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General Information

SPECIFICATIONS

LIFTING

TOWING

LUBRICANTS

CONSUMABLES

OIL CHANGE AND ENGINE OIL REFILLING


ENGINE AND TRANSMISSION ASSEMBLY
VALUES AND ADJUSTMENT
AXLE ASSEMBLIES VALUES AND
ADJUSTMENT

BJ0F - BJ0G - BJ0J - BJ0K - BJ0V

77 11 311 002 DECEMBER 2001 EDITION ANGLAISE

All copyrights reserved by Renault.


"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.
The methods may be modified as a result of changes introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed."

© RENAULT 2001
General Information

Contents

Page Page

01A SPECIFICATIONS ENGINE AND TRANSMISSION


07A ASSEMBLY VALUES AND
Engine - Gearbox 01A-1 ADJUSTMENT
Vehicle identification 01A-2
Capacities - Grades 07A-1
Accessories belt tension 07A-2
Tightening the cylinder head 07A-6
02A LIFTING
Trolley jack - Axle stands 02A-1
Underbody lift 02A-2 AXLE ASSEMBLIES VALUES AND
07B ADJUSTMENT

03A TOWING Wheels and tyres 07B-1


Brakes 07B-2
Underbody heights 07B-3
All types 03A-1
Front axle geometry checking values 07B-4
Rear axle geometry checking values 07B-5

04A LUBRICANTS
Packaging 04A-1

04B CONSUMABLES
Packaging 04B-1

OIL CHANGE AND ENGINE OIL


05A REFILLING

Engine 05A-1
Gearbox 05A-3
Power assisted steering 05A-4
101A
SPECIFICATIONS
Engine - Gearbox 01A
Engine
Vehicle type Cubic capacity Gearbox type
Type
(cm3 )

BJ0K F4R 1998 PK6

BJ0E - BJ0F - BJ0G - BJ0M G9T 2188 PK6 / SU1

BJ0J P9X 2958 SU1

BJ0V V4Y 3498 SU1

VEHICLE IDENTIFICATION

Example: BJ0K

B : Body type (five-door)

J : Project code

0K : Engine suffix

01A-1
SPECIFICATIONS
Vehicle identification 01A
LOCATION OF VEHICLE IDENTIFICATION PLATE

1 Vehicle type and type series number 6 Technical specifications of the vehicle
This information is repeated on marking (B). 7 Vehicle paint reference
2 MGVW (Maximum Gross Vehicle Weight) 8 Equipment level
3 GTW (Gross Train Weight - loaded vehicle with 9 Vehicle type
trailer) 10 Trim code
4 Front axle MGVW 11 Additional equipment details
5 Rear axle MGVW 12 Fabrication number
13 Interior trim code

01A-2
102A
LIFTING APPARATUS
Trolley jack - Axle stands 02A
Safety symbol (special precautions to be taken when carrying out operations).

SPECIAL TOOLING REQUIRED

Cha. 280-02 Adaptor cup for trolley jack

If a trolley jack is used, appropriate axle CAUTION:


stands must always be used. Position the body flange correctly into the shim groove.

IMPORTANT:
The vehicle subframe is protected by products which
guarantee against corrosion for 12 years.

Materials fitted with rubber pads should always be


used to prevent any direct metal to metal contact
which could damage the original corrosion protection.

The vehicle must not be raised by placing the jack


beneath the front suspension arm or under the rear
axle.

To lift a front or rear wheel, place the jack at (B) on the


subframe underbody flange in alignment with
marks (A).

To lift both the front and rear wheels laterally, use the
cup Cha. 280-02.

Place the jack under the sill body flange at the centre
point of the front door.
To move the vehicle onto axle stands, lift the entire
vehicle laterally and position the axle stands under the
body flange stiffeners provided for the tool kit trolley
jack (B).

02A-1
LIFTING APPARATUS
Underbody lifts 02A
SAFETY NOTES FITTING THE STRAPS

For obvious safety reasons, these straps should be


If heavy components need to be removed from the kept in perfect condition (if they become frayed,
vehicle, it is preferable to use a four-post lift if possible. replace them immediately).

In fact, after removing a large component (for When fitting the straps, check that the protectors are
example: engine and transmission assembly, rear located on the seats and the fragile parts of the
axle, fuel tank, etc.), the vehicle has lost a large vehicle, do not overtighten the straps.
proportion of its load and there is a risk that it can
become unstable on two-post lift supports (see the Place the straps under the post-lift arms and pass
position of the arms further on). them around the vehicle.

This is even more dangerous when the vehicle is lifted The following example demonstrates the vehicle
to greater height lashing for an operation on the front of the vehicle.

When the vehicle is lifted from underneath the body by


a two-post lift it is necessary to fit safety straps which
are available at Parts Stores part no.: 77 11 172 554.

02A-2
LIFTING APPARATUS
Underbody lifts 02A
POSITIONING OF THE LIFTING ARMS

Position the lifting arm on the subframe underbody


flange in alignment with the markings (A).

FRONT

REAR

02A-3
TOWING103A
All types 03A
OBSERVE THE TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.

NEVER USE THE DRIVESHAFTS AS AN ATTACHMENT POINT.

The towing points may only be used for towing the vehicle on the road. They should never be used for removing the
vehicle from a ditch or to lift the vehicle, either directly or indirectly.

FRONT REAR

03A-1
104 A
LUBRICANTS
Packaging 04 A
DESCRIPTION PACKAGING PART NUMBER

GREASES

● MOLYKOTE "BR2" 1 kg tin 77 01 421 145


for main bearing journal faces, thrust pad guide tubes,
clutch fork pads, lower suspension arm bearings,
torsion bar splines, steering box and driveshaft splines.

● MOLYKOTE "33 Medium" 100 g tube 77 01 028 179


bushes, tubular rear axle, anti-roll bar bushes.

● ANTI-SEIZE 80 ml tube 77 01 422 307


(high temperature grease) Turbo, etc.

● "MOBIL CVJ" 825 Black Star or MOBIL EXF57C 180 g sachet 77 01 366 100
for driveshaft seals.

● MULTIPURPOSE GREASE Aerosol 77 01 422 308


wheel sensor.

MECHANICAL SEALANTS

● Mastic 1.5 kg tin 77 01 421 161


for sealing exhaust pipe unions.

● RHODORSEAL 5661 – Cartridge 77 01 421 042


– 100 g tube 77 01 404 452

● HARDENER KIT (RHODORSEAL 5661) Kit 77 01 421 080


for side sealing of bearing caps.

● AUTO blue seal 100 g tube 77 01 396 227


sealing paste.

VARNISHES

● "CIRCUIT PLUS" Bottle 77 01 421 135


varnish for repairing heated rear screens.

BRAKES

● Brake fluid 0.5 litre bottle DOT 4 77 11 172 381

● "Low viscosity" brake fluid. 0.5 litre bottle DOT 4 77 11 218 589

04A-1
204B
CONSUMABLES
Packaging 04B
DESCRIPTION PACKAGING PART NUMBER

MECHANICAL SEALANTS

● AUTO grey seal 100 g tubes 77 01 422 750


sealing paste.

● Loctite 518 24 ml syringe 77 01 421 162


for sealing the gearbox housing.

● Leak detector. Aerosol 77 11 143 071

ADHESIVES

● "LOCTITE-FRENETANCH" 24 cc bottle 77 01 394 070


stops bolts loosening and allows them to be released.

● "LOCTITE-FRENBLOC" 24 cc bottle 77 01 394 071


locks bolts.

● "LOCTITE SCELBLOC" 24 cc bottle 77 01 394 072


for bonding bearings.

LUBRICANT CLEANING AGENTS

● "NETELEC" Aerosol 77 11 171 287


unseizing agent, lubricant.

● Carburettor cleaner. 300 ml aerosol 77 11 171 437

● Injector cleaner 355 ml can 77 01 423 189

● Super-concentrated unseizing agent. 500 ml aerosol 77 01 408 466

● "DECAPJOINT" (FRAMET) Aerosol 77 01 405 952


for cleaning the gasket faces of aluminium cylinder
heads.

● Brake cleaner. 400 ml aerosol 77 11 171 911

04B-1
FLUID CHANGE AND105A
FLUID REFILLING
Engine 05A
TOOLING REQUIRED

Engine drain plug spanner

DRAINING: plug (1) G9T ENGINE

FILLING: plug (2)

F4R ENGINE

05A-1
FLUID CHANGE AND FLUID REFILLING
Engine 05A
DRAINING: plug (1) V4Y ENGINE

FILLING: plug (2)

P9X ENGINE

05A-2
FLUID CHANGE AND FLUID REFILLING
Gearbox 05A
DRAINING: plug (1)

FILLING and LEVEL: cap (2)

F4R and G9T ENGINES

Manual gearbox

G9T, P9X and V4Y ENGINES

Automatic gearbox

05A-3
FLUID CHANGE AND FLUID REFILLING
Power assisted steering 05A
CHECKING THE LEVEL

POWER ASSISTED STEERING PUMP LEVEL

For topping up or filling, use ELF RENAULTMATIC D2


or MOBIL ATF 220 oil.

The level, when correct, should be visible between the


MIN and MAX marks on the reservoir (1).

ENGINES OF ALL TYPES

05A-4
107A AND SETTINGS
ENGINE AND GEARBOX VALUES
Capacities - Grades 07A
Average capacity* in litres

Components After an oil change,


After replacing the oil
check using the
filter
dipstick

Diesel engine (oil)

G9T 5.6 6.3

P9X 6.5 7.3

Petrol engine (oil)

F4R 5 5.2

V4Y 4.75 4.8

Manual gearbox

PK6 2.2

Automatic gearbox

SU1 7.6

* Check with dipstick.

NOTE: never exceed the maximum mark on the dipstick.

Components Capacity in litres Grade

Standard: 0.7 SAE J 1703 and DOT 4


Brake circuit ABS: 1 (low viscosity when
cold)

Brake fluids must be approved by the Technical Department.

Components Capacity in litres Grade

Fuel tank Approximately 80 Unleaded petrol Diesel

Power assisted Separate reservoir ELF RENAULT MATIC


steering 1.1 D2 or MOBIL ATF 220
Coolant circuit GLACEOL RX
F4R 6.8 (type D)
G9T 7 add only coolant
P9X 7
V4Y 7.4

07A-1 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
F4R ENGINE Accessories belt tensioning 07A
REMOVAL

Put the vehicle on a two-post lift.

Disconnect the battery.

Remove:
– the engine covers,
– the front right wheel,
– the side protection.

To remove the belt, pivot the automatic belt tensioner


in the direction shown below using a 16 mm angled
ring spanner.

Remove the accessories belt.

REFITTING

NOTE: never refit a belt once it has been removed,


but replace it.

Refitting is the reverse of removal.

Connect the battery and carry out the necessary


programming.

07A-2 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
G9T ENGINE Accessories belt tensioning 07A
REMOVAL

Put the vehicle on a two-post lift.

Disconnect the battery.

Remove:
– the engine covers,
– the front right wheel,
– the side protection.

Special notes for removing the accessories belt

Pivot the auto tensioner to the left using a spanner to loosen the belt. Lock
the tension wheel by putting a 4 mm Allen key in the hole (1).

REFITTING

NOTE: never refit a belt once it has been removed, but replace it.

Refitting is the reverse of removal.

Connect the battery and carry out the necessary programming.

07A-3 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
P9X ENGINE Accessories belt tensioning 07A
REMOVAL

Put the vehicle on a two-post lift.

Disconnect the battery.

Remove:
– the engine covers,
– the front right wheel,
– the side protection.

Special notes for removing the accessories belt

Swivel the auto tensioner as indicated below using a


19 mm offset wrench to loosen the belt.

Remove the belt.

REFITTING

NOTE: never refit a belt once it has been removed,


but replace it.

Refitting is the reverse of removal.

Tighten the tension wheel bolts to a torque of


2.5 daNm.

Tighten the tension wheel bolts to a torque of


5.8 daNm.

Connect the battery and carry out the necessary


programming.

07A-4 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
V4Y ENGINE Accessories belt tensioning 07A
SPECIAL TOOLING REQUIRED

Mot. 1505 Belt tension measuring tool

REMOVAL Air conditioning compressor and alternator belt,

Put the vehicle on a two-post lift.

Remove the engine covers.

Disconnect the battery.

Remove:
– the front right wheel,
– the side protection.

→ tension checking point

Power Air conditioning


assisted compressor and
Components
steering alternator belt,
pump belt,

Fitting tension
234 ± 8 260 ± 8
(Hz)
REFITTING

Power assisted steering pump belt, NOTE: always replace a belt after it has been
removed.

Proceed in the reverse order to removal.

Connect the battery and carry out the necessary


programming.

07A-5 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
F4R ENGINE Tightening the cylinder head 07A
CYLINDER HEAD

The bolts can be reused if the length under the head does not exceed 117.5 mm (otherwise replace all the bolts).

Cylinder head tightening procedure

REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to
achieve correct tightening of the bolts.

Do not oil the new bolts. However, the bolts must be oiled if they are being reused.

Tighten all the bolts to 2 daNm in the order recommended below.

Check that all the bolts are correctly tightened to 2 daNm then, bolt by bolt, tighten to an angle of 165˚ ± 6˚.

Do not retighten the cylinder head bolts after applying this procedure.

07A-6 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
G9T ENGINE Tightening the cylinder head 07A
CYLINDER HEAD

The bolts must be replaced systematically.

Cylinder head tightening procedure

REMINDER: Use a syringe to remove any oil which may have entered the
cylinder head mounting bolt holes to achieve correct tightening of the bolts.

Do not oil the new bolts.

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

Check that all the bolts are tightened to 3 daNm then, bolt by bolt, tighten to
an angle of 300°° ± 6°°.

Do not retighten the cylinder head bolts after applying this procedure.

07A-7 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
P9X ENGINE Tightening the cylinder head 07A
CYLINDER HEAD

The bolts must always be replaced.

Cylinder head tightening procedure

REMINDER: Use a syringe to remove any oil which may have entered the
cylinder head mounting bolt holes to achieve correct tightening of the bolts.

First stage:
– Tighten all the bolts to 3.9 daNm in the order recommended below.

Second stage:
– bolts numbered 1 to 4: angle-tighten to 130°°
– bolts numbered 5 to 8: angle-tighten to 110°°

Third stage:
– bolts numbered 1 to 4: angle-tighten to 130°°
– bolts numbered 5 to 8: angle-tighten to 110°°

A: inlet side

B: exhaust side

Do not retighten the cylinder head after carrying out this procedure.

07A-8 Edition 2
ENGINE AND GEARBOX VALUES AND SETTINGS
V4Y ENGINE Tightening the cylinder head 07A
Cylinder head tightening procedure Rear cylinder head

The bolts can be reused if the difference between D1


and D2 (shown by the dimensions X1 and X2) is less
than or equal to 0.11 mm.

Loosen the bolts.

Tighten to 4 daNm.
X1: 11 mm
First angle-tighten to 95°°.
X2: 48 mm
Then angle-tighten to 95°°.
REMINDER: to achieve correct tightening of the bolts,
use a syringe to remove any oil which may have
Do not retighten the cylinder head bolts after
entered the cylinder head mounting holes.
performing this procedure.
Do not oil the new bolts. However, the bolts must be
oiled if they are being reused.

Tighten all the bolts to 10 daNm in the order


recommended below.

Front cylinder head

07A-9 Edition 2
207B
AXLE ASSEMBLIES VALUES AND ADJUSTMENT
Tyres and wheels 07B
Tyre pressure when cold (in bar) (1)
Engine Rim Tyres
Front Rear

7 J 17 225/55 R 17 2.2
F4R
7.5 J 18 245/45 R 18 2.2

7 J 17 225/55 R 17 2.5
V4Y
7.5 J 18 245/45 R 18 2.6
2.0
7 J 17 225/55 R 17 2.3
G9T
7.5 J 18 245/45 R 18 2.4

7 J 17 225/55 R 17 2.4
P9X
7.5 J 18 245/45 R 18 2.5

(1) Under full load and/or on motorway.

Wheel bolt tightening torque: 11 daNm.

Rim run-out: 0.8 mm

Tyre pressures must be checked when cold. The increase in temperature during driving increases the pressure by
0.2 to 0.3 bar.

If the pressure is checked when warm, take into account this increase in pressure and never deflate the tyres.

Special features of vehicles fitted with the tyre pressure monitor

Each set of four tyres is programmed by computer.

When the winter tyres or wheels are being fitted, and the programming has already been carried out, you only need
to change to winter mode using the diagnostic tool. Similarly, when the summer tyres or wheels are being fitted, you
need to change to summer mode using the diagnostic tool.

07B-1 Edition 2
AXLE ASSEMBLIES VALUES AND ADJUSTMENT
Brakes 07B
Disc thickness (in mm) Disc thickness (in mm)

Maximum disc
Vehicle type Front Rear
run-out (in mm)

Normal Minimum Standard Minimum

ALL TYPES 28 25.4 11 9.5 0.2

Brake pad thickness (in mm) (including mounting)

Vehicle type Front Rear Brake fluid

New Minimum New Minimum

SAE J 1703
ALL TYPES 17.5 8 16.6 8
DOT 4 (1)

(1) For optimal performance of vehicles equipped with the electronic stability program, RENAULT recommends a
brake fluid with low viscosity in cold conditions (maximum 750 mm2 /s at - 40 °C).

07B-2 Edition 2
AXLE ASSEMBLIES VALUES AND ADJUSTMENT
Underbody height 07B
MEASUREMENT POINTS

Dimensions H1 and H4 are measured between the floor and the wheel centrelines.
Dimension H2 is measured between the floor and the lower face of the front securing nut on the lower arm.
Dimension H5 is measured between the floor and the head of the longitudinal arm bearing screw furthest from the
wheel.

07B-3 Edition 2
AXLE ASSEMBLIES VALUES AND ADJUSTMENT
Front axle geometry checking values 07B
Tyres: 225/55 R 17 or 245/45 R 18

POSITION OF
ANGLES VALUES ADJUSTING
FRONT AXLE (mm)

CASTOR 3°51' H5 - H2 = 99
4°07' H5 - H2 = 90
4°23' ± 30' H5 - H2 = 82
4°39' H5 - H2 = 74
4°55' H5 - H2 = 66
Not
Max. right/left adjustable
variance = 1º

CAMBER -0°01' H1 - H2 = 133


-0°05' H1 - H2 = 141
-0°09' ± 30' H1 - H2 = 148
-0°13' H1 - H2 = 155
-0°17' H1 - H2 = 163 Not
adjustable
Max. right/left
variance = 1º

PIVOT 11°48' H1 - H2 = 133


11°59' H1 - H2 = 141
12°10' ± 30' H1 - H2 = 148
12°20' H1 - H2 = 155
12°31' H1 - H2 = 163 Not
adjustable
Max. right/left
variance = 1º

WHEEL ALIGNMENT
(For two wheels)
Locking
-0°10' ± 10' Unladen Adjusted by
17 inch rotating the
rim or
track rod
- 1.3 mm ± 1.3 mm H1 - H2 = 133 sleeves
18 inch
rim
- 1.4 mm ± 1.4 mm

POSITION FOR TIGHTENING RUBBER


BUSHES

- Unladen -

07B-4 Edition 2
AXLE ASSEMBLIES VALUES AND ADJUSTMENT
Rear axle geometry checking values 07B
POSITION OF
ANGLES VALUES ADJUSTMENT
REAR AXLE (mm)

CAMBER
Adjustment by
rotating the
Unladen
eccentric (upper
-0°50' ± 30' or stub-axle carrier
mounting)
H4 - H5 = 45
Refer to
Section 33A.

WHEEL ALIGNMENT
(For two wheels)
Closing Adjustment by
-0°20' ± 10' Unladen moving the
17 inch longitudinal arm
rim or
bearings.
-2.6 mm ± 1.4 mm H4 - H5 = 45 Refer to
18 inch Section 33A.
rim
-2.7 mm ± 1.4 mm

POSITION FOR TIGHTENING RUBBER


BUSHES

- Unladen -

07B-5 Edition 2