vnx.su-clio-2.pdf

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77 11 197 289 DECEMBER 1997 Edition Anglaise

General

SPECIFICATIONS

LIFTING

TOWING

LUBRICANTS, CONSUMABLES

DRAINING, FILLING

BB0A - BB0C - BB0D - BB0E - CB0A - CB0C - CB0D - CB0E

VALUES AND SETTINGS

"The repair methods given by the manufacturer in this document are based on the

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TOWING All types

01

02

03 General

02-1 02-2 03-1 LUBRICANTS CONSUMABLES Packaging 04-1 DRAINING FILLING Engine Gearbox

Power assisted steering

04

05

05-1 05-3 05-4

VALUES AND SETTINGS Dimensions

Capacity - Grades Belt tension

Accessories belt tension Timing belt tension

Tightening the cylinder head Wheels and Tyres

Brakes Brake limiter Underbody heights

Values for checking the front axle geometry

Values for checking the rear axle geometry

07

07-1 07-2 07-5 07-7 07-12 07-13 07-15 07-16 07-17 07-18 07-20 07-21 Page

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The CLIO Workshop Repair Manual has been prepared by repair and diagnostic methods

specialists.

The document contains the methods and diagnostic procedures required in order to obtain

high quality repairs on this vehicle.

However, if removal - refitting involves no special features, difficulties or special tooling

re-quirements, then the method is considered to be very simple for a car repair specialist and

is not described in the manual.

The labour times are the result of operations timings carried out in real time in our

works-hops, even though certain methods are not described in the Workshop Repair Manual.

UNITS OF MEASUREMENT

• All dimensions are given in millimetres (

m m

) unless otherwise indicated.

• Tightening torques are given in deca Newton metres (

daN.m

).

• Pressures are in

bars

(reminder:

1 bar = 100 000 Pa

).

• Electrical resistance values are in ohms (

Ω

).

• Voltages are in Volts (

V

).

TOLERANCES

The following tolerances must be observed for tightening torques given without

tole-rance:

• In

degrees

:

± 3°

.

• In

daN.m

:

± 10 %

.

EQUIPMENT AND TOOLING

The repair methods described for vehicles made by RENAULT require special equipment

and tooling in some cases. A wide range of such items may be found in the specialist

equip-ment and tooling catalogues.

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SPECIFICATIONS

Engine- Clutch - Gearbox

01

Vehicle type

Engine

Type Capacity

(cm3)

Clutch type Manual gearbox type

B/C B0A D7F 1149 180 CP 3300 B/C B0C E7J 1390 180 CP 3300 B/C B0D K7M 1598 200 CPOV 3500 B/C B0E F8Q 1870 200 CPOV 3250 VEHICLE IDENTIFICATION Example : BB0A

B : Body type (5 doors) B : Project code

0A : Engine suffix

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SPECIFICATIONS

Vehicle identification

01

LOCATION OF VEHICLE IDENTIFICATION PLATE

e0-00/00-0000-000-000-00

VF000000000000000

0000 kg

1 -

0000 kg

2 -

0000 kg

000000000000000

RENAULT S.A.

1

2

3

4

5

8

7

6

9

10

13

12

11

1 The type mines of the vehicle and the serial number

2 MTMA (Maximum permitted all up weight) 3 MTR (Maximum permitted total train weight

-vehicle loaded with trailer) 4 MTMA front axle

5 MTMA rear axle

6 The technical features of the vehicle 7 The paint code

8 The equipment level 9 The vehicle type 10 The trim code

11 Additional equipment definition 12 Fabrication number

13 The interior matching trim code

13491R2

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LIFTING

Trolley jack - Axle stands

AXLE STANDS

When putting the vehicle on axle stands, they must be positioned:

- either under the reinforcements provided for lifting the vehicle with its jack,

- or under the jacking points located behind the reinforcements.

The axle stands are positioned at the rear by lifting the vehicle at the side.

02

Safety symbol (special precautions to be taken when carrying out operations).

SPECIAL TOOLING REQUIRED

Cha. 280 -02 Adaptable cross piece for trolley jack Cha. 408 -01

or Adaptable socket for trolley jack Cha. 408 -02

If a trolley jack is used, appropriate axle stands must always be used.

It is forbidden to lift the vehicle by supporting its weight under the front suspension arms or under the rear axle assembly.

Depending on the type of trolley jack, use sockets Cha. 408-01 or Cha. 408-02 in order to fit the cross piece Cha. 280-02.

To lift at the front or the rear, take the weight under the vehicle jacking points.

TROLLEY JACK AT THE SIDE Use the cross piece Cha. 280-02.

Take the weight under the sill, level with the front door.

Position the sill flange correctly in the cross piece groove.

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LIFTING

Vehicle lifts

02

SAFETY INSTRUCTIONS

Various cases may be considered:

1 - REMOVING COMPONENTS

In general, never use a 2 post lift whenever a 4 post lift may be used.

If this cannot be avoided, place lifting pads underneath the sill flange, level with the vehicle jacking points.

2 - REMOVING - REFITTING THE ENGINE AND TRANSMISSION ASSEMBLY

In these cases, the vehicle body must be secured to the arms of the 2 post lift using special pads.

98703S

FRONT

98704S

REAR

These must be placed underneath the vehicle jacking points. They must click into the slots in the sill flanges.

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TOWING

All types

FRONT

03

OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN. NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.

The towing points may only be used for towing the vehicle on the road. They should never be used for remo-ving the vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either direct-ly or indirectdirect-ly.

REAR

13646S 13565S

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DESCRIPTION PACKAGING PART NUMBER 1 kg tin 100 g tube 80 ml tube 180 g sachet Aerosol 77 01 421 145 77 01 028 179 77 01 422 307 77 01 366 100 77 01 422 308 LUBRICANTS

LUBRICANTS CONSUMABLES

Packaging

04

• MOLYKOTE "BR2"

for main bearing journal faces, thrust pad guide tubes, clutch fork pads, lower

suspension arm bearings, torsion bar splines, steering rack, driveshaft splines.

• MOLYKOTE "33 Medium"

tubular rear axle bushes anti-roll bar bushes.

• ANTI-SEIZE

(high temperature grease) Turbo etc.

• "MOBIL CVJ" 825 Black star or MOBIL EXF57C

for driveshaft joints

• MULTIPURPOSE LUBRICANT

wheel sensor

• Perfect-seal "LOWAC"

coating fluid for seals.

• Mastic

for sealing exhaust pipe unions.

• RHODORSEAL 5661

• HARDENER KIT (RHODORSEAL 5661) for sealing sides of bearing caps • AUTO joint blue

sealing paste. 100 g tube 1.5 kg tin 100 g tube Kit 100 g tube 77 01 417 404 77 01 421 161 77 01 421 042 77 01 404 452 77 01 421 080 77 01 396 227 MECHANICAL SEALANTS

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DESCRIPTION PACKAGING PART NUMBER 24 cc bottle 24 cc bottle 24 cc bottle 50 cc bottle 77 01 394 070 77 01 394 071 77 01 394 072 77 01 400 309 ADHESIVES

LUBRICANTS CONSUMABLES

Packaging

04

• "LOCTITE - FRENETANCH"

stops bolts slackening and allows them to be released

• "LOCTITE - FRENBLOC"

locks bolts

• "LOCTITE SCELBLOC"

for bonding bearings

• "LOCTITE AUTOFORM"

for bonding the flywheel to the crankshaft

LUBRICANT CLEANING AGENTS

Aerosol - 150 g 300 ml can 355 ml can Aerosol - 500 ml Aerosol Aerosol - 400 ml 77 01 408 464 77 11 171 437 77 01 423 189 77 01 408 466 77 01 405 952 77 11 170 801 • "NETELEC" unseizes, lubricates • Carburettor cleaner • Injector cleaner

• Super concentrated unseizing agent • "DECAPJOINT " (FRAMET) for cleaning the

gasket faces of aluminium cylinder heads • Brake cleaner MECHANICAL SEALANTS 77 01 422 750 77 01 421 162 77 11 143 071 100 g tube 24 ml syringe Aerosol

• AUTO joint grey

sealing paste.

• LOCTITE 518

for sealing the gearbox housing.

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DESCRIPTION PACKAGING PART NUMBER

LUBRICANTS CONSUMABLES

Packaging

04

• "CIRCUIT PLUS"

varnish for repairing heated screens • "CONTACT PLUS"

varnish for repairing rear screen supply termi-nals Bottle Kit 77 01 421 135 77 01 422 752 VARNISHES BRAKES

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DRAINING - FILLING

Engine

E7J and K7M ENGINES

05

D7F ENGINE TOOLING REQUIRED Engine drain plug spanner

DRAINING: plug (1) 13367R FILLING: plug (2) 13369R 13642R 13567R

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DRAINING - FILLING

Engine

05

F8Q ENGINE

DRAINING: plug (1) FILLING : plug (2)

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DRAINING - FILLING

Gearbox

05

DRAINING: plug (1) FILLING: plug (2) D7F ENGINE 13369R1

E7J and K7M ENGINES

13367R1

F8Q ENGINE

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DRAINING - FILLING

Power assisted steering

05

CHECKING THE LEVEL

POWER ASSISTED STEERING PUMP LEVEL For topping up or filling, use ELF RENAULTMATIC D2 or MOBIL ATF 220 oil.

The level, when correct, should be visible between the MIN and MAX marks on the reservoir (1).

D7F - E7J - K7M and F8Q ENGINES

12422R1

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VALUES AND SETTINGS

Dimensions

07

13491R3

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Other countries 0 °C +30 °C -30 °C -20 °C -10 °C +10 °C +20 °C -15 °C API SH/SJ API SH/SJ API SH/SJ API SH/SJ API SH/SJ

Oil for fuel economy: API SJ-IL SAC GF2 standard

15W40-15W50 10W40-10W50 10W30 5W30 5W40-5W50 E.E.C. countries 0 °C +30 °C -30 °C -20 °C -10 °C +20 °C -15 °C +25 °C ACEA A2/A3 ACEAA1*/A2/A3 ACEA A1*/A2/A3 ACEA A1*/A2/A3 +10 °C

ACEA A1-98 standard

Except turbo - biturbo - F7R - F7P * Oil for fuel economy

15W40-15W50

10W30-10W40-10W50

0W30-5W30

0W40-5W40-5W50

VALUES AND SETTINGS

Capacity - Grades

07

Components When draining 3.5 3.7 (1) 2.7 2.9 (1) 3.5 3.7 (1) Capacity in litres (approx.)* Petrol engine (oil) D7F E7J K7M

* Check with the dipstick (1) After replacing the oil filter

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VALUES AND SETTINGS

Capacity - Grades

07

When draining 4.7 5.2 (1) Diesel engine (oil) F8Q

* Check with the dipstick (1) After replacing the oil filter

Components Capacity in litres (approx)* Other countries 0 °C +30 °C -30 °C -20 °C -10 °C +10 °C +20 °C -15 °C +15 °C API CF API CF API CF API CF 15W40-15W50 10W40-10W50 10W30 5W40-5W50 E.E.C. countries 0 °C +30 °C -30 °C -20 °C -10 °C +20 °C -15 °C +25 °C ACEAB2/B3 ACEAB2/B3 ACEAB2/B3 ACEAB2/B3 +10 °C

ACEA B1 oils must never be used for diesel engines. 15W40-15W50 10W40-10W50 5W30 5W40-5W50 Grade

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VALUES AND SETTINGS

Capacity - Grades

07

Manual gearbox

Components Capacity

in litres Grade Notes

JB1 3.4

Brake circuit Brake fluids must be approved by the Technical Department

SAE J 1703 and DOT 4

All countries: TRANSELF TRX 75 W 80 W ( API GL5 or MIL-L 2105 C or D standards)

Normal : 0.7 ABS : 1 Fuel tank approx.

50 Unleaded petrol / diesel Separate reservoir 1.1 Cooling circuit D7F E7J and K7M F8Q -GLACEOL RX (type D) Only add coolant

of the same type 5

5.5 7.4 Power assisted

steering

-ELF RENAULT MATIC D2 or

MOBIL ATF 220

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-VALUES AND SETTINGS

Belt tension

07

96601R

SPECIAL TOOLING REQUIRED Mot. 1273 Tool for checking belt tension

A Sensor B Display

C Connecting cable

D Calibration checking plate

Principle

The sensor, through the adjusting button (1), the pressure device (2) and the outer lugs (3), applies a constant force to the belt.

The reaction from the belt is measured using a test piece (4) fitted with strain gauges.

Any movement on the gauges creates a variation in their electrical resistance. This variation, once it has been converted by the device, is displayed in SEEM units (US).

Calibrating the device

The device is set in the factory; however it must be recalibrated every six months.

Procedure Resetting to zero:

- switch the device on (button E) with the adjus-ting button (1) fully screwed in,

- if 0 is displayed, do not touch anything, - if nothing is displayed, check the condition of

the 9 volt battery in the device ,

- if a value other than 0 is displayed, adjust screw (F) until 0 is obtained.

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VALUES AND SETTINGS

Belt tension

07

Checking the calibration Switch the device on (button E).

Position the calibration spring plate (Z) on the sensor as shown on the diagram (control value engraved to-wards the top, (A) minimum value, (B) maximum value).

Tighten the adjusting button (1) until it goes "CLICK - CLICK - CLICK". Check that a value X between the values (A and B) (A ≤ X ≤ B) is displayed.

Note: it may be necessary to perform several preliminary tests in order to obtain the correct value. If the correct value if still not obtained after several attempts, contact SEEM.

NOTE : each device has its own calibration spring plate and they are not interchangeable.

96602R

SEEM

Contact your After Sales Head Office for further information.

GENERAL INSTRUCTIONS:

- Never refit a belt which has been removed, re-place it.

- Never retighten a belt for which the tension reading is between the fitting value and the minimum operating value.

- When checking, if the tension is below the mi-nimum operating value, change the belt. 1 Knurled button

A B

Z Calibration plate

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VALUES AND SETTINGS

Accessories belt tension

07

MULTI "V" BELT Tensioning process

Engine cold (ambient temperature). Fit the new belt.

Position the sensor of Mot. 1273.

Turn the wheel of the sensor until it disengages (three "CLICKS").

Tension the belt until the recommended fitting value is displayed on Mot. 1273 . Lock the tensioner, check it, adjust the value.

Turn the crankshaft over three times.

Check that the tension value is within the fitting tension tolerance, otherwise readjust it.

NOTE :

Never refit a belt which has been removed.

Replace the belt, if the tension is below the minimum operating tension. Small cuts or cracks do not mean that the belt has to be replaced.

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VALUES AND SETTINGS

Accessories belt tension

07

10071R2

A Crankshaft B Alternator

C Power assisted steering pump D Air conditioning compressor G Roller

T Tensioner

→ Point for checking belt tension ALTERNATOR BELT D7F ENGINE Tension (US=SEEM unit) Alternator belt multi "V" Power assisted steering belt multi "V" Air conditioning compressor belt multi "V" Air conditioning/ power assisted steering belt multi "V" Fitting 102 ± 7 96 ± 5 104±6 101±6

POWER ASSISTED STEERING BELT SPECIAL TOOLING REQUIRED

Mot. 1273 Tool for checking belt tension

97267R4

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VALUES AND SETTINGS

Accessories belt tension

07

13511R1

C Power assisted steering pump T Tension roller

→ Point for checking belt tension ALTERNATOR BELT E7J and K7M ENGINES Tension (US=SEEM unit) Alternator belt multi "V" Power assisted steering belt multi "V" Fitting 101 ± 6 106 ± 6 Minimum operating 52 59

13510R

Bolt A: alternator belt tension Bolt B: power steering belt tension

NOTE : after tensioning, tighten the nuts of bolts (A) and (B).

13363R1

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VALUES AND SETTINGS

Accessories belt tension

07

E7J and K7M ENGINES

14276R

The belt may be slackened and tensioned by means of bolt (A).

POWER ASSISTED STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT

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VALUES AND SETTINGS

Accessories belt tension

07

13512R ALTERNATOR BELT F8Q ENGINE Tension (US=SEEM unit) Alternator belt multi "V" Power assisted steering belt multi "V" Air conditioning compressor belt multi "V" Fitting 115 ± 5 116 ± 6 115 ± 6 Minimum 70 68 82

13509R

ALTERNATOR AND POWER ASSISTED STEERING BELT

C Power assisted steering pump D Air conditioning compressor T Tension roller

→ Point for checking belt tension

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VALUES AND SETTINGS

Timing belt tension

07

13361R

E7J and K7M engines Tensioning process

Engine cold (ambient temperature). Fit the new belt.

Position the sensor of Mot. 1273.

Turn the wheel of the sensor until it disengages (three "CLICKS").

Tension the belt until the recommended fitting value is displayed on Mot. 1273.

Lock the tensioner, check it and adjust the value. Turn the crankshaft over four times .

Check that the tension value is within the fitting tension tolerance (± 10%), otherwise readjust it by repeating the above operations.

NOTE :

- For the F8Q engine, remove the pin Mot 1054 before fitting the sensor of Mot 1273 and press hard on the piece of belt between the intermediate shaft sprocket (or idle sprocket) and the tension roller, then carry out the mea-surement.

- Never refit a belt which has been removed. - Replace the belt if the tension is below the

mi-nimum operating tension.

D7F engine

There are special notes for the timing belt tension of this engine. Therefore refer to section 11.

Belt tension (in SEEM units) Fitting: 30 U.S. ± 5 %

Minimum operating : 26 U.S. F8Q engine

13094R

Belt tension (in SEEM units) Fitting: 29 U.S. ± 5 %

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VALUES AND SETTINGS

Tightening the cylinder head

07

METHOD FOR TIGHTENING THE CYLINDER HEAD REMINDER:

To ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the cylinder head mounting holes.

All the cylinder head bolts must be systematically replaced after any removal. There is no cylinder head retightening operation.

Using engine oil, lubricate the threads and under the heads of the bolts.

2 7 6 1 0 1 8 4 5 9 3 D7F ENGINE Preseating the gasket

Tighten all the bolts to 2 daN.m, then angle tigh-ten to 90° in the order indicated below.

Wait 3 minutes settling time. Tightening the cylinder head:

- The cylinder head is tightened in stages, ap-plying the following procedure successively to bolts 1-2 then 3-4, 5-6, 7-8 and 9-10.

- Slacken bolts 1-2 until they are completely free. - Tighten bolts 1-2 to 2 daN.m, then angle

tigh-ten to 200°.

- Repeat the slackening and re-tightening opera-tion for bolts 3-4, 5-6, 7-8 and 9-10.

90775S

E7J ENGINE Preseating the gasket

Tighten all the bolts to 2 daN.m, then angle tigh-ten to 97°± 2° in the order indicated below.

2 7 6 1 0 1 8 4 5 9 3 90775S

tigh-ten to 97°± 2°.

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VALUES AND SETTINGS

Tightening the cylinder head

07

K7M ENGINE Preseating the gasket

Tighten all the bolts to2daN.m,then angle tigh-ten to 100°± 6° in the order indicated below.

tigh-ten to 110°± 6°.

2 7 6 1 0 1 8 4 5 9 3 F8Q ENGINE Preseating the gasket

Tighten all the bolts to 3 daN.m, then angle tigh-ten to 80°± 4° in the order indicated below.

- Slacken bolts 1-2 until they are completely free. - Tighten bolts 1-2 to 2.5 daN.m, then angle

tigh-ten to 213°± 7°.

90775S 2 7 6 1 0 1 8 4 5 9 3 90775S

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VALUES AND SETTINGS

Wheels and tyres

07

Vehicle Rim Tyres

Cold inflation pressure (in bars) (1) Front Rear B/C B0A 2.2 2.1 B/C B0C 2.3 2.1 B/C B0D 5 B 13 5,5 J 14 165/70 R 13 T 165/60 R 14 T 165/65 R 14 T 2.4 2.1 B/C B0E 5 B 13 165/70 R 13 T 175/70 R 13 T (2) 2.3 2.1 (1) Fully laden and motorway use.

(2) With air conditioning.

Wheel nuts tightening torque : 9 daN.m Rim run-out : 1.2 mm

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VALUES AND SETTINGS

Brakes

07

Vehicle

Drum diameter or disc thickness (in mm)

Front

Normal Min.

Rear

Normal Max. (1)

Max. disc run-out (in mm)

Front Rear

B/C B0A 12 no ABS 10.5 no ABS 180.25 181.25 0.07

-B/C B0E B/C B0C B/C B0D 12 no ABS 20 with ABS 10.5 no ABS 17.7 with ABS 203.2 204.2 0.07 -B/C B0E (2) (3) B/C B0D (2) 20.6 17.6 203.2 204.2 0.07

-(1) Drum: maximum wear diameter.

(2) With ABS and without underbody protection. (3) With air conditioning.

(1) Primary lining. (2) Secondary lining.

Vehicle

Lining thickness (in mm) (including backing plate)

Front New Min. Rear New Min. Brake fluid B/C B0A 18.2 6 4.85 2 SAE J1703 DOT 4 B/C B0C 18.2 6 4.6 (1) 3.3 (2) 2 SAE J1703 DOT 4 B/C B0E 18.2 6 4.6 (1) 3.3 (2) 2 SAE J1703 DOT 4 B/C B0D 18.2 6 4.6 (1) 3.3 (2) 2 SAE J1703 DOT 4

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VALUES AND SETTINGS

Brake limiter

07

Vehicle Fuel tank level

(driver aboard)

Test pressure (1) (in bars)

Front Rear B/C B0A B/C B0C B/C B0D B/C B0E 100 56 BRAKING PRESSURE 0 - 18 90966S

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VALUES AND SETTINGS

Underbody heights

07

Vehicle At the front

H1 - H2 = ... mm At the rear H4 - H5 = ... mm Dimension X (in mm) R-H and L-H B/C B0A B/C B0C 90.6 - 29 -B/C B0D 98.2 - 23 -B/C B0E 96 - 23 -Tolerance : ± 10.5 mm

The difference between the right-hand side and the left-hand side on the same axle of a vehicle must not ex-ceed 5 mm, with the driver’s side always being the higher.

Any work carried out on the underbody height requires adjustment of the brake limiter and of the hea-dlights.

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VALUES AND SETTINGS

Underbody heights

07

13491R4

NOTE : dimension H5 is measured from the axis of the rubber bush. MEASURING POINTS

(36)

NOT ADJUSTABLE NOT ADJUSTABLE H1-H2 = 17 mm H1-H2 = 89 mm H1-H2 = 115 mm H1-H2 = 179 mm H5-H2 = 32 mm H5-H2 = 51 mm H5-H2 = 70 mm H5-H2 = 89 mm 8°30’ 10°50’ 11°20’ 12°00’

Maximum left / right difference = 1°

4° 3°30’ 3° 2°30’

Maximum left / right difference = 1° H1-H2 = 17 mm H1-H2 = 89 mm H1-H2 = 115 mm H1-H2 = 179 mm 93011-1S 93014-1S 93013-1S 93012-1S

VALUES AND SETTINGS

Values for checking the front axle geometry

07

UNLADEN NOT ADJUSTABLE CAMBER VALUES CASTOR E7J/K7M D7F F8Q 0°16’ 0°54’ - 1°10’ - 0°25’ - 1°20’ - 0°34’ - 0°45’ 0°05’ Maximum left / right

difference = 1°

ADJUSTMENT POSITION OF

FRONT AXLE

KING PIN INCLINATION

PARALLELISM RUBBER BUSHES Adjustable by rotating track rod sleeves. 1 turn= 30’ (3 mm) (For 2 wheels) toe-out + 0°16’ ± 20’ + 1.6 mm ± 2 mm ANGLES UNLADEN - -±30’ ±30’ ±30’ ±30’

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(For 2 wheels) Toe-in - 30’ ± 30’ - 3 mm ± 3 mm - 0°42’ ± 20’ NOT ADJUSTABLE 93013-2S 93011-2S 81603S1

VALUES AND SETTINGS

Values for checking the rear axle geometry

07

UNLADEN CAMBER

VALUES

PARALLELISM ANGLES

UNLADEN NOT ADJUSTABLE

UNLADEN - -RUBBER BUSHES POSITION OF REAR AXLE ADJUSTMENT

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77 11 197 366 DECEMBER 1997 Edition Anglaise

Engine and Peripherals

ENGINE AND PERIPHERALS

TOP AND FRONT OF ENGINE

FUEL MIXTURE

FUEL SUPPLY

-DIESEL EQUIPMENT

ANTIPOLLUTION

STARTING - CHARGING

IGNITION - INJECTION

COOLING EXHAUST FUEL TANK

-SUSPENDED ENGINE MOUNTINGS

BB0A - BB0C - BB0D - BB0E - CB0A - CB0C - CB0D - CB0E

"The repair methods given by the manufacturer in this document are based on the

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(40)

11 Engine and

peripherals

11-1 11-11 11-29 ENGINE AND PERIPHERALS

10

FUEL SUPPLY

-DIESEL EQUIPMENT Fuel supply

Fuel cut out on impact Fuel gallery Fuel filter Pump flow Fuel pressure Antipercolation device Diesel equipment General Specifications Location of components Advance solenoid valve Altimetric corrector Fast idle LDA

Coded solenoid valve Load potentiometer Computer configuration Injector with sensor (needle lift)

Injection warning light Pre-postheating control Fast idle control

Injection/air conditioning programming Computer Defect modes Micrometric pulley Pump Pump - Timing

Pump - Checking the timing Pump - Adjusting the timing Adjusting the idle speed Unions 13-1 13-2 13-6 13-7 13-8 13-11 13-12 13-13 13-15 13-18 13-21 13-24 13-25 13-27 13-31 13-33 13-34 13-35 13-37 13-38 13-39 13-40 13-41 13-43 13-45 13-46 13-48 13-52 13-53

13

FUEL MIXTURE Specifications Throttle body Inlet manifold Exhaust manifold Inlet-exhaust manifolds 12-1 12-10 12-12 12-15 12-17

12

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Page

Cooling Specifications Filling and bleeding Testing

Water pump Diagram Exhaust General

Exhaust pipe assembly Fuel tank

Fuel tank Sender unit

Pump and sender unit assembly Engine mountings

Suspended engine mountings

19-1 19-2 19-3 19-4 19-6 19-10 19-12 19-14 19-23 19-24 19-26 COOLING EXHAUST FUEL TANK -ENGINE SUSPENSION

19

16-1 16-9 STARTING - CHARGING Alternator Starter motor

16

IGNITION - INJECTION Ignition Static ignition Spark plugs Injection General Location of components

Centralised coolant temperature management

Injection fault warning light Immobiliser function Computer configuration depending on gearbox type

17

14-1 14-2 14-7 14-11 ANTIPOLLUTION

Test for the presence of lead Fuel vapour rebreathing Oil vapour rebreathing Exhaust gas recirculation (EGR)

14

17-16 17-17 17-18 17-19 17-21 IGNITION - INJECTION (continued) Injection/air conditioning programming

Idle speed correction Adaptive idle speed correction

Richness regulation

Adaptive richness correction

17

Page 17-1 17-3 17-4 17-8 17-12 17-13 17-14 17-15

Identification

ENGINE AND ENGINE PERIPHERALS

Consumables

10

Type Quantity Components

RHODORSEAL 5661 Coat Driveshaft roll pin holes

Loctite FRENBLOC

Locking and sealing resin Coat Brake caliper mounting bolts Loctite FRENETANCH

Locking and sealing resin Coat Crankshaft pulley mounting bolts

Exhaust pipe paste Coat For sealing the exhaust

Vehicle type Engine Manual

gearbox Capacity (cm3₎ Bore (mm) Stroke (mm) Ratio B/C B0A D7F 720 JB1 1 149 69 76.8 9.65/1 B/C B0C E7J 780 JB1 1 390 75.8 77 9.5 /1 B/C B0D K7M 744 JB1 1 598 79.5 80.5 9.5 /1 B/C B0E F8Q 630 JB1 1 870 80 93 21.5 /1

Engine Workshop Repair Manuals to be consulted depending on the type of engine:

D7F E7J K7M F8Q Mot. D X Mot. E X Mot. K X Mot. F (D) X Engine Document

(43)

ENGINE AND ENGINE PERIPHERALS

Oil consumption

10

OIL CONSUMPTION MEASUREMENT PROCEDURE a) Filling to the maximum level

The operation must be carried out with the engine hot (cooling fan cutting in once) and after settling for 15 minutes to allow all the oil to drain into the sump.

Check visually using the dipstick. Top up to the maximum level.

Seal the drain plug (with a paint mark on both the filler plug and the sump’s drain plug) in order to be able to check later that it has not been removed.

b) Customer driving

Ask the customer to drive the vehicle for a period corresponding to about 1250 miles (2,000 km) or before the minimum level is reached.

c) Refilling to the maximum level

The operation must be carried out with the engine hot (cooling fan cutting in once) and after a settling time of 15 minutes.

Check visually using the dipstick. Top up to the maximum level.

Note the quantity of oil and the mileage covered since the last filling to the maximum level. d) Measurement of the oil consumption

Quantity of topping up oil (in litres) OIL CONSUMPTION =

(44)

87363R1

ENGINE AND ENGINE PERIPHERALS

Oil pressure

10

SPECIAL TOOLING REQUIRED Mot. 836-05 Oil pressure measuring kit

EQUIPMENT REQUIRED 22 mm long socket

CHECKING

The oil pressure should be checked when the en-gine is warm (approximately 80°C).

Contents of kit Mot. 836-05.

USE ENGINE CHECKING D7F engine Idling 0.8 bar 4 000 rpm. 3.5 bars E7J / K7M engines Idling 1 bar 3 000 rpm. 3 bars F8Q engine 1 000 rpm. 1.2 bar 3 000 rpm. 3.5 bars

D engine E engine F engine

(45)

ENGINE AND ENGINE PERIPHERALS

Engine - Gearbox

10

REMOVAL

Put the vehicle on a two post lift.

Remove the battery and the engine undertray. Drain:

- the cooling circuit (bottom hose of the radiator),

- the gearbox and engine oil (if necessary), - the air conditioning circuit (if fitted) using a

filling station. Remove:

- the wheels, - the air intake pipe,

- the expansion bottle and fix it to the engine.

Brake caliper guide bolt 4

Shock absorber base bolts 18

Driveshaft gaiter mounting bolt 2.5 Left-hand suspended engine mounting bolt

on gearbox 6.2

Left hand suspended engine mounting bolt on

body 2.1

Right hand suspended engine mounting bolt on

engine 6.2

Right hand suspended engine mounting bolt on

body 6.2

Wheel bolt 9

TIGHTENING TORQUES (in daN.m)

B. Vi. 31-01 Set of three punches for roll pins

Mot. 1202 Hose clip pliers

Mot. 1448 Hose clip pliers extension Mot. 1273 Tool for checking belt tension Mot. 1311-06 Tool for removal of fuel pipe Mot. 1379 Tool for retaining engine on

sub-frame

T. Av. 476 Ball joint extractor

EQUIPMENT REQUIRED Load positioner D7F engine

(46)

ENGINE AND ENGINE PERIPHERALS

Engine - Gearbox

Left-hand side of the vehicle Remove:

- the brake caliper mounting bolt then fix it to the shock absorber spring,

- the three driveshaft gaiter mounting bolts, - the track rod end using tool T. Av. 476, - the shock absorber base bolts.

Tilt the hub to disconnect the driveshaft from the gearbox.

Right-hand side of the vehicle Remove:

- the driveshaft roll pins with the punches B. Vi. 31-01,

- the brake caliper mounting bolt then fix it to the shock absorber spring,

- the track rod end using tool T. Av. 476, - the shock absorber base bolts.

Tilt the hub to disconnect the driveshaft from the gearbox.

Remove the earth strap mounting bolt (gearbox side).

10

(47)

ENGINE AND ENGINE PERIPHERALS

Engine - Gearbox

- the relay board (4), the connector (5) and the fuse mounting (6) by removing the fuse hol-ders (7),

10

Disconnect the gear selector rod at the gearbox, after releasing the gaiter.

93912R1

Slacken bolt (A) without removing it and remove bolt (B) from the engine tie-bar.

92661R1

Disconnect:

- the accelerator cable, - the canister pipe,

- the brake servo vacuum pipe, - the upper hose on the radiator,

13034R

13085R

- the heater hose (there are two types of assem-bly to be disconnected as shown in the dia-grams below),

(48)

ENGINE AND ENGINE PERIPHERALS

Engine - Gearbox

10

13084R

- the connectors of the oxygen sensor and fan, - the fuel pipes.

Remove:

- the injection computer support plate having disconnected the 55 track connector and the impact switch connector,

13088R2

- the AC pipe mountings (if fitted), and the flange (8) and rest the assembly on the en-gine,

14174R

- the power assisted steering pipe mountings on the engine,

- the power assisted steering pump belt, - the power assisted steering pulley, - the power assisted steering pump bolts. Release the power assisted steering pump unit. Attach the load positioner to the engine lifting rings.

99893S

(49)

ENGINE AND ENGINE PERIPHERALS

Engine - Gearbox

10

- the mounting bolts (2) of the engine rubber mounting pad (1).

Note the position of the engine mounting pad(1) in relation to the body.

REFITTING (Special notes)

Refitting is the reverse of removal.

Tighten the suspended engine mounting bolts to the recommended torque (see section 19

"Suspended engine mounting").

Put RHODORSEAL 5661 on the driveshaft roll pin hole.

Press the brake pedal several times to bring the pistons into contact with the brake pads. Refit the power assisted steering pump belt (see section 07 "Accessories belt tension").

Carry out the following operations: - fill the gearbox with oil,

- top up the engine oil level (if necessary), - fill and bleed the coolant circuit (see section

19 "Filling and bleeding").

12924R2 12924R1

Remove:

- the gearbox side support,

Remove the engine and transmission assembly after taking the power assisted steering unit out of the engine compartment and protecting the radiator.

(50)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

REMOVAL

- the coolant circuit (disconnect the lower radiator hose ),

- the gearbox oil (if necessary), - the engine oil (if necessary). Remove:

- the wheels, - the air intake pipe,

- the upper radiator mountings,

- the expansion bottle and fix it to the engine, - the power assisted steering fluid reservoir,

and secure it onto the engine.

Track rod end 3.7

Front sub-frame mounting bolt 6.2 Rear sub-frame mounting bolt 10.5 Driveshaft gaiter mounting bolt 2.5 Mounting nut for rubber engine mounting pad on left suspended engine mounting 6.2 Mounting bolt for front right suspended

engine mounting on the engine 6.2 Mounting bolt for front right suspended

engine mounting on the body 6.2

Steering shaft yoke bolt 2.5

Wheel bolt 9

SPECIAL TOOLING REQUIRED B. Vi. 31-01 Set of punches for roll pins Mot. 1040-01 Dummy sub-frame for

removing and refitting engine and transmission assembly Mot. 1202 Hose clip pliers

Mot. 1448 Hose clip pliers extension Mot. 1311-06 Tool for removing the fuel

pipe

Mot. 1379 Tool for retaining engine on sub-frame

T. Av. 476 Ball joint extractor

T. Av. 1233-01 Tool for sub-frame and axle assembly

(51)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

Disconnect: - the accelerator, - the canister pipe, - the brake servo pipe,

- the oxygen sensor connector, - the fuel pipes,

- the relay board (4), the connector (5) and the fuse mounting (6) by removing the fuse holders (7),

10

13034R

- the heater hoses (there are two types of as-sembly which must be disconnected as shown in the diagrams below),

13085R

13084R

Remove:

- the shock absorber base bolts , - the steering shaft yoke bolt.

SPECIAL NOTES FOR VEHICLES FITTED WITH DRIVER’S AIR BAG

Remove:

- the tie-rods between sub-frame and body, - the earth strap mounting bolt on the body

side,

- the exhaust downpipe mountings. D7F ENGINE

WARNING

In order to avoid any risk of damage to the rotary switch beneath the steering wheel, the following instructions should be followed:

• Before disconnecting the steering column from the rack, the steering wheel MUST be immobi-lised with the wheels straight with the aid of a "steering wheel lock" throughout the opera-tion.

• If there is any doubt about the rotary switch being properly centred, the steering wheel must be removed in order to apply the centring method described in the Technical Note cove-ring the 2nd generation air bag.

REMINDER: this kind of work must only be carried out by properly trained and qualified staff.

(52)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

14174R

- the AC pipe mountings (if fitted) and the flange (8) and rest the assembly on the en-gine,

14215R2

- the heat shield (A) and the gearbox selector rod.

Fit tool Mot. 1379 onto the sub-frame and take the weight off the right-hand engine mounting, using the threaded rod (1).

10267R1

Fit tool Mot. 1040-01 under the sub-frame having already fitted the shims Mot. 1379 onto this tool. Insert a wooden block between the gearbox and the sub-frame.

Diagram showing the holes drilled in tool Mot. 1040-01 (dimensions in mm).

10621R

(53)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

92442-1R2

Remove:

- the gearbox suspended engine mounting nut, then tap it with a copper hammer to release the suspended engine mounting stud, - the suspended engine mounting bolts on the

engine.

Lower the lift until the tool touches the ground.

Remove the four mounting bolts of the sub-frame.

Take out the engine and transmission assembly by lifting the body.

98755R

REFITTING (Special notes)

Use tool T. Av. 1233-01 to position the engine and transmission assembly in relation to the body. Refitting is the reverse of removal.

Correctly refit the heat shields.

Tighten the suspended engine mounting nuts and bolts to the correct torque (see section 19

"Suspended engine mounting").

Apply Rhodorseal 5661 to the driveshaft roll pin hole.

Press the brake pedal several times to bring the pistons into contact with the brake pads. Fill:

- the gearbox with oil (if necessary), - the engine with oil (if necessary),

- the cooling circuit and bleed it (see section 19 "Filling and bleeding").

(54)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

Front sub-frame mounting bolt 6.2 Rear sub-frame mounting bolt 10.5 Mounting bolt for front right suspended engine mounting cover on engine 6.2 Mounting nut for front right suspended

engine mounting cover 4.4

Mounting nut for rubber engine mounting pad on front left-hand side member support 6.2

Steering shaft yoke bolt 3

Wheel bolt 9

REMOVAL

- the cooling circuit through the lower hose on the radiator,

- the gearbox and the engine (if necessary), - the air conditioning circuit (if fitted) using a

- the front wheels and the wheel arch protec-tors,

- the radiator grille, - the front bumper,

- the tie-rods between sub-frame and body, - the brake calipers (and the ABS sensors if

fit-ted) and attach them to the suspension springs,

- the shock absorber base bolts,

- the heat shield (A) and the geabox selector rod,

14215R3

- the exhaust pipe clamp (B) between the cata-lytic converter and the expansion chamber, - the earth strap on the gearbox,

- the front bumper,

- the air intake pipe from the air filter, SPECIAL TOOLING REQUIRED

Mot. 1040-01 Dummy sub-frame for removing and refitting engine and

transmission assembly

Mot. 1159 Tool for retaining engine on sub-frame

Mot. 1202 Hose clip pliers E7J and K7M

(55)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

- the injection computer support after dis-connecting the 55 track connector and that of the impact switch.

13088R2

Disconnect:

- the hoses on the expansion bottle, - the brake servo pipe,

- the heater hoses (there are two types of as-sembly which must be disconnected as shown in the diagrams below),

13084R

13085R

- the fuse mounting (4) by removing the moun-ting (5) and the relay board (6) and the connector (7),

14176R

- the canister pipe on the solenoid valve, - the accelerator and clutch cables.

Unclip the power assisted steering reservoir and place it on the engine.

(56)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

14174R

Remove:

- the air filter assembly and disconnect fuel in-jection pipes on the gallery ,

- the accelerator and clutch cables,

- the upper mountings of the radiator and at-tach it to the engine,

- the AC pipe mountings (if fitted) and the flange (8) and rest the assembly on the en-gine,

- the nut and the eccentric bolt of the steering shaft yoke, after pushing back the guard.

99024R2

Fit tool Mot. 1159 between the sub-frame and the cylinder block.

Insert a shim between the multi-function support and the sub-frame.

14172S

WARNING

In order to prevent any risk of damage to the ro-tary switch beneath the steering wheel, the follo-wing instructions should be observed:

• Before disconnecting the steering column and the rack, the steering wheel MUST be immobi-lised with the wheels straight, using a "stee-ring wheel lock", throughout the operation. • If there is any doubt that the rotary switch is

properly centred, the steering wheel must be removed in order to apply the centring method described in section 88 "Air bag".

(57)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

Remove the suspended engine mounting cover.

13359R

Insert a shim between the gearbox and the sub-frame.

Remove:

- the nut (1), then tap it with a copper hammer to release the suspended engine mounting stud,

13086R

- the tie rods (3).

14175R

Fix tool Mot. 1040-01 underneath the sub-frame.

98755R1

Lower the lift until the tool touches the ground. Remove the sub-frame mounting bolts and take out the engine and transmission assembly by lif-ting the body.

NOTE : for any operation requiring separation of the engine, gearbox and sub-frame assembly, take care to mark the position of Mot. 1159 on the E7J and K7M

(58)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

REFITTING

The alignment of the sub-frame with the body will be made easier by positioning two threaded rods Mot. 1233-01 in the two front mountings of the sub-frame on the body.

Tighten the sub-frame mounting bolts to a torque of:

- 6.2 daN.m at the front, - 10.5 daN.m at the rear. Refitting is the reverse of removal. Fit the heat shields correctly.

Apply Loctite FRENBLOC to the caliper mounting bolts and tighten them to the recommended tor-que.

Press the brake pedal several times to bring the pistons into contact with the brake pads. Fill:

- the engine and gearbox with oil, if necessary, - the cooling circuit and bleed it (see section 19

"Filling and bleeding"). E7J and K7M

(59)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

Mot. 1040-01 Dummy sub-frame for removing and refitting engine and

transmission assembly

Mot. 1202 Hose clip pliers

Mot. 1448 Hose clip pliers extension Mot. 1311-06 Tool for removing fuel pipe

Front sub-frame mounting bolt 6.2 Rear sub-frame mounting bolt 10.5 Mounting bolt for front right suspended engine mounting cover on engine 6.2 Mounting nut for front right suspended

engine mounting cover 4.4

Mounting nut for rubber engine mounting pad on front left-hand side member support 6.2

Shock absorber base bolt 18

Wheel bolt 9

TIGHTENING TORQUES (in daN.m) - the heat shield (A) and the gearbox selector rod,

REMOVAL

- the cooling circuit through the lower hose on the radiator,

- the gearbox and the engine (if necessary), - the air conditioning circuit (if fitted) using a

- the front wheels,

- the tie-rods between sub-frame and body, - the brake calipers (and the ABS sensors if

fit-ted) and attach them to the suspension springs,

- the shock absorber base bolts,

14215R2

(60)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

- the exhaust downpipe, - the earth strap on the gearbox, - the front bumper,

- the air intake pipe from the air filter,

- the fuel supply and return unions (A) and (B), - the connectors (2), (3), (4) and (5).

Unclip the fuel pipes from the air filter unit and the timing cover and unclip the die-sel filter from its support and move the assembly to one side.

13083-1R

(61)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

Remove the computer support.

13088R1

Disconnect:

- the hoses on the expansion bottle, - the brake servo pipe,

- the heater hoses (there are two types of as-sembly to be disconnected, as shown in the diagrams below),

13085R 11734R

For the locking of the quick release unions, refer to the diagrams below:

11733R

(62)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

Remove:

- the upper mountings of the radiator and at-tach it to the engine,

- the nut and the eccentric bolt of the steering shaft yoke, after pushing back the guard, - the AC pipe mountings (if fitted) and the flange (8) and rest the assembly on the en-gine.

14174R

13084R

14176R

- the fuse mounting (4) by removing the nut (5) and the relay board (6) and the connector (7),

- the accelerator and clutch cables.

Unclip the power assisted steering reservoir and place it on the engine.

F8Q ENGINE

WARNING

In order to prevent any risk of damage to the ro-tary switch beneath the steering wheel, the follo-wing instructions should be observed:

• Before disconnecting the steering column and the rack, the steering wheel MUST be immobi-lised with the wheels straight, using a "stee-ring wheel lock", throughout the operation. • If there is any doubt that the rotary switch is

properly centred, the steering wheel must be removed in order to apply the centring method described in section 88 "Air bag".

(63)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

Remove the suspended engine mounting cover.

13086R1

13086R

Insert a shim between the gearbox and the sub-frame.

Remove the nut (1), then tap it with a copper hammer, to release the suspended engine moun-ting stud.

99024R2

Fit tool Mot. 1159 between the sub-frame and the cylinder block.

Fit tool Mot. 1159 in place of the coolant pipe mounting on the cylinder block.

99310R

(64)

ENGINE AND ENGINE PERIPHERALS

Engine and transmission assembly

10

REFITTING

The alignment of the sub-frame with the body will be made easier by positioning two threaded rods Mot. 1233-01 in the two front mountings of the sub-frame on the body.

Tighten the sub-frame mounting bolts to a torque of:

- 6.2 daN.m at the front, - 10.5 daN.m at the rear. Refitting is the reverse of removal. Fit the heat shields correctly.

Apply Loctite FRENBLOC to the caliper mounting bolts and tighten them to the recommended tor-que.

Press the brake pedal several times to bring the pistons into contact with the brake pads. Fill :

- the air conditioning circuit (if fitted), - the engine and gearbox (if necessary),

- the cooling circuit and bleed it (see section 19 "Filling and bleeding"),

- the power assisted steering circuit (if fitted). Fit tool Mot. 1040-01 under the sub-frame.

98755R1

Lower the lift until the tool touches the ground. Remove the sub-frame mounting bolts and take out the engine and transmission assembly by lif-ting the body.

NOTE : for any operation requiring separation of the engine, gearbox and sub-frame assembly, take care to mark the position of Mot. 1159 on the Remove the tie rods (3).

F8Q engine

(65)

ENGINE AND ENGINE PERIPHERALS

Sump

10

Sump bolt 1

Put the vehicle on a 2 post lift.

Disconnect the battery and remove the engine un-dertray.

Drain the engine. Remove:

- the oil level sensor using a 19 mm half-moon wrench,

- the gearbox - engine guard,

99900S

- the sump bolts.

Rotate the sump towards the rear of the vehicle in order to release the oil pump strainer from the sump partitioning.

Clean the sealing surfaces without scratching the aluminium.

REFITTING

Proceed in the reverse order of removal and fit a new gasket.

(66)

ENGINE AND ENGINE PERIPHERALS

Sump

10

Front sub-frame mounting bolt 6.2 Rear sub-frame mounting bolt 10.5

E7J and K7M sump bolt 1

F8Q sump bolt 1.5

Engine tie-bar bolt 6.2

Wheel bolt 9

REMOVAL

Disconnect the battery and remove the engine un-dertray.

Drain the engine. Remove:

- the front right hand wheel and thewheel arch protector,

- the nut and the eccentric bolt of the steering shaft yoke, after pushing back the guard, - the lower ball joint mountings and the track

rod ends for the E7J and K7M engines, - the tie-rods between sub-frame and body, - the gear control on the gearbox side, - bolt (1), and slacken engine tie-bar bolt (2),

without removing it,

SPECIAL TOOLING REQUIRED Mot. 1233-01 Threaded rods for lowering the

sub-frame

- the bumper lower mountings,

- the exhaust downpipe for the F8Q engine.

Special notes for the E7J and K7M engines Remove:

- the exhaust manifold heat shield, - the catalytic converter,

- the power assisted steering pipe mountings on the cylinder block and the multifunction mounting.

All engine types Remove:

- the tie rods (3),

- the sub-frame mounting bolts, inserting the threaded rods Mot. 1233-01 as you go. E7J/K7M & F8Q

ENGINES

(67)

ENGINE AND ENGINE PERIPHERALS

Sump

10

13507R1

E7J and K7M engines X1 = 9 cm X2 = 13 cm

Remove the sump.

F8Q engine

X1 = 7 cm X2 = 9 cm

Gradually lower the sub-frame with the aid of the threaded rods Mot. 1233-01 until dimensions X1 and X2. are reached approximately.

E7J/K7M & F8Q ENGINES

(68)

ENGINE AND ENGINE PERIPHERALS

Sump

10

REFITTING Clean the sump. E7J and K7M engines

Apply an approximately 3 mm wide bead of RHODORSEAL 5661 as shown in the diagram be-low.

99179S

E7J/K7M & F8Q ENGINES

Do not forget to replace the two half-moon gas-kets on each side of the sump.

F8Q engine

Fit a new after-sales gasket. Refitting is the reverse of removal.

(69)

ENGINE AND ENGINE PERIPHERALS

Crankshaft seal, timing end

10

Crankshaft output mounting bolt 2 + 90° Mounting bolt for front right suspended

engine mounting on the engine 6.2 Mounting bolt for front right suspended engine mounting on the body 6.2

Timing belt tension wheel nut 5

TIGHTENING TORQUES (in daN.m and/or °)

REPLACEMENT REMOVAL

Remove the timing belt (see section 11 "Timing belt").

Use tool Mot. 1374 to remove the crankshaft seal.

99787R

Screw the body of the tool into the seal using nut (1), then use bolt (2) to extract the seal.

SPECIAL TOOLING REQUIRED Mot. 1054 TDC pin

Mot. 1273 Tool for checking belt tension Mot. 1355 Tool for fitting pump seal Mot. 1374 Pump seal extractor

99788R

Refit the new timing belt (see the method descri-bed in section 11 "Timing belt").

D7F ENGINE

REFITTING

Refit the new seal onto the crankshaft output wi-thout damaging it when passing the timing sprocket drive groove.

(70)

ENGINE AND ENGINE PERIPHERALS

Oil pump

10

Crankshaft output mounting bolt 2 + 90° Mounting bolt for front right suspended

engine mounting on the engine 6.2 Mounting bolt for front right suspended engine mounting on the body 6.2

REMOVAL Remove:

- the timing belt (see method described in section 11 "Timing belt"),

- the oil level sensor using a 19 mm half-moon wrench,

- the oil dipstick,

- the crankshaft pulley and sprocket, - the engine flywheel guard.

Lift the engine and gearbox assembly with the aid of tool Mot. 1379.

Remove the sump bolts.

Rotate the sump towards the rear of the vehicle in order to release the oil pump strainer from the sump partitioning.

Remove:

- the oil pump strainer, - the oil pump.

Clean the sealing surfaces without scratching the aluminium.

SPECIAL TOOLING REQUIRED Mot. 1054 TDC pin

Mot. 1273 Tool for checking belt tension Mot. 1355 Tool for fitting oil pump

REFITTING

Replace the oil pressure seal (3).

99790R

(71)

ENGINE AND ENGINE PERIPHERALS

Oil pump

10

99788R

Apply a bead of RHODORSEAL 5661 to the sealing surface.

98964S

IMPORTANT: the oil pump is driven by two studs located on the crankshaft.

D7F ENGINE

Refit:

- the oil pump onto the engine and tighten it to a torque of 0.9 daN.m,

- the new seal onto the crankshaft output wi-thout damaging it when passing the timing sprocket drive groove.

Position it with the aid of tool Mot. 1355.

Refit the strainer with a new O-ring.

Clean the sealing surfaces (cylinder block, sump). Refit the sump.

Tighten the bolts to a torque of 1 daN.m. Refit:

- the timing belt (see method described in section 11 "Timing belt"),

- the new alternator and power assisted stee-ring pump belts (see tension values in section 07 "Accessories belt tension").

(72)

TOP AND FRONT OF ENGINE

Timing belt

REMOVAL

Put the vehicle on a two post lift. Disconnect the battery.

Remove :

- the front right hand wheel, - the accessories belts, - the crankshaft pulley.

11

10267R

Crankshaft accessories pulley

mounting bolt 2 + 90°

Mounting bolt for front right suspended engine mounting on engine 6.2 Mounting bolt for the right hand suspended

engine mounting on the body 6.2

Mot. 1054 TDC pin

Mot. 1135-01 Tool for tensioning timing belt

Mot. 1273 Tool for checking belt tension Mot. 1379 Tool for securing engine to

sub-frame

Mot. 1386 Tool for pre-tensioning the timing belt

Fit tool Mot. 1379. D7F ENGINE

(73)

TOP AND FRONT OF ENGINE

Timing belt

11

Remove the suspended engine mounting.

Use tool Mot. 1054 to pin the engine at TDC by ali-gning the crankshaft and camshaft sprocket mar-kings with the fixed marmar-kings.

12924S1

99795R

11463S

Remove the timing cover and the timing belt. IMPORTANT: The camshaft sprocket bears five markings, of which only the rectangular one on the surface of one of the teeth represents TDC; the other markings are intended as an aid for ad-justing the valve rockers.

10072S

(74)

TOP AND FRONT OF ENGINE

Timing belt

11

10881R

10479R1

REFITTING

Line up the markings of the timing belt with those of the camshaft and crankshaft sprockets. PROCEDURE FOR TENSIONING TIMING BELT Remove pin Mot. 1054.

Fit the spacer (1) of tool Mot. 1386 and tighten the crankshaft sprocket bolt.

Tighten the tension wheel nut.

Turn the engine at least twice (never in the oppo-site direction to normal operation).

Pin the engine at TDC, then remove the pin . Check that the timing is correctly adjusted on the crankshaft and camshaft side.

Slacken the tension wheel nut and turn it slightly clockwise using tool Mot. 1135-01 until the two holes of the tension wheel are lined up

horizontally.

Retighten the tension wheel nut. D7F ENGINE

a) Fit tool Mot. 1273 and, using tool

Mot. 1135-01, turn the tension wheel anti-clockwise until the value of 20 US is obtained (turn the sensor wheel until it is released, as indicated by three clicks).