Workshop Repair Manual: Diesel ENGINE High Pressure Common Rail Cast Iron 4 Cylinders

Workshop Repair Manual
Diesel ENGINE
High Pressure Common Rail
Cast iron 4 cylinders
Vehicle Type Engine

Master XDXG G9T 720
XDXN G9T 722
Espace JE0K/JE0S G9T 710
77 11 303 902 JUNE 2001 EDITION ANGLAISE
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
© RENAULT 2001
Contents
Page
10 ENGINE AND PERIPHERALS

Cleanness & Safety 10-1
Preface 10-6
Identification 10-7
Tightening torque (in daNm or degrees) 10-9
Specifications
Cylinder head 10-11
Piston 10-18
Connecting rods 10-20
Crankshaft 10-23
Bearings 10-24
Piston cooling jets 10-25
Preparing the engine for mounting on the support 10-26
Consumables 10-29
Precaution 10-29
Parts to be replaced after removal 10-29
Essential special tooling 10-30
Essential equipment 10-35
Overhauling the engine
Removing upper engine 10-37
Timing adjustment 10-39
Removing the injector holders 10-48
Stripping the cylinder head 10-55
Cleaning 10-57
Checking the gasket face 10-57
Checking camshaft clearance 10-58
Rebuilding the cylinder head 10-59
Removing lower engine 10-62
Extracting the gudgeon pins 10-69
Fitting connecting rod bearing shells 10-70
Refitting lower engine 10-73
Con rod/piston assembly 10-77
Fitting segments 10-78
Replacing the oil pump sprocket oil deflector 10-79
Fitting intermediate shaft roll pins 10-84
Replacing sprockets with wear compensation 10-87
Method for replacing the high pressure
pump sprocket 10-89
Fitting crankshaft seal, flywheel end 10-90
Fitting no. 2 intermediate shaft seal and
crankshaft seal, timing end 10-95
Refitting upper engine 10-102
Inlet rail 10-103
Exhaust rail 10-103
Fitting camshaft seals 10-113
Timing adjustment method 10-120
Timing belt tension 10-122
Checking the tension and the adjustment 10-124
110
ENGINE AND PERIPHERALS
Cleanness & Safety 10
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE
DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
– damage to or destruction of the high pressure injection system,
– seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE SOME SOURCES OF CONTAMINATION?
Contamination is caused by:

– metal or plastic chips,
– paint,
– fibres:
● of cardboard,
● from brushes,
● from paper,
● from clothing,
● from cloths.
– foreign bodies such as hair,
– ambient air,
– etc.
WARNING: cleaning the engine with a high pressure jet may damage the connections. Also the moisture may
collect in the connectors and cause electrical connection problems.
10-1
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
● Ensure that you have the plugs for the unions to be opened (bag of plugs sold by the Parts Store).
Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is
not sufficient to make them reusable).
Unused plugs must be thrown away.
● Ensure that you have the resealable plastic bags for storing removed parts. There is less risk of parts stored in this
way being exposed to contamination. The bags must be used only once. After being used they must be thrown
away.
● Make sure that lint-free towelettes are available (towelettes part number 77 11 211 707). The use of a normal
cloth or paper for cleaning purposes is forbidden. These are not lint free and may contaminate the fuel circuit
of the system. Each lint-free cloth should only be used once.
CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE CARRYING OUT ANY WORK ON THE FUEL
SYSTEM
● For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
● For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
● Use a brush and thinners to clean the connections to be opened.
● Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection
system zone). Check that no bristles remain adhering.
● Wash your hands before and during the operation if necessary.
● When wearing leather protective gloves, cover these with latex gloves.
10-2
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
● As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The
plugs to be used are available from the Parts Store. 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
contamination.
● All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once
the plugs have been inserted.
● The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
These items are liable to cause the entry of impurities into the system.
● A new component to replace an old one must not be removed from its packaging until it is to be fitted to the vehicle.
10-3
10-4
RAIL PROTECTOR
General information
The rail protector consists of ten parts which isolate the high pressure injection system from the engine
compartment.
THIS RAIL PROTECTOR ENSURES SAFE OPERATION AND REQUIRES SPECIAL ATTENTION
WHEN BEING FITTED.
To ensure its safety function, the rail protector must consist of:
– two pieces of soundproofing material (1) to be replaced if they are damaged or soaked with diesel fuel,
– lower metal protector (2) fixed between the rail and the cylinder head,
– diesel fuel drain pipe (3),
– rubber flap (4) fixed to the metal protector and the valve cover,
– two side partitions (5),
– partition (6) fixed to the valve cover (on some versions),
– two clips for attaching the side partitions to the rubber flap.
During any operations on the rail protector, you must ensure that the system components are fitted properly after
refitting.
NON-OBSERVANCE OF THIS ADVICE MAY HAVE SERIOUS CONSEQUENCES FOR SAFETY.
10-5
Foreword 10
USING THE MANUAL
There are two main sections in this manual:

– technical specifications,
– overhauling the engine.
To repair a component on the vehicle, refer to the

vehicle's Workshop Repair Manual and Technical
Notes.
UNITS OF MEASUREMENT
– All dimensions are expressed in millimetres mm
(unless otherwise stated).
– Tightening torques are expressed in
decanewtonmetres daNm
(reminder: 1 daNm = 1.02 kgm).
– Pressures are expressed in bar
(reminder: 1 bar = 100 000 Pa).
TOLERANCES
Tightening torques given without a tolerance must be

accurate to within:
– in degrees (± 6°),
– in daNm (± 10 %).
10-6
Identification 10
ENGINE IDENTIFICATION Or:
– by means of a label stuck on the valve cover.
There are two means of identification.
Either:
– by means of a plate riveted on the cylinder block.
17945s
15848, 16130-1
These show:
– A: engine type,
– B: engine type approval letter,
– D: Renault code,
– E: engine suffix,
– F: engine fabrication number,
– G: engine assembly plant,
– H: assembled engine number
10-7
Identification 10
Engine Suffix Compression Bore Stroke Cubic capacity
ratio (mm) (mm) (cc)
722
G9T 710 18.3/1 87 92 2188
720
10-8
Tightening torque (in daNm or degrees) 10
UPPER ENGINE
Description Tightening torques
Heater plug 1.5

Injector clamp bolt *
Common rail gallery bolt 2.3
High pressure pipe nut, injector end 2.5
High pressure pipe nut, rail end 2.5
High pressure pipe nut, pump end 2.5
Camshaft bearing cap bolts. *
Camshaft hub bolts 6
Camshaft sprocket bolts 0.9
Hydraulic valve rocker shaft bolts *
Vacuum pump mounting bolts 2.3
Inlet pipe bolt on cylinder head *
Cylinder head cover bolts *
Exhaust manifold nuts 2.7
Cylinder head coolant outlet bolt 1
Turbocharger flange nut 2.7
Turbocharger oil return bolt 0.8
Hollow turbocharger oil supply bolt on cylinder block 2.3
Turbocharger oil supply nut on turbocharger 2.3
EGR valve bolt on the diffuser 1.5
Exhaust heat shield bolt 1
Cylinder head mounting bolt 4.4
Air conditioning compressor bolts 2.1
Alternator bolts 2.1
Assisted steering pump bolts 2.1
Power assisted steering pulley bolt 1
Accessories belt tensioner wheel bolt 2.1
Accessories pulley bolt 4.4
Engine lifting ring bolts
M6 1
M8 3
Timing belt cover bolt 1
Cylinder head mounting bolt *
Timing belt tensioner wheel bolt 2.5
Timing belt pulley mounting bolt 3
* See tightening procedure.
10-9
Tightening torque (in daNm or degrees) 10
LOWER ENGINE
Description Tightening torques
Sump bolts **
Crankshaft pulley bolt 5 plus an angle of 90° ± 6°
Flywheel bolts 2.5 plus an angle of 50 ± 6°
Clutch bolts 1.2
Oil pump bolts 2.5
Anti-emulsion pulley bolt 1
Bolts for detachable bearing caps 2.5 plus an angle of 55° ± 6°
Crankshaft bearing cap bolts 2 plus an angle of 150° ± 10°
Crankshaft bearing cap sump bolts 2
Water pump bolts 1
Water pump cover bolts 1
Water pump sprocket bolt 4
Piston cooling jet mounting bolts 2*
Valve timing cover bolt:
M6 1.2
M8 3
Alternator bracket mounting bolt 3
High pressure pump mounting bolt 3
High pressure pump rear mounting bolt 3
High pressure pump sprocket nut 9
Camshaft sensor mounting bolt 1
Intermediate shaft mounting bolts 2.5 plus an angle of 30° ± 6°
Timing belt pulley bolt 3
Oil filter mounting bracket bolt 2.2
Dipstick guide mounting bolt
Lower mounting 2.5
Upper mounting 1
Oil level sensor mounting bolt 1
TDC plug mounting bolt 3.1
Coolant pipe bolt 3.1
Diffuser mounting bolt 2.2
Catalytic converter mounting nuts 2.1
Catalytic converter stay mounting bolt 2.1
Relay bearing mounting bolt 6.2
* Attention: left-handed thread

** Refer to tightening order.
10-10
Technical specifications 10
CYLINDER HEAD
Cylinder head bolts must always be replaced.
Cylinder head tightening procedure
REMINDER: to achieve 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 the new bolts.
Tighten all the bolts to 3 daNm in the order recommended below.
15852-3
Check that all the bolts are tightened to 3 daNm, then angle tighten (bolt by
bolt) to 300° ± 6°.
Do not re-tighten the cylinder head bolts after performing this

procedure.
10-11
Thickness of the cylinder head gasket WARNING: the gauge follower must not be in the
valve clearance.
The thickness of the cylinder head gasket is measured
at (A):
Thickness of gasket when tightened: 1.16 ± 0.05 mm.
Measure the piston protrusion.
The protrusion must be: 0.395 ± 0.065 mm.
Checking piston protrusion
Clean the piston heads in order to eliminate any traces

of deposits.
Turn the crankshaft one turn in its operating direction

to bring piston No. 1 close to top dead centre.
Put tool Mot. 252-01 in position.
Fit tool Mot. 251-01 equipped with a gauge on its

thrust plate Mot. 252-01, and find top dead centre of
the piston.
NOTE: All measurements must be carried out in the

longitudinal axis of the engine, in order to eliminate
any errors due to tilting of the piston.
10-12
Cylinder head height Hydraulic tappets
H = 90.2 mm These engines are fitted with hydraulic tappets (A) and
roller rockers (B).
Gasket face bow (in mm):
Cylinder head 0.05

Cylinder block 0.06
Test the cylinder head to detect possible cracks

using the cylinder head test tools (comprising a tray
and a kit suited to the cylinder head, plug, sealing
plate, blanking plate). The approval number of the
cylinder head test container is 644 000.
10-13
Valves Valve seat
Stem diameter (in mm) Seat angle α
Inlet 5.972 ± 0.007 Inlet and exhaust: 89˚ 30'

Exhaust 5.957 ± 0.007
External diameter D (in mm)
Head diameter (in mm)
Inlet 32.31 ± 0.01
Inlet 30.6 ± 0.12 Exhaust 31.11 ± 0.01
Exhaust 29.5 ± 0.12
Face angle
Face angle 90° 15'
Valve length (in mm)
Inlet 123.2 ± 0.20

Exhaust 123 ± 0.20
Valve lift (in mm)
Inlet 8.505
Exhaust: 8.605
91880R4
No valve clearance adjustment.

Diameter of the housing in the cylinder head
(in mm)
+ 0.05
Inlet 32.19 + 0.02
+ 0.05
Exhaust 30.995 + 0.02
10-14
Valve guide Valve stems seals must be fitted using
Mot. 1511-01 or other suitable equipment.
Length (in mm)
Inlet and exhaust 50 ± 0.15
Guide external diameter (in mm)
+ 0.039
Inlet and exhaust: 11 + 0.028
Diameter of the guide housing in the cylinder head

(in mm)
Inlet and exhaust: 11
Guide internal diameter (in mm)
Inlet and exhaust

+ 0.12
Not used 5.5 0
+ 0.022
Machined* 6 0
* This dimension is measured with the guide fitted in

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

which must be changed each time the valves are
removed.
NOTE: do not lubricate the valve stem seals before

fitting them.
10-15
Angle of the inlet and exhaust guides (in degrees) Position of the inlet and exhaust valve guides
(in mm)
Inlet 95°
Inlet A = 9.7 ± 0.15
Exhaust A = 14.3 ± 0.15
Exhaust 94°
Valve springs (in mm)
Free length 46.70
Length under load:

18.5 daN 40.50
21.5 daN 39.50
24.5 daN 38.50
35 daN 35
45 daN 32
48.3 daN 31
51.5 daN 30
Length, coils touching 28
Wire diameter 3.20 ± 0.02
Internal diameter 14.10 ± 0.20
External diameter 20.9 MAX.
10-16
Camshaft End play (in mm) 0.05 to 0.13
The camshafts are either identified as follows: Number of bearings 6

– the exhaust camshaft has the vacuum pump
drive (1), Diameter of the camshaft bearings (in mm)
– the inlet camshaft has a plain end.
– on the camshafts 25 0- 0.021
– on the cylinder head 25 ++ 0.061

0.040
Timing diagram (cannot be checked)
Exhaust
Inlet camshaft
camshaft
cam 1 cam 2 cam 1 cam 2
Inlet opening
- 11 - 11 - -
retard*
Inlet closing
16 16 - -
retard
Exhaust
opening - - 28 28
advance
Exhaust closing
- - - 13 - 13
advance**
Or by marking (2).
* If the Inlet Opening Retard is negative, the valves
Detail of the marking:
open after top dead centre.
– marking (B) gives the engine type,
– marking (C) is used to identify the camshafts:
** If the Exhaust Closing Advance is negative, the
A = Inlet
valves open before top dead centre.
E = Exhaust
– marking (D) is only used by the supplier,
10-17
PISTON
Fitting the gudgeon pin in the con rod and in the

piston.
The gudgeon pin is retained by circlips.
These engines are fitted with KOLBENSCHMIDT

pistons.
Piston marking
1 Cylinder block top dead centre fixed mark

2 Flywheel top dead centre mobile mark
3 Flywheel bottom dead centre mobile mark
4 Inlet Opening Retard
5 Exhaust Opening Advance
6 Inlet Closing retard
7 Exhaust Opening Advance
8 Engine operating direction
1 Piston direction Λ flywheel side,

2 Piston height category,
3 Used by the supplier only
4 Used by the supplier only
5 Piston axis of symmetry,
6 Gudgeon pin hole axis,
7 Offset between the pin hole (7) and the piston axis
of symmetry (6) is 0.5 mm.
10-18
Table of gudgeon pin heights Gudgeon pin (in mm)
Length: 64.3 to 65
Gudgeon pin height
* Mark on piston
(in mm)
External diameter: 30.994 to 31
E 54.48
Internal diameter: 15.03 to 15.23
F 54.52
Rings
J 54.56
K 54.60 Three rings (thickness in mm)

– Compression 3
L 54.64
– Sealing 1.75 - 0.01
- 0.025
The tolerance on the pin heights is ± 0.02 mm.
– Scraper 2.5 - 0.01
- 0.03
* The different gudgeon pin heights are exclusively
reserved for the engine assembly plant.
Clearance at the gap
The Parts Store will only supply F and K class
(height) pistons. Clearance at the break
Rings
(in mm)
Measuring the piston diameter.
Compression 0.2 to 0.35
The piston diameter must be measured at height
Sealing 0.5 to 0.7
A = 49 mm.
Scraper 0.25 to 0.5
Piston diameter (in mm) = 86.806 ± 0.007.
10-19
Fitting the rings CON RODS
Rings set to their original adjustment must be free The connecting rods are of the DETACHABLE CAP
within their channels. type.
Ensure the rings are fitted in the correct orientation.
WARNING:
● The bolts must be sealed with engine oil under
the heads and on the threads when the con rods
are fitted in the engine.
● The repositioning of the big end cap on the con
rod is provided by irregularities on the parting
line.
● The occurrence of impacts or a foreign body
between the rod/cap mating surfaces will soon
lead to rupture of the con rod.
10-20
Lateral big end play (in mm)
0.22 to 0.402
Diametrical big end play (in mm)

0.014 to 0.065
Distance between big end and little end centres
4 classes of big end and little end centre

distances* (mm)
1 149.8775 ± 0.0075
2 149.8925 ± 0.0075
3 149.9075 ± 0.0075
4 149.9225 ± 0.0075
* Marking of the rotating assembly on the original

engine is reserved exclusively for the engine
assembly plant.
NOTE: the Parts Store will only supply class 3

connecting rods.
Diameter of the big end (in mm)
There are two big end diameters
51.587 +0 0.019
56.587 +0 0.019
Diameter of the little end (in mm)

– Without bush 33.5 + 0.025
0
– With bush 31 + 0.025

+ 0.013
NOTE: the con rod small end bushes cannot be

replaced.
10-21
WARNING: do not use a sharp point to mark the big end caps in relation
to their con rods, to prevent starting a crack in the rod. Use a permanent
marker pen.
16044
The maximum difference in weight for the same engine must be 25 grams.
10-22
Direction of fitting of the con rod in relation to the CRANKSHAFT
piston
Number of main journals 5
Position the "Λ" (1) engraved on the head of the piston
downwards and the lubrication hole (2) of the little end Lateral crankshaft play (in mm) 0.060 to 0.232
in line with the vertical axis (as shown on the diagram
below). Diametral crankshaft play (in mm) 0.036 to 0.071
Diameter of the main bearing journals
Main bearing journal diameters are shown on the

crankshaft by paint marks.
Paint mark Blue Red
Main bearing
57.98 inclusive to 57.99 inclusive
journal diameters
57.99 exclusive to 58 inclusive
(in mm)
Crankpin diameters (in mm)
There are two crankpin diameters
48 - 0.01
Direction for fitting circlips on the piston - 0.03
Fit the circlips to the piston as shown below. 53 - 0.01

- 0.03
The lateral shims are located on bearing No. 2.
NO CORRECTION IS AUTHORISED
10-23
BEARING SHELLS
Crankshaft bearing shells
These engines are fitted with foolproof bearing

shells.
Direction of fitting:
– on the cylinder block, fit grooved bearing shells on
all the bearings,
– on the bearing caps, fit non grooved bearing shells.
10-24
Con rod bearing shells
These engines are fitted with non-foolproof

bearing shells.
PISTON COOLING JET
ATTENTION: the piston cooling jet mounting bolts

have a LEFT-HAND thread.
Bearing shells are fitted with the help of Mot. 1492 and
Mot. 1492-02 (using the 48 mm or 53 mm diameter).
10-25
PREPARING THE ENGINE FOR
MOUNTING ON THE SUPPORT
Before the engine is mounted on the

stand Mot. 792-03, the engine's
electrical harness must be removed
and the engine oil drained.
Remove:
– exhaust heat shield,
– turbocharger/cylinder block
retaining strut (if fitted).
10-26
Remove:
– turbocharger/cylinder block and
light-off catalytic converter/
cylinder block retaining struts (if
fitted),
– turbocharger oil supply pipe,
– turbocharger oil return pipe,
– three turbocharger mounting
bolts (1),
– exhaust manifold,
– transmission relay bearing.
10-27
NOTE: it is essential to remove the
relay bearing centring dowel to
enable rod D1 to be correctly
positioned.
Install rods (D) and (D1) Mot. 1574

and (T) Mot. 1301 to the cylinder
block so that they fit in the holes (19,
28, 29) in the plate.
10-28
CONSUMABLES
Type Quantity Component concerned Part no.
Cleaner - Cleaning parts 77 01 421 513
DECAPJOINT Coat Cleaning gasket faces 77 01 405 952
RHODORSEAL 5661 Coat Sump 77 01 404 452
Loctite FRENETANCH 1 - 2 drops High pressure pump bolt 77 01 394 070
Tube of RHODORSEAL 5661 Bead Sump 77 00 421 042
WARNING
WARNING: when working on the fuel supply system, the cleanliness rules described in this document
must be strictly complied with.
PARTS TO BE REPLACED AFTER REMOVAL:
– All gaskets,
– Flywheel bolts,
– Crankshaft bearing bolts,
– Crankshaft pulley bolts,
– Big end cap bolts,
– Injector holder copper washers,
– Diesel fuel return pipe,
– High pressure pipe,
– Pipe plugs,
– Belts,
– Timing belt tension wheel,
– Timing pulley.
10-29
Essential special tooling 10
Illustration Method Parts Store Description
part number part numberM.
Gauge stand used with

Mot. 251-01 00 00 025 101
Mot. 252-01
Thrust plate for measuring the

Mot. 252-01 00 00 025 201 protrusion of cylinder liners used
with Mot. 251-01.
Magnetic flexible shaft for

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

Mot. 591-04 00 00 059 104 cylinder head, 1/2" drive with
index.
Engine mounting plate for Desvil

Mot. 792-03 00 00 079 203
stand.
Mot. 1301 00 00 131 100 T marker pin
Crankshaft flywheel end seal

Mot. 1313 00 00 131 300
fitting tool
Mot. 1316 00 00 131 600 Flywheel immobilising tool.
10-30
Pliers for removing valve stem

Mot. 1335 00 00 133 500
seals
Tool for fitting con rod bearing

Mot. 1492 00 00 149 200
shells
Supplementary kit for fitting con

Mot. 1492-02 00 00 149 202
rod bearing shells
Tool for fitting high pressure

Mot. 1503 00 00 150 300
pump nut blanking piece
Mot. 1511-01 00 00 151 101 Tool for fitting valve stem seals
Mot. 1534 00 00 153 400 Inlet camshaft adjustment tool
Mot. 1536 00 00 153 600 TDC setting pin
10-31
Exhaust camshaft adjustment

Mot. 1537 00 00 153 700
tool
High pressure pump gear

Mot. 1538 00 00 153 800
immobiliser.
No. 1 intermediate gear

Mot. 1539 00 00 153 900
immobiliser
Tool for aligning the teeth of

Mot. 1540 00 00 154 000
gears with wear compensation
Oil pump sprocket oil deflector

Mot. 1541 00 00 154 100
fitting tool
Intermediate camshaft roll pin

Mot. 1542 00 00 154 200
fitting tool
High pressure pump gear

Mot. 1548 00 00 154 800
retaining and extraction tool
10-32
Mot. 1549 00 00 154 900 Injector extraction tool
Crankshaft timing gear end seal

Mot. 1560 00 00 156 000
fitting tool
No. 2 intermediate gear seal

Mot. 1561 00 00 156 100
fitting tool
Mot. 1562 00 00 156 200 Tool for fitting camshaft seals.
Crankshaft flywheel end seal

Mot. 1564 00 00 156 400
fitting tool
High pressure pipe removal and

Mot. 1566 00 00 156 600
refitting spanner
Mot. 1573 00 00 157 300 Cylinder head support
10-33
Mot. 1574 00 00 157 400 Engine rod marked D1
Extractor for seals with a

Mot. 1577 00 00 157 700 diameter between 28 mm and 50
mm

mm

mm
Mot. 1628 00 00 162 800 Sleeve for fitting used seals
Emb. 1518 00 00 151 800 Clutch centring tool kit
Self-adjusting clutch mechanism

Emb. 1604 00 00 160 400
compression tool
10-34
Essential equipment 10
Description
Ring for fitting piston with rings into the liner.
Manual extractor for removing the coolant pump gear. e.g. FACOM part number
U43L.
Standard 22 mm long 1/2'' (12.7 mm) square drive socket for removing the oil
pressure checking gauge.
Valve spring compressor.
Cylinder head testing tool kit, e.g. CULASSE EUROPE SERVICE part number
664000.
Standard 1/2" (12.7 mm) square drive 8/12/14 female torx socket.
Angular tightening tool from:

– e.g. STAHL WILLE part number 540 100 03,
– e.g. FACOM part number DM2360,
– e.g. SAM part number 1 SA.
Tool for fitting valve stem seals, e.g. FACOM part number DM6J4.
Gun for using tube of RHODORSEAL 5661.
10-35
Essential equipment 10
Description
Wrench for high pressure pipes, e.g. FACOM part number DM. 19.
Articulated wrench for removing and refitting the heater plugs, e.g. FACOM part
number B10R10A.
Crankshaft bearing puller, e.g. FACOM part number U 49 A D5.
Dummy pre-heater plug, e.g. FACOM part number 911B 049, for measuring the
pressure at the end of compression.
"Crowfoot" end-piece for torque-tightening high pressure pipes, e.g. FACOM part
number 18.17.
10-36
Overhauling the engine 10
REMOVING THE UPPER ENGINE
Remove:
– the accessories belt by turning
the spanner to the left to slacken
the belt. Immobilise the tensioner
by putting a 4 mm Allen key in the
hole (1),
– the cylinder head suspended

mounting.
10-37
Remove:
– the valve timing cover,
– the TDC pin cap.
10-38
TIMING ADJUSTMENT The grooves in the camshafts must be vertical, as
shown in the drawing below.
Method:
Position the top dead centre mark (1) on the

crankshaft accessories belt pulley almost in line with
the engine vertical as shown in the illustration below.
Fit the top dead centre pin Mot. 1536.
Turn the engine clockwise (timing gear end) while

pushing in the top dead centre pin Mot. 1536 until the
timing setting point is reached.
10-39
Adjustment of the inlet and exhaust camshafts is Position tools Mot. 1534 and 1537 in the camshaft
carried out using tools Mot. 1534 and Mot. 1537. grooves, following the instructions below.
For the inlet camshaft:
Fit tool Mot. 1534, screwing in the bolt (1) by hand.
Undo the three camshaft sprocket bolts (2) by up to

one turn.
Turn the inlet camshaft clockwise with the hub

mounting bolt (3) (using a 16 mm box spanner) so that
the Mot. 1534 tool is flat against the cylinder head,
then tighten the bolt (1) of Mot. 1534.
10-40
For the exhaust camshaft:
Loosen the three camshaft sprocket bolts (5) by up to

one turn.
Turn the exhaust camshaft clockwise with the hub

10-41
Slacken the timing belt by undoing
the tensioner wheel bolt (1).
Remove:
– the three bolts (2), then remove
the exhaust camshaft sprocket,
– the timing belt,
– the camshaft hubs by removing

the bolts (3),
10-42
– the strut between the
multifunction support and the
exhaust gas recirculation valve
holder,
– the power steering pump rear
bolt,
– the power steering pump pulley,
10-43
Remove:
– the power assisted steering
pump,
– the accessories belt pulley.
– the accessories belt tensioner
wheel,
– the alternator,
10-44
– the air conditioning compressor.
10-45
Unclip the flap from the valve cover by pushing it as far
Pay strict attention to the rules regarding
to the rear as possible.
cleanliness (see start of document).
Remove the sealing partition (2) attached to the valve
cover by two nuts, holding the stud (on some versions)
Unclip the side partitions (1) of the rubber flap.
and remove the absorbent soundproofing material (3).
10-46
Remove the pre-heater plugs using the correct
equipment.
WARNING: when loosening the high pressure pipe

nuts (7), it is absolutely essential to hold the filter-
rod retaining nuts (8) with a lock-nut spanner.
Remove:
– the injector pipes using tool
Mot. 1566 or other suitable
equipment,
– the high pressure pipe between
the high pressure pump and the
rail (using a "crowfoot" end-
piece).
WARNING: clip (6) is very
fragile,
– the fuel return pipe,
– the oil vapour recirculation pipe.
Fit the protective blanking plugs

to the high pressure pump, the
injectors and the high pressure
pipes.
10-47
REMOVING THE INJECTOR HOLDERS Fit the extractor on an injector holder.
Tighten the knurled ring to bring the two jaws together
Loosen the mounting bolts for each injection holder. on the flat surfaces without over-tightening.
A special extractor must be used to remove the

injectors. Never attempt to remove an injector
holder tightened in its cylinder head well without
using the tool described below.
Description of the extractor Mot. 1549
1 Extractor support chassis; this is fitted on the

cylinder head cover mounting bolts. Check that it is
fitted correctly before use.
2 Extractor.
3 Extractor bolt.
Fit the chassis of tool Mot. 1549 on the cylinder head

cover mounting bolts. Tighten the extraction bolt until
the injector is released from the cylinder head.
Apply releasing agent around the injector.
Remove the washer from the bottom of each injector

well.
10-48
Remove: – the side partition mounting bolt (5),
– the two clips (2), – the lower metal protector mounting bolt (6),
– the ring for lifting the engine at the flywheel end
– the rail protector with the side partition.

– the rail mounting strap (3) on the sheet metal lower
protector,
– the three common rail bolts (4), then remove the rail,
10-49
– the valve cover bolts,
– the vacuum pump,

– the cylinder head coolant outlet
housing.
10-50
Remove:
– the coolant hose,
– the rocker shafts.
10-51
Mark the camshaft bearing caps.
Remove:
– the camshaft bearings. It is very
important to mark the positions
and the direction of fitting of
the bearings.
10-52
– the camshafts,
– the exhaust gas recirculation

pipe,
10-53
– the cylinder head.
10-54
STRIPPING THE CYLINDER HEAD – the cylinder head suspended mounting.
Place the cylinder head on cylinder head support

Mot. 1573.
Remove:
– the inlet manifold,
10-55
Compress the valve springs using a valve spring Fit the pushrod (1) of Mot. 1511-01 on the valve stem
compressor. seal.
Remove:
– the pins,
– the upper spring retaining washers,
– the springs,
NOTE: before removing the valves and the valve

stem seals, it is vital to measure position H of one
of the old seals in relation to the cylinder head
using Mot. 1511 -01 or other suitable equipment.
NOTE: the internal diameter of the pushrod must

be identical to that of the valve.
In addition, the bottom of the pushrod must come
into contact with the metal upper section of the
valve stem seal.
10-56
Fit the guide tube (2) over the pushrod until the guide CLEANING
tube comes into contact with the cylinder head, locking
the pushrod with the knurled wheel. It is very important not to scratch the gasket faces of
any 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

approximately 10 minutes, then remove it using a
wooden spatula.
Wear gloves whilst carrying out this operation.
Do not allow this product to drip on to the paintwork.
Great care should be taken in performing this

operation, to prevent foreign bodies entering the
oilways which carry oil under pressure to the
hydraulic tappets and the camshafts (passages in
both the cylinder block and head) and in the oil
return pipes.
Failure to follow this instruction could lead to the
blocking of the oilways, resulting in rapid and
serious damage to the engine.
Remove the guide tube assembly plus pushrod, being

careful not to loosen the knurled wheel. CHECKING THE GASKET FACE
Remove: Check for gasket surface bow using a ruler and a set
– the valve guide seals using the Mot. 1335 pliers. of shims.
– the lower spring retaining washers,
Maximum distortion: 0.05 mm
Test the cylinder head to detect possible cracks

using the cylinder head test tools (comprising a tray
and the correct kit for the cylinder head: plug, sealing
plate, blanking plate). The approval number of the
cylinder head test container is 664000.
10-57
CHECKING CAMSHAFT END PLAY Check the end play, which must be between 0.05 and
0.13 mm.
Refit:
– the camshafts, positioning them correctly (see
identification of the camshafts in the Technical
specifications section),
– the camshaft bearing caps (without torque tightening
them),
– the rocker shafts without the rocker arms.
Tighten the camshaft bearing caps to a torque of

0.9 daNm.
Fit a cylinder liner retaining strap Mot. 588, so it can

be used as a support for the magnetic holder.
Remove:
– the rocker shafts,
– the camshaft bearing caps,
– the camshafts.
10-58
REBUILDING THE CYLINDER HEAD Place the barrel of the Mot. 1511-01 tool over the
valve stem (the internal diameter of the barrel must be
Fit new valves and grind them gently into their identical to the diameter of the valve stem).
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.
Fit the valve spring collar rings.
It is imperative to refit the valve stem seals using

tool Mot. 1511-01 or other suitable equipment.
NOTE: do not lubricate the valve stem seals before

fitting them.
Fitting new valve stem seals.
Place the valve in the cylinder head.
Keep the valve pressed against its seat.
Place the valve stem seal (not lubricated) over the tool
barrel.
Push the valve stem seal past the tool barrel, then
withdraw the barrel.
10-59
Place the guide tube plus pushrod assembly on the
valve stem seal.
10-60
Push the valve stem seal down by tapping the top of Refit:
the sleeve with the palm of your hand until the guide – the cylinder head suspended mounting by tightening
tube touches the cylinder head. the bolts to a torque of 4.5 daNm,
– the inlet manifold without tightening the bolts.
Repeat these operations for all the valves.
Fit:
– the springs,
– the upper cups,
Compress the springs.

15857
Fit the pins.
10-61
REMOVING THE LOWER ENGINE
– the timing cover over the series of gears,
Fit the flywheel blocker Mot. 1316.
– the seal (1),

Remove:
– the timing belt tensioner and pulley,
– the water pump cover,
– the crankshaft accessories pulley.
10-62
– the high pressure pump sprocket nut (2),
– the number 2 intermediate shaft plug (3),
– the coolant pump nut (4),
– the coolant pump sprocket, using extractor U 43 L for

example,
10-63
Screw pin Mot. 1538 into the high pressure pump Fit tool Mot. 1539 to intermediate sprocket number 1.
sprocket, in order to immobilise the automatic wear Bend the two tabs (7) against the sprocket and lock
compensation system. them.
Remove the mounting bolt (8), then remove the

sprocket.
Fit the Mot. 1548 extractor to the high pressure pump

sprocket by tightening the three bolts (5), then screw in
the bolt (6) to pull off the high pressure pump sprocket.
Remove:
– the crankshaft timing sprocket,
– the spindle and the washer of intermediate sprocket
number 1,
– the intermediate sprocket number 2 by withdrawing
the mounting bolt (9).
10-64
Remove: – the three high pressure pump rear mounting bolts
– the spindle of intermediate sprocket number 2, (12),
– the coolant pump by withdrawing the two bolts (10),
– the high pressure pump by withdrawing the three

– the diffuser unit by withdrawing the three bolts (11), bolts (13),
10-65
– the clutch mechanism and plate, – the sump,
– the flywheel, – the inner timing cover bolts, then remove the cover,
10-66
Remove: – the oil pump complete with its chain,
– the multifunction support, – the oil pump drive sprocket.
– the oil level sensor,
– the oil filter unit bracket.
– the anti-emulsion plate,
– the flywheel sensor,
10-67
110 ENGINE AND LOWER ENGINE
– the crankshaft bearing cap casing. Remove:
– the big end cap bolts and the connecting rod/piston
assemblies.
WARNING: do not use a sharp point to mark the

bearing caps in relation to their con rods to avoid
starting a crack in the rod. Use a permanent It is essential to mark the position of the
marker pen. crankshaft main bearing shells, as the category
may be different for each bearing.
– the crankshaft main bearing shells
10-68
ENGINE AND LOWER ENGINE
– the piston cooling jets. Warning: left-hand thread. Clean:
– the stiffener,
– the cylinder block,
– the crankshaft,
EXTRACTING THE GUDGEON PINS
NOTE: it is imperative to mark the connecting rod

to match it to its piston, because the piston height
classes in the same engine may be different (see
the Technical Specifications section).
To extract the gudgeon pin, remove the circlip with a

screwdriver, then withdraw the pin.
– the crankshaft bearing using tool Mot. 11 or extractor

U 49 AD5, for example.
10-69
FITTING THE CON ROD BEARING SHELLS On the connecting rod
The main bearing shells are fitted with the help of Slide the main bearing shell holder (1) of Mot. 1492-02
Mot. 1492 and Mot. 1492-02 (using the 48 mm or (using the 48 mm or 53 mm diameter bearing shell)
53 mm diameter). into the groove (2) of the base of tool Mot. 1492.
Fit the guide (3) on Mot. 1492-02 (using the 48 mm

or 53 mm diameter guide) on the base plate (as
shown in the drawing).
10-70
Lay the body of the con rod on the base of the tool (as Bring the shell support to a stop at the base of the con
shown in the diagram). Ensure that the lower part (4) rod body.
of the small end of the con rod is in contact with the
guide pin.
Remove the con rod body support and repeat the

operation for the remaining con rod bodies.
Fit the shell (5) on the shell support, then push it in the
direction of the arrow (as shown in the diagram).
10-71
On the con rod cap Fit the shell (7) on the shell support, then push it in the
direction of the arrow (as shown in the diagram).
Fit the con rod cap as shown in the diagram.
Bring the shell support to a stop at the base of the con

Push the guide (in the direction of the arrow) until the rod cap.
con rod cap is in contact with the pins (6) at the base
of the tool.
Remove the con rod cap support and repeat the

operation for the remaining con rod caps.
10-72
REFITTING THE LOWER ENGINE
Refit:
– the piston cooling jets, tightening
them to a torque of 2 daNm,
– the crankshaft main bearing

shells without grooves on the
crankshaft bearing cap casing,
– grooved crankshaft main bearing
shells on the cylinder block
bearings, checking that the
lubrication holes in the main
bearing shells and the cylinder
block crankshaft bearings are
correctly aligned.
Lubricate the crankshaft main
bearing shells with engine oil.
10-73
Refit:
– the lateral shims (1) of the
crankshaft on bearing No. 2
(grooves on the crankshaft side).
– the crankshaft,
– the bearing cap casing by
tightening the centre bolts to a
torque of 2 daNm, plus an angle
of 150° ± 10° in the
recommended tightening order
(use the old centre bolts).
10-74
Check the lateral clearance of the
crankshaft which should be
between 0.042 mm and 0.215 mm.
Remove the sump.

The sump is sealed with a bead of
Rhodorseal 5661 which must have
a width of 1.6 ± 0.4 mm and follow
the line shown here.
10-75
Do not forget to replace the
centre sump bolts.
Refit:
– the sump by tightening the centre
bolts to a torque of 2 daNm, plus
an angle of 150° ± 10° in the
recommended order.
– the outer sump bolts to a torque of

2 daNm in the recommended
order.
Check that the crankshaft rotates
freely.
10-76
"CON RODS/PISTON" ASSEMBLY NOTE: put the gap in the stop ring of the gudgeon
pin at the top at ± 45˚ to the vertical axis of the
The pistons have a "Λ" mark engraved on their heads piston.
on the flywheel side.
Oil the gudgeon pin.
Check that the gudgeon pins rotate correctly in the

new piston and in the matching connecting rod.
Direction of fitting of the con rod in relation to the

piston
Position the "Λ" (1) engraved on the head 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).
10-77
FITTING THE RINGS Check that the big ends have the correct side
clearance of 0.22 mm to 0.402 mm.
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 oriented as

shown in the diagram below.
Check the piston protrusion which must be

0.395 ± 0.065 mm.
Oil the pistons.
Fit the con rod/piston assemblies into the cylinder

block using the ring (e.g.: FACOM 750 TB), being
careful to fit them the right way round ("Λ" towards
the flywheel).
Fit the con rods onto the oiled big end journals of the
crankshaft.
Fit the big end caps, ensuring they are correctly

matched (marks made when dismantling).
Tighten the big end cap bolts to a torque of 2.5 daNm,

plus an angle of 55° ± 6°.
10-78
REPLACING THE OIL PUMP SPROCKET OIL
DEFLECTOR
The oil deflector is fitted using tool Mot. 1541.
Arrange the parts as shown in the drawing, then

tighten the bolt (1) until it locks.
10-79
Refit:
– the anti-emulsion plate without
tightening the bolts,
– the oil pump drive chain and
sprocket.
Tighten the bolts:
● of the oil pump to a torque of
2.5 daNm (in the recommended
order),
● of the anti-emulsion plate to a
torque of 1 daNm (in the
recommended order).
10-80
Clean the inner timing cover. Put all the bolts in position and then tighten in
accordance with the table below.
Check that the oil supply channels (1) and (2) are not
obstructed.
Tightening
Bolt tightening
Assembly torque
order
(in daNm)
Operation No. 1 7-18-5-14-10-3-16- 1

20-12
Operation No. 2 1-2 3
Operation No. 3 3 to 21 1.2
Fit the seal between the cylinder block and the inner
timing cover.
ATTENTION: bolts
● 19/20/21 are M6*100-20 bolts,
● 1 and 2 are M8*125-20 bolts.
10-81
Put some Rhodorseal 5661 in (3). – the multifunction support by placing it tight against
the cylinder block and the inner timing cover at the
same time, then tighten the bolts to a torque of
3 daNm in the recommended order,
– the oil level sensor to a torque of 1 daNm,
– the oil filter holder with a new gasket and new filter
element, then tighten only the two bolts (A) to a
torque of 2.5 daNm,
19609
Refit:
– the sump with a new gasket and pre-tighten the bolts
to a torque of 0.5 daNm, then carry out the final
tightening to a torque of 0.9 daNm in the
recommended order,
10-82
– the high pressure pump, putting one or two drops of – the diffuser unit, tightening the bolts to a torque of
Loctite FRENETANCH, then tighten the bolts to a 2.5 daNm.
torque of 3 daNm,
– the high pressure pump rear support, tightening the

bolts to a torque of 3 daNm,
10-83
FITTING INTERMEDIATE SHAFT ROLL PINS Offer up the intermediate shaft as shown in the
drawing, with the roll pin hole (2) upwards, and the
Roll pins are fitted using tool Mot. 1542. groove (3) in the shaft should fit the lug in the tool
base.
No. 1 intermediate shaft
Install the base (1) of Mot. 1542 in a vice.
Put the roll pin into the hole (4) in the base.
10-84
Tap the roll pin punch with a hammer until the punch Offer up the intermediate shaft as shown in the
comes in contact with the base. drawing, with the roll pin hole (6) upwards, and the
groove (7) in the shaft should fit the lug in the tool
base.
Put the roll pin into the hole (8) in the base.
No. 2 intermediate shaft
Install the base (5) of Mot. 1542 in a vice.
10-85
Tap the roll pin punch with a hammer until the punch
comes in contact with the base.
Lubricate the bores and the intermediate shafts with

engine oil.
Refit:
– No. 1 intermediate shaft (9), positioning the roll pin in
the groove (10).
– No. 2 intermediate shaft (11), positioning the roll pin
in the groove (12).
– the thrust washers (13),
– the coolant pump (fitted with a gasket), pressing on
the bosses (14) in order to place the pump correctly
against the inner timing cover. Tighten the bolts(15)
to 1 daNm.
10-86
REPLACING SPROCKETS WITH WEAR Remove the two tabs from Mot. 1539.
COMPENSATION
Place the intermediate sprocket number 1 on the
Replacement of intermediate sprocket number 1 and centring tool (9).
the high pressure pump sprocket is carried out using
tool Mot. 1540. Tighten the bolt with its washer at (10), to prevent the
sprocket escaping from the centring tool.
Method for replacing intermediate sprocket
number 1. Push the toothed section (11) in the direction of the
arrow to prevent the sprocket rotating, then lock it with
Put the Mot. 1540 tool in a vice and position levers (1) the wing nut (12).
and (2) as shown below:
– for lever (1), put the locating pin (3) in the groove (4),
then tighten the wing nut (5),
– for lever (2), put the locating pin (6) in the groove (7),
then tighten the wing nut (8),
Remove:
– Mot. 1539, holding the levers (2) then (1) alternately,
to facilitate removal of the tool and to prevent the
automatic teeth wear compensation from expanding
suddenly,
– intermediate sprocket number 1.
10-87
Refit the new intermediate sprocket number 1, locking Turn lever (2) in the direction of the arrow to align the
it with bolt (10) and the toothed section (11). teeth of the hub with those of the lower flange.
Check that the locating pins (3) and (6) are correctly in Press on Mot. 1539 until the tool butts up against the
the middle of grooves (4) and (7) levers (1) and (2). upper flange.
Turn lever (1) in the direction of the arrow to align the Remove intermediate sprocket number 1 from
teeth of the upper flange with those of the hub. Mot. 1540, then refit the Mot. 1539 retaining lugs.
Engage Mot. 1539 with the teeth of the lower flange.
10-88
Method for replacing the high pressure pump
sprocket.
Position lever (1) so that locating pin (3) is in groove

(13), then tighten wing nut (5).
Refit the new high pressure pump sprocket, locking it

with bolt (10) and the toothed section (11).
Check that the locating pin (3) is correctly in the middle

of the groove (4) of lever (1).
Place the high pressure pump sprocket on the centring
tool, then tighten bolt (10) with its washer, to prevent
the sprocket escaping from the centring tool.
Push the toothed section (11) in the direction of the

arrow to prevent the sprocket rotating, then lock the
toothed section with the wing nut (12).
Remove Mot. 1538, holding lever (1) to facilitate

removal of the tool and to prevent the automatic teeth
wear compensation from expanding suddenly,
10-89
Turn lever (1) in the direction of the arrow to align the Fitting crankshaft seal, flywheel end
teeth of the upper flange with those of the hub.
This engine can be fitted with two different types of
Screw in Mot. 1538 until it is tight. seal.
Old and new seals are easily recognized.
The old rubber seal is fitted with a spring (2) and has a
"V"-shaped sealing lip (3).
Remove the high pressure pump sprocket from

Mot. 1540.
10-90
The new rubber seal has a flat sealing lip (4) and a For the new seals, follow the method described below.
protector (5) which also assists in fitting the seal to the
engine. Install tool Mot. 1564 on the crankshaft, attaching it
with bolts (36).
For the old seals, Mot. 1313 must be used.

Put the protector with the seal on tool Mot. 1564, being
careful not to touch the seal.
10-91
Fit the cup (37) and nut (38) (putting the threaded part
(39) of the nut on the side away from the engine) of
Mot. 1564.
Remove the nut, cup, protector and base of tool

Mot. 1564.
Screw the nut until the cup makes contact with the
cylinder block.
10-92
Refit: Remove flywheel blocker Mot. 1316.
– the flywheel sensor,
Set the crankshaft to top dead centre using Mot. 1536.
Refit:
– the crankshaft sprocket (1), and the key (2) must be
located towards the top in the vertical line of the
engine,
– the intermediate sprocket number 2, without
tightening the bolt (3),
– the flywheel, immobilising it with tool Mot. 1316 and

tightening the bolts to a torque of 2.5 daNm plus an
angle of 50° ± 6°.
10-93
– intermediate sprocket number 1, tightening the bolt – the high pressure pump sprocket nut, tightening it to
(4) to a torque of 2.5 daNm plus an angle of a torque of 9 daNm,
30° ± 6°, then remove Mot. 1539, – the coolant pump sprocket, tightening the nut to a
torque of 4 daNm,
– flywheel immobiliser Mot. 1316, making sure that the

key (2) of the crankshaft sprocket is at the top and in – the seal of the cover over the series of sprockets,
the vertical line of the engine. Then remove the top having first degreased the sealing surfaces,
dead centre pin Mot. 1536,
– the high pressure pump sprocket, lining up the marks
(5) and (6),
10-94
– the cover housing the series of sprockets, bringing all FITTING No. 2 INTERMEDIATE SHAFT SEAL AND
the bolts into contact with the cover. CRANKSHAFT SEAL, TIMING END
Tighten the bolts: This engine can be fitted with two different types of
● M6 in the recommended order, 10, 4, 8, 7, 12, and seal.
2 to a torque of 0.8 daNm,
● M8 in the recommended order, 13, 14, and 15 to a Old and new seals are easily recognized.
torque of 2.5 daNm,
● M6 in the recommended order, 1, 2, 3, 4, 5, 6, 7, 8, The old rubber seal is fitted with a spring (2) and has a
9, 10, 11, and 12 to a torque of 1.1 daNm. "V"-shaped sealing lip (3).
10-95
The new rubber seal has a flat sealing lip (4) and a Screw the threaded rod (26) of Mot. 1561 into
protector (5) which also assists in fitting the seal to the intermediate shaft No. 2.
engine.
Fitting the seal on intermediate shaft number 2
Remove the bolt (25).
10-96
For the new seal, put the protector with the seal on the Fit the cup (27) and nut (28) (putting the threaded part
intermediate shaft, taking care not to touch the seal. (29) of the nut on the side away from the engine) of
Mot. 1561.
For the old seal, put the protector marked B of

Mot. 1628, with the seal, on the intermediate shaft.
10-97
Screw in the nut until the cup makes contact with the Remove the nut, the cup, the protector and the
cover of the series of sprockets. threaded rod.
Refit the intermediate shaft bolt, tightening it to a

torque of 2.5 daNm plus an angle of 30° ± 6°.
10-98
Fitting the crankshaft seal, timing end
Screw the threaded rod (30) of Mot. 1560 into the

crankshaft.
For the old seal, put the protector marked C of

Mot. 1628, with the seal, on the crankshaft.
For the new seal, put the protector with the seal on the
crankshaft, taking care not to touch the seal, and also
position the groove (31) of the protector opposite the
key of the crankshaft sprocket (32).
10-99
Fit the cup (33) and nut (34) (putting the threaded part
(35) of the nut on the side away from the engine) of
Mot. 1560.
Remove the nut, the cup, the protector and the

threaded rod.
Screw in the nut until the cup makes contact with the
timing cover.
10-100
Refit:
– the plug on intermediate shaft number 2 using tool
Mot. 1488,
– the coolant pump cover fitted with a new seal,

tightening the bolts to a torque of 1 daNm,
– the timing belt pulley, tightening the bolt to a torque
of 4.5 daNm,
– the crankshaft accessories pulley, tightening the bolt
to a torque of 5 daNm plus an angle of 90° ± 6°,
– the tensioner wheel, without tightening the bolt,
positioning the roll pin (1) correctly in the groove (2).
Remove flywheel blocker Mot. 1316.
10-101
To fit the plug on the high pressure pump, it is REFITTING THE UPPER ENGINE
necessary to make a flat where X = 17 mm and
Y = 40 mm on the Mot. 1503 tool. Rocker shaft expertise
WARNING: do not transpose the rocker shaft

spacers.
Position the pistons at mid-stroke.
10-102
INLET ROCKER SHAFT EXHAUST ROCKER SHAFT
Check that the lubrication holes in the rocker shaft, the Check that the lubrication holes in the rocker shaft, the
rocker arms and the bearings are not blocked. rocker arms and the bearings are not blocked.
To ensure correct assembly of the rocker shaft, To ensure correct assembly of the rocker shaft,
position the flat (1) as shown in the drawing and then position the flat (6) as shown in the drawing and then
slide the rocker arms onto the shaft so that the slide the rocker arms onto the shaft so that the
lubrication holes (2) of the shaft coincide with those of lubrication holes (7) of the shaft coincide with those of
the rockers. the rockers.
Fit: Fit:
– the spacer (3), – the spacer (8),
– the clip (4), – the clip (9),
– the bolt (5). – the bolt (10).
Carry out the above operations for the other rocker Carry out the above operations for the other rocker
arms. arms.
Fit the cylinder head gasket (with the gasket markings

oriented upwards), then the cylinder head.
Tighten the cylinder head (see the Cylinder head

characteristics).
10-103
Put some oil on the camshaft
bearings on the cylinder head side.
Refit the camshafts, positioning
them correctly (see camshaft
identification in the Technical
specifications section),
NOTE: gasket faces must be

clean, dry and free from grease
(in particular, avoid finger
marks).
Put a bead of Loctite 518 2 mm
wide on:
– inlet camshaft (1) bearing cap
number 6,
– exhaust camshaft (2) bearing
caps numbers 1 and 6.
10-104
Refit:
– the camshaft bearing caps (in
accordance with the marks made
beforehand), tightening to a
torque of 1.2 daNm only:
● the bolts (4) of inlet camshaft
bearings 1 and 6,
● the bolts (5) of exhaust
camshaft bearings 1 and 6,
– the rocker shafts, positioning

them as follows:
● for the exhaust camshaft, put the
end of the rocker shaft with the
flat (7) at the timing gear end,
● for the inlet camshaft, put the end
of the rocker shaft without the
flat (8) at the timing gear end.
10-105
In order to tighten the shaft
correctly, it is absolutely imperative
to start with:
● the inlet rocker shaft bolts, then
those of the exhaust, tightening
them to a torque of 1.3 daNm and
in the recommended order,
● the inlet camshaft bearing cap
bolts, then those of the exhaust,
tightening them to a torque of
1 daNm and in the
recommended order.
10-106
Refit: – the thermostat housing with new seals, tightening the
– the exhaust gas recirculation pipe with new seals and bolts to a torque of 1 daNm,
tighten the bolts to a torque of 2.5 daNm, – the vacuum pump fitted with a new seal, tightening
the bolts to a torque of 2.3 daNm,
– the coolant hose screw, tightening it to a torque of
3 daNm,
– the coolant hose fitted with a new seal,
10-107
Put some Rhodorseal 5661 in the corners of the Fit all the seals on the valve cover.
camshaft bearing caps and in the half-shell.
Timing end.
Flywheel end.
10-108
NOTE: put a drop of Locite Frenetanch on bolts 1-2-3-4-5-6-7-13.
Refit the cylinder head cover,

tightening the bolts to a torque of
1.2 daNm in the recommended
order.
Tighten the inlet manifold to a torque of 1.2 daNm and – the ring for lifting the engine at the flywheel end
in the recommended order. – the diffuser hose clips.
10-109
Refit the pre-heater plugs, tightening them to a torque Fit a new washer on each injector nozzle.
of 1.5 daNm.
Fit the injector with its bracket and locking spring ring.
Do not remove the protective plugs from any
component until the last minute. Oil the threads of the nuts.
Clean the injector wells and the injector bodies, as well

ATTENTION: tighten nut (A) on the timing side
as their brackets using a lint-free cloth (use the wipes
first, then nut (B) on the flywheel side.
recommended for this purpose, part
no. 77 11 211 207) dipped in clean solvent.
Tighten nut (A) to a torque of 0.6 daNm, then tighten
Dry off using a different new wipe. nut (B) to a torque of 0.6 daNm, starting on the
timing side, then the flywheel side.
Clean one of the old injector mounting bolts and
tighten it to the end of the mounting hole thread to
clean the tappings.
Fit new studs (1) and injector mounting spacers (2)

after coating the threads with oil and screw them in as
far as possible by hand (0.2 daNm). Always replace
the studs and nuts every time they are dismantled.
Turn only nut (B) through an angle of 360° ± 30°

(nut on the flywheel side).
10-110
Refit the rubber flap to the lower metal protector by Refit:
pulling on the five rubber wall staples (4). Check that – the rubber flap/sheet metal lower protector assembly
the wall staples are clipped correctly. to the engine by refitting the sheet metal lower
protector mounting bolt (3),
Put a bead of Rhodorseal 5661 on the cylinder head

at the point indicated by a black line in the drawing. – the injection rail with its partition (10) without
tightening the rail mounting bolts.
10-111
Remove the plugs from the rail, the injector holders, Refit:
the pump and the injection pipes. – the fuel return pipe,
– the oil vapour recirculation pipe.
Fit the injection pipes between:
– the rail and the injectors,
– the rail and the pump.
Pre-tighten the high pressure pipe nuts by hand.
Torque tighten the:

– rail mounting bolts to 2.3 daNm,
– the injection pipe nuts at the injectors end and the
high pressure pump end to 2.5 daNm,
– the injection pipe nuts at the rail end to 2.5 daNm.
Clip the pump/rail pipes mounting clip and tighten the

two mounting bolts.
10-112
FITTING CAMSHAFT SEALS The new rubber seal has a flat sealing lip (4) and a
protector (5) which also assists in fitting the seal to the
This engine can be fitted with two different types of engine.
seal.
Old and new seals are easily recognized.
The old rubber seal is fitted with a spring (2) and has a
"V"-shaped sealing lip (3).
10-113
Screw the threaded rod (22) of tool Mot. 1562 into the For the old seal, put the protector marked A of
camshaft. Mot. 1628, with the seal, on the camshaft.
Fit the cup (23) and the collar nut (24) from Mot. 1562.
For the new seal, put the protector with the seal on the
camshaft, taking care not to touch the seal.
10-114
Screw the collar nut until the canister touches the Remove the nut, the cup, the protector and the
cylinder head. threaded rod.
10-115
Refit the camshaft hubs with the
timing sprockets fitted.
Position the camshaft grooves

vertically, as shown in the diagram:
10-116
Position tools Mot. 1534 and 1537 in the camshaft For the exhaust camshaft:
grooves, following the instructions below.
For the inlet camshaft:
Turn the exhaust camshaft clockwise with the hub
Fit tool Mot. 1534, screwing in the bolt (1) by hand. mounting bolt (6) (using a 16 mm box spanner) so that
Turn the inlet camshaft clockwise with the hub then tighten the bolt (4) of Mot. 1537.
Tighten the camshaft hub bolts (3) and (6) to a torque

of 6 daNm.
10-117
Refit:
– the air conditioning compressor,
2.1 daNm,
– the alternator, tightening the bolts

to a torque of 2.1 daNm,
10-118
– the power assisted steering
pump, tightening the bolts to a
torque of 2.1 daNm,
– the accessories belt pulley,
tightening the bolt to a torque of
4.5 daNm,
– the accessories belt tensioner
wheel, tightening the bolts to a
torque of 2.1 daNm,
– the power assisted steering pump

pulley, tightening the bolts to a
torque of 1 daNm,
10-119
– the strut between the multifunction support and the TIMING ADJUSTMENT METHOD
exhaust gas recirculation valve support, tightening
the bolts to a torque of 1 daNm, Set the crankshaft at top dead centre (the TDC
– the power assisted steering pump rear bolt, mark (1) on the crankshaft accessories pulley
tightening it to a torque of 2.1 daNm, must be in the vertical line of the engine).
Remove the timing sprocket from the exhaust

camshaft, to facilitate the fitting of the timing belt.
Loosen the three inlet camshaft timing sprocket bolts

by up to one turn.
10-120
Fit the timing belt, starting with
the intermediate sprocket (1),
pulley (2), inlet camshaft
sprocket (trying to keep the bolts
in the centre of the sprocket
holes), tensioner wheel (3).
Fit the exhaust camshaft
sprocket to the belt, then position
it on the camshaft hub, trying to
keep the bolts in the centre of the
sprocket holes.
Refit the three sprocket mounting
bolts without tightening them.
10-121
TIMING BELT TENSION The movable index (5) of the tensioner wheel must be
aligned with the prong (6).
Check that the tab (1) of Mot. 1537 has free vertical
movement.
Check that the bolts (8) are not at the stop at the
bottom of the camshaft timing pin lights.
Put a 6 mm Allen key in the hole (2) of the tensioner
wheel eccentric. Tighten:
– the tension wheel bolt (7),
Turn the tensioner wheel eccentric anti-clockwise – the camshaft timing sprocket bolts (8) to a torque of
until the face (3) of the tab (1) and the upper 1 daNm.
surface (4) of Mot. 1537 are aligned.
10-122
Remove the camshaft timing tools Mot. 1534 and For the inlet camshaft
Mot. 1537 and the TDC pin Mot. 1536.
Rotate the crankshaft through two revolutions in a
clockwise direction (timing side). Loosen the three camshaft sprocket bolts (2) by up to
one turn.
Set the crankshaft at top dead centre (the TDC mark
on the crankshaft accessories pulley must be in the Turn the inlet camshaft clockwise with the hub
vertical line of the engine). mounting bolt (3) (using a 16 mm box spanner) so that
The camshaft grooves must be positioned vertically, as then tighten the bolt (1) of Mot. 1534.
shown in the drawing.
Refit tools Mot. 1534 and 1537 in the camshaft

grooves, following the instructions below.
10-123
For the exhaust camshaft: CHECKING THE TENSION AND THE ADJUSTMENT
Fit tool Mot. 1537, screwing in the bolt (4) by hand. Undo the tension wheel bolt (7) while holding the
eccentric with a 6 mm Allen key.
Loosen the three camshaft sprocket bolts (5) by up to
one turn. Turn the tensioner wheel eccentric clockwise until
the face (9) of the tab (1) and the upper surface (4)
Turn the exhaust camshaft clockwise with the hub of Mot. 1537 are aligned.
The pointer (5) of the tensioner wheel must be located

in the middle of the groove (10).
Check that the tab (1) of Mot. 1537 has free vertical
movement.
10-124
Tighten:
– the bolt (7) of the tension wheel to a torque of
2.5 daNm,
– the camshaft timing sprocket bolts (8) to a torque of
1 daNm.
Remove the camshaft timing tools Mot. 1534 and

Mot. 1537 and the TDC pin Mot. 1536.
Refit the TDC pin hole plug applying a drop of

RHODORSEAL 5661 to the thread and tightening to a
torque of 3 daNm.
10-125
Refit:
– the timing cover, tightening the
bolts to a torque of 1 daNm,
– the lifting ring (1), tightening the
bolt to a torque of 2.1 daNm,
– the cylinder head suspended

mounting, tightening the bolts to a
torque of 2.5 daNm,
10-126
Centre the clutch plate, using centring tool Emb. 1518. Tighten the nut fully. Then put a pair of circlip pliers in
(6).
Refit the mechanism.
Self-adjusting clutch mechanisms must be

compressed using the Emb. 1604 tool, following the
method described below.
Put the Emb. 1604 base plate in a vice.
Put the mechanism on the base plate, then the thrust

ball bearing (4) and the nut (5).
10-127
Compress the springs (7), then while holding the Remove the mechanism from the base plate (checking
springs compressed, free the mechanism by undoing that the springs are correctly compressed).
nut (5) completely.
Refit the mechanism on the flywheel, tightening the
bolts to a torque of 1.2 daNm.
10-128
Refit the accessories belt by turning
the spanner to the left to be able to
remove the 4 mm Allen key from the
hole (2).
Remove the engine from the stand
Mot. 792-03.
Refit:
– the exhaust manifold, with a new
gasket (put the foolproof fitting
holes (A) on the timing side), then
tighten the nuts to a torque of
2.7 daNm in the recommended
order,
– the relay bearing, tightening the
bolts to a torque of 6.2 daNm.
10-129
Put some Rhodorseal 5661 on the cylinder head at – fit the upper strap (7).
the point indicated by a black cross in the drawing. – refit the partition mounting bolts (8).
– reconnect the diesel fuel drain pipe (9), checking
carefully that it is not blocked.
To refit the side partition on the lower metal protector it

is essential that you use the following method:
– fit the lower strap (5).
– pieces of soundproofing material, replacing them if
– fit the rubber ring (6) of the partition onto the lower
they are damaged or soaked with diesel fuel,
metal protector.
– then fit the upper section of the partition to the metal
protector.
10-130
Refit the sealing partition, attached to the cylinder
head cover by two nuts.
Check that the mark (10) on the rail partition is

positioned correctly (in the axis of the high
pressure rail outlets).
Check that the new diesel fuel return pipe is

correctly attached at the injectors and at the
pressure relief valve at the end of the rail.
Fold the rubber flap to the front and clip the side
sealing partitions to it.
Check that the clip buttons are correctly joined to

the partitions and that the rubber flap skirts are
correctly positioned. Clip the rubber flap to the cylinder head cover and the
engine mounting.
IMPORTANT: check that the diesel fuel drain
pipe is correctly connected. Check that the rubber flap is correctly clipped to
the cylinder head cover and engine mountings
studs.
10-131
Refit:
– the turbocharger, tightening the
nuts to a torque of 2.7 daNm,
– the turbocharger oil return pipe,
1 daNm,
– the turbocharger oil supply pipe,
tightening the hollow bolts to a
torque of 2.3 daNm,
– the exhaust heat shield,

1 daNm.
10-132

Workshop Repair Manual: Diesel ENGINE High Pressure Common Rail Cast Iron 4 Cylinders

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Workshop Repair Manual: Diesel ENGINE High Pressure Common Rail Cast Iron 4 Cylinders

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Workshop Repair Manual

Vehicle Type Engine

77 11 303 902 JUNE 2001 EDITION ANGLAISE

10 ENGINE AND PERIPHERALS

Risks relating to contamination

WHAT ARE SOME SOURCES OF CONTAMINATION?

Contamination is caused by:

● Use a brush and thinners to clean the connections to be opened.

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

NON-OBSERVANCE OF THIS ADVICE MAY HAVE SERIOUS CONSEQUENCES FOR SAFETY.

There are two main sections in this manual:

To repair a component on the vehicle, refer to the

Tightening torques given without a tolerance must be

Description Tightening torques

Heater plug 1.5

* See tightening procedure.

Description Tightening torques

* Attention: left-handed thread

Cylinder head bolts must always be replaced.

Cylinder head tightening procedure

REMINDER: to achieve correct tightening of the bolts, use a syringe to

Do not oil the new bolts.

Tighten all the bolts to 3 daNm in the order recommended below.

Do not re-tighten the cylinder head bolts after performing this

Thickness of gasket when tightened: 1.16 ± 0.05 mm.

Measure the piston protrusion.

The protrusion must be: 0.395 ± 0.065 mm.

Checking piston protrusion

Clean the piston heads in order to eliminate any traces

Turn the crankshaft one turn in its operating direction

Put tool Mot. 252-01 in position.

Fit tool Mot. 251-01 equipped with a gauge on its

NOTE: All measurements must be carried out in the

Gasket face bow (in mm):

Cylinder head 0.05

Test the cylinder head to detect possible cracks

Stem diameter (in mm) Seat angle α

Inlet 5.972 ± 0.007 Inlet and exhaust: 89˚ 30'

Face angle 90° 15'

Valve length (in mm)

Inlet 123.2 ± 0.20

Valve lift (in mm)

No valve clearance adjustment.

Inlet and exhaust 50 ± 0.15

Guide external diameter (in mm)

Diameter of the guide housing in the cylinder head

Inlet and exhaust: 11

Guide internal diameter (in mm)

Inlet and exhaust

* This dimension is measured with the guide fitted in

The inlet and exhaust guides have valve stem seals

NOTE: do not lubricate the valve stem seals before

Valve springs (in mm)

Free length 46.70

Length under load:

Length, coils touching 28

Wire diameter 3.20 ± 0.02

Internal diameter 14.10 ± 0.20

External diameter 20.9 MAX.

The camshafts are either identified as follows: Number of bearings 6

– on the cylinder head 25 ++ 0.061

Timing diagram (cannot be checked)

Fitting the gudgeon pin in the con rod and in the