Workshop repair manual F9Q

"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by themanufacturer in the production of the various component units and accessoriesfrom which his vehicles are constructed

All copyrights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority ofRenault.

C Renault 1997

ENGINE (with direct diesel injection)4 cylinders - cast iron

77 11 193 300 MARCH 1997 Edition Anglaise

Types

MéganeF9Q

Vehicles

Workshop Repair Manual

Contents

IntroductionSection viewIdentificationTightening torques (in daN.m ordegrees)SpecificationsStandard exchangeSpecial tooling requiredEquipment requiredEngine repair

10-110-210-3

10-510-7

10-1810-1910-2410-25

Page

ENGINE AND PERIPHERALS10

ENGINE AND PERIPHERALS

Introduction 10F9Q

UNITS OF MEASUREMENT

All dimensions are expressed in millimetres : mm(unless specified otherwise).

The tightening torques are given indecaNewtonmetre : daN.m. ( reminder : 1 daN.m= 1.02 m.k.g).

In degrees, the tightening torques withouttolerances must be observed between ± 3o.

The tightening torques without tolerances mustbe observed between ± 10 %.

The pressures are given in bars.

10-1


Section View 10F9Q

PRE1006

10-2


Identification 10F9Q

ENGINE IDENTIFICATION The engine is identified by a plate riveted to thecylinder block.

12585S

0 0 0 0 0 / 0 0

0 0 0 0 0 0 0

G F

A B D E

It shows :- At A : The engine type,- At B : The engine homologation letter,- At D : Renault identity,- At E : Engine suffix,- At F : The engine fabrication number,- At G : Engine assembly factory.

10-3


Identification 10F9Q

(*) Engine without intermediate shaft.

Engine Suffix Vehicle RatioBore(mm)

Stroke(mm)

Capacity(cm3)

F9Q 730734*

XA08XA0N 18.3/1 80 93 1870

10-4


Tightening torques (in daN.m or degrees) 10CYLINDER HEAD

DescriptionTightening torques (in daN.m or

degrees)

Cylinder head cover bolt 1.2

Camshaft bearing casing bolt 2

Camshaft pulley bolt 6

Timing cover bolt 0.9

Inlet and exhaust manifold nut 2.8

EGR pipe mounting nut on exhaust manifold 2.3

EGR mounting bolt 2.3

Heater plug 2.3

Heater plug shunt nut 0.2

Lifting bracket mounting bolt (timing side) 2

Lifting bracket mounting bolt (flywheel side) 1.3

Injector flange bolt mounting bolt 2.7

Vacuum pump mounting bolt and nut 2.3

Injection pump support mounting bolt 2.5

10-5


Tightening torques (in daN.m or degrees) 10CYLINDER BLOCK

DescriptionTightening torques (in daN.m or

degrees)

Sump bolt 1.4

Crankshaft damper pulley bolt2

and angle tighten by 115° ± 15°

Intermediate shaft flange bolt 0.9

Bolt for intermediate shaft housing or idle roller support 1.5

Oil spray jet 2

Crankshaft bearing cap bolt 6.5

Big end cap bolt 5

Crankshaft cover plate bolt 1.5

Oil pump bolt 2.5

Flywheel bolt 5.5

Clutch disc mounting bolt 2

Water pump bolt 1.7

Water pump pulley bolt 2

Bolt for intermediate shaft sprocket or idle roller 5

Multifunction support nut and bolt 4.3

Timing tension wheel nut 4.8

10-6


Specifications 10F9Q

CYLINDER HEAD GASKET

Thickness reference.

First fitting: thickness 1.45 ± 0.05 mm.

94745R

Repair

Thickness: 1.35 ± 0.05 mm.

94745R1

Thickness: 1.55 ± 0.05 mm.

94745R2

The value given is for information only and corre-sponds to a compressed gasket.

NOTE : the gasket thickness reference holes are inzone (R) which is 25 mm, ignore any other holesoutside this area.

The gasket thickness reference (R) is visible oncethe cylinder head has been fitted.

12535R

10-7



NOTE :when replacing :_ the crankshaft- the cylinder block,- the connecting rods,- the pistons,It is imperative to calculate the thickness of thecylinder head gasket.

Checking the piston protrusion

Clean the piston crown to remove deposits.

Turn the crankshaft, in the direction of operation,by one turn to bring piston no. 1 close to TDC.

Fit tool Mot. 252-01.

Fit tool Mot. 251-01 with a dial gauge on the pres-sure plate Mot. 252-01 and find the TDC of the pis-ton.

NOTE : all measurements must be made in thelongitudinal axis of the engine to eliminate anyerror due to the piston tilting.

IMPORTANT: the dial gauge measuring pin mustnot be in the valve opening.

12516R

Measure the piston protrusion.

ONLY TAKE INTO ACCOUNT THE DIMENSION FORTHE PISTON WITH THE LARGEST PROTRUSION.

For a protrusion:- less than 0.653 (exclusive), use a gasket

marked with a tab having two holes(thickness 1.35),

- between 0.653 (inclusive) and 0.786(inclusive), use a gasket marked with a tabhaving one hole (thickness 1.45),

- greater than 0.786 (exclusive), use a gasketmarked with a tab having three holes(thickness 1.55).

12517R

10-8



CYLINDER HEAD

All the cylinder head bolts must be replacedsystematically after removal.

There is no cylinder head retightening operation.

Method of tightening the cylinder head

Preseating the gasket:

Tighten all the bolts to 3 daN.m, then angletighten by 50° ± 4° in the order recommendedbelow.

Wait 3 minutes for the gasket to settle.

27 6 10

18 5 94

3

Tightening the cylinder head

Slacken bolts 1-2 until they are completely free.

Tighten bolts 1-2 to 2.5 daN.m, then angle tightenby 213° ± 7°.

Carry out the same slackening and torque/angletightening operations on the remaining bolts 3-4,5-6, 7-8, 9-10.

Cylinder head height (mm)

H = 162 ± 0.1.

87071-1R

Maximum gasket face bow : 0.05 mm.

THE CYLINDER HEAD MAY NOT BE REGROUND.

10-9



Valves

Diameter of the stem(mm) 7- 0.01- 0.02

Port angle 90°

Head diameter (mm)- Inlet 35.2- Exhaust 32.5

Valve protrusion in relation to the cylinder headgasket face(mm) 0.09±0.12

Maximum valve lift (mm)- Inlet 8.50- Exhaust 10.3

Valve clearances (mm)- Inlet 0.20 ± 0.05- Exhaust 0.40 ± 0.05

Valve seats

Seat angle (α)- Inlet and exhaust 90°

Seat width (X) (mm)- Inlet and exhaust 1.8

Exterior diameter (D) (mm)- Inlet 36.9- Exhaust 33.6

91880R4

Valve guides

Interior diameter (mm) 7 + 0.020

Diameter of location in cylinder head (mm)- Normal 12 - 0.02

- 0.05

Diameter of guide (mm)- Normal 12 + 0.05

+ 0.03

The inlet and exhaust guides are fitted with valvestem seals. They must be replaced whenever thevalves are removed.

Position the inlet and exhaust valve guides in relation to the cylinder headgasket face A (mm) :- Inlet- Exhaust

96794R1

81.05 ± 0.35

10-10



Valve springs

Free length (mm) 45.8

Length under load of (mm)27 daN.m 37.561.4 daN.m 27.5

Length of spring (mm) 25.07

Wire diameter (mm) 3.90

Interior diameter (mm) 21.5

Tappets

Exterior diameter (mm) 35 - 0.01- 0.03

Camshaft

End play (mm) 0.05 at 0.13Number of bearings 5

Timing diagram

- Inlet opening retard (IOR) * - 3- Inlet closing retard (ICR) 21- Exhaust opening advance (EOA) 43- Exhaust closing advance (ECA) ** - 2

* Since the Inlet Opening Retard is negative,the opening of the valve is located after TDC.

** Since the Exhaust Closing Advance is negative,the closing of the valve is located before TDC.

11953S

1 - Fixed mark TDC cylinder block2 - Mobile mark flywheel TDC3 - Mobile mark flywheel BDC4 - Inlet Opening Retard (IOR)5 - Exhaust Closing Advance (ECA)6 - Inlet Closing Retard (ICR)7 - Exhaust Opening Advance (EOA)8 - Engine rotation direction (flywheel side)

10-11



Intermediate shaft (F9Q 730 only)

End play (mm) 0.07 to 0.15

The intermediate shaft is mounted on two bushes.

Interior diameter of inner bush 39.5 mm

Interior diameter of outer bush 40.5 mm

Pistons

The gudgeon pin is fully floating in theconnecting rod and the piston.

The gudgeon pin is secured by circlips.

These engines have SMP pistons.

Piston marking

98368R

1 Piston mounting direction - V towards theflywheel.

2 Height between the gudgeon pin and thetop of the piston (see table below).

3-4-5 Manufacturer’s reference only.

10-12



The offset between the gudgeon pin opening andthe symmetrical axis of the piston is 0.5 mm.

* Marking on the pistonGudgeon pin height

(mm)

J 47.164

K 47.206

L 47.248

M 47.290

N 47.332

P 47.374

Q 47.416

The gudgeon pin height tolerance is ± 0.02 mm.

* The various gudgeon pin heights are exclusivelyreserved for the engine fitting factory.

The Parts Department only supplies one class ofpiston height - M.

Measuring the piston diameter

Measurement of the piston diameter (diameter80 mm) must be carried out at a point where A =39 mm.

86928-4R1

Piston rings

Three rings (thickness in mm)- Upper piston ring 2.5- Taper compression piston ring 2- Scraper ring 3

The rings are supplied adjusted.

Do not cut to adjust play.

12115R

T = Top

10-13



Direction for fitting the circlip on the piston

Fit the circlips on the piston as shown below.

98365S

Direction for fitting the connecting rods

Fit the centring pins on the big ends on the timingside.

Crankshaft

Number of bearings 5

Side clearance (mm) 0.07 to 0.23

Roll hardened journals (mm)- nominal diameter 54.79 ± 0.01

Roll hardened crankpins (mm)- nominal diameter

NO REGRINDING IS PERMITTED.

Connecting rods

Big end side clearance (mm) 0.22 to 0.40

Distance between big and little ends (mm) 139

NOTE : the little end rings cannot be replaced.

IMPORTANT: Do not use a scriber tool for themarking of the big end caps in relation to theirbodies, in order to avoid starting any cracks in theconnecting rods.Use an indelible pencil instead.

48+ 0.02

0

98201R1

Fit the bronze coloured shell (A) on the crankshaftbearing caps.

10-14



Cylinder liners

These are of the "dry liner" type (no regrindingpermitted).

Identification of the cylinder block without inter-mediate shaft

The cylinder block without intermediate shaft isidentified in two ways

- by the lack of casting for the intermediateshaft (1),

Removal

Remove:- the oil pump cover,- the discharge valve and its spring.

86799S12554R

- and that the oil pump is driven by a chain.

Oil pump

Minimum oil pressure at 80°C (bar) :- at 1 000 rpm 1.2- at 3 000 rpm 3.5

Opening pressure of oil spray jetvalves at the bottom of the piston 1.5 bar

10-15



Securing the engine on mounting Mot. 792-03and rod Mot. 995.

Rods (B), (N), (P) Mot. 995 are secured to thecylinder block so that they fit into the holes (26,12, 25) in the plate.

86749R1

NOTE : the turbo and the metal oil vapour rebrea-thing pipe at the bottom of the engine must beremoved.

Checking the oil pump

Check the clearances:

Clearance (A) :- minimum (mm) 0.1 - maximum (mm) 0.24

86801R

Clearance (B) :- minimum (mm) 0.02 - maximum (mm) 0.085

Refit:- the oil pump cover tightening the bolts to a

torque of 1 daN.m,- the discharge valve and its spring.

NOTE : fill the pump with oil (to make re-primingeasier).

86806R

10-16



CONSUMABLES

PRECAUTIONS

WASHING THE ENGINE

Protect the timing and alternator belts to avoidsplashing of water and washing products on tothem.

Do not allow water to penetrate the air inletpipes.

FITTING OF THREAD INSERTS

The threaded holes in all the engine componentsmay be repaired using thread inserts.

Type Quantity Component concernedPart Number (SODICAM)

RAVITOL S 56 - Cleaning parts 77 01 421 513

DECAPJOINT Coat Cleaning gasket faces 77 01 405 952

RHODORSEAL 5661 Coat Crankshaft bearing cap 77 01 404 452

LOCTITE 518 Coat Crankshaft end cover, water pump 77 01 421 162

PARTS TO BE RENEWED WHEN THEY HAVE BEENREMOVED

- All seals.- Flywheel bolts.- Valve guides.- Crankshaft bearing bolts.- Cylinder head bolts.- Camshaft pulley bolts.- Crankshaft pulley bolts.- Big end cap bolts.- Injector holder copper washers.- Pipe plugs.- Cooling circuit rigid pipe.- Intermediate shaft bearing bush.

10-17


Standard exchange 10F9Q

PREPARATION OF USED ENGINE FOR RETURN

The engine should be cleaned and drained (oiland water).

Leave on the used engine or put into the box usedfor returning it:- the dipstick and its guide,- the flywheel,- the clutch disc and mechanism,- the water pump,- the crankshaft pulley,- the cylinder head cover,- the plugs,- the belt tension wheel,- the pressure switch and temperature switch,- the timing cover,- the oil filter.

Do not forget to remove:- all the flexible coolant pipes,- the belt or belts (except timing belt).

The used engine must be fixed on to the base inthe same way as the reconditioned engine:- plastic plugs and caps in place,- cardboard cover all around it.

10-18


Special tooling required 10F9Q

Diagram Methodreference

Part Number Description

Mot. 251-01 00 00 025 101 Dial gauge support. Used with Mot. 252-01

Mot. 252-01 00 00 025 201 Thrust plate for measuring cylinder liner pro-trusion. Used with Mot. 251-01.

Mot. 330-02 00 00 033 002 Cylinder head support.

83812S

Mot. 445 00 00 044 500 Oil filter wrench

Mot. 582-01 00 00 058 201 Flywheel locking tool.

Mot. 591-02 00 00 059 102 Magnetised flexible tool for angular wrenchfor tightening cylinder head.

Mot. 591-04 00 00 059 104 Angular wrench for tightening cylinder head( 1/2" drive ) with index.

Mot. 792-03 00 00 079 203 Engine mounting plate for Desvil stand.

83812S1

68666S1

69716S1

77121S1

77889S1

78181S

82919S1

10-19



Diagram MethodReference

PartNumber

Description

Mot. 799-01 00 00 079 901 Sprocket immobiliser for notched timingbelt.

Mot. 856 00 00 085 600 Dial gauge mounting for timing BOSCHpump

Mot. 856-01 00 00 085 601Adapter for securing dial gauge mountingon injection pump, use with Mot. 856.

80359S1

Mot. 988-02 00 00 098 802 Tool for fitting camshaft seal, timing side

Mot. 989 00 00 098 900 Tool for fitting seal on intermediate shafthousing, F9Q 730 only.

Mot. 990-02 00 00 099 002Tool for fitting crankshaft seal, timing side(engine with intermediate shaft).

Mot. 991-01 00 00 099 101 Tool for fitting crankshaft seal, flywheel side

Mot. 993 00 00 099 300Mandrel for fitting inner bush forintermediate shaft F9Q 730 only.

83375S1

86892S1

86888S1

96897S

96898S

86887S1

10-20



Diagram MethodReference

PartNumber

Description

Mot. 994 00 00 099 400Mandrel for fitting outer bush forintermediate shaft F9Q 730 only.

Mot. 995 00 00 099 500 Set of two rods (use with engine plate Mot.792-03).

Mot. 998 00 00 099 800Inner and outer bush extractor forintermediate shaft F9Q 730 only.

Mot. 1054 00 00 105 400 TDC pin

Mot. 1079-02 00 00 107 902 Dial gauge for setting injection pumps

Mot. 1200 00 00 120 000 Injection pump sprocket locking tool

Mot. 1273 00 00 127 300 Tool for checking belt tension

Mot. 1281-01 00 00 128 101 Oil filter wrench

86889S1

84900S1

86891S1

90277S1

91285S1

94161S1

96508S1

97160-1S2

10-21



Diagram Method reference

PartNumber

Description

Mot. 1358 00 00 135 800 Wrench for adjusting injection pumpsprocket

Mot. 1359 00 00 135 900 Socket for tightening injection pump pulley

Mot. 1364 00 00 136 400 Locking tool for intermediate shaft sprocketor idle roller

Mot. 1366-01 00 00 136 601 Flange tool for valves for removing adjustingshims

Mot. 1383 00 00 138 300 17 mm pipe wrench for removing highpressure pipes.

Mot. 1387 00 00 138 700Tool for checking accessories belt tension(engine fitted with automatic tensioner).

Mot. 1423 00 00 142 300 Tool for removing siliconised crankshaftbearing caps

Mot. 990-03 00 00 099 003Tool for fitting crankshaft seal, timing side(engine without intermediate shaft)

99329S1

99330S1

99514S1

11231S1

10578S1

11923S1

96897S

10-22



Diagram Method reference

PartNumber

Description

Emb. 880 00 00 088 000 Slide hammer

Rou. 15-01 00 01 331 601 Inner shaft protective end piece,diameter 16 mm.

84328S

69306-1S1

10-23


Equipment required 10F9Q

Description

Bush for fitting piston with piston rings into the cylinder liner

Set of burrs for grinding valve seats, for example CERGYDIS C 108 NEWAY.

22 mm long socket, standard 1/2" (12.7 mm) drive, for removing oil pressure testinggauge

Valve lifter.

Angle tightening sector

83391S

10-24


Engine repair 10F9Q

EXPLODED VIEW OF CYLINDER HEAD

PRE1001

10-25


Engine repair 10F9Q

ENGINE REMOVAL

Fit the engine onto support Mot. 792-03.

Drain the engine oil.

Remove the engine wiring.

NOTE : special notes for checking the length ofthe accessories belt automatic tensioner.

Before removing the accessories belt, check thelength (A) of the automatic tensioner using toolMot. 1387.

12205R

Tensioner length (A)

11234R

10-26


Engine repair 10F9Q

METHOD FOR USING TOOL Mot. 1387

Slacken wheel (1) so that arms (2) and (3) can slidein relation to each other.

Fit tool Mot. 1387 onto the two mountings of thetensioner, then lock arms (2) and (3) by turningthe wheel (1).

12205G

Check on tool Mot. 1387 that the measurement iswithin the tolerance range (zone B).

12205R4

NOTE : minimum tolerance= reference mark(4),maximum tolerance= reference mark(5).

10-27


Engine repair 10F9Q

Checking the length of the tensioner allows thecorrect operation of the automatic tensioning sys-tem to be checked. If the length is outside the to-lerance range, check the following:

ENGINE

LENGTHF9Q

Length less thanminimumtolerance

- Check the eccentric plate iscorrectly positioned (atbottom of slot).

- Incorrect belt (too short).

- Belt incorrectly routed.

Length greaterthan maximum

tolerance

- Check the eccentric plate iscorrectly positioned (at bot-tom of slot).

- Incorrect belt (too long).

- Belt incorrectly routed.

10-28


Engine repair 10F9Q

Remove:- the accessories belt, for engines fitted with an

automatic tensioner, first slacken bolt (6) thenbolt (7)to just past the shoulder, while holdingthe automatic tensioner plate using a 9.53 mmdrive (eg. : FACOM J 151 ratchet), then slackenthe belt by moving the ratchet in the directionshown by the arrow,

98837-1R6

- the air conditioning compressor (if fitted),- the alternator,- the multifunction support,

12538R

- the engine lifting bracket on the flywheelside,

- the inlet and exhaust manifolds.

Remove the timing plug from the cylinder blockand position the timing at its setting point.

Turn the engine (clockwise as seen from thetiming side), to align the reference mark on thecamshaft sprocket with the reference mark (8) onthe timing cover and insert the TDC pin Mot. 1054.

12518R1

10-29


Engine repair 10F9Q

Remove the timing covers.

12519R

Remove:- the clutch and flywheel,- the timing belt,- the timing tension wheel,- the injection pump high pressure pipes using

tool Mot. 1383,- the three mounting bolts for the injection

pump mounting and the pump rearmounting.

12518R

Remove the TDC pin Mot. 1054.

Fit the flywheel locking tool Mot. 582-01 andslacken the accessories pulley mounting bolt.

- the camshaft pulley, locking it using tool Mot.799-01,

10-30


Engine repair 10F9Q

98366R

STRIPPING THE CYLINDER HEAD

Fit the cylinder head on the cylinder head standMot. 330-02.

Remove:- the pre-postheating plugs (11) using a 10 mm

pipe wrench,- the injectors, removing the flanges (12) and

retaining the spacers (15),

12521R

- the cylinder head.

- the vacuum pump,- the thermostat unit,- the engine lifting bracket,- the cylinder head cover (13),- the camshaft line casing (14),- the camshaft (16).

Remove:- the inner timing cover (10),

10-31


Engine repair 10F9Q

Remove the tappets and the valve clearanceadjusting shims.

Compress the valve springs.

Remove the half rings. the upper cups, thesprings, the valves, the valve seals using tool Mot.1335 and the lower cups.

Place the parts in order.

Checking gasket face bow

Check with a straight edge and a set of shims tosee if there is any cylinder head bow.

Maximum bow : 0.05 mm

Regrinding of the cylinder head is not permitted.

Check the cylinder head to detect any cracks.

12512R

CLEANING

It is very important not to scratch the sealingfaces of aluminium parts.

Use the product Decapjoint to dissolve any part ofthe seal which remains.

Apply the product to the part to be cleaned; waitabout ten minutes, then remove it by means of awooden spatula.

The wearing of gloves is recommended duringthis operation.

Do not allow any product to drip on to paintwork.

We would like to stress that the utmost careshould be taken in carrying out this operation toprevent foreign bodies from penetrating thepipes feeding oil under pressure to the camshafts(pipes located both in the cylinder block and inthe cylinder head) and in the oil return pipe.

10-32


Engine repair 10F9Q

REGRINDING OF THE VALVE SEATS

Inlet

- Port width X = 1.80 mm

- Angle α = 90°

The port (1) is straightened with cutter 232, angle45°. Reduce the width of this port at (2) with cut-ter n° 605 angle 65° until width (X) is obtained.

Exhaust

- Port width X = 1.80 mm

- Angle α = 90°

The port (1) is straightened with cutter 230, angle45°. Reduce the width of this port at (2) with cut-ter n° 605 angle 65° until width (X) is obtained.

91880R1

NOTE: Observe the position of the valve port on its seat.

88988-1R

10-33


Engine repair 10F9Q

EXAMINATION AND REPAIR OF THE ROCKERSHAFTS

Check that the lubrication pipes for the cylinderhead, camshaft bearings and the tappets are notobstructed.

Replace the worn parts.

REFITTING THE CYLINDER HEAD

Place the new valves in position (26). Lap them ingently on their respective seats. Ensure that allparts are clean and marked, then refit.

Lubricate all the parts.

Place the spring base washers in position (27) .

Fit the seals (28) on the valve guides (29) with theaid of a pipe wrench.

Position :- the new valves as you go along (26),- the springs (30),- the cups (31).

Compress the springs.

Position the half rings (32).

77678R2

10-34


Engine repair 10F9Q

Check the valve protrusion which should be0.09±0.12 mm.

Refit:- the tappets and the valve clearance

adjustment shims,- the camshaft.

Use a roller to apply Loctite 518 to the camshaftbearing casing gasket face until it is "reddish".

CHECKING AND ADJUSTING VALVE CLEARANCES

Position the valves for the cylinder concerned atthe end of exhaust - start of inlet position andcheck the clearance.

12515S

Tighten the camshaft line casing to 2 daN.m, inthe order given below.

98366R1

86911-1S

1 | 4

3 | 2

4 | 1

2 | 3

Check the two values noted against the specifiedvalues and replace any shims as necessary.

Clearance (mm), cold ±0.05

- Inlet 0.20- Exhaust 0.40

Position the valve concerned to the fully openposition (turning the camshaft in the operatingdirection).

Insert tool Mot. 1366-01 into the openingconcerned.

10-35


Engine repair 10F9Q

Remove the adjusting shim using a screwdriverand a magnetic rod.

NOTE : when refitting the adjustment shim,remove any oil in the bottom of the tappet bore(C).

11231R

Turn the camshaft in the operating direction untilthe valve touches tool Mot. 1366-01 (turn thecamshaft through 90° from the fully openposition).

11232-1R

98895R1

Refit the rocker box cover, tightening the bolts toa torque of 1.2 daN.m (remember to refit a newgasket between the camshaft bearing casing andthe rocker box cover).

10-36


Engine repair 10F9Q

Refit:- the thermostat mounting (position the thermostat as shown below),

12525S

- the vacuum pump (remember to refit a new seal between the cylinder head andthe pump),

- the pre-postheating plugs tightening them to a torque of 2.2 daN.m,- the injectors with their copper seals (no fitting direction for copper seal) and

tighten the injector flange bolts to a torque of 2.7 daN.m,- the plug wiring, tightening the nuts to a torque of 0.2 daN.m.

10-37


Engine repair 10F9Q

NOTE : remember to fit the spacer (14) betweenthe cylinder head and the flange.

98366R2

10-38

* Engine with intermediate shaft.** Engine without intermediate shaft.


Engine repair 10F9Q

EXPLODED VIEW OF CYLINDER BLOCK

PRE1002

10-39


Engine repair 10F9Q

Remove the crankshaft timing sprocket, if necessary using a locally made tool and spacer Rou. 15-01(dimensions in mm),

87069R1

A 2 holes, diameter 6.5 mmB Bolt, diameter 12 mm - 1.75 mm thread pitchC 1 hole, diameter 13 mmD Nut, diameter 12 mm - 1.75 mm thread pitch, welded

10-40


Engine repair 10F9Q

Remove:- the water pump pulley,- the water pump,

87078R

12344-2R

- the intermediate shaft sprocket for engineF9Q 730 or the idle roller for engine F9Q 734using tool Mot. 1364.

99731R1

Remove:- the inner timing cover (16),

12521-1R

10-41


Engine repair 10F9Q

For engines fitted with an intermediate shaft

12347R

For engines without an intermediate shaft

12513R

Remove:- the cylinder block timing pulley,- the sump,- the coolant outlet pipe (check the presence of

the O ring (17) on the pipe),

12534R

- the oil decanter,- the oil filter using tool Mot. 1281-01,- the oil pressure sensor,- the oil pump.

10-42


Engine repair 10F9Q

Remove the oil pump chain and the drivesprocket.

Remove the crankshaft cover plate.

12344-1R 12533S

Carry out the marking of the big end shells withreference to their bodies.

WARNING: Do not use a scriber tool for themarking, in order to avoid starting any cracks inthe connecting rods .Use an indelible pencil instead.

12539R

NOTE : check the pad is present on the crankshaftcover plate for engines not fitted with theintermediate shaft.

86951-1R

10-43


Engine repair 10F9Q

- the crankshaft bearing caps (the bearing capsare numbered from 1 to 5 and these numbersare on the intermediate shaft or idle rollerside).

Remove:- the connecting rod - piston assemblies,

12348R

12346R

Bearing n° 1 with the injected silicon paste stripsis removed using tool Mot. 1423.

- the piston rings using piston ring pliers,- circlips (18) retaining the gudgeon pin,- the gudgeon pin (19),

12537R

98365R

10-44


Engine repair 10F9Q

- the plug,- the oil pump drive sprocket.

Remove:- the crankshaft, retaining the side clearance

shims and the bearing shells,- the oil spray jets.

12345R

95651S

- the intermediate shaft retaining flange,

For engines fitted with an intermediate shaft

Remove:- the intermediate shaft housing,

86955-1R

12344R

- the intermediate shaft.

Check the condition of the intermediate shaftbushes in the cylinder block. Replace them ifnecessary.

10-45


Engine repair 10F9Q

REPLACING THE INTERMEDIATE SHAFT BEARINGBUSHES

Both bushes must be replaced.

Remove the front and rear bushes using tool Mot.998 fitted to the slide hammer Emb. 880.

87072R

PRE1003

Fit the inner bush on tool Mot. 993.

Slot (20) in the bush must be aligned withreference mark (21) on the tool.

Align rod (22) on the tool with hole (23) in thecylinder block then press in the bush.

Fitting the bushes

Bush size:

- inner bush L1 : 12.5 mm

- outer bush L2 : 19 mm

87074-1R

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Engine repair 10F9Q

Refit the outer bush in the same manner usingtool Mot. 994.

86889R

87034S

CHECKING

Using a wire of diameter approximately 1.2 mm,check that the holes supplying oil correspond tothe drilled holes in the bushes.

Lubricate the bearing bushes.

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Engine repair 10F9Q

ENGINE REFITTING

Clean:- the cylinder block,- the crankshaft, passing a wire into the

lubrication channels.

REFITTING

Fit the oil pump drive sprocket and the plug withits O ring.

PRE1004

95651S

Fitting the seal

Put the seal support plate on a flat surface.

Press on the seal until tool Mot. 989 is against thesupport.

86908R

The tool is designed to ensure the the seal adjustsposition following wear of the seal seat.

Fit the intermediate shaft housing with a seal orcoat it with Rhodorseal 5661 and torque tightento 1.5 daN.m.

NOTE : for engines without an intermediate shaft,fit the idle roller mounting in place of theintermediate shaft housing. Tighten the bolts to atorque of 1.5 daN.m.

Lubricate and fit the intermediate shaft,tightening the flange bolts to a torque of 0.9daN.m.

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Engine repair 10F9Q

Refit the oil spray jets, positioning them as shownin the diagram below. Torque tighten them to 2daN.m.

12345S

Crankshaft

Fit the bearing shells without a groove on thebearing caps and the shells with a groove on thecylinder block.

12345-1S

Lubricate the crankpins and journals using engineoil.

Refit:- the crankshaft,- the crankshaft bearing caps except cap n° 1

(these are numbered from 1 to 5 - put thesenumbers on the intermediate shaft or idleroller side).

12346S

Fit the crankshaft side clearance shims on bearing2 (grooves on the crankshaft side).

98201R1

Fit the bronze coloured shell (A) on the crankshaftbearing caps.

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Engine repair 10F9Q

Use engine oil to lubricate the threads and underthe heads of the mounting bolts for the cranks-haft bearing caps. Tighten the bearing cap bolts(3), (4), (5) to a torque of 6.5 daN.m. Fit the bea-ring cap (2) without torque tightening the bolts.

Check the crankshaft side clearance, it must bebetween 0.07 and 0.23 mm.

There are various adjusting shims available (referto the PR catalogue).

86909S

Torque tighten the bearing cap (2).

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Engine repair 10F9Q

FITTING BEARING N° 1 WITH SILICON INJECTION

IMPORTANT : injection must be carried out withinapproximately 5 minutes to avoid polymerisationof the mixture in the syringe.

Ensure the surfaces at (25) on the cylinder blockand the crankshaft bearing cap are perfectlyclean. Use a cloth dampened with cleaningsolvent.

Leave to dry.

92791R

92793R

Fit the crankshaft bearing cap (1) and torquetighten to 6.5 daN.m.

Mix 45 ml of Rhodorseal 5661 (approximately halfa 100 grammes tube) with half measure ofhardener using a small stick to give a slightly pinkcoloured, uniform mixture.

Lightly coat the lower faces of the cylinder blockat (26) with Rhodorseal 5661.

89195S

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Engine repair 10F9Q

Put the mixture into the syringe and inject it intothe crankshaft bearing cap grooves.

92794S 89197S

Leave to dry for a few moments then cut thesurplus from the sealing face.

Allow the mixture to ooze out slightly from eitherside of the grooves in the crankshaft bearing capto be sure that the mixture injected hascompletely filled the sealing groove.

92795S

92797S

Use a cloth to wipe off any excess mixture, bothon the inside and the outside of the cylinderblock.

Check that the crankshaft turns freely.

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Engine repair 10F9Q

REFITTING AND ASSEMBLING THE CONNECTINGRODS AND PISTONS

Lubricate the gudgeon pin.

Check that the gudgeon pins turn correctly in thenew piston and the corresponding connectingrod.

To assemble the piston and the connecting rod,ensure the following:- put the V of the piston on the flywheel side,- put the big end bearing cap centring pins on

the timing side.

98365S

Fit the connecting rod bearing shells.

12540R

Fit the gudgeon pin retaining circlips as shown onthe diagram below.

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Engine repair 10F9Q

FITTING THE PISTON RINGS

The rings are adjusted in the factory and shouldturn freely in their grooves.

Ensure the rings are fitted correctly.

72552R

REFITTING

Lubricate the pistons.

Fit the connecting rod - piston assemblies into thecylinder block using a bush, taking care to ensurethe fitting direction is correct (V towardsflywheel).

Fit the connecting rods onto the lubricatedcrankshaft crankpins (lubricated).

Fit the connecting rod bearing caps.

12115R

Stagger the ring openings.

T = Top

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Engine repair 10F9Q

Tighten the new connecting rod bearing cap boltsto a torque of 5 daN.m.

12516R

NOTE : all measurements must be made in thelongitudinal axis of the engine to eliminate anyerror due to the piston tilting.

IMPORTANT: the dial gauge measuring pin mustnot be in the valve opening.

12348R

Checking the piston protrusion

Clean the piston crown to remove deposits.

Turn the crankshaft, in the direction of operation,by one turn to bring piston no. 1 close to TDC.

Fit tool Mot. 252-01.

Fit tool Mot. 251-01 with a dial gauge on thethrust plate Mot. 252-01 and find the TDC of thepiston.

12517R

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Engine repair 10F9Q

Measure the piston protrusion.

ONLY TAKE INTO ACCOUNT THE DIMENSION FORTHE PISTON WITH THE LARGEST PROTRUSION.

For a protrusion:- less than 0.653 (exclusive), use a gasket

marked with a tab having two holes(thickness 1.35),

- between 0.653 (inclusive) and 0.786(inclusive), use a gasket marked with a tabhaving one hole (thickness 1.45),

- greater than 0.786 (exclusive), use a gasketmarked with a tab having three holes(thickness 1.55).

Refit:- the oil pump drive chain and sprocket (for

engines without an intermediate shaft only),

86962-1R

- the crankshaft cover plate, sealed usingRhodorseal 5661.

Apply as shown in the diagram below,tightening to a torque of 1.5 daN.m.

12533S

NOTE : - do not apply too much product toavoid the risk of blocking the oilwaysin zone (C),

- remember to fit the chain pad on thecrankshaft cover plate.

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Engine repair 10F9Q

12534R

Engine without an intermediate shaft

12539R

Refit the oil pump and torque tighten it to 2.5daN.m.

Engine with an intermediate shaft

12347R

Refit :- the oil pressure sensor,- the oil filter,- the oil decanter,- the coolant pipe with a new seal.

12513S

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Engine repair 10F9Q

12342R

- Timing side, use tool Mot. 990-02 for engineswith an intermediate shaft or tool Mot. 990-03 for engines without an intermediate shaft.

12350S

Fitting the crankshaft seals

- Flywheel side, use tool Mot. 991-01.

Refit the sump with a new seal, tightening it to atorque of 1.4 daN.m. The alignment of the cylin-der block and the sump must be respected on theflywheel side to avoid the gearbox damaging theclutch housing on refitting.

12343R

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Engine repair 10F9Q

- the crankshaft timing sprocket,- the intermediate shaft sprocket or the idle

roller, tightening to a torque of 5 daN.m usingtool Mot. 1364,

- the water pump pulley, tightening to a torqueof 2 daN.m.

12344-2R

- the inner timing cover (16),Refit:- the flywheel, tightening the new bolts to a

torque of 5 to 6 daN.m (locking the flywheelusing tool Mot. 582-01),

- the clutch, tightening to a torque of 2 daN.m,- the timing pulley,- the water pump with a new seal, tightening it

to a torque of 1.7 daN.m,

12521-1R

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Engine repair 10F9Q

Wait 3 minutes for the gasket to settle.

Tightening the cylinder head

Slacken bolts 1-2 until they are completely free.

Tighten bolts 1-2 to 2.5 daN.m, then angle tightenby 213° ± 7°.

Carry out the same slackening and torque/angletightening operations on the remaining bolts 3-4,5-6, 7-8, 9-10.

There is no cylinder head retightening operation.

Fitting the camshaft seal

Timing side, use tool Mot. 988-02.

REFITTING THE CYLINDER HEAD

Position the pistons halfway.

Fit the cylinder head gasket using the cylinderhead centring dowels.

All the cylinder head bolts must be replacedsystematically after removal.

Method of tightening the cylinder head

Preseating the gasket:

Tighten all the bolts to 3 daN.m, then angletighten by 50° ± 4° in the order recommendedbelow.

27 6 10

18 5 94

3

12514R1

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Engine repair 10F9Q

- the timing tension wheel.

Position the timing at the setting point, aligningthe reference marks on the belt with thereference marks on the camshaft, injection pumpand crankshaft sprockets.

Refit :- the inner timing cover (10),

12519-1R

12521R

- the camshaft sprocket, torque tightening to 6daN.m,

- the injection pump mounting, tightening thebolts to a torque of 2.5 daN.m,

12519R

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Engine repair 10F9Q

Set the tension wheel against the belt by tighte-ning bolt (25) on the inner timing cover.

Remove pin Mot. 1054.

Press sharply on the intermediate shaft section (oridle roller section)/ tension wheel.

Fit the sensor of tool Mot. 1273.

Turn the wheel of the sensor until it clicks threetimes.

Tighten the belt to obtain the recommendedfitting value of 28 SEEM units, adjusting bolt (25)

Lock the tension wheel, check and adjust thevalue.

Turn the crankshaft a minimum of three times.

CHECKING

Refit pin Mot. 1054 and position the timing at thesetting point.

This operation checks the setting of the timing.


Press sharply on the intermediate shaft section (oridle roller section)/ tension wheel.


Turn the wheel of the sensor until it clicks threetimes.

Check that the tension value is within the fittingvalue tolerance (± 10 %), otherwise adjust again.

12520R2

Tighten the tension wheel nut to a torque of4.8 daN.m.

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Engine repair 10F9Q

Injection pump timing

Remove the rear plug on the injection pump andfit the adaptor Mot. 856-01 and the dial gaugemounting Mot. 856 with a dial gauge with an endpiece.

12532R

Rotate the engine and calibrate the dial gauge onBDC of the injection pump piston.

Position the timing at the setting point (lock theengine using tool Mot. 1054).

Read the piston lift on the dial gauge - it shouldbe 0.45 ± 0.02 mm.

If this is not the case, correct the setting.

IMPORTANT : follow the recommended order ofoperations.

Remove the TDC pin Mot. 1054.

Fit tool Mot. 1200 to immobilise the pulley.

Slightly slacken bolt (1) using tool Mot. 1359 (lefthand thread) to allow flange (2) to turn.

12531-2R

Modification of tool Mot. 1358

To adjust the RAM (micrometric adjustment ) andHTD 2 pullies, tool Mot. 1358 must be modified.The three lugs on the tool must be filed on theinner side to 1.5 mm.

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Engine repair 10F9Q

12275S

Fit tool Mot. 1358 into the three openings on theflange (2).

12531R

Turn the tool and flange assembly so that thethree lugs on the tool fit into the three openingson the annular adjusting bolt.

Turn the tool and flange assembly clockwise untiltool Mot. 1358 locks.

This allows positioning of the pulley at the start ofadjustment.

Remove the pulley locking tool Mot. 1200.

Turn the engine two turns and lock the engine.

Using tool Mot. 1358, adjust by turning the toolanti-clockwise to obtain a setting value of 0.45 ±0.02 mm.

NOTE : if the setting value is exceeded at the timeof adjustment, go backwards to 0.7 mm below thesetting value with tool Mot. 1358, then restart theadjustment of the previous operation.

Tighten bolt (1), Mot. 1359 to 2 daN.m (left handthread).

IMPORTANT: the torque wrench used mustrelease to the left.


Fit the pulley locking tool Mot. 1200.

Turn the engine by hand anti-clockwise to bringthe locking tool against the pulley.

Tighten bolt (1) to a torque of 9 daN.m using toolMot. 1359.

Turn the engine twice and check the pump settingonce more.

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Engine repair 10F9Q

Refit:- the timing covers,

12518R

- the inlet and exhaust manifolds, tighteningthe nuts to a torque of 2.8 daN.m,

- the engine lifting bracket on the flywheel sideand the fuel pipe mounting plate,

- the multifunction support, tightening thebolts and the nut to a torque of 4.3 daN.m,

12538R

- the alternator,- the air conditioning compressor,- the crankshaft accessories pulley, tightening

the new bolt to a torque of 2 daN.m thenangle tighten by 115° ± 15°.

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Engine repair 10F9Q

Fitting the belt and tensioning it for versions withair conditioning

Refit plate (26) on its mounting without lockingbolts (27) and (28).

A CrankshaftB AlternatorC Power assisted steering pumpD Air conditioning compressorE Water pumpG RollerT Tension wheel

The new belt is tensioned by bringing theautomatic tensioner plate against bolt (28),without forcing it, using a 9.53 mm drive(example: FACOM J151 ratchet).

98837-1R5

Tighten bolts (27) and (28).

11234R3

11234-1R2

Fit the belt.

99706R

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Engine repair 10F9Q

Fitting the belt and tensioning it for versions withpower assisted steering

Fit the belt.


Turn the sensor wheel until it clicks three times.

Tighten the belt until the display on tool Mot.1273 shows the recommended fitting value of 107± 3 SEEM units.

Lock the tension wheel, check and adjust thevalue.

Turn the crankshaft three times.

Check the tension value is within the fittingtolerances otherwise adjust again.

Refit the engine wiring.

Remove the engine from the stand.

Refit:- the metal oil vapour rebreathing pipe from

the bottom of the engine,- the turbo.

98751R2

A CrankshaftB AlternatorC Power assisted steering pumpE Water pump→ Point for checking belt tension

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Workshop repair manual F9Q

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Transcript of Workshop repair manual F9Q