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
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared.
OCTOBER 1999
All copyrights reserved by Renault.
EDITION ANGLAISE
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 1999
Contents
Pages
10
ENGINE AND PERIPHERALS

- Cleanliness / Safety - Foreword - Engine identification - Tightening torques (in daN.m or in degrees) - Specifications - Standard replacement - Essential special tooling - Essential equipment - Overhauling the engine 10-1 10-4 10-5 10-6 10-8 10-32 10-33 10-37 10-38
ENGINE AND PERIPHERALS 110 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 Cleanliness / Safety

INSTRUCTIONS TO BE FOLLOWED BEFORE ANY REPAIRS ON THE INJECTION SYSTEM
!
10
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
ENGINE AND PERIPHERALS Cleanliness / Safety
10
10-3
ENGINE AND PERIPHERALS Foreword

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.
10
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 AND PERIPHERALS Engine identification

ENGINE IDENTIFICATION The engine is identified by a plate riveted onto the cylinder block. It contains: A: the engine type B: the engine approval letter C: the Renault identification D: the engine suffix E: the engine assembly factory F: the engine fabrication number
10
Capacity Engine Suffix (cm 3 ) 1998
Bore (mm) 82.7
Stroke (mm) 93
Compression ratio 11.5/1
F5R
740
10-5
ENGINE AND PERIPHERALS Tightening torques (in daN.m or in degrees)

Top of engine: Description
Air filter unit mounting bolt Oil separator bolt (refer to tightening order) *** Camshaft bearing cap housing bolts Camshaft pulley nuts Cylinder head bolts Cylinder head suspension mounting nuts and bolts: - M10 nuts and bolts - M8 bolts Intermediate timing housing bolts Spark plugs Assisted steering pump bolts Alternator bolts Air conditioning compressor bolts Alternator support and air conditioning compressor bolts Assisted steering pump support bolts Accessories belt tensioning roller bolts (air conditioning version) Accessories belt fixed roller bolts (air conditioning version) Exhaust manifold nuts (refer to tightening order) Exhaust manifold upper and lower heat shield bolts Oxygen sensor (see assembly recommendation) Exhaust manifold stay mounting: - Bolts - Nuts Petrol rail mounting bolts Petrol HP pump bolts Ignition rail Coil support mounting nut Inlet manifold M8 nuts and bolts Inlet manifold M6 bolts EGR valve support bolts Additional air actuator valve bolts Throttle body bolts Lifting lug bolts Thermostat housing cover bolts Coolant temperature sensor on cylinder head coolant outlet housing 1 1.8 1.5 1.2 1 2.5 2.5 1 1 1 1 0.9 1 3.8 3.5 2.5 1 2.5 to 3 2.1 2.1 2.1 4.4 2.1 2.1 2.1 1.8 1 4.5
10
0.9 1.3
Tightening torque
(refer to tightening order) ** 3 plus an angle of 90 *
* ** ***
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
ENGINE AND PERIPHERALS Tightening torques (in daN.m or in degrees)

Engine peripherals: Description
Sump bolts (refer to tightening order) Crankshaft pulley bolts Crankshaft closure panel Flywheel bolts Clutch bolts Oil pump bolts Big end bolts Crankshaft bearing cap bolts Water pump bolts Water pump pulley bolts Timing fixed roller bolts: - M10 bolts - M8 bolts Timing tensioning roller nut Water pump inlet pipe bolts Pinking sensor Multifunction support bolts 5 2.5 2.8 3.6 2 4.4
10
1.2 to 1.5
Tightening torque
2 plus an angle of 115 15 1.5 5 to 5.5 2 2.2 to 2.7 2 plus an angle of 40 6 6 to 6.7 1.7 2
10-7
ENGINE AND PERIPHERALS Specifications

CYLINDER HEAD
10
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

Thickness of the cylinder head gasket The thickness of the cylinder head gasket is measured at (A): thickness of the compressed gasket: Cylinder head height H = 138.4 mm.
10
0.65 0.02 mm.
Gasket face bow: Firing order 1 - 3 - 4 - 2. No rectifications are allowed.
0.05 mm.
Test the cylinder head to detect any cracks. Spark plug tightening torque: 2.5 to 3 daN.m.
10-9

Hydraulic tappets This engine is fitted with hydraulic stops (A) and roller tappets (B). Setting angle Inlet and exhaust:
10
90
Valve length (in mm) Inlet: Exhaust: VALVE SEATS Seat angle Inlet and exhaust: 89 113.55 0.20 113.97 0.20
Bearing width X (in mm) Inlet:

15658R1
1.8 0.1 1.8 0.1
Exhaust:
VALVES Valve lift (in mm) Inlet : Exhaust: Stem diameter (in mm) Inlet: Exhaust: Head diameter (in mm) Inlet: Exhaust: 31.5 0.12 27.46 0.12 5.485 0.011 5.445 0.011 9.687 9
External diameter D (in mm) Inlet: Exhaust: 32.53 0.008 28.43

+ 0.006 0.007
10-10

VALVE GUIDES Length (in mm) Inlet and exhaust: Guide external diameter (in mm) Inlet and exhaust: Guide internal diameter (in mm) Inlet and exhaust Non machined: Machined*: 5 5.5
+ 0.075 0 + 0.018 0
10
Fitting valve stem seals Position the valve in the cylinder head. 40.5 0.15
11
+ 0.068 + 0.05
This dimension is measured with the guide fitted in the cylinder head.
15771S
The inlet and exhaust guides have valve stem seals which also act as a lower bearing washer for the valve spring. The valve stem seals must be fitted using tool Mot. 1511 or with the FACOM tool, part number DM6J4 for example.
Put the plug of tool Mot. 1511 on the valve stem (the internal diameter of the plug must be the same as that of the valve stem).
15771-1S
NOTE: do not oil the valve stem seals before fitting.
10-11

Keep the valve pressing against its seat. Fit the valve stem seal (non oiled) onto the plug. Fit the pushrod (1) on the valve stem seal.
10
15771-5R 15771-2S
Push on the valve stem seal until its goes past the plug then remove the plug.
NOTE: the internal diameter of the pushrod must be the same as that of the valve stem. In addition, the bottom of the pushrod must press against the part of the valve stem seal which acts as the lower bearing washer for the valve spring.
15771-3S
10-12

Press the valve stem seal down by tapping with the palm of your hand on the top of the pushrod, until the valve stem seal touches the cylinder head.
10
63
Angle of the inlet and exhaust guides (in degrees) Inlet:
15771-6S
15646S
Exhaust:
61
15770S
10-13

Position of the inlet and exhaust valve guides (in mm) Inlet: Exhaust: A = 9.5 0.15 A = 9.5 0.15 CAMSHAFT
10
The camshaft can be identified with a marking (A).
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 Example: 43.42 34.50 24.50 23 15.80 23.12
Valve springs (in mm) Free length: Length under load: 22.5 daN 52.5 daN Number of coils: Internal diameter: External diameter: Oval type wire cross section.
10-14

Longitudinal clearance (in mm) Between 0.08 and 0.178. Number of bearings: 6 Inlet opening delay* Inlet closing delay Exhaust opening advance Exhaust closing advance**
*
10
Exhaust camshaft Cam 1 Cam 2 Cam 2 - 15 45
Timing diagram (cannot be checked) Inlet camshaft Cam 1
Diameter of the cylinder head camshaft bearings (in mm) Flywheel side 1 2 3 4 5 6 28
+ 0.061 + 0.04 **
- 11 41
27
31
25
+ 0.061 + 0.04
-4
-8
As the Inlet Opening Delay is negative, the valves open after TDC. As the Exhaust Closing Advance is negative, the valves close before TDC.
Timing side Diameter of the camshaft bearings (in mm) Flywheel side 1 2 3 4 5 6 28
0 0.021
25
0 0.021 R
A)
Timing side B)
A4 - 1 = Inlet of cylinder 4 and cam n 1. or E4 - 1 = Exhaust of cylinder 4 and cam n 1. A4 - 2 = Inlet of cylinder 4 and cam n 2. or E4 - 2 = Exhaust of cylinder 4 and cam n 2.
10-15

PISTONS MAHLE piston
10
The pin is free in the con rod and in the piston.
Piston marking
1 2 3 4 5 6 7
Cylinder block TDC fixed reference Flywheel TDC moving reference Flywheel BDC moving reference Inlet Opening Delay Exhaust Opening Advance Inlet Closing Delay Exhaust Opening Advance
R
1 2 3 4 5 6 7
Piston direction flywheel side Piston class (2 - 3 ) Used by the supplier only Used by the supplier only Piston axis of symmetry Gudgeon pin hole axis 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 reference 2 or B Piston diameter (mm) 82.680 0.007 Cylinder diameter (mm) 82.710 inclusive to 82.720 exclusive 82.720 inclusive to 82.730 inclusive
3 or C
82.690 0.007
10-16

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.
10
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 on the cylinder block T = 13 mm
Reference of the class on the piston 2 or B
Barrel diameter (mm) 82.710 inclusive to 82.720 exclusive 82.720 inclusive to 82.730 inclusive
Piston diameter (mm) 82.680 0.007
T = 19 mm
3 or C
82.690 0.007
10-17

Measuring the piston diameter The diameter must be measured at the point: E = 12 mm. RINGS Three rings (thickness in mm) Compression: Sealing: Scraper which consists of three parts:
! !
10
1.2 1.5
0.01 0.03 0.01 0.03
two steel rails (1), a spring ring (2).
Clearance at the break Clearance at the break (in mm) 0.2 to 0.35 0.4 to 0.6 0.2 to 0.9
Rings Compression Sealing Scraper
10-18

Gudgeon pin (in mm) Length: External diameter: Internal diameter: 58.7 to 59 E = 20.995 to 21 C = 17 0.2 I = 12.5
+ 0.1 0.2
10
Fitting the rings Rings set to their original adjustment must be free within their channels. Ensure the rings are fitted in the correct direction.
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) 51.587 Diameter of the little end (in mm) 23 (without ring) 21 (with ring)
0 0.019
10-19

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.
10
15183S
10-20

Direction of fitting of the con rod in relation to the piston 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 below). CRANKSHAFT Number of bearings: Burnished main bearing journals: nominal diameter (in mm)
10
5
54.795 0.010
Burnished big end journals: nominal diameter (in mm)
48
0 0.02
Crankshaft lateral clearance (in mm): Crankshaft diametrical clearance (in mm):
0.07 to 0.23
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 gudgeon pin at the top at 45 to the vertical axis of the piston. The engine is fitted with bearing shells without a foolproofing device.
16082S
15197S
10-21

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.
10
15181S
Cylinder block Fit tool Mot. 1493 on the cylinder block.
Fit the bearing shell in tool Mot. 1493, then press at (A) until the bearing shell is touching tool Mot. 1493 at (B).
15469-1R
10-22

Bearings Fit tool Mot. 1493 on the bearing.
10
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

CON ROD BEARING SHELLS The engine is fitted with bearing shells without a foolproofing device.
10
Fitting the bearing shell in the con rod body Select the bearing shell support (1) corresponding to 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

Place the bearing shell (5) on the bearing shell support as shown on the diagram below.
10
Fitting the bearing shell on the con rod cap 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 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

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).
10
R 10024
10-26

Checking the oil pump clearances Clearance (A) (in mm): min max 0.110 0.249
10
Clearance (B) (in mm): min max 0.020 0.086
10-27

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).
10
R 10024
10-28

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,
10
16079S1
Remove: the EGR valve / hose assembly, the oxygen sensor using tool Mot. 1495.
16080S
10-29

the exhaust manifold.
10
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

CONSUMABLES Type Cleaner DECAPJOINT RHODORSEAL 5661 Loctite 518 Loctite FRENETANCH Tube of RHODORSEAL 5661 WARNING WARNING: when working on the fuel supply system, the cleanliness rules described in this document must be strictly complied with. Quantity Coat Coat Coat 1 - 2 drops Bead Component concerned Cleaning parts. Cleaning gasket faces. Crankshaft bearing cap. Camshaft bearing cap housing Cylinder head stud Crankshaft closure plate
10
Part number 77 01 421 513 77 01 405 952 77 01 404 452 77 01 421 162 77 01 394 070 77 01 421 042
PARTS TO BE REPLACED WHEN THEY HAVE BEEN REMOVED All the gaskets. 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 camshaft bearing cap housing. Con rod cap nuts. Belts. Timing tensioning roller. Timing fixed rollers. Petrol high pressure pump shim. Exhaust camshaft sealing plug. Injector clips.
10-31
ENGINE AND PERIPHERALS 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, 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
10-32
ENGINE AND PERIPHERALS Essential special tooling

Illustration Method Reference Part Number Description
10
Emb. 880
00 00 088 000
Pin extractor.
Mot. 445
69716S1
00 00 044 500
Oil filter wrench.
Mot. 582-01
00 00 058 201
Tool for immobilising flywheel.
Mot. 588
00 00 058 800
Liner retaining strap.
Mot. 591-02
00 00 059 102
Magnetised flexible shaft for angular wrench for tightening cylinder head.
Mot. 591-04
00 00 059 104
Angular wrench for tightening cylinder head, 1/2" drive with index.
Mot. 792-03
00 00 079 203
Engine support plate.
Mot. 799-01
80359S
00 00 079 901
Tool for immobilising pinions for toothed timing belt.
10-33

10
Mot. 990-03
96897S
00 00 099 003
Tool for fitting crankshaft seal, timing side.
Mot. 991-01
00 00 099 101
Tool for fitting crankshaft seal, flywheel side.
96898S
Mot. 995
84900S1
00 00 099 500
Set of 2 rods (used with engine plate Mot. 793-03).
Mot. 1054
00 00 105 400
Top dead centre pin
Mot. 1329
97160-1S1
00 00 132 900
Oil filter spanner.
Mot. 1335
00 00 133 500
Pliers for removing valve steam seals.
Mot. 1383
10578S1
00 00 138 300
17 mm pipe wrench for removing high pressure pipes
Mot. 1423
00 00 142 300
Tool for removing silicon coated crankshaft bearings.
12875S1
10-34

10
Mot. 1485 Mot. 1485-01

15868S1
00 00 148 500 00 00 148 501
Tool for removing piston coolers.
Mot. 1488
00 00 148 800
Tool for refitting exhaust camshaft covers.
Mot. 1492
15867S1
00 00 149 200
Tool for fitting con rod bearing shells.
Mot. 1493
15866S1
00 00 149 300
Tool for fitting crankshaft bearing shells.
Mot. 1495
00 00 149 500
Socket for removing and refitting oxygen sensor.
Mot. 1502
00 00 150 200
Valve spring compressor.
Mot. 1511
15737S1
00 00 151 100
Tool for fitting valve stem seals.
Mot. 1512
00 00 151 200
Tool for fitting camshaft seals.
10-35

10
Mot. 1516
00 00 151 600
Tool for fitting piston coolers orientated at 5.
15863S1
Mot. 1516-01
00 00 151 601
Plate for refitting piston coolers orientated at 3 (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
ENGINE AND PERIPHERALS Essential equipment

Description
10
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
ENGINE AND PERIPHERALS Overhauling the engine

Removing the engine Remove: the air expansion chamber, the inlet manifold,
10
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 coil and the ignition harness,
the high pressure fuel pipe using the Mot. 1383 tool, the high pressure fuel pump.
15617R3
15615S
Fit the protective blanking covers to the fuel pump, the high pressure pipe and the fuel injector gallery.
10-38

Remove: 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), the Top Dead Centre setting pin cap,
10
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.
10
15740-1R
15614-1S
10-40

Then insert the Top Dead Centre setting pin Mot. 1054, so that it is between the balancing hole and the crankshaft locking slot. Correct position (crankshaft locked)
10
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.
10
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).
10
Remove: the middle timing cover,
15578-5S
10-43

the lower timing cover,
10
15578-2S
the crankshaft accessories pulley.
15578-1S
10-44

Slacken the tension wheel securing nut (3). Remove: the pulley (4),
10
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,
10
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,
10
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.
10
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 protective blanking pieces over the injector inlet holes. The injectors are extracted using the Mot. 1530 tool.
10
Fit the Mot. 1530 tool to the injector, then rotate it to break the oil-carbon deposit on the head of the injector.
16635S
Fit the protective blanking pieces on the injector heads.
Remove: the oil filler orifice,
15612S
10-49

the EGR valve mounting,
10
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,
10
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,
10
15656S
the hydraulic valve rockers and stops,
15657S
10-52

the cylinder head.
10
15659S
10-53

The valve springs are compressed using the Mot. 1502 tool.
10
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: the pins, the upper cups, the springs, the valves, the valve guide seals using the Mot. 1335 clamp. CHECKING THE GASKET FACE
10
0.05 mm
Check for gasket face bow using a straight edge and a set of shims. Maximum bow
CLEANING It is very important not to scratch the gasket faces of 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.
No regrinding of the cylinder head is permitted. Check the cylinder head for cracks.
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.
10
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
10
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 Locate the valve in the cylinder head. Keep the valve pressed against its seat.
10
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 identical to that of the valve stem).
Push the valve stem seal past the tool barrel, then withdraw the barrel.
15771-1S
15771-3S
10-58

Place the pushrod (1) over the valve stem seal.
10
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 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.
15771-6S
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.
10
16086S
Refit the keys using tweezers.
16087R
16084S
16085S
10-60

Remove: the clutch and the engine flywheel, the various components (illustrations 1 to 7).
10
15159S1
15159-1S1
10-61

3 5
10
15160-2S
15161-1S
15161S
10-62

WARNING: do not use a sharp point to mark the big end caps in relation to their connecting rod, to avoid initiating a crack in the rod. Use an indelible marker pen.
10
15183S
Remove the bearing caps and the connecting rod/piston assemblies.
15184S
10-63

NOTE: the crankshaft main bearing caps are numbered from 1 to 5.
10
15182S
10-64

Remove the crankshaft main bearing caps, using the Mot. 1423 tool exclusively for bearing N 1. Remove: the oil filter, the coolant hose, the knock detector, the oil pressure sensor.
10
It is essential to mark the position of the crankshaft shells, as the category may be different for each bearing.
15190S
10-65

Extracting the gudgeon pins To extract the gudgeon pin, remove the spring ring using a screwdriver, then release the pin. Fitting the connecting rod shells
10
The shells are fitted using the Mot. 1492 tool.
15743R1 15654S
On the connecting rod It is essential to mark the position of the connecting rod shells, as the category may be different for each rod. Choose the shell mounting (1) corresponding to the 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 shown in the illustration below). Ensure that the lower part (4) of the small end of the connecting rod is in contact with the guide pin.
10
Push against the shell mounting (in the direction of the arrow) until it is hard up against the body of the connecting rod.
15745S R
Lay the shell (5) on the shell mounting as shown in the illustration below.
Remove the shell support and repeat the operation for the remaining connecting rods.
15744-1R
10-67

On the big end cap Place the big end cap against the guide pins (6) on the base of the tool, then fit the shell (7) against the shell mounting. Removal
10
Replacement of the piston base cooling jets
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.
NOTE: do not remove the ball (4): this will prevent swarf entering the cooling circuit.
15747S
10-68

Remove the swarf using a brush.
10
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.
10
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 Locate the plate (3) of the Mot.1516-01 tool on the cylinder block (as shown in the illustration below) without tightening the two bolts (1) of Mot. 1516 tool. Insert the jet in the pushrod.
10
Tighten the two bolts (1), then withdraw the guide rod.
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 orifice, in order to centre the plate (3).
Insert the pushrod in place of the guide rod. 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 Position the plate (3) of tool Mot. 1516-01 on the cylinder block (as shown in the diagram below) without tightening the two bolts (1) of tool Mot 1516. Insert the cooler into the pushrod.
10
Tighten the two bolts (1), the remove the guide rod.
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 order to centre the plate (3).
Fit the pushrod in place and instead of the guide rod. 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).
10
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
Reassembling the engine Clean the cylinder block. Refit: the new oil filter, the coolant pipe fitted with a new seal, the oil pressure sensor, the pinking sensor. NOTE: put the break in the spring ring of the gudgeon pin at the top at 45 to the vertical axis of the piston.
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 On the cylinder block Position tool Mot. 1493 on the cylinder block.
10
Fit the grooved bearing shell in tool Mot. 1493, then press at (A) until the bearing shell is touching tool Mot. 1493 at (B).
15469-1R R
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.
10
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.
10
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.
10
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 grooves of the crankshaft bearing cap.
10
Using a cloth, wipe off the excess mixture, both inside and outside the cylinder block.
92794S
89197S
Allow the mixture to flow out slightly on either side of the grooves of the crankshaft bearing cap, to ensure that the injected mixture has totally filled the sealing groove.
Allow to dry for a few moments and cut the excess off the gasket face.
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.
10
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).
10
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.
10
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 wide and be applied in accordance with the diagram below.
15161S
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.
10
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 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. 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. Fitting the crankshaft seals Flywheel side, use tool Mot 991-01.
10
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 Position the pistons at mid-stroke. Position the cylinder head gasket then the cylinder head. Check the bolts, then tighten the cylinder head (see "Cylinder head specifications" section). Refit the coolant housing fitted with a new seal and tighten it to a torque of 1 daN.m.
10
After a certain amount of time, the hydraulic tappet may have drained itself and it must be reprimed. To check whether it needs repriming, press the top of the tappet at (A) with your thumb. If the piston can be pressed into the tappet, immerse it in a container filled with diesel. Refit the hydraulic tappets and valve rockers.
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.
10
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.
10
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,
10
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)).
10
Refit: the oil separator, tightening it to a torque of 1.3 daN.m in the recommended order (selftapping bolts must be tightened to the correct torque using a torque wrench).
10-88

Before refitting the injectors on the rail, the Teflon seals of the injectors must be replaced. 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,
10
Fit: the cone of tool Mot. 1533 on the tip of the injector, the seal.
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 body of tool Mot. 1533 until the body comes into contact with part (1) of the injector. Replace: the injector clips, the injector O-rings. Put the clips on the injectors.
10
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,
10
15613S
the rear timing tab,
15574S1
10-91

the camshaft seals using tool Mot. 1512 (use the old nuts (B)),
10
the air conditioning compressor, tightening the bolts to a torque of 2.1 daN.m,
15644R1
15576-1S
the multifunction support, tightening the bolts and stud to a torque of 4.4 daN.m,
the alternator, tightening the bolts to a torque of 2.1 daN.m,
15576S
15576-3S
10-92

the bolts and nut (1) of the assisted steering pump bracket and the bolts (2) of the assisted steering pump to a torque of 2.1 daN.m, the assisted steering pump pulley,
10
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).
10
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 Top Dead Centre and not in the balancing hole. Incorrect position Correct position
10
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.
10
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 Check that there is always a clearance of 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).
10
Position reference (8) of the exhaust camshaft pulley opposite the thread (9) of the exhaust camshaft sensor.
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 screwdriver, then turn the bolt of the accessories crankshaft pulley through an angle of 115 15. Incorrect position
10
15163S
15108S
Fit the tool for locking the camshaft pulleys Mot. 1535 (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 Mot. 1535 for locking the camshaft pulleys, and tool Mot. 1054 the Top Dead Centre pin. Checking the timing and the tension Checking the tension: Rotate the crankshaft through two revolutions in a clockwise direction (timing side), before the end of the two revolutions in other words, half a tooth before the exhaust camshaft reference and the camshaft sensor thread are aligned. Remove the Top Dead Centre pin.
10
Check that the references of the tensioning roller are correctly aligned, otherwise repeat the tensioning operation. Slacken the nut of the tensioning roller by a maximum of one turn, holding it with a 6 mm Allen key. Align the references of the tensioning roller and tighten the nut finally to a torque of 2.8 daN.m. 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,
10
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,
10
15578-3S
the accessories belt. To position the belt, pivot the key to the right. Block the tensioner using a 6 mm Allen key (1).
NOTE: when fitting the belt it is essential to ensure that the tooth (which corresponds to X) inside the pulleys remains "FREE".
15579-1R
The engine must be rotated through two revolutions in order to position the belt correctly.
10-101

Refit: the petrol high pressure pump (fitted with a new 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,
10
the rail and the ignition coil (check that the spark plug leads are not touching the inlet 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.
10
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,
10
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: - MEGANE: DA03 F5R 740 EA03

ENGINE AND PERIPHERALS

ENGINE AND PERIPHERALS 110 Cleanliness / Safety

ENGINE AND PERIPHERALS Cleanliness / Safety

INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

ENGINE AND PERIPHERALS Cleanliness / Safety

ENGINE AND PERIPHERALS Foreword

ENGINE AND PERIPHERALS Engine identification

Capacity Engine Suffix (cm 3 ) 1998

Bore (mm) 82.7

Compression ratio 11.5/1

ENGINE AND PERIPHERALS Tightening torques (in daN.m or in degrees)

(refer to tightening order) ** 3 plus an angle of 90 *

ENGINE AND PERIPHERALS Tightening torques (in daN.m or in degrees)

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications

0.65 0.02 mm.

Gasket face bow: Firing order 1 - 3 - 4 - 2. No rectifications are allowed.

ENGINE AND PERIPHERALS Specifications

Bearing width X (in mm) Inlet:

1.8 0.1 1.8 0.1

External diameter D (in mm) Inlet: Exhaust: 32.53 0.008 28.43

ENGINE AND PERIPHERALS Specifications

NOTE: do not oil the valve stem seals before fitting.

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications

Angle of the inlet and exhaust guides (in degrees) Inlet:

ENGINE AND PERIPHERALS Specifications

The camshaft can be identified with a marking (A).

ENGINE AND PERIPHERALS Specifications

Timing diagram (cannot be checked) Inlet camshaft Cam 1

ENGINE AND PERIPHERALS Specifications

The pin is free in the con rod and in the piston.

ENGINE AND PERIPHERALS Specifications

Position of the holes T on the cylinder block T = 13 mm

Reference of the class on the piston 2 or B

Piston diameter (mm) 82.680 0.007

ENGINE AND PERIPHERALS Specifications

two steel rails (1), a spring ring (2).

Rings Compression Sealing Scraper

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications

Burnished big end journals: nominal diameter (in mm)

0.04 to 0.075 The lateral shims are located on bearing n 2.

ENGINE AND PERIPHERALS Specifications

Cylinder block Fit tool Mot. 1493 on the cylinder block.

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications

The bearing shells are fitted using tool Mot. 1492.

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications

Clearance (B) (in mm): min max 0.020 0.086

ENGINE AND PERIPHERALS Specifications

ENGINE AND PERIPHERALS Specifications