24 SAUNT 7 gay erent See eerste. [ ee 1} ed OCI) 5 PACER ORM euW- Ure)RENAULT Workshop manual TYPE S 8U140) 4 cylinder Engines With cast iron cylinder block April 1981 Edition Anglaise 77 01.448 100 $3 FADLILNLGENERAL ~ Engine identification ~ Cross section - Tightening torques = Longitudinal section - tightening torques SPECIFICATION = cylinder head - Valves - valve conrEnrs page seals - Valve guides - Valve springs - Camshaft - Pistons - Connecting rods - Liners - Crankshaft - Lubrication - Oil filter ~ Special features CYLINDER HEAD = Exploded view = Tightening - retightening - ‘Tappet adjustment ~ Changing a gasket - Changing = Changing a pre-combustion chamber = Changing valves = Recutting valve seats ~ Measuring valve recess = Changing a valve spring in situ 8 and 9 10 u-12 13 to 15 16 to 18 19 20 21 22 23 CYLINDER BLOCK = Exploded view - stripping Dismantiing ~ Re-assembling = Pistons - Connecting rods - Reassembling = Checking piston protrusion = Refitting VALVE GEAR = Exploded view ~ Valve timing and fitting the toothed timing belt ANCILLARY UNITS GROUP Exploded view Removing - Refitting Dismantling checking Refitting SPECIAL TOOLS page 24 25 26 27 - 28 29 - 30 31 32 33, 34 = 35 36 37 = 38 38 40 - 41 42 43 to 45ENGINE IDENTIFICATION - Engine Cubic capacity Bore Stroke Compression (co) (am) (am) ratio 9140-61-230 D 2445 93 90 22 tol ‘The engine number is stamped directly onto the top side of the cylinder block under the manifolds. — 0000-00000 _ 000000 30363, It comprises + At A: Engine type At B : Engine No. 5073-1 FLUID CAPACITIES Engine oil (Litre) ...--.5 It is forbidden to flush out the engine oil due to the oil reserve in the cylinder head. Oil filter (1itre).....0,5 Engine oil drain/refill every 7500 km (5000 miles)GENERAL CROSS SECTION - TIGHTENING TORQUES (m. da N) 4 75 pre-tightening Engine cold : ‘tightening 15 5280LONGITUDINAL SECTION - TIGHTENING TORQUES (m. da N) 25 25. 20. Fixing bolts : injection pump sprocket Fixing nuts : ~ toothed belt tensioner bracket = toothed belt tensioner njection pump drive sleeve ~ heater plugs = oil filter union | 12, 35381HEAD Target clearance adjustment (mm) (engine cold) + anlet 0,40 (.016 + exhaust 0,40 (,016") operation is carried out by tappet pad selection (every 30000 km) (20000 miles) cylinder head height (am) — 150%0,10 (5.905 Resurfacing not permitted. max. bow of gasket face (mm) 0,05 (.002 Pre-combustion chamber protrusion (mm) (© to 0,04 (0 to .0016") @.: Stem diameter (mm) 8 (.315") Angle (included) = Ist. model 2nd, model . inlet 90° 120° |. exhaust 90° 90° Head diameter (nm) : - inlet 4. (1.614") + exhaust. 33 (1-300") Valve recess in relation to gasket face (mm) 1 to 1,40 (.039 to .055") VALVE SEATS Seat anlges = lst. model 2nd. model. + inlet 90° 120° + exhaust 90° 90° External dia. (mm) . inlet a1 (2.614")| - exhaust 33. (1.300")| Seat width (mm) . inlet and exhaust 2,7 (.106")| ° SPECIFICATIONS VALVE GUIDES Bore (nm) 8 (.315") External dia. (am) 13,05 (.514") 13,10 (.516") 13,25 (.522") + nominal « Ast. repair size « 2nd. xepair size ‘The valve guide location in the cylinder head should be about 0,1 mm less than the valve ste o/d. to ensure an interference fit. ‘he inlet valve guides are fitted with an oil seal for the valve stems. protrusion into tappet location A= 19 mm (.748") Y, IS 1 RSS cS) 135205 VALVE SPRINGS Inlet and exhaust valve springs are identical. Inner outer spring spring Free length (mm) 45,5 (1.791") 52 (2.047" Length under load of 16 da N (35 Ibs) 33,5 (1.319") 30 da N ( 66 Ibs) 23,5 ( .925") 43 da N ( 94 Ibs) 38,5 (1.515" 76 da n (167 lbs) 28,5 (1,122' Wire diam. (mm) 2,9 ( 114") 4,6 (1.811" Coil int. dia. (mm) 19,9 ( .744") 29 (1.141"SPRCTFICATIONS CAMSHAFT Number of bearings 5 End play (mm) 0,20 to 0,50 (.008 to .020") Valve timing : jst. model 2pd. model inlet valve opens e BT.D.C. 8 B.T.D.C. inlet valve closes 489 a.B.D.c. 37° A.B.D.c. exhaust valve opens 48° B,B.D.C, 48° B.B.D.C. exhaust valve closes 8° A.7.D.C. 8° A.T.D.C. with theoretical tappet clearances 0,50 mm (.020"). of The theoretical clearance is only valid for a valve timing check and is in no way related to the normal tappet running clearances. PISTONS = sold individually to original size (um) measuring 92,86 to 92,87 55mm from bottom of skirt = also available in sets of 4 in the following repair sizes + + 0,2, + 0,4 and +0, == ——— £/ © Ll) Fully floating gudgeon pins. 85255 Direction of fitting : Turbulence chamber in crown facing injectors Gudgeon pin length (mm) 79,4 (3.126" Gudgeon pin dia. (mm) 43° (1.259%) 3 piston rings, thickness (mm) Ist. model 2nd. model + top a 3 + compression 2 2 + scraper 4 4 Gap measurement + supplied pre-gapred rhe 0,30 to 0,55 7 smmpeenston 0,30 to 0,55 0,25 to 0, Piston protrusion above cylinder block (nm) 0,75 to 1,09 (.029 to .042 Equalization of piston weights Max, weight difference : * 3 grams. Metal my be removed for this purpose @. from zones lcommmcrzNe RODS small end play (mm) 0,20 to 0,45 (.008 to .018")| JTme small ends are bushed. ‘he top big-end bearing shells and the big-end Jare drilled to allow oil to spray the underside Jof the piston. LINERS Dry-type liners, press fitted and then bored in position are fitted, Bore size (sm) Nominal 93 to 93,018 (3.661 to 3.662") Repair sizes : + 0,2 (.008") + 0,4 (,016") +0,6 (,024") External dia. (mm) Nominal 96,02 to 96,05 Repair size (3.780 +0,PANKSHAFT m, Mer of bearings 5 0,05 to 0,31 (.002 to .012") nd play (am) ne thrust washers are integral with the alf bearing (U-shape) . oll-hardened main bearing journals 16,187 to 76,20 (2.999 to 3") ominal dia. (mm) oll-hardened crankpins jominal dia. 56,52 to 56,535 (2.2252 to 2.2257") (am) rinding tolerances for main bearing agnais and crankpins (nm) Ast. regrind : nominal dia. -0,127 2nd. regrind : nominal dia. -0,254 3rd. regrind : mminal dia. -0,508 et 73260-1 ~ ter regrindiny, Use xoll-hardeped sono chould till remain intact over the 140° zones shown by he arrows. whese zones axe marked (A) and (B) in the lustration below. SPECIFICATION LUBRICATION oil capacity (litres) = total, 6,6 (114 Imp. pts.) = drain/refill every 7500 km : (5000 miles) = = without filter change : 5 ( 8% Imp. pts.) = with £ilter change : 5,5 ( 9% Imp. pts.) An ofibath is cast into the cylinder head to lubricate the camshaft and tappets (this must be refilled with oil on replacing the cylinder head). Min, oil pressure at 100° (bars) = on idling ~ at 3800 r.p.m. 0,8 (114 pst) 3,9 (56 psi) OL FILTER ‘The oil filter is peculiar to this engine + union (D) has an imperial thread 4" x 16. ‘The oil filter should be changed every 15000 km (10000 miles). Details of the calibration for the relief valve spring will be found in the chapter "ancillazy Units Group." Spring height under a load of : 39 om 32 om - 8,8 dan - 12,9 dan‘SPECIFICATION MATERIAL SPECIAL FEATURES ‘Type Application Supermagnusol 5 Magnus Magstrip or Décaploe 88 Loctite Frenetanch or equivalent Loctite Autoform or equivalent Siliconet Component cleaning Cleaning cylinder head joint face Fixing bolts : flywheel, crankshaft pulley, camshaft sprocket, ancillaries group, cylinder head coolant pipe. Flywheel bolting face O%1 pump cover COMPONENTS TO BE CHANGED AT EACH DISMANTLING ~ Flywheel fixiing bolts = All oil seals = All "Oo" wings. ENGINE SUPPORT - Fixing the engine to dismantling support Mot.792 ~ Three 14,5 mm dia, holes marked 18, 19 and 20 must be drilled in this plate : ~ Scribe a horizontal line passing through the centre of holes 3 and 9, ~ Now scribe a line passing through the centres of the support fixing holes = Mark out and drill as shown below. Mot.792__,| ewsSPECIFICATION SPECIAL FEATURES Serew studs Mor.928 (mark M) into the corresponding holes in the cylinder block. Pitting thread inserts ‘Thread inserts may be used to restore threads on engine components. CYLINDER BLOCK jhe cast iron cylinder block is made up of two components which are a machine pair ; they cannot be interchanged. Dowels hold the gasket in place. MAINTENANCE - ENGINE TUNING ‘The following are not included in F,0.C. operations : For Master diesel + = every 30000 km (20000 miles), check tappet clearances, = every 60000 km (40000 miles), change heater plugs and check injector calibration, = every 105000 km (70000 miles), change the toothed timing belt (or earlier, af it is contaminated with vil).(CYLINDER HEAD EXPLODED VIEW i 10CYLINDER HEAD cere = eertcenmric ~ nore? ADTUENNRE ‘SPECIAL sons Methods pacertptton Essential _sefal Mot. 69 Torsus wrench 7 Mot. 855 = Sprocket holding tool Mot.915 = Tappet compressor . Mot.928 Tappet pad pliers . sore TAPPED ansusmvat ‘This operation must be carried out after the cylinder head has been refitted. - Pre-tightening - Tightening 4m, da N (30 1b/t) 7,5 m, da N (58 1b/ft) Run the engine for 20 minutes, allow it to cool for at least 24 hours then retighten. RETIGHTENING ‘This operation must be carried out when the engine is cold at least 24 hours after the engine has been switched off. 1 During the Ist. Inspection and Checks between 1000 and 3000 km (500 and 2000 miles). 2 ~ After a change of cylinder head gasket and after the engine has been run. 3 ~ When a Standard Service Exchange engine is being fitted (while it is still on its pallet and accessible). Method Loosen bolt No. 1 by half-a-turn and retorque tighten it to 7,5 m. da N (58 1b/ft). Repeat for the other bolts in the sequences show. 16 4 6 14 192 0 9 0 2 0 12 © 22 OOC?. 2 ia fo} Oo Oo 2 00 9019 oo 0 3 6 8 5 ee ‘54592 Use a syringe to remove oil lying in the cylinder head. - turn the engine using a box or ring wrench on the crankshaft pulley bolt. - on a removed cylinder head, use sprocket holding tool Mot.855 to turn the camshaft.CYLINDER HEAD Method Use tool Mot.929 to extract the pads. Turn the camshaft so that the valves in No.1 cylinder are on balance (end of exhaust, commencement of inlet) and check the tappet clearances on cylinder No.4, then repeat the process for cylinders 3, 4 and 2. - tappet clearances (engine cold) = Inlet 0,40 mm (.016") ~ Exhaust 40 mm (,016") Changing the tappet pads ~ Bach pad is marked with its thickness ; the figures should face downwards. ~ Check pad thickness with a micrometer. > Tappet pads are available from the Parts Dept. in the following thicknesses (mm) : 3,55 - 3,60 - 3,65 ~ 3,70 - 3,75 - 3,80 - 3,85 3,90 - 3,95 - 4,05 - 4,10 = 4,15 - 4,20 (um). Turn the tappets so that their slots (A) are parallel to the camshaft. Insert tappet compressor Mot.915 from the intet manifold sige and press down the tappets. Slots (A) must be at! right « angles to the cashshart. 12CYLINDER HEAD CHANGING THE CYLINDER HEAD GASKET Methods Description Mot. 50 Torque wrench —O————————— Essential Useful ‘TIGHTENING TORQUES cylinder head fixing bolts : 4m, da N (30 1b/ft) 7,5 m. da N (58 1b/ft) = pre-tightening ~ tightening REMOVING Remove the water pump bottom hose to drain the coolant. Remove the fittings on the cylinder head. Note Leave the inlet-exhaust manifold assembly so that it may be used for leverage when the cylinder head is removed. Remove the timing belt : = loosen a tension roller nut (1) - place a hammer shaft (arrow) and push the tensioner plunger in ; tighten the roller nut in this position. ~ Remove idler (2).CYLINDER HEAD CHANGING THE’ CYLINDER HEAD GASKED { Use a syringe to remove any oil lying in the top of the cylinder head so that the bolt heads may be reached. - Remove = the injector clamps - and cylinder head fixing bolts. Note : ‘The cylinder head is located on the block by 2 dowels (3). DO NOP PIVOT THE CYLINDER HEAD : lift it to unstick it. (the liners are a press fit and there is no risk that they will move). Remove the cylinder head. 14 CLEANING It is important not to scrape gasket faces on aluminium parts. Use Magnus Magstrip or Décaploc 88 to dissolve any part of the gasket still stuck. eee ee aie about 10 minutes then ILft off the remants es ease Gloves should be worn during this operation. avoid dropping any 1iguté on paintwork. eee ee ee provent foreign natter from entering the Pressure fed ofl channele. Use a syringe to remove any oil lying round the fixing bolt holes. checking the gasket face for bow Remove the pre-combustion chambers first then use a straight edge and set of feelers to check if bow is present. Max. permissible bow : 0,05 mm (002g ‘The cylinder head cannot be resurfaced.CYLINDER HEAD CHANGING THE CYLINDER HEAD GASKET REFITTING = turn the crankshaft so that the pistons are halfway up their bores. Wit the cylinder head gasket over the locating dowels (the gasket will only fit one way). 2077 Fit: anew "0" ring over the hollow dowel (oil feed to camshaft) and fit 2 new oil seals to cylinder head coolant pipe (4). J- the cylinder head, locating it on dowels (3) and and coolant pipe (4). Lubricate the bolt threads and washers with clean ie oil. o - insert the bolts and tighten them in the recommended sequence as shown below : ° 1308 5) 3 7 15 17 84592 - Use torque wrench Mot.50. oo 4m. da N (30 1b/ft) - Tighten 7,5 m, da N (58 1b/ft) 15 Fit and adjust the timing belt (see paragraph "VALVE GEAR" : Valve timing). Change the timing belt if there are any signs of oil on it or if it is worn and also every 105000 km (70000 miles) Reconnect + ~ wiring, ~ hoses, = and exhaust downpipe clamp. Fix : - the timing belt cover - heater piugs relay, - tappet cover sound damping cover, - and torque tighten the injector brackets to 5m. da N (37 lb/ft), placing washer (A) with taper side downwards. = the fuel pipes. Fill and bleed the cooling circuit Retighten the cylinder head (see paragraph ‘ “CYLINDER SEAD" - Tightening ~ Retightening). 44 “|CYLINDER HEAD (CHANGING @ SPECIAL Methods ‘ Essential Useful ae Beet Description Mot. 50 Torque wrench . Mot. 330-01 Cylinder head support . Mot.865 Sprocket holding tool . Mot.913 camshaft oi1 seal inserting tool # Mot.921 Injector extractor . Emb. 880 Impact tool : TIGHTENING TORQUES Remove cylinder head fixing bolts + the canshatt sprocket using toot wot 055 pre-tightening 4m, da N (30 1b/ft) enue 7,5 m. da N (58 1b/ft) Camshaft sprocket bolts 2,5 m. daN (19 1b/ft) Injector bracket bolts 5 m. da N (37% 1b/ft) Camshaft bearing cap nuts 2/5 m. daN (19 1b/ft) Heater plugs 1,5 m, daN (11 1b/Et) Service cylinder heads are supplied with the following already fitted : ~ valves and valve springs Sree eee - The camshaft bearing caps are numbered, = pre-combustion chanbers No. 1 ie at the sprocket end, ¢ Foes eee ~ Nunber them if necessary. There is therefore no need to remove the above components from the old cylinder head. Remove the cylinder head (see "Changing the cylinder head gasket"). DISMANTLING Fasten support Mot.330-01 to the cylinder head then attach the assembly to DESVIL stand. 16(CYLINDER HEAD Remove : CHANGING = the marked components from the cylinder head. om OA, | = the injectors, us: RE-ASSEMBLING attached to impa (retain the copp® 3 ~ ft the new cleaned cylinder head to support tions as for dismantling.CYLINDER HEAD (CHANGING ~ fit the coolant pipe (10) using some adjust the tappet clearances using sprocket Loctite Frenetanch or equivalent. holding tool Mot.855 to turn thé camshaft. = fit all the components : rear plate (4), therzostat body (1), tensioner roller (2), manifolds, etc. refit the cylinder head. (Refer to paragraph "CYLINDER HEAD ~ Changing the gasket") . 10 85 106 Fit: = canshaft (9) camshaft bearing caps (8). Make sure the nunbers made on @ismantling match and torque tighten the nuts to 2,5 m. daw (19 1b/ft). = sprocket (7), valve timing mark facing the camshaft.@ CYLINDER HEAD CHANGING A PRE-COMBUSTION CHAncER | SPECIAL Methods Description Essential Useful = Mot. 251-01 Set of 3 drifts Clock gauge bracket Mot. 252.01 Tarust plate for checking protrusion . Injector extractor . Impact tool. . cylinder head must be removed for this ration. 7ING Remove : |= the injector concerned using extractor Mot.921 fastened to impact tool Emb.880. = the heater plug. B.Via101 Use drift B.Vi.31-0l inserted through the injector location to tap out the pre-conbustion chamber. 8206 19 REFITTING = A removed pre-coubustion chamber must not be refitted ; fit a new part. = Align locking ball (A) on the pre-combustion chanber in relation to location in the cylinder head. - Insert the pre-combustion chanber and the protrusion using the clock gauge bracket Mot.251- and thrust plate Mot.252-01. It should be between O and 0,04 mm (0 and .0016") ‘Two thicknesses of pre-combustion chambers are available : 4,50 to 4,52 mm and 4,52 to 4,54 mm. Mot. 251-01 83245-1CYLINDER HEAD CHANGING VALVES CYLINDER HEAD RE-ASSEMBLING Compress the valve springs using Facom Fit the new valves and lightly grind them in. compressor U 43 L. Clean all the arts and re-assemble. Lubricate all the parts before fitting. S1ip base washers (B) before oil seals (c) over the inlet valves. Fit the inner and outer Remove the split cotters, top cups, springs, valve springs and top cupwashers. oil seals (on ihlet valve guides), bottom cups Use the Facom compressor U 43 L to compress and valves. the valve springs. Insert the split cotters (identical for inlet an exhaust valves). FACOMU43L___, | 85020 20CYLINDER HEAD RECUTTING VALVE SEATS ‘ToourNc = pilot No, 150-8 = NEWAY cutter No.208 = NEWAY cutter No.213 for recutting face for reducing seat wiath. Refer to your local After-Sales Head Office for details of how to obtain the above tooling. included angles of the valve seats are : Ast. model 2nd. model Inlet + 90° 120° Exhaust 90 90° 9} Z Z ZA YA 21 fonty the minimum amount of metal must be removed from the valve seats in order for the valves to remain within the recessing [tolerance Once a satisfactory seating (1) has been cut, reduce its width with a NEWAY cutter No.213, Cut first at (2) and then at (3) to obtain the correct width of seat. Width of seat = 2,7 mm.CYLINDER HEAD MEASURING VALVE RECESSES SPECIAL Methods ‘Toons ref. Description Essential useful protrusion Mot. 916 Mot. 251-01 Clock gauge bracket Mot. 252-01 Thrust plate for checking Valve stem height gauge Clean the valve head faces and measure the distance between the cylinder head joint face and the inlet and exhaust valve heads using tools Mot.251-0l and Mot.252-01, > valves should be recessed between 1 and 1,4 mm (.039 and .055"). Mot. 252.01 22 CHECKING THE HEIGHT OF A VALVE STEM Once the valve seats have been recut and the valve lightly ground in, the valve stem protrusion must be checked, The valve stem should protrude within the "So" and "No Go" Limits on height gauge mot.916. Excess protrusion should be removed by lightly grinding the valve stem face.CYLINDER HEAD CHANGING A VALVE SPRING IN SITU speci athode pesoription Povential useful Wot. 382 Valve Spring compressor Mot. 913 Oil seal inserting sleeve . Mot. 914 Bar for valve spring : compressor Mot. 382 = eno spectan Pons covceRNiNs REFITTING urn the crankshaft so that the piston concerned is on T.D.C. . the tappet cover ) toothed timing belt + camshaft 1 and the tappet and tappet pad. Fit bar Mot.914 to tie camshaft bearing cap studs. = compress the valve springs using Mot. 362. = remove the split cotters. = remove the inner and outer springs. Mot. 382 Mot. 914 23 Insert the camshaft oil seal using sleeve Mot.913.(CYLINDER BLOCK® en STRIPPING SPECIAL Nethods bie as Description Essential Useful Mot. 50 Tozgue wrench . Mot. 251.01 Clock gauge bracket : Mot.25201 Thrust plate for checking otrusion Mot.763 _Erankshat’ oi1 seal inserting tool (flywheel end) . Mot.792 Engine support for fitting to DESVIL stand . Mot.861 Piston ring compressor Mot.911 Crankshaft ofl seal inserting ® tool (timing ear end) . Mot.919 Flywheel locking sector Mot.823 cylinder block Lifting bracket Mot.928 set of 3 threaded rods Z (taxk #) TIGHTENING TORQUES cylinder block base fixing belts = pre-tightening @ x, da N ( 60 1b/#t) = tightening 16 m. da N (120 1b/ee) Flywheel fixing bolts 12 a. dan (90 ww/ee) | __PRBY Big-end cap bolts Lim, dan ( e2hib/#t) Ancillary units group fixing bolts + Gum dia. bolts 2,5 m, da N ( 19 1b/tt) @ 2 m aia, bolts 6,5 m, da N ( 50 1b/ft) cylinder head fixing bolts : 24809 = pre-tightening 4m da N ( 30 1b/#t) = tightening 7,5 a, da N (58 1b/Et) Drain the sump Crankshaft pulley bolt 20 m da N (150 1b/#t) | onoye ; = the sump and tooth timing belt ; compress the tensioner spring and use a 14 mm nut split Removing the engine from the vehicle. with a hacksaw as shown below to act as a keep at : the back of the plunger. = fit dismantling support Mot.792 to the adjustable stand + Screw the 3 studs Mot.928 into the cylinder block in their correct positions. (see chapter "SPECIFICATION - Special Features") 8588.1 25CYLINDER BLOCK STRIPPING - DISMANTLING Remove = the cylinder head. Do NoT PIVOT THE CYLINDER HEAD because it is located by dowels (A) on top of the cylinder block. Lift it up straight taking care not to Gamage coolant pipe (B) supplying the cylinder head. ~ Strip the cylinder head (see exploded view). SPECIAL FEATURE Use locking sector Mot.919 to hold the flywheel when unscrewing ‘the crankshaft pulley aut. DISMANTLING Mark the connecting rods and big-end caps at the ancillary units group end, No.1 cylinder is at the timing gear end. Remove : ~ the piston-connecting rod assemblies ~ cylinder block base (18) ~ crankshaft and its bearing shells + Fit lifting bracket Mot.923 and remove the cylinder block from support Mot. 792(CYLINDER BLOCK RE-ASSEMBLING ‘he service cylinder block is supplied with pistens, piston rings and gudgeon pins already fitted. Mark the fosition of the pistons in the cylinder block. RE-ASSEMBLING Check that the cylinder head bolts screw in without tight spots 7 if necessary, screw ‘them in and out several times to ease threads. = fit the cylinder block to support Mot.792. (Refer to chapter "SPECIFICATIONS - Special Features") . = unbolt base (18) from cylinder block. ~ insert the bearing half-shells in the base and the cylinder block. = the top (cylinder block) half-shells have oilways. ~The rear main bearing shells (flywheel end) act as thrust washers. Lubricate the main bearing journals and lower the crankshaft into position. = place gaskets (20) and base (18). ‘These gaskets have pips moulded into them to hold them in position. Lubricate the bearing shells. - Flt the base to the cylinder block and torque ‘tighten the bolts in the sequence shown below : ~ Pre-tightening 8m, da N ( 60 1b/ft) = wightening a6 m, da W (120 1b/tt) arCYLINDER BLOCK RE-ASSEMBLING (CHECKING CRANKSHAFT END PLAY Attach a clock gauge with a magnetic base to the cylinder block and place the stem on the end of the crankshaft. Check the amount of end play which should be between 0,05 and 0,31 mm (,002 and .012"), Change the rear pair of bearing shells (flywheel end) if the endplay is incorrect. offer up and fit + = Crankshaft oi1 seal housing (10) (timing gear end) with its oil seal in position using inserting tool Mot.911. Mot. 911 asa92 28 ~ Crankshaft oi1 seal housing (13) (flywheel end) with its oil seal in position using inserting tool Mot. 788. ~ Plate (21) ~ Plate (12) between engine and clutch housing. ePISTONS - CONNECTING smear sone Loctite Autoform or oquivalent on the crankshaft mounting face for the flywheel. Fit flywheel (11) + use new bolts and torque tighten them to 12 m. da N (90 1b/ft) using torque wrench Mot.50. = prevent the flywheel from turning with locking sector Mot.919. PREPARING THE PISTONS Fully floating gudgeon pins are fitted. Check the weight of each piston and equalize them if replacements are made (refer to chapter "SPECIFICATIONS - Pistons"). ake the piston and matching connecting rod for the cylinder concerned. e é 85308 29 CYLINDER BLOCK RODS - RE-ASSEMBLING = When assembling the gudgeon pin, make sure that. turbulence recess (A) in the piston crown is on the same side as cap and big-end marking (B) denoting the cylinder number. c A Ns nee Note : Letter (Cc) in the diagram represents the position of the ancillary units group. - Fit the piston rings a 2H a 3 728821CYLINDER BLOCK [RE-ASSEMBLING Insert the piston-connecting rod assemblies in their respective cylinders so that marks (B) face the ancillary wiils group (c). Use piston ring compressor Mot.851 No.1 cylinder is at the timing gear end. - Draw the connecting rods down onto the lubricated crankpins. = Fit the big-end caps with their bearing shells, making sure that the dismantling marks are in line. Screw on and torque tighten the big-end cap bolts to 11m. da N (824 1b/ft) using torque wrench Mot.50. 30 15. = Fit the oi1 pump gauze body (15) and the suction pipe "Oo" ring. = Fit sump (14) with its gasket.® necking piston protrusion lean the piston crowns carefully and rotate ne crankshaft one complete turn. place thrust block Mot.252-0l and clock gauge Not.251-01 over each piston in turn and find D.C. ead off piston protrusion which sniould be etween 0,75 and 1,09 mm (.0295 and .0429") CYLINDER BLOCK CHECKING 31 Fit the tensioner roller (8) for the timing belt. OO asta = and crankcase vapour collector (4).CYLINDER BLOCK RE-ASSEMBLING Offer up and fix timing belt shield (9). ~ Insert the dipstick tube (3) using new "o" rings. - Fit new "0" rings over the oflway locating dowels on the anci}lary units group (2). 32 ‘Torque tighten the bolts. m, da N (19 1b/£t) m, da N (50 1b/£t) Fit the ancillary units group (2) to the cylinder block. ~ Turn the crankshaft so that the pistons are halfway up their bores. ~ Refit the cylinder head (Refer to paragraph "CYLINDER HEAD" - Changing the gasket") and set the valve timing (Refer to paragraph "VALVE GEAR").VALVE GEAR EXPLODED VIEW 85264VALVE GEAR VALVE TIMING AND FITTING THE TOOTHED TIMING BELT Methods eet Description Essential Useful. Mot. 910 Set of 2 T.D.C. rods REMOVING-REFITTING ‘he toothed timing belt may be removed and refitted more easily : = by removing shield (1). compress tensioner roller (2). loosen nut (3), compress plunger (4) using screwdriver and tighten nut (3) in this position. = reuove tensioner roller (5) 85396 VALVE ‘TIMING Line up marks A and B. A - Camshaft sprocket timing mark. B - Tappet cover timing mark (boss) . Use timing rods Mot.910 to position injectioi |pump driving sprocket. 34VALVE GEAR VALVE TIMING AND FITTING THE TOOTHED TIMING BELT ‘Align crankshaft pulley (Cc) in line with timing mark (D) on the oil seal housing using timing rod Mot.910. fit toothed timing belt (7) roller (5) = release and tighten tensioner roller (2) secure timing rod Mot.910 checking ~ Turn the crankshaft 2 complete turns in its normal direction of rotation and recheck the 3 timing marks using rods Mot.910. = Loosen tensioner (2) so that it takes up the slack. NB - The toothed timing belt must not be folded at acute angles nor compressed with tools otherwise the fibres will be irrevocably damaged. ‘The toothed timing bolt must be changed automatically once every 105000 km (70000 miles) gf immediately oil stains on it are noticed. 35EXPLODED VIEWANCILLARY UNITS GROUP REMOVING - REFITTING ee Description Essential Useful Ref. Mot, 69 Torque wrench . Mot.789 Oil seal inserting tool Mot. 855 Sprocket holding tool Mot. 917 O{1 pump drive gear locking tool . Mot.918 0:1 pump gear fit checking tool 7 Ancillary units group Mot.920 aac cort F he ancillary units are grouped together on | mounting fixed to the top of the cylinder Lock. hey are driven by the toothed timing belt. he group consists of : - the injection pump - oil pump, relief valve and fiter (full flow) - vacuum pump . P,T.0. for electric motor - and speedo drive. Silways are cast or machined in the mounitng for the various units. is accessible on removing fe: The P.T.O, cover plate (10). 37 REMOVING Remove : = the’ timing belt - the fuel pipes lead in to the injection pump = the dipstick tube clip and the fixing bolts ; fit the group on support Mot.920.ANCILLARY UNITS GROUP REFITTING = offer up the group to the cylinder block. ‘Torque tighten the bolts using torque wrench Mot.50. @ mm dia. bolte - 2,5 m. da N (19 1b/£t) 12 mm dia. bolts = 6,5 m. da N (50 1b/ft) = tighten the dipstick tube top clip. 25399 = reconnect the fuel pipes to the injection pump. = Set the valve timing sprockets. Refit the timing belt. - Time the injection pump. Refer to MR.216 - IS SA. = Bleed the fuel circuit of air. 38® DISMANTLING enove : oil filter (QD, injection pump, vacuum pump (2), oil pump rear cover (3) which acts as the vacuum pump support, and oil pump drive gear. the timing sprocket (50 using holding tool Mot. 855). ‘cover (6) on the timing gear side. 39 ANCILLARY UNITS GROUP = injection pump drive gear (7).ANCILLARY UNITS GROUP CHECKING THE OIL PUMP check + = clearnaces at (A), + min, : 0,06 mm (,0024") 2 max. + 0/17 mm (" .006") - tooth backlash + max. : 0,12 mm (.0047") ~ ofl pump gears end play min, + 0,06 mm (.0024") + max, : 1,13 mm ( .044") change all worn parts. cHEcKENG @ CHANGING THE OTL PUMP DRIVE GEAR Press out the ofl pump drive gear (8).CHECKING DRIVE GEAR INTERFERENCE FIT ON THE SHAFT - tnsert the new oil pump drive gear in the ancillary units casing. = Heat up the gear to a temperature uf between 200 and 250°C, slip it onto the oil pump shaft (9) and press it in position flush with the end of the shaft. = prevent arive gear (8) from turning using locking tool Mot.917. = scribe a line (R) across shaft and gear. Mot. 920 R au922 ANCILLARY UNITS GROUP CHECKING Using torque wrench Mot.50 and gear fit checking tool Mot.919, apply a torque of 6,5 n. da N (50 1b/ft) « check that the scribed line is still true. Mot. 918 Mot. 50 3823 aANCILLARY UNITS GROUP Ca RE-ASSEMBLING Fit oil pump gear (4). Smear some Silicomet on the oil pump casing face for sealing. Fit vacuum pump (2) by aligning the driving dogs. and gear (7) which drives the injection pump. g Sy 5194-1 ~ the injection pump, making certain that the foolproofing double tooth is in line with driving sprocket (7). ‘A new oil filter. Remove support Mot.920 from the group. 85101 | Fit the ancillary units group to the cylinder & 42SPECIAL TOOLS —. 8 Sa alesse ll fase eel leet etal VERoed \" square drive ( choc snags beeteefor mening gee ee et pele Mot. 252-01 00 00 025 201 protrusion - use with Mot.251-0l wt e Mot. 788 00 00 078 800 Crankshaft oil seal inserting tool - timing Mot. 789 00 00 078 900 Crankshaft oil seal inserting tool - timing Sole leclsbetahl eet tebe iene attests Mot. 851 00 00 085 100 Piston ring compressorSPECIAL TOOLS * Special tools introduced for this engine METHODS Ref. Part No. DESCRIPTION CBR on 055700085500 sprocket nodaing tant exze9 Ta) Mot. 910 0000091000 Set oF 2 "D.C. Fods for valve timing 4918 3 Mot.911 0000091100 Crankshaft oil seal inserting tool - timing gear end 4919 o") XMot.812 0000081 300 canshatt oi seal inserting toot 24919 3 Mot.914 0000091400 Bar tool for valve spring compressor Mot. 382 897 3K Mot.915 0000091500 —Tappet compressing tool for tappet adjustnd| a 77 xe mot.916 0000091600 valve stem height checking gause —_ s& Mot.917 0000091700 1 pump drive gear locking tool arse Bp 2K Mot. 918 0000091 800 01 pump gear fit checking tool e wares 44* special tools introduced for this engine METHODS Ref. Part NO. SPECIAL TOOLS DESCRIPTION 0000091900 Flywheel locking sector arse No EZ Z > 2 Mot.920 00 00.092 000 Ancillary unit group support (injection TH pump and other units) ess 0000092100 —xnjector extractor (use with impact too: Eb. 880) oars 00 00 092 300 .Cylinder block lifting bracket wars ZZ 2K Mot.928 0000092800 Set of 3 studs for fixing engine to place wot. 792 > Sac Mot.929 0000092900 ‘Tappet pad pliers uss Emb. 880 00 00 088 000 Impact tool for clutch fork pin and injector extraction (use with Mot.921) exe —== ——>— B.Vi. 31.01 00 01 259 401 Set of 3 drifts for inserting 5 mm dia. rollpins = 45