1.2 L Renault D4F I4 Engine Manual

Technical Note 6004A
DXX, and D4D or D4F

D4 4-cylinder petrol engine
77 11 328 182 JULY 2004 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s. 2004

D4 4-cylinder petrol engineContentsPage
D4 4-cylinder petrol engine
Contents
10A ENGINE AND LOWER ENGINE ASSEMBLY 10A ENGINE AND LOWER ENGINE ASSEMBLY
General information 10A-1 Engine: Refitting 10A-127
Engine identification 10A-2 Timing belt: Removal 10A-130
Tightening torque 10A-4 Timing belts: Refitting 10A-133

Upper engine: Specifications 10A-12
Engine peripherals:
Specifications 10A-19
Consumables 10A-26
Parts to be replaced
systematically 10A-27
Special notes 10A-28
Standard replacement 10A-29
Special tooling 10A-30
Equipment 10A-40
Engine: Dismantling 10A-42
Timing - cylinder head:

Removal 10A-45
Stripping the cylinder head 10A-50
Upper engine: Cleaning 10A-56
Upper engine: Checking 10A-57
Rebuilding the cylinder head 10A-65
Cylinder block: Dismantling 10A-78
Running gear:Removal 10A-83
Lower engine: Cleaning 10A-85
Lower engine: Check 10A-86
Running gear Refitting 10A-91
Cylinder block: Refitting 10A-100
Timing - cylinder head:

Refitting 10A-114
ENGINE AND LOWER ENGINE ASSEMBLY
General information 10A
D4D, and 700 or 712 or 720 – D4F, and 702 or 706 or 708 or 712 or 714 or 716 or 722 or 728 or 730 or 740
I -UNITS OF MEASUREMENT
- All dimensions are expressed in millimetres (mm) (un-
less stated otherwise).
- Tightening torques are expressed in Newton metres
(Nm) (reminder: 10 Nm = 1.02 m/kg)
- Pressures are expressed in bar (reminder: 1 bar = 100
000 Pa).
II - TOLERANCES
Tightening torques given without a tolerance must be
accurate to within:
- in degrees (± 6˚),
- in Nm (± 10%).
10A-1
Engine identification 10A
I -ENGINE IDENTIFICATION Details of markings
The engine identification is located on the cylinder 1 2 3
block under the inlet manifold.
4 5
19858
The markings include:
- (1): the engine type
- (2): the engine approval letter
- (3): the engine suffix
- (4): the factory where the engine was fitted
- (5): the engine production number
18636
II - ENGINE SPECIFICATION TABLES
Vehicle After- Engine Engine Cubic capa- Bore Stroke Com-

Sales type suffix city (cm3) (mm) (mm) pression
Type: ratio
C06H D4D 712 999 69 66.8 9.8 ± 0.6
X06C D4F 702 1149 69 76.8 9.8 ± 0.6

TWINGO
X06D
X06K
XB06 D4D 700 999 69 66.8 9.8 ± 0.6
XB05 706
XB0W 712
XB11 714
CLIO II XB19
D4F 1149 69 76.8 9.8 ± 0.6
XB1Y
XB2T 722
XB2U 728
XB2V
10A-2
Engine identification 10A
Vehicle After- Engine Engine Cubic capa- Bore Stroke Com-

Sales type suffix city (cm3) (mm) (mm) pression
Type: ratio
XC06 D4D 720 999 69 66.8 9.8 ± 0.6
XC05 714
KANGOO XC0T 716

D4F 1149 69 76.8 9.8 ± 0.6
XC03
XC1D 730
MODUS JP0C D4F 740 1149 69 76.8 9.8 ± 0.6

JP0K
10A-3
Tightening torque 10A
Upper engine
4
5
18
7 16
3 8
9 15
10 14
17
10
9
13
12
11
11
12
110408
10A-4
Upper engine
Tightening torques in Nm and/or in ˚
1 Camshaft pulley bolt 30 + 45˚ ± 6˚
2 Timing tensioner nut 24
3 Timing tension wheel stud 10
4 Camshaft securing bolt 7 + 50˚ ± 6˚
5 Valve clearance adjusting nut 10
6 Upper timing cover bolt 33
7 Cylinder head bolts see tightening procedure
8 Spark plugs 27 to 20
9 Rocker cover bolts 12 / see order of tightening
10 Inlet manifold / rocker cover 8
11 Inlet manifold / cylinder head bolts 10 / see order of tightening
12 Motorised throttle valve bolt 10
13 Injection rail bolt 10
14 Coolant temperature sensor 22
15 Exhaust manifold nut 25 / see order of tightening
16 Heat shield nut 15
Mark 17 Cylinder head coolant outlet unit mounting bolt 10
Mark 18 Ignition coil 7
10A-5
Rotating parts
2 4
5
110410
Rotating parts
1 Crankshaft accessories pulley bolt 40 + 70˚ ± 6˚
2 Crankshaft bearing bolts 20 + 76˚ ± 6˚
3 Con rod cap bolt 14 + 39˚ ± 6˚
4 Flywheel bolts 18 + 110˚ ± 6˚
5 Clutch pressure plate bolt 25
10A-6
Lower engine:
3 1
6
5
9
10
8
11
14
15
16
12 13
110409
10A-7
Lower engine:
1 Intermediate timing housing bolts 10
2 Lower timing cover bolt 10
3 Water pump bolts 9
4 Coolant pump inlet pipe bolts 9
5 Pinking sensor 20 ± 4
6 Crankshaft closure panel bolt 9
7 Oil pump housing bolt 9
8 Oil pump strainer bolt 9
9 Oil pressure sensor 32 ± 2
10 Water pump inlet pipe bolts 9
11 Oil level sensor 30 ± 5

Blanking cover cap
12 Oil drain plug 20
13 Oil sump bolt 10 / see order of tightening
14 Oil filter fitting 15 ± 3
15 Oil filter 10
16 Oil filter 20
10A-8
Accessories end: Alternator / Power assisted steering / Air conditioning
10 5 7
4
8 9
3
1
110411
1 Alternator mounting bolt 50
2 Alternator upper M8 bolt 21
3 Alternator lower M10 bolt 50
4 Power assisted steering mounting bolt 50
5 Power assisted steering pump bolt 21
6 Air conditioning compressor bracket bolt 50
7 Air conditioning compressor bolt 50
8 Air conditioning compressor strut bolt 12
9 Strut bolt on the cylinder block 21
10 Manual tensioner bolt 37
10A-9
11
10
5
6
5
7 8 9
3
1
110412
1 Alternator mounting bolt 50
2 Alternator upper M8 bolt 21
3 Alternator lower M10 bolt 50
4 Power assisted steering mounting bolt 50
5 Power assisted steering pump bolt 21
6 Air conditioning compressor bracket bolt 50
8 Air conditioning compressor strut bolt 12
9 Strut bolt on the cylinder block 21
11 Pulley bolt 21
10A-10
Accessories end: Alternator / Air conditioning
110413
Accessories end: Alternator / Air conditioning
- Multifunction accessories mounting bolt 50
1 Alternator bolt 21
10A-11
Upper engine: Specifications 10A
UPPER ENGINE 2 - Cylinder head gasket
1 - Cylinder head tightening procedure 1
WARNING
- To ensure that the bolts are correctly tightened,
use a syringe to remove any oil that may be in the
cylinder head mounting holes.
WARNING
- Replace the cylinder head mounting bolts with new
ones whenever they are removed.
19598
WARNING The thickness of the cylinder head gasket is measured

at (1) : 0.49 ± 0.04 mm
- Do not oil the new bolts.
3 - Cylinder head
10 6 2 3 7
9 5 1 4 8
H
18641
Preseating the gasket:
18708
- Tighten to torque, in the correct order, the cylinder
head mounting bolts20 Nm ± 2 Nm The height of the cylinder head (H) is measured 99 ±
0.05 mm.
Tightening the cylinder head:
- Loosen and retighten to torque, bolt by bolt, in the or- Maximum bow of sealing surface:
der and to the correct angle: 20 Nm ± 2 Nm + 230˚ ±
6˚. - cylinder head: 0.05 mm.
- cylinder block: 0.03 mm

WARNING
Test the cylinder head for possible cracks with the cy-
Do not retighten the cylinder head bolts after linder head test kit (see Garage Equipment Catalo-
applying this procedure. gue).
10A-12
b - Maximum valve lift
WARNING
No regrinding is permitted. D4D, and 712 – D4F, and 702 or 706 or 708 or 712
or 714 or 716 or 722 or 728 or 730
4 - Ignition Inlet: 8.849 mm.
The firing order is 1 - 3 - 4 - 2 . Exhaust: 8.850 mm.

Cylinder no. 1 is at the flywheel end.
Spark plugs
Electrode gap = 0.90 ± 0.05 mm.
D4F, and 740
The tightening torque of the spark plugs should be 20
to 27 Nm. Inlet: 8.004 mm.
Exhaust: 8.850 mm.

5 - Valves
a - Valve dimensions
6 - Checking the valve clearance
a Clearance when cold (mm)
- Inlet: 0.05 to 0.15 mm.

D1
- Exhaust: 0.10 to 0.20 mm.
D2
Tighten to torque the rocker arm adjusting nut 10 Nm.
L
7 - Valve seats
19598
Inlet Exhaust
(D1)Stem dia- 5.48 0 -0.015 5.47 0 -0.015

meter (mm)
(D2)Head dia- 26 ± 0.12 22.1 ± 0.12

meter (mm)
(L)Total length 110.54 to 112.27 to X

(mm) 110.99 112.72
(A)Face angle 90
(˚)
D1
106964
10A-13
Inlet Exhaust
Face angle α (˚) 89˚30’
Mating face 0.994 ± 0.403 1.136 ± 0.377

width (mm)
External diame- 28 ± 0.005 24 ± 0.005

ter of seat D1
(mm)
8 - Valve guides
a - Valve guide dimensions
Inlet Exhaust
Guide length (mm) 40.5 ± 0.15
Guide external dia- 11 +0.068

+0.050
meter (mm)
Internal diameter of 5 +0.075

0
non-machined guide
(mm)*
Internal diameter of 5.5 +0.018

0
non-machined guide
(mm)*
Internal diameter of 11 ± 0.013

seat in cylinder head
(mm)
* The dimension is measured with the guide fitted to the

cylinder head.
10A-14
b - Angles and positions of the guides
2 1
18943
Guide angles
- (1)Inlet: α = 27˚,
Note:
- (2)Exhaust: α = 21˚. There are two types of valve stem seal:
Guide positions: - the valve stem seal with a lower spring retaining
- Inlet and exhaust:(x) = 10.3 ± 0.15 mm. washer (1),
- the valve stem seal without a lower spr ing retai-
9 - Valve stem seals ning washer (2)
The valve stem seals must be replaced each time the

valves are removed.
1
110683
10A-15
98503
Removal is carried out using tool (Mot. 1335).
It is imperative to fit the valve stem seals using these to-
ols:
18077
- or using suitable equipment (for both types of seal).
WARNING
Do not lubricate the valve stem seals before fitting
them.
10 - Valve springs
15737
- kit (Mot. 1511) for seal types (1).
1 2
16051
The valve stem springs may either be of the cylindrical

type(1) or the conical type(2).
10A-16
a - Conical springs
Flywheel end
Free length 40.20 mm
5 27.98 ± 0.01 28.05 ± 0.01
Length under load:
- 145 ± 8 N: 34 mm Timing end
- 428 ± 20 N: 25.15 mm
b - Cam height H (mm)
Length of coiled seals 23.50 mm
Wire diameter: 3.10 ± 0.03 mm
Internal diameter:
- at top: 14.10 ± 0.2 mm,
- At bottom: 16.80 ± 0.2 mm.
External diameter:
H
- at top: 20.30 ± 0.2 mm,
- At bottom: 23 ± 0.2 mm.
b - Cylindrical type springs

Free length: 42.9 ± 1 mm
102771
Length under load:
- 156 ± 10 N: 36 mm
D4D, and 712 – D4F, and 702 or 706 or 708 or 712
- 420 ± 20 N: 27.15 mm
or 714 or 716 or 722 or 728 or 730
Diameter of wire: 3 ± 0.03 mm.
Internal diameter: 14.1 mm - Inlet cam: 38.586 ± 0.03 mm
External diameter: 20.6 mm - Exhaust cam: 38.794 ± 0.03 mm
11 - Camshaft
a - Bearing diameters (mm)

Number of bearings: 5 D4F, and 740
Longitudinal play: 0.08 to 0.178 mm

Diametric clearance: 0.05 to 0.09 mm
- Inlet cam: 38.163 ± 0.03 mm
- Exhaust cam: 38.794 ± 0.03 mm

Flywheel end
Diameters of the Diameters of the

journals on the bearings on the
camshaft (mm) cylinder head (mm)
1 c - Timing graphs (degrees ˚) (non verifiable)
2
24.98 ± 0.01 25.05 ± 0.01 D4D, and 712 – D4F, and 702 or 706 or 708 or 712
3 or 714 or 716 or 722 or 728 or 730
4 Theoretical settings for a lift of 0.7 mm zero play.
10A-17
Inlet Exhaust
Inlet opening retarda- 1 0˚ -

tion*
Inlet closing retarda- 31˚ -

tion
Exhaust opening - 25˚

advance
Exhaust closing - 8˚
advance**
D4F, and 740

Theoretical settings for a lift of 0.7 mm zero play. 11953
1 - Cylinder block TDC fixed marking
Inlet Exhaust 2 - Engine flywheel TDC moving marker

3 - Engine flywheel BDC moving marker
Inlet opening retarda- 10˚ -
tion* 4 - Inlet opening retardation
Inlet closing retarda- 24˚ - 5 - Exhaust closing advance

tion 6 - Inlet closing retardation
Exhaust opening - 25˚ 7 - Exhaust opening advance

advance 8 - Crankshaft direction of rotation
Exhaust closing - 8˚
advance**
Note:
*If the inlet opening retardation is negative, the val-
ves open after top dead centre.
If the exhaust closing advance is negative, the val-
ves open before top dead centre.
10A-18
Engine peripherals: Specifications 10A
I -PISTONS
D4F
1 - Piston markings
Model 1
D4D
5 6
5 6
4
3
4
3
2
2 1
1
7
18940
7
18940
Model 2
(1) Direction of fitting of the piston, arrow towards the
flywheel. 5 6
(2) Class of piston (A-B).
(3) Used by the supplier only.
(4) Used by the supplier only. 4
(5) Piston axis of symmetry.
(6) Gudgeon pin hole axis.
(7) Offset between gudgeon pin hole and piston axis of 1
symmetry is 0.8 mm. 2
3
7
110754
(1) Direction of fitting of the piston, arrow towards the
flywheel.
(2) Class of piston (A-B).
(5) Piston axis of symmetry.
10A-19
(6) Gudgeon pin hole axis. II - GUDGEON PIN
(7) Offset between gudgeon pin hole and piston axis of
symmetry is 0.8 mm. 1
2 - Measuring the piston diameter
X2
X1
18939
X1 The gudgeon pin is fitted freely in the piston and tight in
the con rod.
The gudgeon pin has an inner shoulder (1).
2 3
16234
D4D
The piston diameter should be measured at height X1
= 10 mm for a diameter of:
12367
- class (A): 68.956 ± 0.006 mm.
The gudgeon pins are fitted using ring 19 B, centring
- class (B): 68.969 ± 0.006 mm. device C19(2) and fitting shaft A19(3) of (Mot. 574-25)
.
Measuring the gudgeon pin
The height of the piston is X2 = 50.86 mm.
- External diameter: 17.495 to 17.499 mm
- Internal diameter: 10.3 to 10.6 mm
- Length: 53.8 to 54 mm
D4F - Internal diameter of shoulder: 9.66 ± 0.2 mm
The piston diameter should be measured at height X1 - Length of inner shoulder: 8.2 ± 0.15 mm
= 9 mm for a diameter of:
- class (A): 68.976 ± 0.006 mm.
- class (B): 68.989 ± 0.006 mm.
The height of the piston is X2 = 44,70 mm.
10A-20
III - PISTON RINGS IV - CON RODS
1 - Con rod measurements

1 Big end side clearance: 0.21 to 0.453 mm
Big end diametric clearance: 0.025 to 0.064 mm
2
Centre-to-centre distance between the big end and the
small end: 122 ± 0.03 mm
Diameter of the big end: 43.639 to 43.650 mm,
Diameter of the small end: 17.461 to 17.479 mm
3
4 The maximum weight difference for the con rod/piston/
gudgeon pin assembly for the same engine must be 11
g.
18715-1
Piston rings are supplied ready adjusted.

The piston rings must be free to move in their grooves.
1 - Thickness (mm)
18648-2
Compression (1) :
- (D4D 700 / D4F 702,704,708,712,722,728,730,740):
WARNING
1.175 to 1.19,
Do not use a punch or an etching tool to mark the
- (D4D 700,706,712,720,726 / D4F 702,706,712,716): con rod caps to match their bodies, to prevent inci-
1.5. pient breakage of the con rod.
Sealing (2) : 1.475 to 1.49 Use a permanent marker pen.
Scraper ring: 2.31 to 2.46
which consists of three parts:
two steel rings (3),
a circlip piston ring (4).
2 - End gap (mm)

Compression ring: 0.2 to 0.35
Sealing ring: 0.35 to 0.50
Scraper ring: 0.2 to 0.9
10A-21
2 - Direction of fitting for con rod on the piston - D4F: 76.8 ± 0.05 mm.
The lateral shims must be flush with bearing N˚3.
VI - CYLINDER BLOCK
Identifying the cylinder barrel diameter
2 1
1 2
T T
18709
Position arrow (1) on the piston facing downwards and
index (2) on the con rod as shown in the drawing.
V - CRANKSHAFT
Crankshaft measurements
12120
Number of journals: 5
Burnished main bearing journals: nominal diameter 44
± 0.01 mm, WARNING
0 It is essential to observe the diameter pairings of the
Burnished big end journals: nominal diameter 40 -0.016 pistons and the cylinder block barrels.
mm,
Crankshaft lateral play: 0 to 0.275 mm. The position of holes (T) in relation to the cylinder block
sealing surface is used to identify the original nominal
Crankshaft diametrical play: 0.02 to 0.046 mm. dimension of the barrel and consequently the diame-
The lateral shims must be on bearing n˚3. ters of the corresponding pistons.
Crankshaft travel:
- D4D: 66.8 ± 0.05 mm, D4D
Cylinder block barrel diameter table
Position of Class Piston diameter Cylinder block bar-

the holes (T) marking (mm) rel diameter in mm
1 = 5 mm A 68.956 ± 0.006 69 to 69.015
2 = 9 mm B 68.969 ± 0.006 69.015 to 69.030
10A-22
D4F
Cylinder block barrel diameter table
Position of Class Piston diameter Cylinder block bar-

the holes (T) marking (mm) rel diameter in mm
1 = 5 mm A 68.976 ± 0.006 69 to 69.015
2 = 9 mm B 68.989 ± 0.006 69.015 to 69.030
The bearing shells are fitted using tool (Mot. 1493-02).
VII - BEARING SHELLS X2

X2
2 3
1 - Crankshaft bearing shells
4 5
X3
X3
1
110773
Holes (2) and (3) correspond to class A and B upper
bearings and are positioned at (X2) = 5 mm from the
crankshaft vertical axle.
There cannot be only a single hole (A or B) correspon-
ding to the single class of upper bearing shells.
15197
Holes (4) and (5) are only used in the factory and are
The engine is fitted with bearing shells without foolproo- located at (X3) = 12 mm from the crankshaft vertical
fing. axis.
The bearing shells are engraved with a letter (1) corres-
ponding to their colour. (B = blue, J = yellow, M =
brown, R = red, V = green).
Definition of an upper bearing shell
Hole (2) Hole (3)
Class type Class A Class B
10A-23
Hole (2) Hole (3)
Diameter of oil sump bearing 47.612 inclusive to 47.618 inclusive to

47.618 exclusive 47.625 inclusive
Marking and thickness of upper "B" blue "V" green

bearing shell
1.792 inclusive to 1.798 inclusive to
1.798 exclusive 1.804 inclusive
Definition of a lower bearing shell
Crankshaft bushing dia- A = 44.003 inclusive B = 43.997 inclusive C = 43.990 inclusive

meter measurement to 44.010 inclusive to 44.003 exclusive to 43.997 exclusive
Marking and thickness of "M" brown "J" yellow "R" red

lower bearing shell
1.792 inclusive to 1.798 inclusive to 1.805 inclusive to
1.798 exclusive 1.804 inclusive 1.811 inclusive
Combinations
Oil sump bearing diameter Class A Class B
Upper bearing shell marking "B" blue "V" green
Crankshaft bearing diameters A B C A B C
Lower bearing shell marking "M" "J" yel- "R" red "M" "J" yel- "R" red
brown low brown low
Combinations 1 2 3 4 5 6
Play between 0.020 and 0.046 mm in consideration of 0.014 mm expansion.
2 - Con rod bearing shells
15198
10A-24
The engine is fitted with bearing shells without foolproo-
fing.
The bearing shells are fitted using tools (Mot. 1492)
and (Mot. 1492-04).
10A-25
Consumables 10A
CONSUMABLES
Type Quantity Component concerned Part no.
DECAPJOINT Coat Cleaning gasket faces 77 01 405 952
RHODORSEAL 5661 Coat Engine oil sump 77 01 404 452

Water pump
Oil pump
Crankshaft closure panel, engine
flywheel end
LOCTITE FRENETAN- 1 - 2 drops - 77 01 394 070

CHE
Fluoride grease Bead Spark plug lead caps 82 00 168 855
10A-26
Parts to be replaced systematically 10A
PARTS ALWAYS TO BE REPLACED IN AN ENGINE
REBUILD
- All seals
- The oil filter
- The valve guides
- The valve stem seals
- The cylinder head bolts,
- The engine flywheel bolts
- The crankshaft bearing cap bolts
- the con-rod cap bolts
- the piston-gudgeon pin assembly (when they have
been separated),
- The camshaft pulley bolt,
- The timing and accessories tensioners and pulleys,
- the belts,
- The crankshaft accessories pulley bolt
- The thermostat
- The cooling circuit hoses if they are damaged
10A-27
Special notes 10A
I -CLEANING THE ENGINE
Protect the various accessories to prevent them being
splashed by water and cleaning products.
Do not allow water to enter the water intake pipes.
II - FITTING THREAD INSERTS

All the threaded holes of the assembly including the en-
gine (except the rocker cover) may be repaired using
tool threading repair kit.
III - CLEANING ENGINE PARTS
WARNING
When cleaning parts, it is essential to not knock the
parts against each other, or their mating faces may
be damaged and therefore their adjustments may
be altered, which could damage the engine.
10A-28
Standard replacement 10A
STANDARD EXCHANGE ENGINE - the accessories multifunction mounting.
1 - Preparation of the old engine for return

WARNING
Clean the engine. The engine is supplied without oil.
Drain the oil and coolant from the old engine. Fill the engine.
Secure the old engine to the stand and in the same con-
ditions as the standard exchange engine:
- fit plastic plugs and covers,
- fit the cardboard cover over the whole assembly.
2 - Parts to leave on the old engine

Parts to leave on the old engine or to include in the re-
turn box:
- the dipstick,
- the oil pump housing,
- the oil filter,
- the water pump,
- the rocker cover,
- the entire timing end (crankshaft sprocket, belt, ten-
sioner, camshaft sprocket),
- the timing gear cases,
- the crankshaft accessories pulley,
- the flywheel or the starter plate,
- the clutch pressure plate and disc,
- the cylinder head suspended mounting support,
- the spark plugs.
3 - Parts to remove from the old engine

Parts to remember to remove from the old engine:
- all the coolant circuit pipes,
- the lifting rings,
- the oil pressure switch,
- the pinking sensor,
- the coolant temperature sensor,
- the coolant inlet pipe,
- the coolant outlet unit,
- the inlet distributor,
- the exhaust manifold,
- the ignition coil,
- the accessories (alternator, air conditioning compres-
sor, power assisted steering pump),
10A-29
Special tooling 10A
69716
Procedure Parts Depart- Description

part number ment Number
110418 (Mot. 445) 00 00 044 500 Universal strap

wrench for oil
filter
(Emb. 1518) 00 00 151 800 Set of clutch

plate centring
mandrels
10052
Procedure Parts Description

part number Department
Number
10250
(Mot. 574- 00 00 057 Tooling for repla-
22) 422 cing gudgeon
Procedure Parts Depart- Description pins. Set in case.
(Ele. 1382) 00 00 138 200 Set of spark

plug spanners
10A-30
Special tooling 10A

(Mot. 582-01) 00 00 058 201 Engine

flywheel immo-
bilising tool.
77889

110433 (Mot. 591-02) 00 00 059 102 Magnetised

indexed flexi-
ble arm for
Procedure Parts Description cylinder head
part number Department tightening
Number angular wrench
(Mot. 574- 00 00 057 Shaft A19 and
25) 425 Shim C19 for fit-
ting gudgeon pins
78181
99614
10A-31
Special tooling 10A
Procedure Parts Depart- Description Procedure Parts Depart- Description

part number ment Number part number ment Number
(Mot. 591-04) 00 00 059 104 Cylinder head (Mot. 799-01) 00 00 079 901 Tool for locking
tightening sprockets on
angular wrench toothed timing
(1/2" drive) belt
82919

(Mot. 792-03) 00 00 079 203 Engine sup- 84757

port plate for
Desvil engine
stand (with Procedure Parts Depart- Description
studs from A to part number ment Number
W)
(Mot. 923) 00 00 092 300 Engine lifting
ring.
80359
90277
10A-32
Special tooling 10A
Procedure Parts Description Procedure Parts Depart- Description

part num- Depart- part number ment Number
ber ment Num-
ber (Mot. 1335) 00 00 133 500 Tool for remo-
ving valve stem
(Mot. 1054) 00 00 105 TDC setting rod seals
400
99516
97160

Procedure Parts Depart- Description part num- Depart-
part number ment Number ber ment Num-
ber
(Mot. 1330) 00 00 133 000 Oil filter remo-
ving tool (66 (Mot. 1354) 00 00 135 Tool for fitting
mm diameter). 400 crankshaft seal 70 x
86 x 8
98503
99517
10A-33
Special tooling 10A

ber ment Num-
ber (Mot. 1360-01) 00 00 136 001 W1 stud, repla-
ces Mot. 1360
(Mot. 1355) 00 00 135 Tool for fitting oil stud W
500 pump seal 32 x 44 x
6
10039
99814
part num- Depart-
Procedure Parts Depart- Description ber ment Num-
part number ment Number ber
(Mot. 1360) 00 00 136 000 Stud W and (Mot. 1381) 00 00 138 Camshaft seal
support plate 100 extractor 30 x 42 x 7
H1 for engine
support, can
be adapted to
a DESVIL sup-
port.
10039
17772
10A-34
Special tooling 10A

ber ment Num-
ber (Mot. 1492) 00 00 149 200 Tool for fitting
con rod bea-
(Mot. 1374) 00 00 137 Oil pump seal ring shells
400 extractor
19950
10158

Procedure Parts Description part num- Depart-
part num- Depart- ber ment Num-
ber ment Num- ber
ber
(Mot. 1492- 00 00 149 Adaptation kit for fit-
(Mot. 1377) 00 00 137 Crankshaft oil seal 04) 204 ting the separable
700 removal tool, 80 x 70 con rod bearing
x 8. shells.
15867 19951
10A-35
Special tooling 10A

ber ment Num-
ber (Mot. 1505) 00 00 150 500 Belt tension
setting tool
(Mot. 1493- 00 00 149 Crankshaft bearing (frequency
02) 302 centring tool meter)
16088 15737
Procedure Parts Description Procedure Parts Description

part num- Depart- part num- Depart-
ber ment Num- ber ment Num-
ber ber
(Mot. 1502) 00 00 150 Tool for removing (Mot. 1511) 00 00 151 Tool for fitting valve
200 valve stem collets 100 stem seals (with
valve spring lower
washer)
16171
17670
10A-36
Special tooling 10A
Procedure Parts Depart- Description Procedure Parts Description

part num- ment Num- part num- Depart-
ber ber ber ment Num-
ber
(Mot. 1573) 00 00 157 300 Cylinder head
support (Mot. 1605) 00 00 160 Tool for fitting cylin-
500 der head cap.
18895
18896

part num- Depart- Procedure Parts Description
ber ment Num- part num- Depart-
ber ber ment Num-
ber
(Mot. 1587) 00 00 158 Tool for fitting PTFE
700 camshaft seal (Mot. 1625) 00 00 162 Tool for fitting PTFE
500 crankshaft seal at
the crankshaft end
20228
18897
10A-37
Special tooling 10A

part num- Depart-
ber ment Num-
ber
(Mot. 1626) 00 00 162 Tool for fitting PTFE

600 crankshaft seal,
timing end

part num- Depart-
ber ment Num-
ber
(Mot. 1661) 00 00 166 Tool for fitting spark

100 plug wells
110417

part num- Depart-
ber ment Num-
ber
(Mot. 1716) 77 11 381 Silicone seal casing

716 extractor

part num- Depart-
ber ment Num-
ber
(Mot. 1723) 77 11 172 Engine support plate

300 (holding the engine
by the mating surfa-
106507 ces)

part num- Depart-
ber ment Num-
ber
(Mot. 1715) 77 11 381 Belt tension setting

715 tool (frequency
meter)
10A-38
Special tooling 10A
19675

part num- Depart-
ber ment Num-
ber
(Mot. 1755) 77 11 175 Tool for fitting valve

500 stem seals (with
valve spring lower
washer)
10A-39
Equipment 10A
THE TOOLS REQUIRED ARE:
- standard 1/2" female torx socket 8/12/14 (12.7

mm squared),
- tweezers for removing/refitting the valve stem cot-

ters,
- threading repair kit,
83391
- piston ring compressor,
18077
- valve stem seal fitting kit,
12624
- Jacking point,
- cylinder head testing tool,

- Circlip pliers,
- angular tightening wrench,

- Sliding calliper,
- low torque wrench,

- Micrometer,
- Dial gauge,
10A-40
Equipment 10A
- Dial gauge support,
- Cylinder head rule,
- Height gauge,
- 1500-watt heater panel.
17771
- Set of spark pug spanners
- Dowel machine.
- Self-fluxing solder.
10A-41
Engine: Dismantling 10A
1 - ENGINE SECURED BY THE ACCESSORIES END
Essential special tooling
Mot. 1360 Stud W and support

plate H1 for engine
support, fits on DES-
VIL support.
1 2
Mot. 1360-01 W1 pin, replaces W
pin of Mot.1360.
Mot. 792-03 Engine mounting plate

for Desvil stand
PREPARING THE ENGINE TO BE PLACED ON THE

STAND
18496
a Loosen tensioner bolt (1).
a Turn the hexagon bolt (2) in an anti-clockwise direc-
tion.
1 a Remove the air conditioning compressor accesso-
ries belt.
1
100606
IMPORTANT
In order to work on the engine in complete safety,
it is essential to have the new stand, or have the
old stand modified by the manufacturer. When
the engine is on the stand, it is essential to fit
mounting pads (1).
3
a Drain the engine oil.
a
18495
Note: a Loosen alternator bolts (3).
There are two procedures for securing the engine a Remove the alternator accessories belt.
to the stand:
- by the accessories end,
- by the clutch end.
10A-42
18490
a
Note:
Before mounting the cylinder block rods, modify
18493
rod W1 by making a chamfer with the following
dimensions:
a Remove:
X = 10 mm,
- the alternator ,
Y = 15 mm.
- the air conditioning compressor.
18492
a Remove:
- the accessories mountings,
- the coolant inlet pipe.
10A-43
2 3 1
H
H1
G W1
18491 20152
a Modification of the DESVIL engine stand head used
Engine stand plate in engine repair: replacement of head TS 126 (1)
with head TS 127 (2).
a Special features of this new head
- rotation axle permanently lubricated,
- variable locking of the head.
WARNING
The clamping bolt (3) must be fully undone to
release the head when there is no longer an
engine resting on the stand.
10099
a Fit the studs G,H and W1 and the plate H1 of tool
(Mot. 1360) and (Mot. 1360-01) (including the rod
W1 and the plate H1), on the cylinder block so that
they fit the holes (18.8 and 4) on the engine moun-
ting (Mot. 792-03).
2 - ENGINE SECURED BY THE CLUTCH END

a Fit the studs, mounting them on the cylinder block
such that they fit in the holes in the engine stand pla-
te. Mot. 1723.
Note:
A Technical Note will eventually be available
regarding the use of tool Mot.1723 on the
various engines.
10A-44
Timing - cylinder head: Removal 10A
Mot. 582-01 Flywheel locking tool

(K engines)
Mot. 1054 TDC setting pin
Mot. 1573 Cylinder head support
I -REMOVING THE ACCESSORIES BELT (ON

ENGINES MOUNTED AT THE CLUTCH END)
1 2
3
18495
a Loosen alternator bolts (3).
a Remove the alternator accessories belt.
II - REMOVING THE TIMING
18496
a Loosen tensioner bolt (1).
a Turn the hexagon bolt (2) in an anti-clockwise direc-
tion.
a Remove the air conditioning compressor accesso-
ries belt.
18498
a Fit the flywheel immobiliser tool. (Mot. 582-01).
10A-45
18504 18505
a Remove: a Refit the crankshaft accessories pulley bolt with a
spacer.
- the crankshaft accessories pulley (1),
- the timing intermediate housing (2),
- the upper timing cover (3),
- flywheel immobiliser tool (Mot. 582-01).
5
6
18501
a Rotate the crankshaft in its operating direction (cloc-
kwise, timing end) to position the crankshaft sproc-
ket mark (5) one half-tooth before the alignment of
fixed mark (6) on the oil pump body.
18503
a Remove the lower housing(4)
10A-46
III - REMOVING THE CYLINDER HEAD
110419
a Remove the spark plug caps using a screwdriver.
a Remove the coil / ignition wire assembly.
18499
D4F, and 708 or 722 or 740
a Insert the TDC pin (Mot. 1054).
a Turn the crankshaft to the setting point.
110421
a Remove the four inlet manifold upper bolts,
18505-1
a Check that mark (7) of the crankshaft pulley is verti-

cal to the engine.
a Loosen the timing tension wheel nut (8).
a Remove:
- the timing belt,
- the TDC setting pin (Mot. 1054).
10A-47
- the inlet distributor.

or 716 or 728 or 730 D4F, and 708 or 722 or 740
1
18638 110422
a Remove the four inlet manifold upper bolts, a Remove the rocker cover.
WARNING
Do not pull wiring harness section (1) because it
is positioned between the rocker cover and the
inlet manifold.
18444
a Remove the inlet manifold wiring harness.

a Remove:
- the inlet manifold bolts (2),
10A-48

or 716 or 728 or 730
18721
a Position the cylinder head assembly on the on the
mounting tool (Mot. 1573).
18640 a Remove the cylinder head gasket from the cylinder

block.
a Remove the rocker cover.
18641
a Remove:
- the cylinder head mounting bolts,
- the cylinder head assembly.
10A-49
Stripping the cylinder head 10A
Mot. 799-01 Tool for locking sproc-

kets on toothed timing
belt
Mot. 1381 Camshaft oil seal

removal tool, 30 x 42 x
7.
Mot. 1502 Tool for removing valve

stem cotters

stem seals
Essential equipment
1
valve stem seal fitting kit
STRIPPING THE CYLINDER HEAD 18721-1

a Remove:
- the exhaust manifold,
- the fuel pipe retaining bracket. (1)
18721
a Remove the heat shield.
18722
a Remove:
- the camshaft pulley bolt using (Mot. 799-01),
- the camshaft pulley,
- the timing tension wheel.
10A-50
18722-1 18723
a Remove the lip seal by screwing extractor (Mot. a Remove:
1381) into the seal.
- the lifting eye,
- the coolant outlet unit,
- the camshaft cap.
2
18722-2
a Remove the seal by tightening bolt (2) of the (Mot.
1381).
18724
a Remove the rocker arm rails, unscrewing bolts (3).
10A-51
18724-1 18724-3
a Mark the camshaft bearing caps with a permanent a Remove the camshaft.
marker pen.
18724-2
a Remove the camshaft bearing caps.
10A-52
5 4 6
18724-4 16087
16088
a Remove the valve springs using tool (Mot. 1502).
18725-1
a To correctly compress the valve springs, the piston
(4) of (Mot. 1502) must be centred on the valve stem
seal.
The upper cup of the spring should enter housing (5)
of socket (6) of (Mot. 1502).
10A-53
Valve stem seal with lower spring washer
18725-2 15738
a Remove: a
- the cotters,
Note:
- the upper cups,
Before removing the valve stem seals (2), it is
- the springs, essential to mark the position (H) of the old seals
on the intake side, then the exhaust side (the fit-
- the valves.
ting dimension of the seals may differ between
the intake and exhaust sides).
a Fit a valve, then take the measurement (H) from an

old seal in relation to the valve spring lower washer
using (Mot. 1755) or valve stem seal fitting kit.
1
110683
a
Note:
There are two types of vaIve stem seal:
- the valve stem seal with a lower spring retaining
washer (1),
- the valve stem seal only (2).
10A-54
6
5
15738-1 15738-3
a Insert sleeve (5) into the guide tube, until it comes
a Position the pushrod (3) of tool (Mot. 1755) onto the
into contact with the pushrod.
valve stem seal.
a Lock the sleeve using tumblewheel (6).
a Remove the guide tube/sleeve assembly, being ca-
Note: reful not to loosen the tumblewheel.
The internal diameter of the pushrod must be a Remove:
identical to that of the valve. In addition, the bot-
tom of the pushrod must cover the metal upper - the valves,
section of the valve stem seal. - the valve stem seals using tool . (Mot. 1335).
15738-2
a Fit the guide tube (4) above the pushrod until it co-
mes into contact with the cylinder head.
10A-55
Upper engine: Cleaning 10A
CLEANING THE CYLINDER HEAD
a
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Wear gloves during the operation.
- Clean the sealing surfaces with DECAPJOINT
compound to dissolve any parts of the seal that
are still attached.
- Apply the product to the section to be cleaned,
Wait around ten minutes, then remove the resi-
due using a wooden spatula.
WARNING
- Do not allow this product to drip on to the pain-
twork.
- Clean the cylinder head carefully to prevent any
foreign bodies entering the oil supply and return
pipes.
Failure to follow this advice could lead to various
oil inlet ducts blocking, resulting in rapid damage
to the engine.
WARNING
When cleaning parts, it is essential to not knock
the parts against each other, or their mating faces
may be damaged and therefore their adjustments
may be altered, which could damage the engine.
10A-56
Upper engine: Checking 10A
2 - Checking the cylinder head gasket face
Essential equipment a Check using a Cylinder head rule and a set of
shims for deformation of a sealing surface.
Sliding calliper
Maximum bow: 0.05 mm
Micrometer
Dial gauge WARNING

No regrinding is permitted.
Dial gauge support
Cylinder head rule
Height gauge
cylinder head testing equipment
CHECKING THE UPPER ENGINE
a Essential measuring tools:
- Sliding calliper,
- Micrometer,
- Dial gauge,
- Height gauge.
1 - Checking the height of cylinder head
18708
a Measure the height of the cylinder head (x) which

should be 99 mm using a Height gauge.
10A-57
3 - Checking the cylinder head seal
110415
a Check the cylinder head for any cracks using cylin- 4 - Cam height checks
der head testing equipment (see Garage Equip-
ment Catalogue).
WARNING
It is essential to replace the coolant temperature
sensor by a bolt at (1).
a For the use of a heating bench, refer to technical H

note NT 2781E.
102771
a Measure the height of the cam lobes.

or 714 or 716 or 722 or 728 or 730
a Cam height:
- Inlet: 38.586 mm,
10A-58
- Exhaust: 38.794 mm.
D4F, and 740

a Cam height:
X
- Inlet: 38.163 mm,
- Exhaust: 38.794 mm.
5 - Check the camshaft bearing diameters
110416
a Measure the external diameter of each camshaft
bearing:
- bearing no. 1: 25.05 ± 0.01 mm,
- bearing no. 2: 25.05 ± 0.01 mm,
- bearing no. 3: 25.05 ± 0.01 mm,
- bearing no. 4: 25.05 ± 0.01 mm,
102772 - bearing no. 5: 28.05 ± 0.01 mm.

a Measure the external diameter of each camshaft
bearing: 6 - Checking camshaft end play
- bearing no. 1: 24.98 ± 0.01 mm, a Refit:
- bearing no. 2: 24.98 ± 0.01 mm, - the camshaft,
- bearing no. 3: 24.98 ± 0.01 mm, - the camshaft bearing caps,
- bearing no. 4: 24.98 ± 0.01 mm, - the rocker arms.
- bearing no. 5: 27.98 ± 0.01 mm.
10A-59
11 1
7 2
3
6
10
12
8
4
19597
a Torque tighten bolts (1) and (2) to 9 Nm.
a Pretighten bolts (3), (4), (5), (6), (7), (8), (9), (10),
(11), (12) to 3 Nm.
a Unscrew bolt (3) until it comes free.
a Torque tighten bolt (3) to 5 Nm.
a Repeat the operation on bolts (4), (5), (6), (7), (8),

(9), (10), (11), (12).
18726
a Check the longitudinal play of the camshaft which

should be 0.08 to 0.178 mm.
10A-60
7 - Check the rocker arms
18945
a Examine the condition of the bearing surfaces and
the rocker arm bolts.
a Check that the cam/tappet lubricating holes are not
blocked.
10A-61
8 - Checking the valves
D1
D2
H
L
102777
102778 a Make the valve head exceed a height (H) of 25mm,
a Measure the valve stem diameter (D1) : then, using a dial gauge, measure in the direction of
the arrows, keeping the angle at 90˚ in relation to the
- Inlet: 5.48 0-0.015 mm, camshaft axis. The clearance between the valve and
the guide is equal to half the measured value.
- Exhaust: 5.47 0-0.015 mm,
Measure the valve head diameter (D2) :

- Inlet: 26 ± 0.12 mm,
- Exhaust: 22.1 ± 0.12 mm.
Measure the valve length (L) :
- Inlet: 110.54 to 110.99 mm,
- Exhaust: 112.27 to 112.72 mm.
Measure the seat angle:
- Inlet: 90˚,
- Exhaust: 90˚.
102782
9 - Checking the clearance between the valve and
a Or measure the external diameter of the valve stem
the guide
and the internal diameter of the valve guide.
a The clearance between the valve and the guide can
a Clearance between the valve and the valve guide
be checked in two different ways.
should be:
- Inlet: 0.020 to 0.053 mm,
- Exhaust: 0.030 to 0.063 mm.
10A-62
10 - Checking the valve springs a - Conical spring
102776 16051-1
a Check the strength of the springs concerned. a Free length: 40.20 mm.
Length under load:
- 145 ± 80 N : 34 mm,
- 428 ± 20 N: 25.15 mm.
Wire diameter: 3.10 mm
Internal diameter:
- at top: 14.10 ± 0.2 mm,
- At bottom: 16.80 ± 0.2 mm.
External diameter:
- at top: 20.30 ± 0.2 mm,
- at bottom: 23 ± 0.2 mm.
10A-63
b - Cylindrical spring
104720
a Free length: 42.90 ± 1 mm
Length under load:
- 156 ± 10 N: 36 mm
- 420 ± 20 N: 27.15 mm.
Diameter of wire: 3 ± 0.03 mm.
Internal diameter: 14.10 mm.
External diameter: 20.60 mm
10A-64
Rebuilding the cylinder head 10A
I -REFITTING THE VALVE STEM SEALS
Mot. 1511 Tool for fit ting valve

stem seals

stem cotters
Mot. 1605 For fitting cylinder

head cap.
Ele. 1382 Spark plug key kit 16 &

21 mm torque 1.75 & 2
2.8 daNm + 9-9.52
square drive for span-
ner Ele. 1086 1
110683
Mot. 1587 Tool for fitting cams-
a
haft "PTFE" seal.
Note:
kets on toothed timing There are two types of vaIve stem seal:
belt
- the valve stem seal with a lower spring retaining
washer (1)
- the valve stem seal without a lower spring retai-
Tightening torquesm
ning washer(2)
cylinder head plenum 10 Nm
a Lubricate the inside of the valve guide.
chamber bolts
the engine lifting eye at 22 Nm

the flywheel end.
spark plugs 20 to 27 Nm
camshaft pulley bolt 30 Nm + 45˚ ±

6˚
exhaust manifold nuts 25 Nm
exhaust manifold strut 21 Nm

bolt
exhaust heat shield bolt 15 Nm

15737
a It is imperative to fit the seals using:
- kit (Mot. 1511) for seal types (1),
10A-65
18077 15771-1
a - Or using suitable equipment (for both types of seal).
a Fit the valve insert of tool (Mot. 1511) on the valve
stem (the internal diameter of the valve insert should
1 - VALVE STEM SEAL WITH SPRING LOWER be the same as the valve stem).
RETAINING WASHER (1)
15771 15771-2
a Place the valve in the cylinder head. a Keep the valve pressed against its seat.
WARNING
Do not lubricate the valve stem seals before fit-
ting them.
a Fit the valve stem seal on the barrel.
10A-66
15771-3 15771-5
a Push the valve stem seal past the tool barrel, then a Push home the valve stem seal by gently striking the
withdraw the barrel. top of the pushrod with the palm of the hand, until the
valve stem seal makes contact with the cylinder
head.
15771-4
15770
a Place the pushrod(1) over the valve stem seal.
a Repeat these operations for all the valves.
Note:
The internal diameter of the pushrod must be
identical to the diameter of the valve stem.
Also, the base of the pushrod must press against
the part of the valve stem seal that acts as the
lower thrust washer for the valve spring.
10A-67
2 - VALVE STEM SEAL WITHOUT SPRING LOWER
RETAINING WASHER (2)
15739-2
15739
a Keep the valve pressed against its seat.
a Place the valve in the cylinder head.

WARNING
Do not grease the valve stem seals.
a Fit the valve stem seal (not lubricated) over the valve
insert.
a Push the valve stem seal until it goes past the valve
insert.
15739-1
a Fit the valve insert of tool (Mot 1755) on the valve
stem (the diameter of the valve insert should be the
same as the valve stem).
15739-3
a Remove the valve insert.
10A-68
2 1 3
18725-1
a To correctly compress the valve springs, the piston
of (1)(Mot. 1502) must be centred on the valve stem
seal.
The upper cup of the spring should enter housing (2)
of socket (3) of (Mot. 1502).
15739-4
a Place the guide tube and sleeve assembly over the
pushrod.
a Push the valve stem seal down by tapping the top of
the sleeve with the palm of your hand until the guide
tube touches the cylinder head.
a Repeat these operations for all the valves.
II - REASSEMBLING THE CYLINDER HEAD

a Refit:
- the springs,
- the valve spring upper cups,
10A-69
18725-2 19595
18725 19594
a Refit the cotters using tweezers. a Apply:
- two beads (4 ) of RHODORSEAL 56612 mm in
width to bearing no. 5 on the cylinder head,
- two beads (5) of RHODORSEAL 5661 to bearing
no. 1 on the cylinder head
a Apply a blob of oil to the camshaft bearings.
10A-70
18724-3
a Refit the camshaft.
18724-2
a Refit the camshaft bearing caps.
a Torque tighten the two bearing no. 5 bolts to 9 N.m
at (6) and (7).
10A-71
Intake rocker arm rails
18945
a Refit the intake rocker arm rail positioning:
- the rails in relation to the tappets,
- mark (8) end timing.
10A-72
Exhaust rocker arm rail
18944
a Refit the intake rocker arm rail positioning:

- the rails in relation to the tappets,
- mark (9) end flywheel.
10A-73
8 4 1 5 9
7 3 2 6 10
18724 18723
a Tighten in order and to torque the camshaft bearing a Refit the cylinder head outlet plenum chamber with a
caps to 5 Nm. new seal.
a Completely loosen bolt (1). a Tighten to torque the cylinder head plenum cham-
ber bolts (10 Nm).
a Torque and angle tighten bolt (1) to 7 Nm + 50˚ ± 6˚.
a Refit the engine lifting eye at the engine flywheel
a Carry out the previous operations for each bolt from
end.
(2) to (10).
a Tighten to torque the the engine lifting eye at the
flywheel end. (22 Nm).
a Refit the spark plugs using a tool kit (Ele. 1382).
a Tighten to torque the spark plugs (20 to 27 Nm).
20058
a Refit a cap at the end of the camshaft with tool (Mot.
1605).
10A-74
III - REFIT THE CAMSHAFT SEAL
1 2
19592-1
18687 a Fit the seal gasket and protector on the camshaft. Be
a careful not to touch the seal.
WARNING
This type of seal is extremely FRAGILE. When
handling it, it is essential to hold it by protector
(1). It is strictly forbidden to touch seal (2) to pre-
vent any oil from leaking out once the seal is fit-
4 5
ted onto the engine.
The seal is fitted using tool (Mot. 1587).
19592-2
a Fit the cover (4) and collar nut (5) of tool (Mot. 1587).
19592
a Tighten the threaded rod (3) of tool (Mot. 1587) in the

camshaft.
10A-75
19592-3 19592-5
a Remove:
- the nut,
- the cover,
- the protector,
- the threaded rod.
19592-4
a Screw on the collar nut until the cover touches the
cylinder head.
18722
a Refit the camshaft pulley with a new bolt.
a Tighten to torque the camshaft pulley bolt (30 Nm

+ 45˚ ± 6˚) using tool (Mot. 799-01).
10A-76
5
1
6 4
2
3
7
109761 18721-1
a Refit a new tensioner wheel positioning the two in- a Refit the exhaust manifold with a new seal.
dexes (6) between the cylinder head groove.
a a Tighten to torque and in order the exhaust manifold
nuts (25 Nm).
Note:
a Refit the exhaust manifold strut (if fitted).
- Do not remove pin (7) before refitting the timing
belt. a Tighten to torque the exhaust manifold strut bolt
(21 Nm).
5
1
4
2
3
18721
a Refit the exhaust heat shield.
a Tighten to torque the exhaust heat shield bolt (15

Nm).
10A-77
Cylinder block: Dismantling 10A

(K engines)
Mot. 1716 Removes housing with

silicone seals.
Mot. 1377 Crankshaft oil seal

removal tool, 80 x 70 x
8.
Mot. 1374 Oil pump seal removal

tool
Mot. 1330 Oil filter removing tool

- 66 mm diameter
I -REMOVING THE ACCESSORIES FOR ENGINES

FITTED AT THE CLUTCH END
110425
a Remove the accessories mountings.
II - REMOVING THE ENGINE PERIPHERALS
2
110424
a Remove:
- the alternator ,
- the air conditioning compressor.
110426
a Remove:
- the coolant inlet pipe,
- pinking sensor (1),
- the oil level sensor or blanking cover cap (depen-

ding on the equipment) (2).
10A-78
110428 110430
a Fit flywheel immobiliser tool (Mot. 582-01). a
a Remove: Note:
- the clutch pressure plate, - The flywheel can only be mounted in one posi-
- the clutch plate (mark the direction of fitting). tion.
- Make a mark to indicate the correct position
using a permanent marker pen.
18643
a Remove the oil sump mounting bolts.
10A-79
4
110431 18644-1
a Remove the oil sump using tool (Mot. 1716). a Remove the seal by tightening bolt (4) on tool (Mot.
1377).
18644 5
a Fit tool (Mot. 1377) to extract the flywheel end lip 18645-1
seal. a Fit tool (Mot. 1374) to extract the timing end lip seal.
a Tighten nut (3). a Tighten nut (5).
10A-80
6
18645-2 18646
a Remove the seal by tightening bolt (6) on tool (Mot. a Remove the oil filter.
1374).
Note:
The oil filter may be either of the following types:
- recyclable paper cartridge,
- non-recyclable paper cartridge to be removed
using tool (Mot. 1330)
a Remove:
- the screen and its seal (if fitted).
- the oil pump.
Note:
The oil pump cannot be repaired.
10A-81
18646-1
a Remove the water pump.
7
18647
a Remove oil pressure feed O-ring (7).
10A-82
Running gear:Removal 10A
Mot. 574-22 Tooling for replacing

gudgeon pins
I -REMOVING THE ROTATING PARTS
18648
a Remove:
- the con rod cap bolts,
- the con rod caps,

- the con rod/piston assemblies,
18648-2
- the con rod bearing shells.
a
WARNING
Do not use a punch or an etching tool to mark the
con rod caps to match their bodies, to prevent
incipient breakage of the con rod.
Use an indelible marker pen.
18648-1
a Remove:
- the crankshaft bearing cap bolts,
- the crankshaft bearing caps,
- the crankshaft,
10A-83
Running gear:Removal 10A
- the crankshaft bearing shells.
II - EXTRACTING THE GUDGEON PINS

a Remove the piston rings using piston ring pliers.
10052
18712
a Use tool kit (Mot. 574-22)
a Place the piston on the base.
a Align the gudgeon pin with the base clearance hole.
a Remove the gudgeon pin using the press and the ex-
traction pin.
110433
a Use base (1) contained in kit (Mot. 574-22) and an
extraction pin (2).
10A-84
Lower engine: Cleaning 10A
CLEANING THE ENGINE PERIPHERALS
a Clean:
- the cylinder block,
- the crankshaft,
- the oil sump,
- the crankshaft closure panels,
- the crankshaft bearing caps.
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Wear gloves during the operation.
- Clean the sealing surfaces with DECAPJOINT
compound to dissolve off any parts of the seal
that are still attached.
- Apply this product to the cylinder head and roc-
ker cover sealing faces; Wait around ten minutes,
then remove the residue using a wooden spatula.
WARNING
- When cleaning parts, it is essential to not knock
them against each other, or their mating faces
may be damaged and their settings may be
disrupted, which could damage the engine.
- Failure to observe this advice could rapidly des-
troy the engine.
- Do not allow this product to drip onto the pain-
twork.
- Carefully clean the cylinder block to prevent
foreign bodies from entering the oil inlet and
return pipes.
- Failure to follow this advice could lead to the
blocking of the various oil inlet ducts, resulting in
rapid destruction of the engine.
10A-85
Lower engine: Check 10A
1 - Checking the cylinder block surface
Mot. 1493-02 Crankshaft bearing

centring tool - adapter
for MOT 1493.
Essential equipment
Sliding calliper
Micrometer
Dial gauge
Dial gauge support
Cylinder head rule

102786
Height gauge
a Check using a cylinder head ruler and a set of shims
that the gasket face bow does not exceed 0.03 mm.
Tightening torquesm
crankshaft bearing cap 20 Nm + 76˚ ± WARNING

bolts 6˚
No regrinding of the cylinder block is authorised.
I -CYLINDER BLOCK CHECK

2 - Measuring the diameter of the crankshaft
a Essential measuring tools:
bearings on the cylinder block
- Sliding calliper,
- Micrometer,
- Dial gauge,
- Height gauge.
18648-1
a Refit the crankshaft bearing caps placing cap n˚1 on

the flywheel end.
a Tighten to torque and angle the crankshaft bearing

cap bolts (20 Nm + 76˚ ± 6˚)
10A-86
2 - Measuring the crankpin diameter
X1
X3
102806
a The diameter of crankpins (X3) must be between

39.984 and 40 mm.
10021
3 - Checking the crankshaft diameter clearance
a Measure the internal diameter of crankshaft bea-
rings (X1) which should be between 47.612 and a Refit the crankshaft bearing shells using (Mot. 1493-
47.625 mm. 02) (see 10A, Engine and peripherals, Rotating
parts: Refitting).
a Remove the crankshaft bearing caps.
II - CRANKSHAFT CHECK
1 - Measuring the journal diameters
X2
102805
103281
a Measure the diameter of crankshaft bushings (X2)
which should be 44 ± 0.01 mm. a
Note:
Never turn the crankshaft during the operation.
a Remove any oil that may be on the crankshaft jour-

nals and cylinder block bearings.
a Refit the crankshaft.
10A-87
8
4
2 1
7 5
3 9
1 10
102807 18648-1
a Cut bits of wire (1) to measure the clearance. a Refit the crankshaft bearing caps, fitting n˚1 at the
flywheel end.
a Insert the wire into the axis of the crankshaft journals
(avoiding the bearing lubrication holes). a Pretighten to torque and in order the crankshaft
bearing cap bolts to 20 Nm.
a Tighten to angle and in order the crankshaft bea-
ring cap bolts by 76˚ ± 6˚.
a Remove:
- the crankshaft.
a Measure the flattening of the clearance measuring
wire using wrapping paper (2).
a Check the clearance value, which must be between
0.020 and 0.046 mm.
a Clean any traces of measuring wire off the cranks-
haft and the bearing shells using DECAPJOINT.
4 - Checking the crankshaft lateral clearance

a Oil the crankshaft bearings (only the surface that co-
mes into contact with the crankshaft).
10A-88
103281 18713
a Refit the crankshaft. a Check the lateral clearance of the crankshaft, which
must be:
a Lubricate the journals with engine oil.
- without lateral shim wear: 0 to 0.275 mm.
a Check that the crankshaft turns freely, with no hard
point.
a Remove:
8
4
- the crankshaft.
1
7 5
3 9
6
10
18648-1
a Refit the crankshaft bearing caps, fitting n˚1 at the
flywheel end.
a Pretighten to torque and in order the crankshaft
bearing cap bolts to 20 Nm.
a Tighten to angle and in order the crankshaft bea-
ring cap bolts by 76˚ ± 6˚.
10A-89
III - CHECKING THE PISTONS AND PISTON RINGS 2 - Checking the piston ring end gap
1 - Checking the clearance between the piston

grooves and piston rings
5
A
4
3
102793
B a Insert the piston ring (3) in the cylinder.
a Push the piston ring (3) to the centre of the cylinder
102795 using the piston (4).
a Measure the clearance between the piston grooves
a Measure the piston ring end gap using a set of shims
and piston rings using a set of shims (1).
(5).
- (A): Set of shims incorrectly positioned,
a - Compression ring end gap must be 0.20 to 0.35
- (B): Set of shims correctly positioned. mm
a For the upper piston ring the clearance must be 0.04 a - Sealing ring end gap must be between 0.35 and
to 0.075 mm. 0.50 mm.
a The sealing ring clearance must be between 0.03 a - Scraper ring end gap must be between 0.2 to 0.9
and 0.065 mm. mm.
a The scraper ring clearance must be between 0.05
and 0.22 mm.
a If the clearance value is outside tolerance, replace
the piston-gudgeon pin assembly or the piston rings.
10A-90
Running gear Refitting 10A
2 - Direction of fitting for crankshaft bearing shells
Mot. 1493-02 Crankshaft bearing

centring tool - adapter
for MOT 1493.
Mot. 1492 Tool for fitting linkage

bearings
Mot. 1492-04 Tool for fit ting main

bearing shells - adap-
ter for MOT1492.
Mot. 574-22 Tooling for replacing

gudgeon pins
Mot. 574-25 Pin A19 and shim C19

for fitting gudgeon
pins.
Essential equipment
Circlip pliers 18649

a Fit the grooved bearing shells on all the cylinder
piston ring compressor
block bearings.
The lateral shims are integrated into bearing shell
Tightening torquesm n˚3.
crankshaft bearing cap 20 Nm + 76˚ ±

bolts 6˚
con rod cap bolts 14 Nm + 39˚ ±

6˚
I -REFITTING THE CRANKSHAFT BEARING

SHELLS
1 - Determining the crankshaft bearing shells

a To identify the crankshaft bearing shells (see 10A,
Engine and peripherals, Engine peripherals:
Specifications.
18649-1
a On the bearing caps, fit the non-grooved bearing
shells on all the bearings.
10A-91
3 - Fitting the bearing shells on the cylinder block 4 - Fitting the bearing shells onto the bearing caps
19942
19940
a Fit tool (Mot. 1493-02) on the cylinder block.
a Fit tool (Mot. 1493-02) on the bearing cap.
3 4
1 2
19943
a Insert the grooved bearing shell into tool (Mot. 1493- 19941
02).
a Insert the bearing shell into tool (Mot. 1493-02).
a Press down at (1) until the bearing shell comes into
contact with tab (2). a Press down at (3) until the bearing shell comes into
contact with tab (4).
II - CRANKSHAFT REFITTING
a Oil the crankshaft bearing shells (only the surface

that is in contact with the crankshaft).
10A-92
III - FITTING THE CON ROD BEARING SHELLS
8
4
1
7
5
3
9
2
6
10
18648-1
a Refit: 15198
- the crankshaft, a The engine is fitted with bearing shells without fool-
proofing.
- the crankshaft bearing caps, positioning n˚1 and
the arrows at the flywheel end. a The con rod bearing shells are fitted using tools (Mot.
a Tighten to torque, to angle and in order the cranks- 1492) and (Mot. 1492-04).
haft bearing cap bolts (20 Nm + 76˚ ± 6˚).
a Check that the crankshaft turns freely, with no hard 1 - On the con rod body
point.
19944
a Remove pin (1) from tool (Mot. 1492) (using a vice

fitted with jaws).
a Replace the pin with pin (2) of tool (Mot. 1492-04).
10A-93
4 3
5
16352 19946
a Slide bearing shell holder (3) of (Mot. 1492-04) into a Push the bearing shell holder (in the direction of the
groove (4) in the base of (Mot. 1492). arrow) until it is fully inserted in the body of the con-
necting rod.
a Position rail (5) of (Mot. 1492-04) on the base.
a Remove the con rod body support and then repeat
the operation for the other con rods.
7 6
2 - On the con rod cap
19945
a Fit the con rod body on the base.
a Check that the lower part (6) of the little end is in con-
tact with the centring pin.
19947
a Mount the bearing shell (7) on the bearing shell sup-
a Fit bar (8) and the con rod cap.
port.
10A-94
IV - CON ROD/PISTON ASSEMBLY
10052
a The gudgeon pins are tight in the con rods and are
able to rotate in the pistons.
19948
a Push the rail (in the direction of the arrow) until the 3
con rod cap touches the bar.
a Mount the bearing shell (9) on the bearing shell sup-
port.
2 4
19949
110433
a Push the bearing shell support (in the direction of the
arrow) until it comes to the end of the con rod cap. a Use kit components (Mot. 574-22) and (Mot. 574-
25).
a Remove the con rod cap support and repeat the ope-
ration for the remaining con rod caps. - base (1),
- fitting ring 19 B(2),
- fitting shaft A19(3),
- centring device C19(4).
10A-95
1 - Preparing the piston/gudgeon pin assembly
A
A
B
B C
C
D
D 103310
10
a At (5) on each small end, place (as a temperature in-
a The parts supplied in the set are identical. dicator) a piece of self-flux tin with a melting point of
a Mark all of the parts in each box from (A) to (D) to en- approximately 250˚ C.
sure that they remain matched.
a Heat each small end until the self-fluxing solder
a Completely dissolve the rust-proofing film without melts.
scratching the parts.
3 - Preparing the gudgeon pins

2 - Preparing the con rods
a Check that the gudgeon pins rotate properly in the
a Visually inspect:
pistons.
- the condition of the con rods (torsion and squaring),
- the cleanliness of the con rod cap and body bearing
surfaces.
a Use a 1500 W heating plate.
a Put the small ends on the heating plate.
a Ensure that the whole small end surface is in contact
with the plate.
3 6 4
103309
a Use fitting shaft A19(3) centring device C19(4) from

kit (Mot. 574-25).
a Fit the gudgeon pin (6) onto the fitting shaft (3).
a Screw in the locator (4) until the assembly locks.
a Loosen by a quarter of a turn fitting shaft (3).
10A-96
4 - Direction of fitting for pistons in relation to con
rods
9
8
19596
a Secure the piston using pin (9).
18709
a Check carefully that the gudgeon pin hole is aligned
a Fit: with the hole in ring 19 B (the arrow in the piston
should face downwards).
- arrow (7) engraved on the piston crown facing
downwards, a Lubricate the locator and gudgeon pin with engine
oil.
- con rod boss (8) as shown in the drawing (or next
to the dipstick on the cylinder block). a Drive the gudgeon pin into the assembly to check
that it can slide freely, and re-centre the piston if ne-
cessary.
5 - Follow these instructions when assembling the
piston and con rod: a The following operations should be carried out quic-
kly to prevent heat loss.
18710
a Position ring 19 B on the base.
10A-97
18711
a When the solder reaches welding point (becomes li-
quid):
- wipe off the solder,
- insert the locator into the piston,
- insert the con rod (correctly positioned) in the pis-
ton,
18715-1
- quickly drive in the gudgeon pin until the locator a Observe the gap and direction of fitting for each pis-
reaches the end of the support base. ton ring.
a Ensure that the gudgeon pin remains withdrawn a Refit the piston rings using a Circlip pliers.
from the piston diameter for all con rod positions in
the piston.
VI - REFITTING THE PISTONS AND CON RODS
V - REFITTING THE PISTON RINGS a Before fitting, oil:
a The piston rings, at their original settings, must be - the cylinder block barrels,
free in their grooves. - the piston rings,
a Ensure the rings are fitted in the correct direction, - the piston skirts,
with the word TOP facing upwards.
- the crankshaft crankpins.
10A-98
98965 18648
a Tighten to torque and angle the con rod cap bolts
a Refit the piston/con rod assemblies using the piston
(14 Nm + 39˚ ± 6˚).
ring compressor , having first verified that:
- the piston matches the cylinder block barrel (N˚1 at

flywheel end).
- the piston marking is in the correct place, with the

arrow pointing towards the flywheel.
a Fit the con rods onto the crankshaft crankpins.
18648-2
a Refit the con rod caps corresponding to the con rod

bodies.
10A-99
Cylinder block: Refitting 10A
Essential special tooling Tightening torquesm
Mot. 1626 Tool for fitting cranks- Air conditioning com- 25 Nm

haft "PTFE" seal, pressor bolt
timing end.
coolant inlet pipe bolt 10 Nm
Mot. 1355 Oil pump oil seal fitting
tool 32 X 44 X 6 alternator mounting 25 Nm
bolts
Mot. 923 Engine lifting ring.
Air conditioning com- 50 Nm
Mot. 1625 Tool for fitting cranks- pressor bolt
haft "PTFE" seal,
flywheel end. power assisted steering 25 Nm
pump support bolts
Mot. 1354 Crankshaft oil seal fit-
ting tool, 70 x 86 x 8. power assisted steering 22 Nm
pump bolts
(K engines)
I -REFITTING THE ENGINE PERIPHERALS
Emb. 1518 Set of clutch plate cen- a
tring mandrels
WARNING
Essential equipment The sealing surfaces of the cylinder block and
crankshaft closure cover must be clean, dry and
Jacking point free from grease (avoid finger marks).
Tightening torquesm WARNING

crankshaft closure cover 9 Nm Excess sealant may be squeezed out when the
bolts (flywheel end) parts are tightened. The sealing compound/fluid
mixture can cause damage to certain compo-
water pump bolts 9 Nm nents (engine, radiator, etc.).
water pipe bolts 9 Nm
oil pump bolts 9 Nm
oil pressure sensor 32 ± 2 Nm
oil pump screen bolts 9 Nm
oil sump bolts 10 Nm
pinking sensor 20 ± 4 Nm
oil level sensor or blan- 30 ± 5 Nm

king cover cap
flywheel bolts 18 Nm + 110˚ ±

6˚
clutch pressure plate 25 Nm

bolts
recyclable oil filter 20 Nm
non-recyclable oil filter 10 Nm
10A-100
1 - Water pump with gasket
a
1 WARNING
The cylinder block sealing surfaces and water
pump must be clean, dry and free from grease
(no finger marks).
18716 2
a At (1), apply a bead of RHODORSEAL 56611.3 mm
wide to the crankshaft closure cover at the flywheel
end.
107294
a Refit the water pump fitted with a new seal if the sea-
ling face of the water pump is flat (2).
2 - Water pump sealing lug

3
a
4
WARNING
2
The cylinder block sealing surfaces and water
pump must be clean, dry and free from grease
5 (no finger marks).
1
WARNING
Excess sealant may be squeezed out when the
parts are tightened. The sealing compound/fluid
18644-2 mixture can cause damage to certain compo-
a Tighten to torque and in order the crankshaft closu- nents (engine, radiator, etc.).
re cover bolts (flywheel end) (9 Nm).
Note:
- There are two types of seal depending on the
water pump.
10A-101
a
WARNING
3
The water pipe sealing surfaces and water pump
must be clean, dry and free from grease (no fin-
ger marks).
4 WARNING
nents (engine, radiator, etc.).
18717 5
wide to the water pumps if the sealing face of the wa-
ter pump has a groove (4).
2
3
1
4
7
6 5
18719
wide to a water pipe that has been sealed using
RHODORSEAL 5661.
a Replace the gasket on the water pipe that was sea-
led using a gasket.
a Tighten to torque the water pipe bolts (9 Nm).
18646-1
a Tighten to torque and in order the water pump bolts
(9 Nm).
10A-102
10275 18718
a Always replace oil pressure feed seal (6). a At (7), apply a bead of RHODORSEAL 56611.3 mm
a wide to the oil pump.
WARNING
The cylinder block sealing surfaces and oil pump WARNING
must be clean, dry and free from grease (no fin- The oil pump is driven by two studs located on
ger marks). the crankshaft.
WARNING
2
3 4
5
1
6
7
18646
a Tighten to torque and in order the oil pump bolts (9

Nm).
a Tighten to torque the oil pressure sensor (32 ± 2

Nm).
10A-103
98972
a
Note:
- The plastic screens are not fitted with O-rings.
110432
Refit the screen fitted with its new O-ring (if fitted).
a At (8), apply a bead of RHODORSEAL 56613 mm
a Tighten to torque the oil pump screen bolts (9 Nm). wide to the oil sump.
a
WARNING 11 7 3 1 4 8
The cylinder block and oil sump sealing surfaces
must be clean, dry and free from grease (no fin-
ger marks). 15
12
17
WARNING
16
parts are tightened. The sealing compound/fluid 14
10 6 2 5 9 13
18643
a Tighten to torque and in order the oil sump bolts (10
Nm).
10A-104
9
1
10
2
110426 20256
a Refit: a The old elastomer seal is fitted with a spring (1) and
a V-shaped sealing lip (2).
- the coolant inlet hose fitted with a new O-ring,
- pinking sensor (9).
a Tighten to torque the pinking sensor (20 ± 4 Nm).
a Refit the oil level sensor or blanking cover cap (de-

pending on the equipment) at (10).
a Tighten to torque the oil level sensor or blanking

cover cap (30 ± 5 Nm).
II - REFITTING THE SEALS
1 - GENERAL INFORMATION 3 4
a Developments in engine elastomer seals (fitted to
the camshafts and crankshaft).
a Fitting and removing the new type elastomer seal

from the engine requires new tools and precautions
when compared to the old type seal. 20257
a The old and new type of seal may both be used on a The new elastomer seal is fitted with a flat sealing lip
the same engine. They are not interchangeable. An (3) and a guard (4) which is also used for fitting the
old type seal must be replaced with an old type seal seal to the engine.
(still available from the Parts Department), and a
new type seal must be replaced with a new type seal.
a An old type seal may be replaced by a new type seal

in the event of a crankshaft or camshaft replace-
ment. This is possible if the engine is fitted with one
during its lifetime in series production.
a Old and new seals are easily recognised.
10A-105
2 - OIL PUMP SIDE
a - New elastomer seal
20784
5 6
a Tighten the threaded rod of (Mot. 1626) in the
crankshaft
18687
a
WARNING
This type of seal is extremely FRAGILE. During
the operation, it is essential to hold protector (5).
Touching seal (6) is strictly prohibited in order to
prevent any oil leaks once the seal is fitted to the
engine.
20782
a Fit the seal and protector on the crankshaft, taking
care not to touch the seal.
10A-106
1 2
20783 20781
a Fit cover (1) and collar nut (2) of (Mot. 1626).
20780
a Tighten the collar nut until the cup touches the
crankshaft closure panel.
10A-107
3 - FLYWHEEL END
a
WARNING
It is essential to remove the engine from its
mounting to refit the seal at the flywheel end.
20779
a Remove:
- the nut,
- the cover,
- the protector, 84757

a Fit tool (Mot. 923) on the cylinder block sealing sur-
- the threaded rod.
face.
a Remove the engine from its mounting using Jacking
b - Old elastomer seal point.
18645
a Refit the seal on the oil pump side using tool (Mot.
1355).
10A-108
a - New elastomer seal
2 3
20775
20773 a Fit cover (2) and nut (3) (with the thread of the nut
a Position tool (Mot. 1625) on the crankshaft, securing towards the outside of the engine).
it using bolts (1)
20774
a Fit the protector with its seal in place on tool , taking
care not to touch the seal.
10A-109
20776 20778
a Remove:
- the nut,
- the cover,
- the protector,
- the base.
b - Old elastomer seal
20777
a Screw on the nut until the cover touches the cylinder
block.
18644-3
a Refit the seal at the flywheel end using tool (Mot.

1354).
10A-110
III - REFITTING THE FLYWHEEL
110427
110429 a Refit:
a Refit the flywheel, aligning it with mark (1) made du-
- the clutch plate,
ring removal.
- the clutch pressure plate.
a Replace the mounting bolts with new ones.
a Centre the clutch plate using tool (Emb. 1518).
a Fit flywheel immobiliser tool (Mot. 582-01).
a Tighten to torque the clutch pressure plate bolts
a Tighten to torque and angle the flywheel bolts (18
(25 Nm).
Nm + 110˚ ± 6˚).
a Remove flywheel immobiliser tool (Mot. 582-01).
10A-111
IV - REPLACING THE OIL FILTER
1 - Recyclable cartridge
18946
1 a Fit a new oil filter cartridge.

a Tighten to torque the recyclable oil filter (20 Nm).
18948
a When replacing oil filter (1), replace the two O-rings
2 - Non-recyclable cartridge
(2).
a Oil the oil filter seal.
a Tighten to torque the non-recyclable oil filter (10
Nm).
18947
a Hold the filter upside down and tap it on a piece of
wood to remove the filter element.
10A-112
V - REFITTING THE ACCESSORIES
110424
110425 a Refit the alternator.
a Refit the air conditioning compressor support.
a Do not tighten the alternator mounting bolts.
a Tighten to torque the Air conditioning compressor
a Refit the air conditioning compressor.
bolt (25 Nm).
a Tighten to torque the Air conditioning compressor
a Tighten to torque the coolant inlet pipe bolt (10
bolt (50 Nm).
Nm) at (1).
a Refit the power assisted steering pump support (if fit-
a Refit the alternator mounting.
ted to the engine).
a Tighten to torque the alternator mounting bolts (25
a Tighten to torque the power assisted steering
Nm).
pump support bolts (25 Nm).
a Tighten to torque the power assisted steering
pump bolts (22 Nm).
10A-113
Timing - cylinder head: Refitting 10A

1

belt

(K engines)
Mot. 1715 Belt tension setting

tool (frequency meter)

tool (frequency meter) 19598
a Fit the cylinder head gasket onto the cylinder block
Essential equipment positioning mark (1) on the oil filter side.
angular tightening wrench a Refit the cylinder head.
a Tighten in the correct order to torque and angle the
cylinder head bolts (refer to 10A, Top and lower en-
Tightening torquesm gine assembly, Upper engine: Specifications).
timing tensioner, 24 Nm
II - REFITTING THE TIMING BELT
rocker cover bolts 12 Nm
a
inlet manifold / cylinder 10 Nm
head bolts WARNING
inlet manifold / rocker 8 Nm The following parts must be replaced with new
cover bolts ones if they have been removed:
- the belt (timing and accessories),
intermediate timing hou- 10 Nm
sing bolts - the crankshaft accessories pulley bolt.
upper timing cover bolt 33 Nm

WARNING
crankshaft accessories 40 Nm + 70˚ ±
pulley bolts 6˚ When replacing the belt, be sure to replace the
tension wheels and idler pulleys.
alternator upper bolt 25 Nm
alternator lower moun- 50 Nm

ting bolt
tension wheel bolts 37 Nm
I -REFITTING THE CYLINDER HEAD

a Position the pistons at mid-stroke.
a Degrease the cylinder head and cylinder block com-
bustion surfaces.
a Check that the two centring dowels are present on
the cylinder block.
10A-114
1 - Adjusting the timing
1 2
3
104703
a 109761
a Check that the two indexes (2) are between the cy-
Note: linder head rib.
Be sure to degrease: a Do not remove pin (3) before refitting the timing belt.
- the end of the crankshaft (timing end),
- the timing sprocket bearing faces and bore at
(1),
- the contact surfaces of the crankshaft accesso-
ries pulley.
WARNING
Never turn the engine against its operating direc-
tion.
a Refit the crankshaft sprocket.
18499
a Insert the TDC pin (Mot. 1054);.
10A-115
4
5
18501 18505
a The crankshaft sprocket (4) should be aligned at a Fit the crankshaft accessories pulley and its retai-
fixed mark (5) on the oil pump body. ning washer.
a Torque tighten the crankshaft accessories pulley
to 15 Nm
7 a Fit the timing belt aligning the belt marks with the
crankshaft sprocket and the camshaft pulley.
6 a Remove the TDC pin (Mot. 1054).
18502
a Refit the rocker cover with four mounting bolts (to
check the alignment with the camshaft pulley).
a Align the camshaft pulley mark (6) with fixed mark (7) 8
on the rocker cover using tool (Mot. 799-01).
109761
a Remove the timing tensioner wheel pin (8).
10A-116
a Check that the camshaft and crankshaft markings
are correctly aligned with the fixed markings.
a Remove the TDC setting rod. (Mot. 1054).
11
9
109763
a Turn the tensioner wheel eccentric using a 6 mm Al-

len key in an anti-clockwise direction. 10
109764
a Move the moving tensioner wheel index (9) to the po- a Loosen the tensioner wheel nut holding it with a 6
sition indicated above. mm Allen key.
a Tighten to torque the timing tensioner, (24 Nm). a Return the moving index (10) of the tensioner wheel
in a clockwise direction to the position indicated abo-
a Rotate the crankshaft through six revolutions in a ve.
clockwise direction (timing side).
WARNING
There should be a gap of approximately 5 mm
between the tensioner wheel and the edge of the
cylinder head (11).
If the tensioner wheel is in contact with the edge
of the cylinder head, restart the belt tensioning
procedure.
a Torque tighten the timing tensioner wheel to 24

Nm.
18499
10A-117
2 - Setting the valve clearances
18499
a Check that the crankshaft is at its setting point with
tool (Mot. 1054)
a Remove the rocker cover.
110423
a Fit tool angular tightening wrench to the crankshaft
accessories pulley bolt.
10A-118
a Setting 4:
A1 A2 A3 A4 - Position tool angular tightening wrench at 0˚,
- Rotate the crankshaft 240˚ in a clockwise direction
(timing end),
- Adjust the inlet valve clearances I2 and I4 to 0.10 ±
0.05 mm.
a
WARNING
The cylinder head and rocker cover sealing faces
must be clean, dry and free from grease (avoid
finger marks).
WARNING
Excess sealant could be squeezed out when the
E1 E2 E3 E4
18641
a (I1): Inlet cylinder 1,
- (I2): Exhaust cylinder 2,
- (I3): Exhaust cylinder 3,
- (I4): Exhaust cylinder 4.
- (E1): Exhaust cylinder 1,
- (E4): Exhaust cylinder 4.
a Setting 1:
- Position tool angular tightening wrench at 0˚,
- Turn the crankshaft 20˚ in a clockwise direction (ti-
ming end),
- Adjust the exhaust valve clearance E1 and E3 to
0.15 ± 0.05 mm.
a Setting 2:
- Position tool angular tightening wrench to 0˚,
- Turn the crankshaft 240˚ in a clockwise direction (ti-
ming end),
- Adjust the inlet valve clearances I1 and I3 to 0.10 ±
0.05 mm.
a Setting 3:
- Position tool angular tightening wrench at 0˚,
- Rotate the crankshaft 120˚ in a clockwise direction
(timing end),
- Adjust the exhaust valve clearances E2 and E4 to
0.15 ± 0.05 mm.
10A-119
D4F, and 708 or 722 or 740
7 11 3 2 12 6 10
2
18442
8 4 1 5 9
110422
a Tighten to torque and in order the rocker cover
bolts (12 Nm).
2
18441
a Apply beads (2) of RHODORSEAL 5661 around the
rocker cover mounting bolts and on bearings no. 1
and 5 of the camshaft.
a Refit the rocker cover, fitted with a new gasket.
10A-120

or 716 or 728 or 730 3
11 3 7 1 9 5 13
18639
a Before refitting the inlet manifold, check that the wi-
12 4 8 2 10 6 14 ring harness is correctly positioned at (3) and (4).
18640 a Replace the inlet manifold seals.

a Offer up the inlet manifold.
a Tighten to torque and in order the rocker cover bolt
to 12 Nm. a Apply a bead of LOCTITE FRENETANCH on the in-
let manifold bolts.
4 1 5
7 8
3 2 6
18444
a Screw in the eight bolts finger tight.
a Pretighten bolts (4) and (5) to 6 Nm.
a Completely loosen bolts (4) and (5).
a Tighten to torque and in order the inlet manifold /
cylinder head bolts (10 Nm).
18637
a Refit the spark plug well seals using a socket with an

external diameter of 41 mm (32 mm socket for
example).
10A-121
D4F, and 708 or 722 or 740 D4D, and 712 – D4F, and 702 or 706 or 712 or 714
or 716 or 728 or 730
110421
a Cross tighten to torque the inlet manifold / rocker 18638
cover bolts (8 Nm). a Cross tighten to torque the inlet manifold / rocker
cover bolts to 8 Nm.
10A-122
106640
a Place a bead of fluoride grease2 mm in diameter
on the periphery of the high voltage caps.
a Refit the ignition coil assembly with spark plug leads.
a Check that the spark plug leads are correctly paired
with the ignition coil.
18498
10A-123
18503 18504
a Refit the lower timing cover. a Refit the timing intermediate housing (1).
a Tighten to torque the intermediate timing housing
bolts (10 Nm).
a Refit the upper timing cover (2)
a Tighten to torque the upper timing cover bolt (33
Nm).
a Refit the crankshaft accessories pulley.
a Refit, using a new bolt, the crankshaft accessories
pulley (3).
a Tighten to torque the crankshaft accessories pul-
ley bolts (40 Nm + 70˚ ± 6˚).
III - REFITTING THE ACCESSORIES BELT (ON

a
WARNING
Replace any belt removed with a new one.
WARNING
When replacing the belt, be sure to replace the
10A-124
Air conditioning compressor / Power assisted
steering pump
3 5 3
4
1
1
97267-1
a (1) Crankshaft
(3) Power assisted steering pump
2
(4) Air conditioning compressor
18496
(5) Tension wheel
a Refit:
(M) Measuring point
- a new tensioner wheel
- Fitting tension (Hertz): 210 ± 5
- a new tensioner wheel mounting bolt,
- new accessories belts.

a Apply and check the accessories belt tension using
tool (Mot. 1715) or (Mot. 1505).
Accessories belt tension values
Alternator
10071
a (1) Crankshaft
(2) Alternator
(M) Measuring point
10A-125
Air conditioning compressor / Power assisted
steering pump
4
3
5
1
M
14263
a (1) Crankshaft
(5) Tension wheel
(6) Pulley
(M) Measuring point
a Tighten to torque:
- the alternator upper bolt (25 Nm) at (1),
- the alternator lower mounting bolt (50 Nm) at (2).
a Tighten to torque the tension wheel bolts (37 Nm)
at (3).
a Rotate the crankshaft twice to correctly position the
accessories belt.
a Check the accessories belt tension, readjust if ne-
cessary.
10A-126
Engine: Refitting 10A
Mot. 792-03 Engine mounting plate

for Desvil stand
H1 H
Mot. 1360-01 W1 pin, replaces W

pin of Mot.1360.


G W1
18491
Tightening torquesm
a Remove the studs G,H and W1 and the plate H1 of
air conditioning com- 25 Nm tool (Mot. 1360-01) (including the rod W1 and the
pressor bolts plate H1).
coolant inlet pipe bolt 10 Nm
alternator mounting bolt 25 Nm
air conditioning com- 50 Nm

pressor bolts
1
power assisted steering 25 Nm
mounting bolts
2
power assisted steering 22 Nm
pump bolt
alternator upper bolt 25 Nm
alternator lower moun- 50 Nm

ting bolt 3
I -ENGINE SECURED BY THE ACCESSORIES END

18492
a Remove the engine from the support (Mot. 792-03).
a Refit:
- the coolant inlet pipe with a new O-ring,
- the air conditioning compressor mounting (1).
a Tighten to torque.
- the air conditioning compressor bolts (25 Nm),
- the coolant inlet pipe bolt (10 Nm) at (2).
a Refit the alternator mounting (3).
a Tighten to torque the alternator mounting bolt (25

Nm).
10A-127
7
4
6
18493 18496
a Refit the alternator. a Refit:
a Do not tighten the alternator mounting bolts. - a new tensioner wheel
a Refit the air conditioning compressor.
a Tighten to torque the air conditioning compressor
bolts (50 Nm) at (4). - new accessories belts.
a Refit the power assisted steering mounting (if the en- a Apply and check the accessories belt tension using
gine has one). tool (Mot. 1715) or (Mot. 1505).
Accessories belt tension values
- the power assisted steering mounting bolts (25
Nm),
- the power assisted steering pump bolt (22 Nm). Alternator
WARNING
2
WARNING
When replacing the belt, be sure to replace the 1
10071
a (1) Crankshaft
(2) Alternator
(M) Measuring point
10A-128
Air conditioning compressor / Power assisted Air conditioning compressor / Power assisted
steering pump steering pump
5 3 6
4
4
1 3
5
M
97267-1 1
a (1) Crankshaft M
(5) Tension wheel 14263
(M) Measuring point a (1) Crankshaft

(5) Tension wheel
(6) Pulley
(M) Measuring point
- the alternator lower mounting bolt (50 Nm) at (6)

at (7)

accessories belt.
a Check the accessories belt tension, otherwise, read-

just.
II - ENGINE SECURED AT THE CLUTCH END
a Remove:
- the engine from the plate support tool (Mot. 1723).
- the studs from the cylinder block.
10A-129
Timing belt: Removal 10A
I -REMOVING THE ACCESSORIES BELT
1 2
18495
a Loosen alternator bolts (3).
a Remove the alternator accessories belt.
18496
II - REMOVING THE TIMING
a Loosen tensioner bolt (1). a Insert a large screwdriver to immobilise the flywheel.
a Turn the hexagon bolt (2) in a clockwise direction.
a Remove the air conditioning compressor accesso-
ries belt.
18504
a Remove:
- the crankshaft accessories pulley (1),
- the timing intermediate housing (2),
- the timing upper housing (3)
10A-130
4
5
6
18503 18501
a Remove the lower housing.(4) a Rotate the crankshaft in its operating direction (cloc-
kwise, timing end) to position the crankshaft sproc-
ket mark (5) one half-tooth before the alignment of
fixed mark (6) on the oil pump body.
18505
a Refit the crankshaft accessories pulley bolt and its
retaining washer.
18499
a Rotate the crankshaft to the setting point.
10A-131
18505-1
a Check that mark (7) of the camshaft pulley is vertical
to the engine and aligned with the rocker cover mark.
a Loosen the timing tension wheel nut (8).
a Remove:
- the timing belt,
- the timing tension wheel,
- the crankshaft sprocket,
10A-132
Timing belts: Refitting 10A
There are three distinct tension procedures that must
be observed, according to the engine family.
Some engines require:
- a pretensioning torque to be applied (using the special
tooling for the engine type) to the belt section to be
measured to compensate for all the belt play.
- a pre-stress T1 slightly greater than the final fitting
tension T2 to be applied.
The purpose of these two operations is to stabilise the
belt's internal voltage, to make a reliable tension
measurement.
WARNING
Replace any removed belt.
WARNING
When replacing the timing belt specified by the
manufacturer, the belt, tension wheel and pulley(s)
must be replaced.
I -NO PRETENSIONING TORQUE
II - WITH PRETENSIONING TORQUE
III - WITH PRETENSIONING TORQUE AND PRE-

STRESS
10A-133

belt

(K engines)
Mot. 1715 Belt tension setting 1


Tightening torquesm
timing tensioner, 24 Nm
104703
intermediate timing hou- 10 Nm a
sing bolts
Note:
upper timing cover bolt 33 Nm
Be sure to degrease:
crankshaft accessories 40 Nm + 70˚ ± - the end of the crankshaft (timing end),
pulley bolts 6˚
- the timing sprocket bearing faces and bore at
alternator upper bolt 25 Nm (1),
alternator lower moun- 50 Nm - the contact surfaces of the crankshaft accesso-

ting bolt ries pulley.

WARNING
Never turn the engine against its operating direc-
I -REFITTING THE TIMING BELT
tion.
a
a Refit the crankshaft sprocket.
WARNING
The following parts must be replaced with new

ones after being removed:
- the belt (distribution and accessories),
- the crankshaft accessories pulley bolt.
WARNING
When replacing the belt, be sure to replace the
10A-134
Adjusting the timing
4
5
3
18501
109761 a The crankshaft sprocket (4) should be aligned at
a Refit a new tensioner wheel. fixed mark (5) on the oil pump body.
a Position both indexes (2) between the cylinder head
groove.
a Do not remove pin (3) before refitting the timing belt. 7
18502
a Align the camshaft pulley mark (6) with fixed mark (7)
on the rocker cover using tool (Mot. 799-01).
18499
a Check that the crankshaft is at its setting point with
the TDC setting rod (Mot. 1054).
10A-135
9
18505 109763
a Fit the crankshaft accessories pulley and its retai- a Turn the tensioner wheel eccentric using a 6 mm Al-
ning washer. len key in an anti-clockwise direction.
a Torque tighten the crankshaft accessories pulley
to 15 Nm a Move the moving tensioner wheel index (9) to the po-
sition indicated above.
a Fit the timing belt aligning the belt marks with the
crankshaft sprocket and the camshaft pulley. a Tighten to torque the timing tensioner, (24 Nm).
a Remove the TDC pin (Mot. 1054).
a Rotate the crankshaft through six revolutions in a
clockwise direction (timing side).
109761
a Remove the timing tensioner wheel pin. (8)
18499
10A-136
a Check that the camshaft and crankshaft sprockets
markings are correctly aligned with the fixed mar-
kings.
a Remove the TDC setting pin. (Mot. 1054).
11
18498
10
109764
a Loosen the tensioner wheel nut holding it with a 6
mm Allen key.
a Return the moving index (10) of the tensioner wheel
in a clockwise direction to the position indicated abo-
ve.
WARNING
There should be a gap of approximately 5 mm
between the tensioner wheel and the edge of the
cylinder head (11).
If the tensioner wheel is in contact with the edge
of the cylinder head, restart the belt tensioning
procedure.
a Torque tighten the timing tensioner wheel to 24

Nm.
18503
a Refit the lower timing cover.
10A-137
13 1
12
14
2
18504 18496
a Refit the timing intermediate housing (12). a Refit:
a Tighten to torque the intermediate timing housing - a new tensioner wheel
bolts (10 Nm).
a Refit the upper timing cover (13)
a Tighten to torque the upper timing cover bolt (33 - new accessories belts.
Nm). a Apply and check the accessories belt tension using
a Refit the crankshaft accessories pulley. tool (Mot. 1715) or (Mot. 1505).
a Refit, using a new bolt, the crankshaft accessories

pulley (14). Accessories belt tension values
a Tighten to torque the crankshaft accessories pul-
ley bolts (40 Nm + 70˚ ± 6˚). Alternator
II - REFITTING THE ACCESSORIES BELT (ON

a
2
WARNING
1
WARNING
When replacing the belt, be sure to replace the M
10071
a (1) Crankshaft
(2) Alternator
(M) Measuring point
10A-138
Air conditioning compressor / Power assisted Air conditioning compressor / Power assisted
steering pump steering pump
5 3 6
4
4
1 3
5
M
97267-1 1
a (1) Crankshaft M
(5) Tension wheel 14263
(M) Measuring point a (1) Crankshaft

- Fitting tension (Hertz): 210 ± 5 (3) Power assisted steering pump
(5) Tension wheel
(6) Pulley
(M) Measuring point
- the alternator lower mounting bolt (50 Nm) at (2)
at (3)
accessories belt.
a Check the accessories belt tension, otherwise, read-
just.
10A-139

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Technical Note 6004A

DXX, and D4D or D4F

77 11 328 182 JULY 2004 Edition Anglaise

© Renault s.a.s. 2004

D4 4-cylinder petrol engine

General information 10A-1 Engine: Refitting 10A-127

Engine identification 10A-2 Timing belt: Removal 10A-130

Tightening torque 10A-4 Timing belts: Refitting 10A-133

Special notes 10A-28

Standard replacement 10A-29

Special tooling 10A-30

Engine: Dismantling 10A-42

Timing - cylinder head:

Stripping the cylinder head 10A-50

Upper engine: Cleaning 10A-56

Upper engine: Checking 10A-57

Rebuilding the cylinder head 10A-65

Cylinder block: Dismantling 10A-78

Running gear:Removal 10A-83

Lower engine: Cleaning 10A-85

Lower engine: Check 10A-86

Running gear Refitting 10A-91

Cylinder block: Refitting 10A-100

Timing - cylinder head:

II - ENGINE SPECIFICATION TABLES

Vehicle After- Engine Engine Cubic capa- Bore Stroke Com-

C06H D4D 712 999 69 66.8 9.8 ± 0.6

X06C D4F 702 1149 69 76.8 9.8 ± 0.6

XB06 D4D 700 999 69 66.8 9.8 ± 0.6

Vehicle After- Engine Engine Cubic capa- Bore Stroke Com-

XC06 D4D 720 999 69 66.8 9.8 ± 0.6

KANGOO XC0T 716

MODUS JP0C D4F 740 1149 69 76.8 9.8 ± 0.6

Tightening torques in Nm and/or in ˚

1 Camshaft pulley bolt 30 + 45˚ ± 6˚

2 Timing tensioner nut 24

3 Timing tension wheel stud 10

4 Camshaft securing bolt 7 + 50˚ ± 6˚

5 Valve clearance adjusting nut 10

6 Upper timing cover bolt 33

7 Cylinder head bolts see tightening procedure

9 Rocker cover bolts 12 / see order of tightening

10 Inlet manifold / rocker cover 8

11 Inlet manifold / cylinder head bolts 10 / see order of tightening

12 Motorised throttle valve bolt 10

13 Injection rail bolt 10

14 Coolant temperature sensor 22

15 Exhaust manifold nut 25 / see order of tightening

16 Heat shield nut 15

Mark 17 Cylinder head coolant outlet unit mounting bolt 10

Mark 18 Ignition coil 7

Tightening torques in Nm and/or in ˚

1 Crankshaft accessories pulley bolt 40 + 70˚ ± 6˚

2 Crankshaft bearing bolts 20 + 76˚ ± 6˚

3 Con rod cap bolt 14 + 39˚ ± 6˚

4 Flywheel bolts 18 + 110˚ ± 6˚

5 Clutch pressure plate bolt 25

Tightening torques in Nm and/or in ˚

1 Intermediate timing housing bolts 10

2 Lower timing cover bolt 10