen:
the inlet camshaft bearing cap
cover by tapping the lugs (1) with
a mallet,
15612-1R
the exhaust camshaft bearing cap cover by tapping

the lugs (2) with a mallet and, at the same time,
sliding a screwdriver under the lug (3) to act as a
lever.
15660-1R
10-51
Remove:
the camshafts,
15656S
the hydraulic valve rockers and

stops,
15657S
10-52
the cylinder head.
15659S
10-53
The valve springs are compressed using the
Mot. 1502 tool.
16086S
To correctly compress the valve springs, 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) of the Mot. 1502 tool.
16085S
10-54
Remove: CHECKING THE GASKET FACE
the pins,
the upper cups, Check for gasket face bow using a straight edge and a
the springs, set of shims.
the valves,
the valve guide seals using the Mot. 1335 clamp.
Maximum bow 0.05 mm
CLEANING No regrinding of the cylinder head is permitted.
It is very important not to scratch the gasket faces of Check the cylinder head for cracks.
the aluminium components.
Use DECAPJOINT to dissolve any part of the seal

which remains stuck to the metal surface.
Apply the product to the part to be cleaned; wait for

about ten minutes then remove it using a wooden
spatula.
Wear gloves whilst carrying out this operation.
Do not allow this agent to drip on to the paintwork.
Great care should be used in performing this

operation, to avoid the entry of foreign objects into
the piping taking oil under pressure to the
hydraulic stops and the camshafts (piping in both
the cylinder head and its cover) and the oil return
piping.
Failure to take this advice could lead to the

blocking of the oilways, resulting in rapid and
serious damage to the engine.
10-55
Checking camshaft end play
Refit:
the camshafts, positioning them
correctly (see identification of the
camshafts in the "Technical
data" section),
the camshaft bearing cap covers,
tightening the bolts to a torque
value of 1.2 daN.m and in the
recommended order.
15612-2R
Check the end play, which must be between 0.08 and

0.178 mm.
NOTE: to attach the magnetic gauge to the cylinder

head, you must use a Mot. 588 clamp and secure it
using the oil filler attachment bolts (1) and spacers (2)
with the following dimensions:
external diameter 18 mm,
diameter of bolt (1) hole 9 mm,
height 15 mm.
Measurement of inlet camshaft play.
10-56
Measurement of exhaust camshaft play. REASSEMBLING THE CYLINDER HEAD
Fit new valves, grind them gently into their respective

seats. Clean all the parts thoroughly, mark them for
identification purposes, then carry out the refitting
operation.
Lubricate the inside of the valve guide.
The valve stem seals must be fitted using the

Mot. 1511 tool or the FACOM tool, part number
DM6J4, for example.
15742S
Again remove the camshaft bearing cap covers and

the camshafts.
NOTE: do not lubricate the valve stem seals before

fitting them.
10-57
Fitting the valve stem seals Keep the valve pressed against its seat.
Locate the valve in the cylinder head. Place the valve stem seal (not lubricated) over the tool
barrel.
15771S
15771-2S
Place the barrel of the Mot. 1511 tool over the valve
stem (the internal diameter of the barrel must be Push the valve stem seal past the tool barrel, then
identical to that of the valve stem). withdraw the barrel.
15771-1S 15771-3S
10-58
Place the pushrod (1) over the valve stem seal. Push home the valve stem seal by gently striking the
top of the pushrod with the palm of the hand, until
the valve stem seal makes contact with the cylinder
head.
15771-5R
NOTE: the internal diameter of the pushrod must 15771-6S

be identical to that of the valve stem. In addition,
the base of the pushrod must make contact with
the part of the valve stem seal which operates as
the lower thrust washer for the valve spring.
15770S
Repeat the foregoing sequence of operations for all

the valves.
10-59
Fitting:
the springs,
the upper cups,
To correctly compress the valve springs, 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) of the Mot. 1502 tool.
16086S
Refit the keys using tweezers.
16087R
16084S
16085S
10-60
Remove:
the clutch and the engine 1
flywheel,
the various components
(illustrations 1 to 7).
15159S1
15159-1S1
10-61
3 5
15160-2S 15161-1S
15161S
10-62
WARNING: do not use a sharp
point to mark the big end caps in 6
relation to their connecting rod,
to avoid initiating a crack in the
rod. Use an indelible marker pen.
15183S
Remove the bearing caps and the

connecting rod/piston assemblies. 7
15184S
10-63
NOTE: the crankshaft main bearing
caps are numbered from 1 to 5.
15182S
10-64
Remove the crankshaft main bearing caps, using the Remove:
Mot. 1423 tool exclusively for bearing N 1. the oil filter,
the coolant hose,
the knock detector,
the oil pressure sensor.
It is essential to mark the position of the

crankshaft shells, as the category may be different 15190S
for each bearing.
10-65
Extracting the gudgeon pins Fitting the connecting rod shells
To extract the gudgeon pin, remove the spring ring The shells are fitted using the Mot. 1492 tool.
using a screwdriver, then release the pin.
15743R1
15654S
On the connecting rod
It is essential to mark the position of the
connecting rod shells, as the category may be Choose the shell mounting (1) corresponding to the
different for each rod. engine (engine type (2) marked on the mounting).
Slide the shell mounting into the slot (3) in the base of
the tool.
10-66
Lay the connecting rod on the base of the tool (as Push against the shell mounting (in the direction of the
shown in the illustration below). Ensure that the lower arrow) until it is hard up against the body of the
part (4) of the small end of the connecting rod is in connecting rod.
contact with the guide pin.
15745S
R
Remove the shell support and repeat the operation for

Lay the shell (5) on the shell mounting as shown in the the remaining connecting rods.
illustration below.
15744-1R
10-67
On the big end cap Replacement of the piston base cooling jets
Place the big end cap against the guide pins (6) on the Removal
base of the tool, then fit the shell (7) against the shell
mounting. To remove the piston base cooling jets (1), they must
be drilled with a 7 mm diameter drill. This is necessary
in order to remove the spring stop (2) and the spring
(3).
Push against the shell mounting (in the direction of the

arrow) until it is hard up against the big end cap. R
NOTE: do not remove the ball (4): this will prevent

swarf entering the cooling circuit.
15747S
10-68
Remove the swarf using a brush.
15179-1S
Screw :
the Mot. 1485 or Mot. 1485-01 tool into the drilled out
jets using a 6 mm Allen key which you slide inside
the tool
10-69
the Emb. 880 inertia extractor to the Mot. 1485 or Mot. 1485-01 tool and extract the jet.
15178-1R1
Fitting piston base cooling jets
The jets must be fitted using the Mot. 1516 tool and
the Mot. 1516-01 plate.
10-70
Fitting the jets for cylinders 1 et 3 Tighten the two bolts (1), then withdraw the guide rod.
Locate the plate (3) of the Mot.1516-01 tool on the Insert the jet in the pushrod.
cylinder block (as shown in the illustration below)
without tightening the two bolts (1) of Mot. 1516 tool. NOTE: ensure the correct alignment of the jet, the
jet tip (4) should be pointing towards the centre of
the cylinder.
15572-2R
15262-1R
Insert the guide rod (2) of the Mot. 1516 tool into the
plate (3) and the end of the guide rod into the jet Insert the pushrod in place of the guide rod.
orifice, in order to centre the plate (3).
Using a mallet, tap the pushrod until its shoulder (5)
makes contact with plate (3).
15572-1R
15572R1
10-71
Fitting the coolers in cylinders 2 and 4 Tighten the two bolts (1), the remove the guide rod.
Position the plate (3) of tool Mot. 1516-01 on the Insert the cooler into the pushrod.
cylinder block (as shown in the diagram below) without
tightening the two bolts (1) of tool Mot 1516. NOTE: check the cooler is correctly orientated with
the end of the cooler (4) directed towards the
centre of the cylinder.
15571-2R
15262R1
Position the guide rod (2) of tool Mot. 1516 in the plate
(3) and the end of the guide rod in the cooler hole, in Fit the pushrod in place and instead of the guide rod.
order to centre the plate (3).
With a hammer, tap the pushrod until the shoulder (5)
of the pushrod comes into contact with the plate (3).
15571-1R
15571R1
10-72
Orientation of the piston coolers (see diagram below). Direction of fitting of the con rod in relation to the
piston
Point the "V" (1) engraved on the top of the piston

downwards and the lubrication hole (2) of the little end
in line with the vertical axis (as shown on the diagram
below).
A: Orientation of the coolers of cylinders 2 and 4

B: Orientation of the coolers of cylinders 1 and 3
R
Reassembling the engine
Clean the cylinder block. NOTE: put the break in the spring ring of the
gudgeon pin at the top at 45 to the vertical axis
Refit: of the piston.
the new oil filter,
the coolant pipe fitted with a new seal,
the oil pressure sensor,
the pinking sensor.
ASSEMBLING THE "CON RODS - PISTONS"
The pistons are referenced by a L engraved on the

tops indicating the flywheel side.
16082S
10-73
FITTING THE CRANKSHAFT BEARING SHELLS Fit the grooved bearing shell in tool Mot. 1493, then
press at (A) until the bearing shell is touching tool
On the cylinder block Mot. 1493 at (B).
Position tool Mot. 1493 on the cylinder block.
15469-1R
Refit the lateral shims (1) of the

crankshaft on bearing N 2
(grooves on the crankshaft side).
10-74
On the bearings
Position tool Mot. 1493 on the bearing.
Fit the non grooved bearing shell in tool Mot. 1493,

then press at (A) until the bearing shell is touching tool
Mot. 1493 at (B).
10-75
Refit the crankshaft.
Oil the main journal bearings with
engine oil.
Refit the crankshaft bearing caps
except cap N 1 (these are
numbered from 1 to 5) and tighten
the bolts to a torque of
6 to 6.7 daN.m.
15182S
Check the lateral clearance of the crankshaft which

should be between 0.07 and 0.23 mm.
Check that the crankshaft rotates freely.
86909S
10-76
FITTING BEARING N 1 WITH SILICON INJECTION
IMPORTANT: the mixture must be injected within

approximately 5 minutes to prevent it from
polymerising in the syringe.
Clean the surfaces thoroughly at (25) of the cylinder

block and the crankshaft cap, using a cloth soaked in
cleaning thinner.
Allow to dry.
Fit the crankshaft bearing cap N 1 and tighten to a

torque of 6 - 6.7 daN.m.
Mix 45 ml of RHODORSEAL 5661 (approximately half

of a 100 gram tube) with half of the tube of hardener
using the mixing stick to obtain a uniform, slightly pink
mixture.
R 92791
Coat the lower surfaces of the cylinder block at (26)

with a thin layer of RHODORSEAL 5661.
89195S
10-77
Insert the mixture into the syringe and inject it into the Using a cloth, wipe off the excess mixture, both inside
grooves of the crankshaft bearing cap. and outside the cylinder block.
92794S 89197S
Allow the mixture to flow out slightly on either side of Allow to dry for a few moments and cut the excess off
the grooves of the crankshaft bearing cap, to ensure the gasket face.
that the injected mixture has totally filled the sealing
groove.
92797S
92795S
Check that the crankshaft rotates freely.
10-78
FITTING THE RINGS
Rings set to their original adjustment must be free

within their channels.
Ensure the rings are fitted the correct way round with
the word TOP pointing upwards.
Orientation of the rings in the piston
Ensure the break in each ring is correctly orientated as

shown in the diagram below.
15650S
10-79
REFITTING
Oil the pistons.
Fit the con rod - piston assemblies
into the cylinder block using the
ring (e.g.: FACOM 750 TB), paying
attention to the direction
("V" towards the flywheel).
Fit the con rods onto the oiled big
end journals of the crankshaft.
Fit the con rod caps, ensuring they
are correctly matched (marks
made when dismantling).
15183-1S1
Tighten the new nuts of the con rod

caps to a torque of 2 daN.m, then
tighten to an angle of 40 6
15184S
10-80
Refit the oil pump chain. Refit:
the crankshaft closure panel, tightening it to a torque
of 1.5 daN.m,
the water pump (fitted with a new seal), tightening it
to a torque of 1.7 daN.m,
15161-1S
NOTE: the crankshaft closure panel is sealed with

RHODORSEAL 5661. The bead (1) must be 1.6 mm 15161S
wide and be applied in accordance with the
diagram below. the water pump pulley, tightening it to a torque of
2 daN.m,
the new timing fixed rollers tightening roller (1) to a
torque of 5 daN.m (M10 bolt) and roller (2) to a
torque of 2.5 daN.m (M8 bolt).
R 16247
15160-2R
10-81
Refit:
the anti-emulsion plate,
the oil pump tightening it to a
torque of 2.2 to 2.7 daN.m,
the oil level sensor.
15159-1S1
Put a drop of RHODORSEAL

5661 at (A) (on either side of
bearing N 1), and at the
intersection of the crankshaft
closure panel and the cylinder
block at (B).
15159-2R1
10-82
Refit the sump with a new seal, pre-tightening it to a Fitting the crankshaft seals
torque of 0.8 daN.m, then finally tightening it to a
torque of 1.2 to 1.5 daN.m in the recommended order. Flywheel side, use tool Mot 991-01.
The alignment of the cylinder block and the sump must
be complied with on the flywheel side to prevent the
clutch housing from being damaged when fitting the
gearbox.
15158-2R
Timing side, use tool Mot. 990-03.

R
15160-3R
12350S
Refit:
the flywheel tightening the new bolts to a torque of
5 to 5.5 daN.m (tightening in a star sequence),
the clutch, tightening it to a torque of 2 daN.m.
10-83
REFITTING THE CYLINDER HEAD After a certain amount of time, the hydraulic tappet
may have drained itself and it must be reprimed.
Position the pistons at mid-stroke.
To check whether it needs repriming, press the top of
Position the cylinder head gasket then the cylinder the tappet at (A) with your thumb. If the piston can be
head. pressed into the tappet, immerse it in a container filled
with diesel.
Check the bolts, then tighten the cylinder head
(see "Cylinder head specifications" section). Refit the hydraulic tappets and valve rockers.
Refit the coolant housing fitted with a new seal and

tighten it to a torque of 1 daN.m.
15640S
10-84
Oil the camshaft bearings.
Be careful not to spill oil onto the
gasket face of the camshaft
bearing cap housings.
Refit the camshaft, ensuring it is
correctly positioned.
The inlet camshaft has a drive for
the petrol high pressure pump.
15656S
Check for the presence of the

centring pins of the camshaft
bearing cap housings.
15656-1S
10-85
Position the grooves of the
camshafts as shown on the
diagram.
15614S
NOTE: the gasket faces must be clean, dry and

free from grease (in particular, avoid finger marks).
Using a stipple roller, apply Loctite 518 to the gasket

face of the camshaft cap housing until it turns reddish
in colour.
NOTE: using a cloth, remove the Loctite 518

located at (1) from the six bearings of the camshaft
bearing cap housing.
10-86
Refit:
the camshaft bearing cap
housings tightening them to a
torque of 1.2 daN.m,
15612-2R
the EGR valve bracket.
15612-3S
10-87
NOTE: the gasket faces must be clean, dry and
free from grease (in particular, avoid finger marks).
Using a stipple roller, apply Loctite 518 to the gasket

face of the oil separator, until it turns reddish in colour
(do not put Loctite 518 on the partitions (1)).
Refit:
the oil separator, tightening it to a
torque of 1.3 daN.m in the
recommended order (self-
tapping bolts must be tightened
to the correct torque using a
torque wrench).
10-88
Fit:
Before refitting the injectors on the rail, the
the cone of tool Mot. 1533 on the tip of the injector,
Teflon seals of the injectors must be replaced.
the seal.
To do this:
clean the tip of the injector by immersing it in suitable
clean thinner. The use of a wire brush, sand paper
or an ultrasound cleaner is forbidden,
wipe the tip of the injector using a lint free cloth,
carefully cut the seal with circlip pliers taking
care not to mark the injector,
Push the Teflon seal manually until it goes past the

cone, then remove the cone.
16373S
clean the throat of the injector; the Teflon seal is fitted

using tool Mot. 1533.
16375S
10-89
The Teflon seal must be shrunk. To do this, insert the Replace:
body of tool Mot. 1533 until the body comes into the injector clips,
contact with part (1) of the injector. the injector O-rings.
Put the clips on the injectors.
Correctly position the injectors on the rail (see diagram

below).
16376R1
16125S
10-90
Refit:
the petrol rail fitted with the
injectors tightening the bolts to a
torque of 1.5 daN.m,
15613S
the rear timing tab,
15574S1
10-91
the camshaft seals using tool Mot. 1512 (use the old the air conditioning compressor, tightening the bolts
nuts (B)), to a torque of 2.1 daN.m,
15644R1 15576-1S
the multifunction support, tightening the bolts and the alternator, tightening the bolts to a torque of
stud to a torque of 4.4 daN.m, 2.1 daN.m,
15576S 15576-3S
10-92
the bolts and nut (1) of the assisted steering pump the assisted steering pump pulley,
bracket and the bolts (2) of the assisted steering
pump to a torque of 2.1 daN.m,
15576-2S
15575R2 the timing tensioning roller, correctly positioning the

lug (3) of the roller in the groove (4).
15576-4R1
R
10-93
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 may
damage the engine.
NOTE: to make it easier to position

the grooves horizontally, fit the
camshafts and the old nuts,
tightening them to 1.5 daN.m
MAXIMUM.
Position the grooves of the

camshafts horizontally and offset
towards the bottom as shown on
the diagram (by rotating the
camshafts using tool Mot. 799-01
if necessary). 15614S
Fit tool Mot. 1526, onto the end of the camshaft.
Remove the old nuts from the pulleys and replace

them with new nuts (without locking the nuts,
clearance between the nut-pulley of 0.5 to 1 mm).
R 16077
10-94
Check that the crankshaft is correctly pinned at Correct position
Top Dead Centre and not in the balancing hole.
Incorrect position
15163-1S
15163S
The groove (1) of the crankshaft

must be located in the middle of the
two webs (2) of the crankshaft
closure housing.
Position reference (3) of the

exhaust camshaft pulley opposite
the thread (4) of the exhaust
camshaft sensor.
15577R1
10-95
Refit:
the timing belt,
the tensioning roller applying
Loctite Frenetanch, then
tighten the mounting bolt to a
torque of 5 daN.m.
15578S
NOTE: the bolt of the

accessories crankshaft pulley
can be reused if the length
under the head does not exceed
49.1 mm (otherwise replace it).
Position the crankshaft
accessories pulley, pre-tightening
the bolt (without locking the bolt,
clearance of 2 to 3 mm between
the bolt and the pulley).
15578-1S
10-96
Belt tension Position reference (8) of the exhaust camshaft pulley
opposite the thread (9) of the exhaust camshaft
Check that there is always a clearance of sensor.
0.5 to 1 mm between the nuts and pulleys of the
camshafts.
NOTE: do not rotate the tensioning roller in an

anticlockwise direction.
Align the references (6) and (7) of the tensioning roller,

using a 6 mm Allen key at (B).
Tighten the bolt of the crankshaft accessories pulley to

2 daN.m (Top Dead Centre pin still inserted in the
crankshaft).
REMOVE THE TOP DEAD CENTRE PIN.

15649R1
Pre-tighten the nut of the tensioning roller to a torque

of 0.7 daN.m.
NOTE: ensure that the camshaft nuts do not touch

their respective pulleys. In addition, from time to
time, push the camshaft pulleys against the
camshafts.
Rotate the timing through six revolutions using the

exhaust pulley using tool Mot. 799-01.
Align the marks (6) and (7) if necessary, slackening the

nut of the tensioning roller by a maximum of one turn,
holding it with a 6 mm Allen key. Then tighten the nut
finally to a torque of 2.8 daN.m.
10-97
Lock the flywheel using tool Mot. 582-01 or a large Incorrect position
screwdriver, then turn the bolt of the accessories
crankshaft pulley through an angle of 115 15.
15163S
Fit the tool for locking the camshaft pulleys Mot. 1535
15108S (put the bolt of the intermediate timing housing in the
hole (5) in order to lock tool Mot. 1535).
Pin the crankshaft using the reference of the exhaust
camshaft pulley and the thread of the camshaft sensor
(the references should be aligned) which will ensure
that the pin is in the pinning hole and not in a
crankshaft balancing hole.
Correct position
16078R3
Tighten the nut of the inlet camshaft pulley to a torque

of 3 daN.m, then turn through an angle of 90.
Tighten the nut of the exhaust camshaft pulley to a

torque of 3 daN.m, then turn through an angle of
90.
15163-1S
10-98
Remove tool Mot. 1526 for setting the camshaft, tool Remove the Top Dead Centre pin.
Mot. 1535 for locking the camshaft pulleys, and tool
Mot. 1054 the Top Dead Centre pin. Check that the references of the tensioning roller are
correctly aligned, otherwise repeat the tensioning
Checking the timing and the tension operation.
Checking the tension: Slacken the nut of the tensioning roller by a maximum
of one turn, holding it with a 6 mm Allen key.
Rotate the crankshaft through two revolutions in a
clockwise direction (timing side), before the end of the Align the references of the tensioning roller and tighten
two revolutions in other words, half a tooth before the nut finally to a torque of 2.8 daN.m.
the exhaust camshaft reference and the camshaft
sensor thread are aligned. Checking the timing:
Ensure that the references of the tensioning roller are

correctly positioned before checking the setting of the
timing.
Fit the Top Dead Centre pin (check that the reference
of the exhaust camshaft pulley and the camshaft
sensor thread are aligned).
Fit (without forcing) tool Mot. 1526 for setting the

camshafts (the camshaft grooves must be horizontal
and offset towards the bottom). If the tool cannot be
inserted, repeat the timing setting and tensioning
operation.
15740-1S
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.
R 16077
10-99
Refit:
the plug of the Top Dead Centre
pin, putting a drop of
RHODORSEAL 5661 on the
thread,
the intermediate housing
tightening the bolts to a torque of
1 daN.m,
15578-2S
the upper timing housing

tightening the bolts to a torque of
3.5 daN.m for the M10 bolts
and 2.5 daN.m for the M8 bolts,
15578-5S
10-100
the upper timing belt cover,
15578-3S
the accessories belt. To position the belt, pivot the NOTE: when fitting the belt it is essential to ensure
key to the right. that the tooth (which corresponds to X) inside the
pulleys remains "FREE".
Block the tensioner using a 6 mm Allen key (1).
R
15579-1R
The engine must be rotated through two

revolutions in order to position the belt correctly.
10-101
Refit: the rail and the ignition coil (check that the spark plug
the petrol high pressure pump (fitted with a new leads are not touching the inlet manifold),
shim), tightening the bolts to a torque of 1.2 daN.m,
the high pressure pipe,
the seal between the EGR valve support and the
manifold,
15617S
the new plug of the exhaust camshaft using tool

Mot. 1488,
15615S
the inlet manifold tightening the M8 nuts and bolts to

a torque of 2.5 daN.m and the M6 bolts to a torque of
1 daN.m.
15616S
10-102
the air resonator.
15618S
Remove the engine from the stand

Mot. 790-03.
Refit the exhaust manifold

tightening it to a torque of
1.8 daN.m in the recommended
order.
If the studs were slackened at the
same time as the nuts, a drop of
Loctite FRENETANCH must be
applied.
15619R1
10-103
Refit the oxygen sensor using tool
Mot. 1495 , tightening it to a torque
of 4.5 daN.m.
NOTE: check that the exhaust

heat shield is correctly
positioned between the oxygen
sensor and the manifold (so as
to prevent a chimney effect
which might destroy the wiring
of the oxygen sensor).
Refit:
the EGR valve, tightening the two
bolts to a torque of 2.7 daN.m,
16080S
the exhaust heat shield,

tightening it to a torque of
1 daN.m.
16079S1
10-104

Workshop Repair Manual: Engine Fitted On The: - Megane: DA03 F5R 740 EA03

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Workshop Repair Manual: Engine Fitted On The: - Megane: DA03 F5R 740 EA03

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Workshop Repair Manual

PETROL DIRECT INJECTION ENGINE

Engine fitted on the:

77 11 292 042 OCTOBER 1999 EDITION ANGLAISE

10 ENGINE AND PERIPHERALS

- Cleanliness / Safety 10-1

- Engine identification 10-5

- Tightening torques (in daN.m or in degrees) 10-6

- Standard replacement 10-32

- Essential special tooling 10-33

- Essential equipment 10-37

- Overhauling the engine 10-38

RISKS LINKED TO POLLUTION

WHAT ARE THE POLLUTING ELEMENTS?

The elements which pollute are:

INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT

! Wash your hands before and during the operation if necessary.

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

There are two main sections in this manual:

overhauling the engine.

To repair a component on the vehicle, refer to the

All dimensions are given in millimetres (mm) (except

Tightening torques are expressed in deca-Newton

Tightening torques given without a tolerance must be

Capacity Bore Stroke Compression

F5R 740 1998 82.7 93 11.5/1

Description Tightening torque

Air conditioning compressor bolts 2.1

* Refer to tightening procedure on page 10-8.

Description Tightening torque

Cylinder head tightening procedure

Tighten all bolts to 2 daN.m in the order recommended below.

The thickness of the cylinder head gasket is measured H = 138.4 mm.

Gasket face bow: 0.05 mm.

1 - 3 - 4 - 2. No rectifications are allowed.

Test the cylinder head to detect any cracks.

Spark plug tightening torque: 2.5 to 3 daN.m.

This engine is fitted with hydraulic stops (A) and roller

Valve length (in mm)

Inlet: 113.55 0.20

Inlet and exhaust: 89

Bearing width X (in mm)

Inlet: 1.8 0.1

VALVES External diameter D (in mm)

Valve lift (in mm)

Stem diameter (in mm)

Inlet: 5.485 0.011

Head diameter (in mm)

Inlet: 31.5 0.12

Length (in mm) Position the valve in the cylinder head.

Inlet and exhaust: 40.5 0.15

Guide external diameter (in mm)

Guide internal diameter (in mm)

Inlet and exhaust

* This dimension is measured with the guide fitted

The inlet and exhaust guides have valve stem seals

NOTE: do not oil the valve stem seals before

Detail of the marking (A):

Length under load:

Internal diameter: 15.80

External diameter: 23.12

Oval type wire cross section.

Between 0.08 and 0.178.