Renault Automobile Parts 852 User Guide
Workshop repair manual  
ENGINE (Diesel)  
Indirect injection  
Aluminium, 4 cylinders  
Types  
Vehicles  
Renault 18  
Fuego  
852  
J8S  
Renault 20  
Renault 21  
Renault 25  
Renault 30  
Safrane  
Espace  
Trafic  
Master  
Jeep  
Cancels and replaces note dated JULY 1991  
DECEMBER 2000  
EDITION ANGLAISE  
77 11 293 322  
All copyrights reserved by Renault.  
"The repair methods given by the manufacturer in this document are based on the  
technical specifications current when it was prepared.  
Copying or translating, in part or in full, of this document or use of the service part  
reference numbering system is forbidden without the prior written authority of Renault.  
The methods may be modified as a result of changes introduced by the manufacturer  
in the production of the various component units and accessories from which his  
vehicles are constructed."  
© RENAULT 2000  
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ENGINE AND PERIPHERALS  
110  
Foreword  
10  
USING THE MANUAL  
There are two main sections in this manual:  
– technical specifications,  
– overhauling the engine.  
To repair the component on the vehicle, refer to the  
Workshop Repair Manual and Technical Notes for  
the vehicle.  
UNITS OF MEASUREMENT  
– All dimensions are given in millimetres (mm)  
(except where stated otherwise).  
– Tightening torques are expressed in  
decaNewtonmetres (daNm).  
Reminder: 1 daNm = 1.02 m.kg.  
– Pressures in bar  
Reminder: 1 bar = 100 000 Pa.  
TOLERANCES  
Tightening torques given without a tolerance must be  
accurate to within:  
– in degrees (± 3˚).  
– in daNm (± 10 %).  
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10-1  
ENGINE AND PERIPHERALS  
Diagram  
10  
J8S TURBO ENGINE  
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10-2  
ENGINE AND PERIPHERALS  
Diagram  
10  
J8S AND 852 ENGINES  
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10-3  
ENGINE AND PERIPHERALS  
Engine identification  
10  
The engine is identified by a plate riveted onto the  
cylinder block.  
It includes:  
A: the engine type  
B: the engine approval letter  
C: the manufacturer code  
D: the engine index  
E: the engine fabrication number  
F: the engine assembly works  
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10-4  
ENGINE AND PERIPHERALS  
Engine identification  
10  
Compression  
ratio  
Bore  
(in mm)  
Stroke  
(mm)  
Capacity  
(in cm )  
Engine  
Index  
Type  
3
700  
710  
720  
1276  
1344, 2354, 1354  
Pxx3  
852  
Txx3  
Vxx3  
750  
240  
330  
600  
604  
620  
622  
704  
708  
714  
738  
742  
746  
758  
774  
786  
788  
J115, S115  
Rxx3  
X480  
X48A  
PxxF  
TxxK  
X486  
B290  
X488  
B29W  
X488  
J8S  
21/1  
86  
89  
2068  
X486, X48W  
TxxF  
J114  
X487  
X48P  
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10-5  
ENGINE AND PERIPHERALS  
Engine identification  
10  
Compression  
ratio  
Bore  
(in mm)  
Stroke  
(in mm)  
Capacity  
(in cm )  
Engine  
Index  
Type  
3
610  
612  
702  
706  
711  
712  
736  
740  
760  
772  
776  
778  
J63D, S63D  
J63E  
1270  
B296  
1344 TA, 1354TA  
1346, 1356, 1366  
B296  
X48, 6, V, V 4x4  
B546  
21.5/1  
86  
89  
2068  
J8S  
J635, S635  
J634  
J633  
784  
800  
814  
X480  
CJ  
XJ  
J8S  
21.5/1  
86  
89  
2068  
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10-6  
ENGINE AND PERIPHERALS  
Tightening torques (in daNm)  
10  
A
B
C
D
E
F
0.5 to 0,9  
2.5 to 3  
1.3 to 1.8  
2
6 to 6.5  
13  
G
H
J
2.5  
1.3  
5
K
1.25  
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10-7  
ENGINE AND PERIPHERALS  
Tightening torques (in daNm)  
10  
CYLINDER BLOCK  
A
B
C
2
2
2.5  
*
Preheating shunt nut connector: 0.25 daNm  
** Aluminium sump : 1.4 to 1.7 daNm  
Metal sump 1.25 daNm  
:
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10-8  
ENGINE AND PERIPHERALS  
Tightening torques (in daNm)  
10  
A
B
C
D
3.2 to 3.9  
2
1.3  
1.4  
*
Turbo:  
IHI  
: 4.5 daNm  
Garrett : 2.6 daNm  
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10-9  
ENGINE AND PERIPHERALS  
Tightening torques (in daNm)  
10  
A
B
C
D
E
F
5
5
2.25 to 2.75  
5
13  
2.5  
1.3  
G
*
Turbo:  
IHI  
: 4.5 daNm  
Garrett : 2.6 daNm  
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10-10  
ENGINE AND PERIPHERALS  
Tightening torques (in daNm)  
10  
A
B
C
2
4
5 to 5.5  
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10-11  
ENGINE AND PERIPHERALS  
Tightening torques (in daNm)  
10  
A
B
C
D
E
F
7
2.3  
6.5±0.25  
8.75 to 9.75  
1.3  
4 to 4.5  
*
Spark plug M12 tighten to 2 daNm  
Spark plug M10 tighten to 1.6 daNm  
st  
**  
1
–
–
2
–
model:  
coolant pipe  
coolant rail  
model:  
:
:
0.8 to 1 daNm  
2 to 2.5 daNm  
nd  
cooling jets only  
:
1.2 to 1.4 daNm  
*** Seethe cylinder head tightening procedure page 10-16  
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10-12  
ENGINE AND PERIPHERALS  
Tightening torques (in daNm)  
10  
A
B
C
D
E
3.2 to 3.9  
8.75 to 9.75  
2.5 to 3  
3
2.3  
*
Turbo:  
IHI  
: 4.5 daNm  
Garrett : 2.6 daNm  
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10-13  
ENGINE AND PERIPHERALS  
Lubrication circuit diagram  
10  
Key:  
All types  
Turbo with radiator  
Turbo with heat  
exchanger  
1
2
returning cooling jets  
integrated cooling jets  
st  
1
fitting  
3
integrated cooling jets  
nd  
2
fitting  
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10-14  
ENGINE AND PERIPHERALS  
Lubrication circuit diagram  
10  
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10-15  
ENGINE AND PERIPHERALS  
Specifications  
10  
CYLINDER HEAD  
Unscrew bolt 1 until it is completely free, and then  
carry out:  
Tightening procedure  
st  
1 retightening  
2 daNm  
All the cylinder head bolts must always be  
changed after removal (including the mounting  
studs).  
nd  
2
retightening (angle) according to the table:  
Angle  
(in degrees)  
Angle  
(in degrees)  
Lubricate the threads and under the bolt heads  
with engine oil.  
Symbol  
Symbol  
1
2
3
4
5
6
7
8
9
105  
60  
60  
80  
70  
60  
60  
105  
105  
10  
11  
12  
13  
14  
15  
16  
17  
60  
60  
80  
70  
60  
60  
90  
80  
REMINDER: Use a syringe to remove any oil which  
may have entered the cylinder head mounting bolt  
holes to achieve correct tightening of the bolts.  
J8S transverse engine  
Carry out the following in the order prescribed:  
Repeat the above operation for all the bolts.  
st  
1 tightening :  
3 daNm  
5 daNm  
nd  
2
tightening :  
nd  
3
retightening (angle) according to the table:  
Angle  
(in degrees)  
Angle  
(in degrees)  
Symbol  
Symbol  
1
2
3
4
5
6
7
8
9
105  
60  
60  
80  
70  
60  
60  
105  
105  
10  
11  
12  
13  
14  
15  
16  
17  
60  
60  
80  
70  
60  
60  
90  
80  
83174S2  
There is no cylinder head retightening operation.  
Wait 3 minutes settling time.  
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10-16  
ENGINE AND PERIPHERALS  
Specifications  
10  
J8S longitudinal engine  
Unscrew bolt 1 until it is completely free, and then  
carry out:  
Carry out the following in the order prescribed:  
st  
1 retightening  
2 daNm  
st  
1 tightening :  
3 daNm  
5 daNm  
nd  
2
retightening (angle) according to the table:  
nd  
2
tightening:  
Angle  
(in degrees)  
Angle  
(in degrees)  
Symbol  
Symbol  
1
2
3
4
5
6
7
8
9
105  
60  
60  
70  
70  
60  
60  
105  
105  
10  
11  
12  
13  
14  
15  
16  
17  
60  
60  
70  
70  
60  
60  
80  
80  
Repeat the operation for all the bolts.  
83174S2  
Wait 3 minutes settling time.  
nd  
3
retightening (angle) according to the table:  
Angle  
(in degrees)  
Angle  
(in degrees)  
Symbol  
Symbol  
1
2
3
4
5
6
7
8
9
105  
60  
60  
70  
70  
60  
60  
105  
105  
10  
11  
12  
13  
14  
15  
16  
17  
60  
60  
70  
70  
60  
60  
80  
80  
There is no cylinder head retightening operation.  
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10-17  
ENGINE AND PERIPHERALS  
Specifications  
10  
nd  
Thickness of the cylinder head gasket  
2
model  
nd  
There are several different thicknesses of cylinder  
head gasket as replacements. When the 1 model (A)  
gaskets have been used up, the Parts Store will only  
On engines fitted with a 2 model cylinder head  
gasket, the label showing the gasket thickness can be  
seen from the outside. There is no need to recalculate  
the gasket thickness if the operations performed have  
not involved modifying the piston protrusion  
dimension.  
nd  
deliver 2 model (B, C or D) gaskets.  
st  
B - Cylinder head gasket thickness 1.6 mm:  
marked with a hole  
1
model  
st  
C - Cylinder head gasket thickness 1.7 mm:  
no hole  
D - Cylinder head gasket thickness 1.8 mm:  
marked with two holes  
On engines fitted with a 1 model cylinder head  
gasket (marked A on the drawing opposite), the label  
showing the gasket thickness cannot be seen from the  
outside. The thickness of the gasket must therefore be  
calculated before each operation.  
Cylinder head gasket thickness 1.6 mm:  
– 1.6 is stamped on the gasket.  
Cylinder head gasket thickness 1.7 mm:  
– not stamped.  
Cylinder head gasket thickness 1.8 mm:  
– 1.8 is stamped on the gasket.  
16621R  
NOTE: if replacing:  
– the crankshaft,  
– the cylinder block,  
– the con rods,  
– the pistons,  
it is essential to calculate the thickness of the  
cylinder head gasket.  
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10-18  
ENGINE AND PERIPHERALS  
Specifications  
10  
rd  
Cylinder head cover gasket  
3
model:  
nd  
same position as the 2 model.  
All types except J8S 736  
st  
1
model:  
This gasket is not symmetrical.  
Cylinder side graphitised surface.  
93780R  
nd  
2
model:  
This gasket has a an area intended to prevent  
confusion; it is located opposite the timing end.  
93779-1R  
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10-19  
ENGINE AND PERIPHERALS  
Specifications  
10  
Height of the cylinder head (in mm)  
H = 104.5 ± 0.04  
Engine type  
Normally  
Turbo  
aspirated  
Channel angle  
35˚  
31˚  
(α)  
A drill  
stamp  
Mark (X)  
None.  
Diameter (D) of the housing in the cylinder head  
(in mm)  
– Original dimension 1  
– Original dimension 2  
35.5  
35.7  
16721R  
Original dimension 2 is exclusively for works-repaired  
cylinder head dimensions.  
NO REDRESSING IS PERMITTED  
Test the cylinder head for cracks. (refer to the mating  
face checking section in the Engine overhaul  
section).  
Protrusion in relation to cylinder head:  
it should be between 0.01 and 0.04 mm.  
Maximum mating face deformation  
0.05 mm  
Prechamber  
Assembled prechamber  
This is fitted in the cylinder head.  
16546R  
86188-1R  
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10-20  
ENGINE AND PERIPHERALS  
Specifications  
10  
Bare prechamber  
Half-prechamber  
Valve seats  
α
Seat angles ( )  
Inlet and exhaust:  
90˚  
Mating surface width X (in mm)  
Inlet and exhaust:  
External diameter D (in mm)  
Inlet:  
1.75 ± 0.2  
+ 0.13  
42  
+ 0.11  
+ 0.03  
+ 0.01  
Exhaust:  
34.6  
92448-1S  
Valves  
Stem diameter (in mm)  
+ 0  
- 0.02  
Inlet:  
7.991  
7.978  
+ 0  
- 0.02  
Exhaust:  
Setting angle  
90˚  
73928R  
Head diameter (in mm)  
See the "Overhauling the engine" section for how to  
redress the valve seats.  
Inlet:  
Exhaust:  
40.32 ± 0.12  
33.32 ± 0.12  
Maximum valve lift (in mm)  
Inlet:  
9.27  
Exhaust:  
8.80  
Valve set back in relation to the  
cylinder head mating surface  
(in mm)  
0.80 to 1.15  
Valve clearance settings (in mm)  
Inlet:  
Exhaust:  
0.20 ± 0.02  
0.25 ± 0.02  
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10-21  
ENGINE AND PERIPHERALS  
Specifications  
10  
Valve guides  
Position of the inlet and exhaust valve guides  
Position of guides in relation to the cylinder head  
mating face (in mm):  
Internal diameter (in mm)  
8
External diameter (in mm):  
D = 32.5  
– Normal  
– Repair (two grooves)  
13.10  
13.35  
The inlet and exhaust guides have valve stem seals  
which must be changed every time the valves are  
removed.  
The valve stem seals must be fitted using tool  
Mot. 1511 or with the FACOM tool, part number  
DM6J4 for example.  
83172R  
The diameter of the housing is smaller  
(by approximately 0.1 mm) to obtain the necessary  
seal.  
It is vital to drill the guide after fitting.  
15737R1  
NOTE: do not lubricate the valve stem seals before  
fitting them.  
Mot. 1511 consists of:  
– four cores (1),  
– four pushrods (2),  
– one guide tube (3),  
– one sleeve (4).  
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10-22  
ENGINE AND PERIPHERALS  
Specifications  
10  
Valve springs  
The inlet and exhaust valve springs are identical.  
Rocker arm rail  
When performing operations on faults that cause  
metallic particles to become suspended in the  
lubricating oil, e.g.:  
– damaged con rod bearing shells or crankshaft,  
– parts grating,  
Free length (in mm):  
45.2  
Length under a load of (in mm):  
23 daNm  
39.3  
29.8  
it is essential to replace:  
60 daNm  
– the oil filter (A) located in the rocker arm rail shaft,  
– the oil filter located on the main pipe,  
– the lubricating oil.  
Sealing turns (in mm):  
Wire diameter (in mm):  
Internal diameter (in mm):  
27.2  
4.25  
REMINDER: The rocker arm rail filter must be  
replaced if an operation requires the removal of the  
rocker box cover.  
21.5  
Camshaft  
All types except J8S 736 and J8S 740  
Longitudinal play (in mm):  
Number of bearings  
0.05 to 0.15  
5
Timing diagram:  
– Inlet opening advance  
– Inlet closing retardation  
– Exhaust opening advance  
– Exhaust closing retardation  
14˚  
46˚  
50˚  
10˚  
With a theoretical clearance to the valve stem of  
0.35 mm (All types).  
Engines J8S 736 and J8S 740  
Longitudinal clearance (in mm)  
0.05 to 0.15  
Number of bearings:  
5
Timing diagram:  
– Inlet opening advance  
– Inlet closing retardation  
– Exhaust opening advance  
– Exhaust closing retardation  
14˚  
46˚  
58˚  
14˚  
The value of the theoretical clearance to the valve  
stems is only valid following a check on the timing  
diagram and has no relation to the rocker arm  
clearances.  
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10-23  
ENGINE AND PERIPHERALS  
Specifications  
10  
PISTONS  
These engines are fitted with Floquet Monopole  
pistons.  
The gudgeon pin is free in the con rod and in the  
piston.  
Piston marking  
16576R  
16576-2R  
16576-1R  
16576-3R  
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10-24  
ENGINE AND PERIPHERALS  
Specifications  
10  
The paint mark that indicates diameter class is also  
present on the piston.  
Table of gudgeon pin heights  
Classes and marks on  
piston  
Shaft height  
(in mm)  
H
K
M
P
R
50.890 to 50.930  
50.931 to 50.970  
50.971 to 51.010  
51.011 to 51.050  
51.051 to 51.090  
Measuring the piston diameter  
The diameter of the piston (86 mm diameter) should  
be measured at position:  
16577R  
Piston measuring  
Engine type  
point (A) (in mm)  
1
Height between the gudgeon pin and the top of the  
piston (see table below).  
Modification index, for supplier's use only.  
For supplier's use only.  
J8S 852  
24.35  
2
3
4
5
normally aspirated  
Dater, for supplier's use only.  
Diameter class mark, paint mark (see following  
table).  
J8S Turbo  
24  
Table of piston diameter classes  
Piston mark  
Piston diameter (in mm):  
Blue  
85.875 to 85.890  
85.890 to 85.905  
Red  
86928-4R1  
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10-25  
ENGINE AND PERIPHERALS  
Specifications  
10  
Rings  
FITTING THE RINGS  
Three rings (thickness in mm)  
Rings set to their original adjustment must be free  
within their channels.  
Normally aspirated engine  
Ensure the fitting direction is observed.  
– Compression  
– Sealing  
– Scraper  
2
2
2
(tapered)  
(rounded)  
Turbo engine  
– Compression  
– Sealing  
– Scraper  
2.5  
2.5  
4
(trapezoidal)  
(trapezoidal)  
(rounded)  
Gudgeon pin (in mm)  
– Length:  
– External diameter:  
– Internal diameter:  
75  
28  
16  
86187R  
Fit the rings so that the gaps are equally spaced  
around the piston.  
72552R  
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10-26  
ENGINE AND PERIPHERALS  
Specifications  
10  
CON RODS  
Refitting and assembling con rods and pistons  
Direction of fitting:  
in mm  
rotochamber on the injector side or the side opposite  
the oil filter.  
Lateral play in the big end  
0.31 to 0.57  
Check that the gudgeon pins rotate properly in the new  
piston and the con rod.  
Centre-to-centre distance between  
big end and small end  
155 ± 0.035  
+ 0.019  
- 0.005  
Oil the gudgeon pin.  
Big end diameter  
60  
Ensure that the piston and con rod are fitted the right  
way around (follow the arrows):  
Small end diameter  
● without ring  
+ 0.021  
0
30  
28  
Engines 852 J8S all types except turbo  
+ 0.01  
+ 0.003  
● with ring  
The small end has a bush.  
N.B.: the small end bushes cannot be replaced or re-  
drilled.  
WARNING: do not use a sharp point to mark the  
bearing caps in relation to their con rods as this could  
start a crack in the rods. Use an indelible marker pen.  
Normally aspirated engine  
The big end and the half bearing are pierced to allow  
an oil jet to pass through.  
Turbo engine  
Turbo engine  
The con rods do not have a hole for an oil jet. The  
upper and lower bearing shells are not pierced.  
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10-27  
ENGINE AND PERIPHERALS  
Specifications  
10  
Direction for fitting the circlips on the piston  
Fit the circlips on the piston as shown below.  
CRANKSHAFT  
Number of bearings  
Burnishing  
5
●
●
●
normally aspirated engine  
with  
without  
with  
st  
turbo engine 1 fitting  
nd  
turbo engine 2 fitting  
in mm  
Longitudinal play  
● normally aspirated engine  
1 model: 1 to 32 909  
0.07 to 0.25  
0.20 to 0.30  
0.20 to 0.30  
st  
● normally aspirated engine  
nd  
2
model: from 32 910  
● turbo engine  
st  
nd  
1 and 2 models  
98365S  
Bushing  
- 0  
Nominal diameter  
Repair diameter  
Crankpin  
62.88  
- 0.019  
- 0  
- 0.019  
62.63  
- 0.010  
- 0.029  
Nominal diameter  
Repair diameter  
56.296  
56.046  
- 0.010  
- 0.029  
N.B.: non-burnished crankshafts fitted on turbo  
engines can be redressed using the values given in  
the table.  
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10-28  
ENGINE AND PERIPHERALS  
Specifications  
10  
Burnished crankshaft  
Identification of crankshafts:  
In case of correction, the burnishing must remain intact  
on 140˚ in the areas indicated by the arrows.  
Normally aspirated engine  
● eight counterweights,  
● Burnished bushings and crankpins.  
88007S  
Turbocharged engine  
These zones are defined in sections (A) and (B), used  
as examples.  
● four counterweights,  
● Burnished or non-burnished bushings and  
crankpins according to model.  
88006S  
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10-29  
ENGINE AND PERIPHERALS  
Specifications  
10  
RELAY SHAFT  
CLUTCH SHAFT CENTERING BEARINGS  
Gearbox:  
Longitudinal play (in mm)  
0.05 to 0.15  
– with bearing in the clutch housing: short clutch  
shaft (A).  
– without bearing in the clutch housing: long clutch  
PISTON BASE COOLING RAIL  
shaft (B).  
86609R  
Never remove the mounting bolts (H) if the sump is  
not removed.  
16547R  
If the gearbox is fitted with a long shaft (B) it is  
essential to fit a bearing in the crankshaft. In cases  
where the flywheel has no stop, cement the bearing  
into the crankshaft using Loctite FRENBLOC.  
If the gearbox is fitted with a short shaft (A) it is  
essential to remove the bearing from the crankshaft.  
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10-30  
ENGINE AND PERIPHERALS  
Specifications  
10  
CYLINDER LINER  
Assembling cylinder liners - cylinder block  
in mm  
86  
in mm  
93.035  
to  
93.065  
Internal diameter  
Height (H) of the cylinder liner  
Depth (K) of cylinder block  
Diameter of the base centering (D)  
93.6  
92.945  
to  
92.985  
Protrusion of cylinder liner without  
gasket (X)  
0.07 to 0.13  
Base seal (J)  
Shaft seal (F)  
O ring.  
barrel shape  
75615-2G 83968  
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10-31  
ENGINE AND PERIPHERALS  
Specifications  
10  
Identification of liners  
Normally aspirated engine  
st  
1
model  
nd  
2
model  
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10-32  
ENGINE AND PERIPHERALS  
Specifications  
10  
Turbo engine  
st  
rd  
1
model  
3
model  
Cylinder liner with two notches and piston fitted cooling  
oil jets.  
Cylinder liner with no notches and tube piston cooling  
oil jets.  
nd  
th  
2
model  
4
model  
Cylinder liner with four notches and integral piston  
cooling oil jets.  
Special Parts store cylinder liner with four notches.  
May be fitted on all types of turbo engines.  
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10-33  
ENGINE AND PERIPHERALS  
Specifications  
10  
OIL PUMP  
Removal  
Clearance (B)  
– minimum (in mm)  
– maximum (in mm)  
0.02  
0.10  
Remove:  
– the oil pump cover,  
– the discharge valve and its spring.  
86303-1R  
Refit:  
– the oil pump cover by tightening the bolts to a torque  
of 1 daNm,  
Checking clearances  
– the discharge valve and its spring.  
Clearance (A)  
– minimum (in mm)  
– maximum (in mm)  
0.05  
0.12  
N.B.: Pour oil into the pump (to make repriming  
easier).  
80142R  
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10-34  
ENGINE AND PERIPHERALS  
Specifications  
10  
PREPARING THE ENGINE TO BE SET ON THE  
STAND  
Before fitting the engine to support plate Mot. 792-03,  
remove the engine electrical wiring harness and drain  
the engine oil and the coolant by removing the drain  
plug (A).  
16535R  
Turbo engine  
Remove:  
– the supply and oil return pipes (D),  
– the strut (B),  
– the turbocharger mounting bolts (C) and the  
turbocharger.  
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10-35  
ENGINE AND PERIPHERALS  
Specifications  
10  
FITTING THE ENGINE TO SUPPORT Mot. 792-03  
AND THE THREE RODS A, B AND C  
Engines of all types  
Remove the intake and exhaust manifolds,  
The rods (A), (B) and (C) are mounted on the cylinder  
block so that they fit into the holes (1, 8, 17) on the  
plate.  
90749R1  
SAFETY PRECAUTIONS WHEN STOPPING THE  
ENGINE  
Let the engine run at idle speed for 30 seconds  
and then switch off the ignition.  
Do not rev the engine to avoid starting the  
SAFETY PRECAUTIONS  
turbocharger. If this occurs, the turbo may run by  
inertia without lubrication when the ignition is switched  
off and there is a risk that the turbine shaft will grate.  
Turbocharger engine  
After performing an operation on the engine that  
involves disconnecting the oil gallery, it is essential to  
reprime the turbocharger oil circuit, ensuring that the  
following conditions are respected:  
– connect the oil return and attach it using a new bolted  
clamp,  
– fill up the turbo with engine oil through the inlet  
opening (A),  
– run the starter motor to reprime the turbocharger oil  
circuit, until the oil begins to escape from the  
turbocharger inlet opening,  
– reconnect the turbocharger inlet pipe,  
– run the engine at idle speed so that the circulation of  
oil in the turbocharger is reestablished.  
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10-36  
ENGINE AND PERIPHERALS  
Specifications  
10  
CONSUMABLES  
Type  
Quantity  
Component concerned  
Cleaning parts  
Part no.  
RAVITOL S 56  
-
Coat  
77 01 421 513  
77 01 405 952  
77 01 404 452  
77 01 421 162  
77 01 394 070  
DECAPJOINT  
Cleaning gasket faces  
Crankshaft bearing cap  
Crankshaft cover, coolant pump  
-
RHODORSEAL 5661  
Loctite 518  
Coat  
Coat  
Loctite FRENETANCH  
1 - 2 drops  
PRECAUTIONS  
PARTS TO BE REPLACED WHEN THEY HAVE  
BEEN REMOVED  
WASHING THE ENGINE  
– All the gaskets.  
Do not let the alternator come into contact with water  
or cleaning products.  
– Flywheel bolts.  
– Flywheel mounting bolt stops.  
– Con rod bolts.  
Do not let water run into the air intake pipes.  
– Rocker arm rail oil filter.  
– Cylinder block cap seals if they have been removed.  
– Timing sprocket split pins on the crankshaft.  
– Belts.  
FITTING THREAD INSERTS  
– Timing gear tensioner.  
– Cylinder head bolts  
Threaded holes on all engine component parts can be  
repaired by using thread inserts.  
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10-37  
ENGINE AND PERIPHERALS  
Standard exchange  
10  
PREPARING THE USED ENGINE FOR RETURN  
The engine should be cleaned and drained (oil and  
water).  
Leave on the used engine or include in the return box:  
– the dipstick,  
– the water pump,  
– the cylinder head cover,  
– the heater plugs,  
– the timing belt tensioner,  
– the timing gear cases,  
– the oil filter,  
– the injection pump pulley,  
– the camshaft pulley,  
– the relay shaft pulley,  
– the crankshaft timing pulley,  
– the clutch and the engine flywheel,  
– the crankshaft accessories pulley,  
– the injection pump,  
– the injector pipes,  
– the injectors,  
82638-1S  
– the vacuum pump.  
NEW EXCHANGE ENGINE  
Remember to remove:  
– the coolant hoses,  
– the water pump pulley,  
– the oil pressure switch,  
– the thermostat and its mounting.  
The new engine does not have:  
– a clutch mechanism,  
– a clutch plate,  
– a flywheel.  
The engine being returned should be attached to the  
wooden base in the same way as the service  
exchange engine:  
– plastic plugs and covers fitted,  
– cardboard cover over the assembly.  
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10-38  
ENGINE AND PERIPHERALS  
Essential special tooling  
10  
Parts Department  
Tool number  
Illustration  
Description  
number  
Mot. 11  
Mot. 251-01  
Mot. 252-01  
Mot. 382  
00 01 072 500  
00 00 025 101  
00 00 025 201  
00 00 038 200  
00 00 044 500  
00 00 045 200  
Crankshaft spigot bush extractor.  
Dial gauge support. Used with  
Mot. 252-01.  
Dial gauge support thrust plate. Used  
with Mot. 251-01.  
Valve spring compressor tool.  
Oil filter strap wrench.  
Mot. 445  
Oil pressure contact wrench  
(22 mm across flats).  
Mot. 452  
Mot. 521-01  
Mot. 582  
00 00 052 101  
00 00 058 200  
Cylinder liner clamp.  
Flywheel locking tool.  
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10-39  
ENGINE AND PERIPHERALS  
Essential special tooling  
10  
Parts Department  
Tool number  
Illustration  
Description  
number  
Magnetised flexible shaft for cylinder  
head angular wrench.  
Mot. 591-02  
Mot. 591-04  
00 00 059 102  
00 00 059 104  
Cylinder head angular wrench, 1/2"  
drive with gauge.  
Mot. 647  
00 00 064 700  
Tappet adjuster.  
Mot. 720  
00 00 072 000  
00 00 079 203  
00 00 079 901  
Cylinder head locating tool.  
Engine support plate for Desvil engine  
stand.  
Mot. 792-03  
Mot. 799-01  
Timing gear wheel immobiliser  
Liner seal compression tool.  
Mot. 853  
Mot. 854  
00 00 085 300  
Diesel injection pump sprocket locking  
tool.  
00 00 085 400  
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10-40  
ENGINE AND PERIPHERALS  
Essential special tooling  
10  
Parts Department  
Tool number  
Illustration  
Description  
number  
Mot. 855  
Mot. 856  
00 00 085 500  
00 00 085 600  
00 00 086 100  
00 00 099 701  
Timing gear locking strap.  
BOSCH diesel injection pump timing  
gauge support.  
Mot. 861  
TDC setting rod.  
Mot. 997-01  
Diesel injector removal/refitting wrench.  
Mot. 1054  
Mot. 1063  
Mot. 1079  
00 00 105 400  
00 00 106 300  
00 00 107 900  
TDC setting rod.  
Socket spanner for removal/refitting  
engine sump bolts.  
Timing gauge kit for Roto-Diesel pumps  
with rear cover access.  
Spare checking rod and support bracket  
for Mot 1079. Used with Mot. 1079-02.  
Mot. 1079-01  
00 00 107 901  
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10-41  
ENGINE AND PERIPHERALS  
Essential special tooling  
10  
Parts Department  
Tool number  
Illustration  
Description  
number  
Dial gauge for Mot. 1079-01 timing  
gauge kit for Roto-Diesel pumps.  
Mot. 1079-02  
00 00 107 902  
Mot. 1281-01  
00 00 128 101  
00 00 129 700  
Oil filter removing tool 96 mm diameter.  
Crankshaft oil seal fitting tool (flywheel  
end).  
Mot. 1297  
Crankshaft oil seal fitting tool (timing  
end).  
Mot. 1298  
Mot. 1299  
Mot. 1300  
00 00 129 800  
00 00 129 900  
00 00 130 000  
Intermediate shaft oil seal fitting tool.  
Camshaft oil seal fitting tool.  
Mot. 1335  
Mot. 1383  
00 00 133 500  
Tool for removing valve stem seals.  
17 mm diesel pump HP connection  
spanner.  
00 00 138 300  
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10-42  
ENGINE AND PERIPHERALS  
Essential special tooling  
10  
Parts Department  
Tool number  
Illustration  
Description  
number  
Mot. 1384  
Mot. 1505  
Mot. 1511  
Mot. 1573  
00 00 138 400  
00 00 150 500  
00 00 151 100  
00 00 157 300  
Belt tensioner adjusting tool.  
Belt tension setting tool.  
Valve stem seal tool.  
Cylinder head support.  
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10-43  
ENGINE AND PERIPHERALS  
Essential equipment  
10  
Description  
Ring for fitting piston with rings into the liner.  
Grinding kit for redressing the valve seat, for example CERGYDIS C 108  
NEWAY.  
Valve lifter.  
Angular tightening tool:  
– STAHLWILLE, part number 540 100 03 for example,  
– FACOM, part number DM360 for example.  
Tooling for testing the cylinder head, including: a tray and the various kits  
suited for each model of cylinder head (plug, sealing plate, blanking plate).  
The approval number of the cylinder head test container is 664 000  
Cylinder ring pliers.  
Tool for fitting the valve stem seals, FACOM part number DM 6J4 for  
example.  
Standard 22 mm 1/2" (12.7 mm square) drive socket for removing the oil  
pressure gauge.  
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10-44  
ENGINE AND PERIPHERALS  
10  
Cylinder head exploded drawing  
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10-45  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
REMOVING THE TOP ENGINE  
Remove:  
– the accessories belt,  
– the air conditioning compressor (if fitted),  
– the power assisted steering pump,  
– the alternator,  
– the multifunction mounting,  
– the engine lifting bracket on the flywheel end.  
Fit the flywheel locking tool Mot. 582 and loosen the  
accessories belt bolt.  
16531R  
Remove the TDC setting rod cap (B).  
16535R1  
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10-46  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Adjusting the timing  
Fit the TDC setting rod on Mot. 861  
or Mot. 1054, then turn the engine  
(clockwise from the timing end) to  
bring the camshaft sprocket and  
injection pump marks in line with  
the valve timing cover marks (start  
to pull on the rod one half-tooth  
before the marks are aligned), in  
order to avoid dropping into a  
balance hole.  
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10-47  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Check the timing on the camshaft  
sprocket and injection pump  
(marks on the valve timing cover  
must be aligned with pulley marks).  
Remove the timing cover.  
Check the marks on the crankshaft  
timing sprocket (see diagram).  
Make a fixed mark on the cylinder  
head cover and another on the  
injection pump where they are  
aligned with the pulley marks.  
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10-48  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Remove the TDC setting rod  
Mot. 861 or Mot. 1054.  
Slacken and then re-tighten the  
tensioner in order to remove the  
timing belt.  
Remove:  
– the fuel return pipes,  
– the high pressure pipes on the  
injection pump using Mot. 1383,  
– the cold start coolant pipe,  
– the injection pump rear  
mounting bolt on the cylinder  
head,  
– the timing cover support,  
– the rocker box cover.  
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10-49  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Remove the camshaft lateral shim  
(pulley end).  
Undo the rocker arm adjusting  
bolts.  
Remove the rocker arm rail.  
Remove the cylinder head bolts  
and fastening nuts.  
Insert a wooden shim and strike  
the side of the cylinder head to  
unstick it from the sealing face  
within the clearance limit  
between the cylinder head and  
the studs. As the cylinder head  
gasket is cemented to the cylinder  
block, the cylinder head and the  
cylinder liners, it is very important  
not to raise the cylinder head,  
which would unstick the cylinder  
liners from their base and allow dirt  
to penetrate.  
Remove the cylinder head.  
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10-50  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
STRIPPING THE CYLINDER  
HEAD  
Place the cylinder head on the  
cylinder head support Mot. 1573.  
Remove:  
– the heater plugs and their  
electrical wiring,  
– the injectors and injector holders  
with seals,  
– the flame-shield washers  
between the cylinder head and  
the injector holder,  
– the thermostatic unit,  
– the camshaft pulley using Mot. 799-01 (take care  
with the key),  
16534S  
16544R  
– the gasket.  
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10-51  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Remove:  
– the camshaft,  
– the prechambers (11) and, if necessary, gently tap  
with tool B. Vi. 31-01 inserted in the injector housing.  
NOTE: before removing the valves and the valve  
stem seals, it is vital that you measure position H  
of one of the old seals in relation to the cylinder  
head using Mot. 1511 or using a FACOM tool with  
part number DM6J4.  
Some prechambers may be free; be careful not to  
let them fall out.  
15738R  
83246R  
Fit the pushrod from Mot. 1511 on the valve stem seal.  
Compress the valve springs.  
15738-1S  
16545S  
Remove the half rings, the upper and lower cups and  
the springs.  
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10-52  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
NOTE: the internal diameter of the pushrod must  
be identical to that of the valve. Moreover, the  
pushrod must contact the metallic upper section  
of the valve stem seal.  
Fit the guide tube from above the pushrod until it  
comes into contact with the cylinder head.  
15738-3R  
Remove:  
– the guide tube and sleeve, being careful not to  
loosen the wheel,  
– the pushrod.  
Remove:  
– the valves,  
15738-2S  
– the valve stem seals using pliers Mot. 1335,  
– the lower cups,  
Insert sleeve (1) in the guide tube, until the sleeve  
comes into contact with the pushrod.  
Then secure the sleeve using the wheel (2).  
16559R  
Put the parts in order and mark them.  
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10-53  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
CLEANING  
CHECKING THE GASKET FACE  
It is very important not to scratch the mating faces  
of any aluminium components.  
Check for gasket face bow using a straight edge and a  
set of shims.  
Use the Décapjoint product to dissolve any part of the  
Maximum bow  
0.05 mm  
gasket which remains attached.  
No regrinding of the cylinder head is permitted.  
Apply the product to the parts to be cleaned; wait  
about ten minutes, then remove it using a wooden  
spatula.  
Wear gloves whilst carrying out this operation.  
Do not allow this agent to drip on to the paintwork.  
Great care should be used in performing this  
operation to avoid allowing foreign objects into the  
piping taking oil under pressure to the camshafts  
(piping in both the cylinder head and its cover) and  
the oil return piping.  
83179S  
Test the cylinder head for cracks using the cylinder  
head test tools (a container and a kit for the particular  
cylinder head, plug, sealing plate, blanking plate).: The  
approval number of the cylinder head test container is  
664 000  
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10-54  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
REDRESSING THE VALVE SEATS  
INLET  
EXHAUST  
Width of mating faces X (in mm)  
1.75± 0.2  
Width of mating faces X (in mm)  
Angle (α)  
1.75± 0.2  
Angle (α)  
90˚  
90˚  
The mating face is corrected (1) using burr N 208 46˚.  
Reduce the width of this mating face at (2) using burr  
N 213 15˚ until width X is obtained.  
The mating face is corrected (1) using burr N 204 46˚.  
Reduce the width of this mating face at (3) using burr  
N 212 75˚ until width X is obtained.  
N.B.: respect the mating face position of the valve on its seat.  
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10-55  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
ASSESSMENT AND REPAIR OF ROCKER ARM  
They comprise:  
RAILS  
– a greasing hole (G) for corresponding camshaft  
bearings,  
The filter (24) located in the rocker arm rail (17) must  
be replaced in all operations on faults that cause  
metallic particles to become suspended in the  
lubricating oil.  
– an offset (F) directed towards the flywheel.  
In this case, the engine oil and oil filter on the main  
pipe must also be replaced.  
Removal  
Remove the cap at the end of the rocker arm shaft and  
the filter. Separate the different parts and clean them.  
Put them in order.  
16523-1R  
Bearing (E) also comprises:  
– two threaded holes (T) for attaching the shim to limit  
camshaft side play,  
– a threaded hole (V) for attaching the bolts to orient  
the rocker arm shaft.  
Identification of parts:  
Rocker arm shaft bearings  
Bearings A, B, C and D are identical.  
16523R  
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10-56  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
The rocker arm shaft is oriented using a full dog point  
Refitting  
screw.  
Place the bearing (E) on the shaft and fix it so that the  
greasing holes point towards the bearing plate.  
The shaft bearing greasing holes are directed towards  
the camshaft (the oil passes through the rocker arm  
shaft bearings).  
Then fit:  
– a rocker arm,  
– a spring,  
– another rocker arm,  
– an intermediate bearing, offset (F) pointing to the  
flywheel.  
Continue refitting in the same order, fit the cap with a  
new oil filter and tighten to a torque of 2 daNm.  
This torque has to be respected as the rocker arm  
shaft is only kept rotating by the full dog point screw on  
the bearing (E).  
Rocker arms  
The inlet and exhaust rocker arms are identical and  
both have an oil way to lubricate the cams on the  
camshaft.  
REBUILDING THE CYLINDER HEAD  
Fit new valves, grind them gently into their respective  
seats. Clean all the parts thoroughly, mark them for  
identification purposes, then carry out the refitting  
operation.  
Oil all the parts.  
16526R  
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10-57  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
The valve stem seals must be fitted using tool  
Mot. 1511 or with the FACOM tool, part  
number DM6J4.  
Place the barrel of the Mot. 1511 tool over the valve  
stem (the internal diameter of the barrel must be  
identical to the diameter of the valve stem).  
15737R  
15739-1S  
NOTE: do not lubricate the valve stem seals before  
fitting them.  
Keep the valve pressed against its seat.  
Fitting new valve stem seals.  
Place the valve stem seal (not lubricated) over the tool  
barrel.  
Locate the valve in the cylinder head.  
15739S  
15739-2S  
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10-58  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Push the valve stem seal past the tool barrel, then  
withdraw the barrel.  
15739-5S  
NOTE: the internal diameter of the pushrod must  
be identical to the diameter of the valve stem.  
Moreover, the pushrod must be in contact with the  
upper section of the valve stem seal.  
Place the pushrod over the valve stem seal.  
15739-4S  
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10-59  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Place the guide tube and sleeve assembly, adjusted at  
removal, over the pushrod.  
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.  
15738-4S  
15739-6S  
Repeat the above sequence of operations for all the  
valves.  
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10-60  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Fit:  
Check the amount by which the valve is retracted from  
the cylinder head gasket face using tools Mot. 251-01  
and Mot. 252-01.  
– the spring collar rings (7),  
– the springs (8) (inlet and exhaust springs are  
identical),  
– the cups (9).  
It should be between 0.80 and 1.15 mm.  
Compress the springs.  
Fit the half rings (10) (inlet and exhaust valve half rings  
are identical).  
16546-1R  
It is essential to take a note of the valve retraction for  
later checks on the piston-cylinder head clearance.  
77678R5  
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10-61  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Turbo engine  
Fit the prechambers (11) then use tools Mot. 251-01  
and Mot. 252-01 to check their protrusion.  
Mark X: a drill stamp.  
It should be between 0.01 and 0.04 mm.  
Normally aspirated engine  
Mark X: none.  
86188-1R  
16546R1  
Engines J8S 736 and 740  
DI1074  
Diameter (D) in mm:  
– Original dimension 1 = 35.5  
– Original dimension 2 = 35.7  
It is essential to take a note of the diameter (D) of  
the prechamber housing in the cylinder head and  
to refit a chamber of the same diameter.  
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10-62  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Refit the heater plugs (12) and their electrical wiring.  
All engine types except J8S 736 and 740  
Place new heat flange welds (27) on a cylinder head  
being re-used.  
Take a note of the dimensions of the removed flame-  
shields and replace them with new ones of the same  
diameter.  
Diameter (D) in mm:  
– original dimension 1 = 15.5  
– original dimension 2 = 17.7  
Replace the injector flame-shield washers (13) making  
sure that they are the right way round.  
The mark (C) points towards the prechamber.  
83173R  
Replace the injectors and injector holders fitted with  
new copper seals and tighten the nuts to torque  
(2 daNm).  
Tighten both nuts equally.  
Refit the thermostatic unit fitted with a new seal.  
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10-63  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Engines J8S 736 and 740  
Injector holders - special features  
The cylinder head has been modified to accept  
BOSCH "KCA" threaded injector holders.  
92448-2R  
1 Flame-shield  
2 Flame-shield washer  
3 Seal  
Fit a new seal and a new flame-shield washer  
(oriented as shown in the diagram) every time the  
injector holder is refitted.  
Tighten the injector holders to 7 daNm using tool  
Mot. 997-01.  
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10-64  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
CYLINDER BLOCK EXPLODED DRAWING  
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10-65  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
REMOVING THE BOTTOM ENGINE  
Fit the cylinder liner clamp Mot. 521-01.  
Fit the flywheel locking tool Mot. 582 and remove the  
clutch and the flywheel.  
16558R  
Remove:  
– the water pump.  
16531R  
Unscrew the three mounting bolts on the injection  
pump support to remove the unit comprising the pump,  
the support and the injection pump pulley.  
Remove the vacuum pump then remove the pinion  
and the six pieces holding the oil pump.  
16532-3S  
16533S  
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10-66  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
– the tension wheel,  
– the relay shaft cover,  
– the seal using a lever,  
16532-2S  
16532S  
– the relay shaft pinion, use immobiliser Mot. 855,  
– the key,  
– the relay shaft retainer,  
– the relay shaft (2),  
16532-1R  
16557R  
– the crankshaft timing sprocket using a two handle  
extractor,  
– the key.  
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10-67  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Remove the sump.  
Remove:  
– the crankshaft seals,  
– the oil filter using Mot. 1281-01.  
st  
1
model  
Three types of bolt marked A, B and C.  
Position the pistons at mid-stroke.  
Disconnect the connection tube between the oil pump  
and the lubricating gallery (if fitted).  
90571R  
nd  
2
model  
Two types of bolt marked as follows:  
– 13 bolts (M7 x 100-40),  
Remove the oil pump.  
– 8 bolts (M7 x 100-52).  
16553S  
16562S  
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10-68  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
For engine sump with reinforcing plate  
Remove:  
– the oil pump strainer, bolt (A), keeping the pump  
pinions,  
91576R  
– the two bolts on the oil pump body,  
– the oil pump body,  
– the oil level sensor,  
– the plate mounting bolts (then remove all the marked  
bolts).  
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10-69  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Marking of the mounting bolts on the cylinder block plate and on the sump on the plate.  
4 types of bolt marked as follows:  
: 17 bolts (M7 x 100-50).  
: 21 bolts (M6x100-16),  
: 1 bolt (M10x150-40),  
: 9 bolts (M10x150-75),  
: bolt not used  
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10-70  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Mark the bearing caps according to  
their con rods:  
– n˚ 1 flywheel end,  
– relay shaft end.  
WARNING: do not use a sharp  
point for marking as this could start  
a crack in the rods. Use an  
indelible marker pen.  
Remove the bearing caps and  
shells.  
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10-71  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Extract the cylinder liners and pistons (mark them).  
Remove:  
– the crankshaft,  
Mark the crankshaft bearing caps according to their  
housing and then remove them.  
– the lateral play stops,  
– the crankshaft bearing shells,  
– the piston base cooling jets incorporated in the  
cylinder block.  
16530S  
16529-1S  
NOTE:  
For engines fitted with a cooling gallery, remove the  
piston base cooling gallery.  
Extracting crankshaft bearings 1 and 5  
To extract the silicone injected crankshaft bearings 1  
and 5 use a locally manufactured metal tool of an  
approximate thickness of 2.5 mm.  
86609R  
REMINDER: never remove the mounting bolts (H) if  
the sump is not removed.  
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10-72  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Remove the filter holder.  
Remove the bearing using tool Mot. 11.  
77443R  
Replacing the bearing  
NOTE: if the gearbox is fitted with a short shaft (A), it  
does not need a bearing in the crankshaft.  
Refitting the bearing  
If the gearbox is fitted with a long shaft (B) the  
crankshaft must be fitted with a bearing.  
Cement the bearing with loctite FRENBLOC for  
engines fitted with flywheel mounting bolts that have  
no stop.  
16547R  
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10-73  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
EXTRACTING THE CON RODS - PISTONS  
It is very important not to scratch the mating faces  
of any aluminium components.  
Remove:  
– the rings using ring pliers,  
– the circlips (E) retaining the gudgeon pin,  
– the gudgeon pin (F).  
Use the Décapjoint product to dissolve any part of the  
gasket which remains attached.  
Apply the product to the parts to be cleaned; wait  
about ten minutes, then remove it using a wooden  
spatula.  
Wear gloves whilst carrying out this operation.  
Do not allow this agent to drip on to the paintwork.  
CLEANING  
Remove the threaded plugs in the lubricating pipes to  
clean the cylinder block.  
Your attention is drawn to the care which must be  
taken when carrying out his operation to prevent  
the introduction of foreign bodies into the  
pressurized oil feed pipes leading to the camshafts  
(pipes located both in the cylinder block and in the  
cylinder head).  
Failure to follow to this advice could lead to  
blocking of the filter in the rocker arm rails or the  
jets and thus quickly cause damage to the cams  
and tappets.  
83342S  
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10-74  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Clean the cylinder head mounting holes, especially in  
the oil outlet duct (C).  
REFITTING THE BOTTOM ENGINE  
Replace the lubrication channel plugs, tightening them  
to:  
● 8 daNm for the plugs (A),  
● 2 daNm for the plugs (B) for bearing n˚ 1,  
● 4 daNm for the other plugs.  
16527R  
This is necessary in order to obtain the correct  
tightening of the bolts.  
83342R1  
Check that the cylinder head mounting bolts can be  
screwed easily.  
Also pass a wire through the crankshaft pipes.  
Screw and unscrew the bolts several times to clear the  
threads if necessary.  
The cylinder head studs in the cylinder block must be  
fitted with Loctite SCELBLOC.  
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10-75  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
When fitting the dipstick guide tube, fit the collar to butt  
Replace the piston base cooling jets incorporated in  
against the cylinder block.  
the cylinder block and tighten to a torque of 1.2 to  
1.4 daNm. Check that the O-ring is present.  
If necessary, wind a cloth around the external diameter  
of the tube to make fitting easier and coat it with  
Loctite SCELBLOC.  
Fit the various mounting studs. The water pump,  
cylinder block and timing belt studs need one or two  
drops of Loctite FRENETANCH, as their threads  
extend into the cooling system.  
16529-1S  
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10-76  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
For engines fitted with a piston base cooling rail, the oil  
Engines 852 before n˚ 42 253  
gallery mounting bolts (H) need a drop of Loctite  
FRENETANCH. Do not add more, as too much  
increases the risk of blocking the oil circulation around  
the mounting bolt.  
Check that seals (D) are present between the original  
bolts (E) and the bearing bolt, oil filter side of bearings  
2, 3 and 4.  
If the engine does not have these seals, fit a seal (D)  
and a cap (F) coated with Loctite FRENETANCH and  
secure tightly using a 6 mm Allen key (200 mm long).  
This is to prevent oil entering the cooling system.  
86609R  
86741R  
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10-77  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Fitting the crankshaft bearing shells  
Grease the crankpins and bushings with engine oil.  
Identification  
Refit:  
– the crankshaft,  
Only grooved and pierced crankshaft bearing shells  
are supplied as spares, whatever the crankshaft  
lubrication configuration.  
– the crankshaft bearing caps except caps 1 and 5.  
Tightening torque: 8.75 to 9.75 daNm  
Fit the shells on to the bearings and the cylinder block  
and oil them.  
Fit the side shims for crankshaft n˚ 2 (grooves on the  
crankshaft side).  
16530S  
16529S  
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10-78  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Temporarily fit bearing n˚ 1 with no lateral seals in  
Fitting the crankshaft bearings  
order to fit the magnetic holder.  
There are two ways to ensure that bearings 1 and 5  
are properly sealed:  
1 - Fit butyl rubber seals.  
2 - Inject with silicone.  
1 - Fitting butyl rubber seals  
Position bearing caps 1 to 5.  
Measure dimension (C) using a drill.  
Checking end play (in mm):  
852  
J8S  
0.07 to 0.25 (1)  
0.20 to 0.30 (2)  
0.20 to 0.30  
If the dimension (C) is less than or equal to 5 mm, use  
a 5.1 mm thick seal.  
st  
(1) 1 model: n˚ 1 to 32909  
nd  
(2) 2 model: n˚ 32910 to ...  
If the dimension (C) is greater than 5 mm, use a colour  
marked 5.4 mm thick seal.  
Fit the lateral seals:  
– seal groove pointing to the outside,  
– protrusion d = 0.2 mm approximately on (A).  
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10-79  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Apply a thin coating of RHODORSEAL 5661 to the  
Remove the shims and the studs.  
supports on bearings 1 and 5 without blocking the oil  
return on the sump seals.  
Cut the side seals so that they protrude 0.5 to 0.7 mm  
in relation to the sump gasket face.  
Screw the ∅ 12 mm centering studs (G) (span 1.50) in  
to the cylinder block.  
Fit the bearings.  
Oil the two seals.  
Use two steel shims placed either side of the bearing  
cap.  
Lower the whole assembly.  
When the bearing is almost in place, make sure that  
the side seals protrude slightly over the cylinder block  
on the pressure face side.  
Check that the crankshaft rotates freely.  
2 - Injecting with silicone.  
To carry out this operation you will need:  
– a 50 ml syringe  
– a 5 ml tube of hardener,  
– a spatula for mixing,  
– a user's guide.  
IMPORTANT: the mixture must be injected within  
approximately 5 minutes to prevent it from curing in  
the syringe.  
80352S  
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10-80  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Thoroughly clean the cylinder block and the bearing  
NOTE: New fitting (J engine)  
cap surfaces (A). Degrease using a cloth soaked in  
diluted cleaning agent.  
The bearing caps have watertight grooves (C).  
Allow to dry.  
Following modifications to the bearing caps:  
– do not coat the inner surfaces of the cylinder block,  
– fit the crankshaft and timing seal(s) before injecting  
the silicone.  
– let the silicone run out through the watertight grooves  
on the crankshaft bearing.  
NOTE: older engines have grooves (B) in their cylinder  
blocks. Do not obstruct these oil grooves when  
applying RHODORSEAL 5661.  
96597R  
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10-81  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Lightly coat the inner surfaces of the cylinder block in  
(B) with RHODORSEAL 5661 without obstructing the  
oil grooves.  
Insert the mixture into the syringe and inject it into the  
grooves of the crankshaft bearing cap.  
89194R  
Fit the caps and tighten them to a torque of 8.75 to  
9.75 daNm.  
Mix 45 ml of RHODORSEAL 5661 (approximately half  
a 100 g tube) with half the tube of hardener. Stir with  
the spatula until the mixture forms a smooth, light pink  
paste.  
89196S  
Let the paste run out slightly on either side of the  
grooves of the crankshaft bearing cap, to ensure that it  
has completely filled the sealing groove.  
89195S  
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10-82  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Use a cloth to wipe up any excess paste, both inside  
and outside the cylinder block, and at (A).  
Allow to dry for a few moments and cut the excess off  
the gasket face.  
89199S  
89197R  
Pass a thin wire through the lubricating channels to  
check that they have not been blocked (this can also  
be done using a compressed air gun).  
89198S  
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10-83  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
REFITTING AND ASSEMBLING PISTON CON  
Turbo engine  
RODS  
Go to the cylinder liner-pistonreplacement section.  
The parts in the cylinder liner-piston section are  
identical to those used for this operation.  
Mark the parts in each box from A to D to ensure they  
remain identical.  
Completely dissolve the non-stick film without  
scratching the parts.  
Oil the gudgeon pin.  
Check that the gudgeon pins rotate properly in the new  
piston and the corresponding con rod.  
Some con rods are pierced to allow an oil jet to pass  
through; ensure that these are not blocked.  
Fit the con rod bearing shells.  
Ensure that the piston and con rod are fitted the right  
way round:  
Normally aspirated engine  
83241R1  
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10-84  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
FITTING THE PISTON RINGS  
CHECKING CYLINDER LINER PROTRUSION  
Rings set to their original adjustment must be free in  
their channels.  
This engine is fitted with cylinder liner base O-rings (J)  
and cylinder liner shaft seals (F).  
Ensure the rings are fitted in the correct orientation.  
The seals only maintain tightness  
The cylinder liner is directly supported by the cylinder  
block and the cylinder liner protrusion (X) is assured  
by the manufactured dimensions.  
86187R  
Fit the rings such that the gaps are equally spaced  
around the piston.  
72552R  
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10-85  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Therefore, the protrusion (X) should be checked in the  
following way:  
NOTE: the parts supplied in the cylinder liner-piston  
operation kit are identical to those used for this  
operation. Mark the parts in each box from A to D to  
ensure they remain identical.  
– place the cylinder liner not fitted with seals, in the  
cylinder block,  
Once the correct protrusion has been obtained,  
reassemble groups A, B, C and D with the cylinder  
liners, pistons and gudgeon pins and mark their  
position in the cylinder block.  
– check protrusion (X) using tools Mot. 251-01 and  
Mot. 252-01. It should be between 0.07 and  
0.13 mm.  
NOTE: If the protrusion is incorrect, check using a new  
cylinder liner set to find out whether the cylinder block  
or the cylinder liner is at fault.  
REFITTING CYLINDER LINERS - PISTONS - CON  
RODS  
Oil the pistons.  
Fit the piston-con rod assemblies into the cylinder  
liners with the tool, paying attention to the direction  
(the V towards the flywheel).  
The big end surfaces must be parallel with the flat  
bottom of the cylinder liner.  
16528R  
Position the cylinder liners so that:  
– the protrusion is graduated from cylinder n˚ 1 to  
cylinder n˚ 4 (or vice versa),  
– the difference in protrusion between two  
neighbouring cylinders is no more than 0.04 mm (in  
tolerance).  
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10-86  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Before fitting the cylinder liners-pistons-con rods  
assemblies in the cylinder blocks, don't forget to  
place an O-ring on each cylinder liner, making sure  
that it is not twisted, as well as a shaft seal..  
Fit the cylinder liner retaining flange Mot. 521-01 and  
tighten the bolts and mounting nuts to 5 daNm.  
Fit the cylinder liners-pistons-con rods assemblies  
in the cylinder block, making sure they are in the right  
positions.  
The cylinder liner flat surfaces need to be parallel.  
The piston combustion cut-out should be pointing  
towards the relay shaft side.  
If the con rod is pierced, point the oil jet towards the  
end opposite the relay shaft.  
16558R  
Fit the con rods onto the oiled big end journals of the  
crankshaft.  
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10-87  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Fit the con rod bearings caps with  
their shells, observing the pairing  
with the con rods.  
Fit and tighten the new con rod  
bearing bolts to a torque of  
6.5 daNm.  
Check that the mobile assembly can rotate freely.  
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10-88  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
CHECKING PISTON PROTRUSION  
Example:  
Protrusion in position 2: 1.09 mm.  
Clean the piston heads.  
Turn the crankshaft once clockwise at the timing end  
to bring piston n˚ 1 near to top dead centre.  
Position 2  
Place tool Mot. 252-01 on the piston.  
Place tool Mot. 251-01 fitted with a gauge on the thrust  
plate Mot. 252-01, the dial gauge measuring pin being  
in contact with the cylinder block, and look for the TDC  
of the piston (turn the crankshaft clockwise at the  
timing end).  
Without putting pressure on the tools or the piston,  
to avoid tilting of the piston during measurement,  
measure the protrusion when the piston is in position  
1, then in position 2 and calculate the average of the  
two measurements.  
Example:  
Protrusion in position 1: 0.83 mm.  
Position 1  
83815R  
Calculate the average piston protrusion:  
(083 + 1.09): 2 = 0.96 mm  
Carry out this procedure for the other pistons (look for  
the TDC by turning the crankshaft clockwise at the  
timing end, do not put pressure on tools Mot. 251-01,  
and Mot. 252-01 or on the piston).  
ONLY CONSIDER THE DIMENSIONS OF THE  
PISTON WITH THE GREATEST PROTRUSION  
For a protrusion:  
– less than 0.96 mm use a cylinder head gasket  
1.6 mm thick, marked with 1.6 or 1 hole,  
– between 0.96 and 1.04 mm, use a cylinder head  
83814R  
gasket 1.7 mm thick, without a stamped mark or  
a hole,  
– more than 1.04 mm use a cylinder head gasket  
1.8 mm thick, marked with 1.8 or 2 holes.  
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10-89  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Assessment and repair of the oil pump  
Removing the valve  
Checking the oil pump  
Check the clearances:  
Clearance A  
–
–
minimum (in mm)  
maximum (in mm)  
0.05  
0.12  
80142R  
Clearance B  
–
–
minimum (mm)  
maximum (mm)  
0.02  
0.10  
86303-1R  
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10-90  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Refitting the oil pump  
Refit the oil pump control shaft, circlip on the oil pump  
side.  
Check for the presence of the two centring pins (A).  
Refit the oil pump and tighten to a torque of 4 daNm.  
16562S  
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10-91  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Refitting the relay shaft  
Oil and fit the relay shaft, tightening the clamp bolts to  
a torque of 1 daNm.  
Refit the vacuum pump.  
On APG pumps, the pinion (A) is force fitted.  
16557S  
16548R  
On the BARMAG pumps, the pinion (B) is not fixed to  
the pump. Refit the relay shaft before refitting the  
pinion (B).  
16524R1  
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10-92  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Refitting the oil filter holder  
Fitting the crankshaft seals  
Replace the O-rings (G) when refitting.  
– flywheel side, Mot. 1297.  
83334R  
– timing side, Mot. 1298.  
Fitting the relay shaft seal  
Push the seal in until tool Mot. 1299 butts up against  
the holder.  
If the seal lip marks the crankshaft mating face, a  
1.5 mm thick washer must be placed between the seal  
and the tool to shift the mating face.  
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10-93  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Refitting the sump  
Metal sump  
Aluminium sump  
Fit a rubber gasket. The alignment of the cylinder block  
and the sump must be respected (flywheel side) to  
prevent the clutch housing from being damaged when  
the gearbox is fitted to the engine.  
st  
1 model:  
Fit a cork or rubber gasket.  
DI1051R  
16580S  
st  
A
B
1 model  
The sump is refitted with a new gasket and tightened  
to a torque of 1.4 to 1.7 daNm.  
nd  
2
model  
nd  
2
model:  
Only fit a rubber gasket.  
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10-94  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
For engine sump with reinforcing plate  
Refitting  
Remove all traces of grease from the cylinder block  
and the reinforcing plate with brake cleaner (for  
example).  
Fit two threaded rods (T) ∅ 7 length 30 mm and cut a  
groove at the end of one rod with a hacksaw.  
91510R  
Put a blob of RHODORSEAL 5661 where bearing  
caps 1 and 5 are joined to the cylinder block. Do not do  
this if the injection was done using butyl seals.  
89197R1  
Position the oil pump control shaft, circlip on the oil  
pump side.  
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10-95  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Marking of the bolts fitting the plate to the cylinder block plate and the sump to the plate.  
NOTE: the plate gasket is fitted dry.  
Four types of bolt marked as follows:  
: 17 bolts (M7 x 100-50), tightening torque: 1.2 to 1.8 daNm  
: 21 bolts (M6x100-16), tightening torque: 0.7 to 1.1 daNm  
: 1 bolt (M10x150-40), tightening torque: 3.2 to 4.8 daNm  
: 9 bolts (M10x150-75), tightening torque: 3.2 to 4.8 daNm  
: bolt not used  
Fit and tighten the oil pump body (4 to 4.5 daNm).  
(Ensure that the drive shaft and pinions are correctly positioned).  
Remove the threaded centring rods and fit the bolts.  
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10-96  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Fitting the flywheel  
Close the stop, if there is one fitted on the flywheel.  
Use Loctite AUTOFORM to coat the flywheel bearing  
Refit:  
face on the crankshaft  
– the clutch, tightening it to a torque of 2 daNm.  
– the timing tensioner roller,  
Fit the flywheel.  
– the coolant pump and the coolant return pipe on the  
cylinder block. The water pump should be fitted with  
a new seal and tightened to a torque of 1.3 daNm.  
– the crankshaft timing sprocket,  
Place a drop of Loctite FRENETANCH on the new  
bolts.  
– the relay shaft pinion with the key and tighten to a  
torque of 5 daNm using Mot. 855,  
Replace the flywheel bolt stop if there is one fitted.  
– the water pump pulley by tightening it to a torque of  
2 daNm.  
73834S  
Lock off the flywheel using locking tool Mot. 582 and  
tighten the bolts to a torque of 6 to 6.5 daNm.  
16531R  
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10-97  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
REFITTING THE TOP ENGINE  
Position the pistons in mid-stroke and remove tool  
Mot. 521-01.  
Positioning the cylinder head gasket  
It is necessary to use tool Mot. 720 placed in the hole  
(A) on the cylinder block. Check for the presence of  
the centring pin (B).  
Fit the cylinder head gasket.  
16556R  
Refit the cylinder head and centre it on the studs.  
Lubricate the threads on the mounting bolts and the  
washers under the heads with engine oil.  
All the cylinder head bolts must always be  
changed after removal (including the studs).  
Lubricate the threads and under the bolt heads  
with engine oil.  
Tightening procedure for cylinder head  
REMINDER: Use a syringe to remove any oil which  
may have entered the cylinder head mounting bolt  
holes to achieve correct tightening of the bolts.  
Consult the Technical specifications section for  
information on the cylinder head tightening procedure.  
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10-98  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Checking the piston-cylinder head clearances  
Checking the piston-valve clearances  
Using a locally manufactured tool (formerly tool Rou. 541) fixed to a camshaft  
bearing mounting, place the dial gauge on the stem of the valve retained for  
measuring the valve clearance dimensions.  
A
B
C
foot dimension: 20 x 4 x 163.5  
arm dimension: 20 x 4 x 50  
two spot weld points  
The piston must be near to top dead centre.  
Check this by putting pressure on the valve stem.  
Remove the keys and the valve spring (use tool Mot. 382).  
Using the dial gauge and keeping the valve pressed down on the piston,  
bring the piston to top dead centre.  
Set the dial gauge to zero, and then pull on the valve stem until it touches the  
seat. The resulting measurement corresponds to the piston - valve distance.  
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10-99  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Value of the piston-cylinder head clearances  
2) Valve clearance (measurement B)  
th  
Form this dimension (piston - valve), subtract the valve  
clearance value measured earlier; the result (piston -  
cylinder head clearance) should be more than 0.6 mm.  
On the inlet and exhaust valves of the 4 cylinder:  
Inlet:  
Exhaust:  
B = 0.92 mm  
B = 0.87 mm  
(The clearance is between 0.80 and 1.15 mm).  
In this case, use the measurement B = 0.87 mm for  
the exhaust valve, it being the smaller.  
Cylinder head fitted on the engine (with the cylinder  
head gasket and tightened to torque):  
3) Valve - piston clearance (measurement C)  
On the exhaust valve stem of the 4 th cylinder  
(reminder: piston at top dead centre):  
C = 1.57 mm  
which gives the PISTON/CYLINDER HEAD  
CLEARANCE:  
83367S  
D = C - B = 1.57 - 0.87 = 0.7 mm  
Example of completed measurement, cylinder  
head removed from the engine:  
(This clearance is thus greater than 0.6 mm).  
1) Piston protrusion (after turning the crankshaft  
clockwise at the timing end)  
(Measurement A):  
– cylinder n˚ 1, A = 1.05 mm  
– cylinder n˚ 2, A = 1.04 mm  
– cylinder n˚ 3, A = 1.05 mm  
– cylinder n˚ 4, A = 1.07 mm  
In this case use measurement A = 1.07 mm for  
cylinder 4.  
This measurement being greater than 1.04 mm, fit a  
cylinder head gasket 1.8 mm thick.  
Refit:  
– the camshaft (16),  
– the rocker arm rail (17),  
– the fuel return rail to the tank, fitted with new copper  
seals.  
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10-100  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Fitting the camshaft seal (timing side)  
Refit:  
– the camshaft sprocket and tighten to a torque of  
5 daNm,  
– the injection pump rear mounting by tightening the  
bolts to a torque of 2.5 daNm (do not tighten the  
bolts at the front of the pump to carry out the  
injection pump setting),  
Fit the seal (18) to the mounting bush Mot. 1300. Oil  
the external diameter of the seal. Fit the assembly on  
to the camshaft (16).  
– Timing tensioning roller.  
A: fitting dimension with tool Mot. 1300  
B: fitting dimension with tool Mot. 1300, and the  
washer (repair).  
If the seal lip marks the crankshaft mating face a  
1.5 mm thick washer (fitting the tool) must be placed  
between the seal and the tool to shift the seal.  
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10-101  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Adjusting the rocker arms  
Bring the exhaust valve of cylinder n° 1 to the fully  
open position, then adjust the inlet valve clearance for  
cylinder n° 3 and the exhaust valve clearance for  
cylinder n° 4.  
Use the same method for the other cylinders following  
the order given in the table below. To adjust the rocker  
arms, use tool Mot. 647.  
83366R  
Clearance (in mm) when the engine is cold:  
Inlet  
Exhaust  
0.20 ± 0.02  
0.25 ± 0.02  
Exhaust valve to the fully open  
Inlet valve to be adjusted.  
Exhaust valve to be adjusted.  
position  
1
3
4
2
3
4
2
1
4
2
1
3
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10-102  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Setting the timing  
Check the existing clearance between the tension  
wheel support in locked position and the setting bolt  
(A); a 0.1 mm feeler gauge should fit between the  
support and the bolt, and then tighten the lock nut.  
16535-1R  
Information:  
– the diameter of the balancing holes is 12 mm,  
– the diameter of the TDC setting rod is 8 mm.  
16555R  
Fit TDC setting rod Mot. 861 or Mot. 1054.  
Bring the camshaft sprocket and the injection pump  
marks in line with the marks made earlier, located on  
the cylinder head cover and the injection pump.  
16552S  
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10-103  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
NOTE: fit the air conditioning compressor belt (if fitted) before replacing the  
timing belt.  
Fit the timing belt starting from the crankshaft and working towards the relay  
shaft.  
Line up the markings of the timing belt with those of the pulleys and  
crankshaft sprockets.  
Check that the timing belt is stretched between the camshaft sprockets, the  
injection pump, the relay shaft and the crankshaft, so that the belt tension is  
not altered by the tension wheel.  
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10-104  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Remove TDC setting rod Mot. 861 or Mot. 1054 and  
replace the cap.  
Turn the crankshaft four times and re-position the  
timing at setting point.  
Undo the tension wheel fasteners half a turn again and  
it will automatically shift under the action of its spring  
and come into contact with the belt. Redo the  
fasteners.  
Check the fitting tension.  
16535-1R  
Engine fitted with an automatic tension wheel  
Undo the tension wheel fasteners half a turn and it will  
automatically shift under the action of its spring and  
come into contact with the belt. Redo the fasteners.  
16536S  
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10-105  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
NOTE:  
Using device Mot. 1505  
Switch on the device and bring the read head (A) up to  
the belt wire for measuring.  
Hold the read head between approximately 5 and  
10 mm from the belt (distance X).  
The measurement can be read on side (1) or (2) of the  
belt as appropriate.  
Either sensor, (a) or (b), may be used, provided that  
the sensor being used as reference is outside the field  
of measurement.  
16165R  
16164R  
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10-106  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
The two sensors must not both be facing the belt at the  
same time during measurement.  
Take the measurement by vibrating the belt with your  
finger.  
A bleep sounds to confirm the measurement.  
16168S  
16166S  
16169S  
16167S  
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10-107  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
TENSIONING PROCEDURE  
852 - J8S engines (without pretensioning)  
It is very important to follow these instructions for tightening the belt:  
– engine cold (ambient temperature),  
– fit the new belt; the timing should be at the setting point (top dead centre),  
– bring the tension wheel against the belt using Mot. 1384 and tighten the belt  
to the required fitting tension using Mot. 1505.  
FITTING TENSION IN FITTING TENSION IN  
ENGINE MODEL  
SEEM UNITS  
HERTZ  
J8S (all types)  
852 (all types)  
except J8S 760  
45  
50  
84 ± 5  
J8S 760  
104 ± 4  
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10-108  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
– tighten the tension wheel,  
– turn the crankshaft four times and re-position the timing at setting point,  
– Position the read head of Mot. 1505 and take the measurement. Check to  
see if it is within in the fitting tension tolerance, and if not, adjust it using the  
tension setting tool,  
– and tighten the tension wheel nut to a torque of 2.25 to 2.75 daNm.  
NOTE: this procedure is only valid for engines fitted with dynamic  
tensioners; for tensioners with springs, only test the fitting tension after  
installing the tensioner.  
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10-109  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Injection pump setting  
Remove the injector pump rear cap and fit dial gauge  
support Mot. 856 and a dial gauge fitted with an  
adapter.  
16541R1  
Turn the engine over once and calibrate the dial gauge  
on the bottom dead centre of the injection pump  
piston (check that the dial gauge pin can move freely  
in the pump body).  
Turn the timing to the setting point (pin the engine  
using Mot. 861 or Mot. 1054).  
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10-110  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Read the piston lift on the dial gauge, which should be:  
Top dead centre setting  
(rod in the crankshaft)  
MANUFACTURER  
TYPE  
Piston lift (mm)  
Pin lift (mm)  
VE.. R452  
BOSCH  
VE.. R452-1  
VE.. R452-2  
0.75  
-
-
BOSCH  
VE.. R158  
0.70  
-
dimension "X" on  
pump  
ROTO DIESEL  
DPC R 8443 B403C  
VE.. R449  
VE.. R449-1  
BOSCH  
BOSCH  
0.75  
0.70  
-
-
VE.. R153  
VE.. R153-1  
VE.. R345  
VE.. R345-1  
VE.. R423  
VE.. R423-1  
VE.. R423-2  
VE.. R423-3  
BOSCH  
BOSCH  
0.75  
0.75  
-
-
VE.. R309  
VE.. R309-1  
VE.. R309-2  
VE.. R309-3  
VE.. R309-4  
VE.. R153  
BOSCH  
BOSCH  
VE.. R153-1  
VE.. R153-2  
0.70  
0.70  
-
-
VE.. R69  
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10-111  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Top dead centre setting  
(rod in the crankshaft)  
MANUFACTURER  
TYPE  
Piston lift (mm)  
Pin lift (mm)  
VE.. R484  
VE.. R484-1  
BOSCH  
0.75  
-
-
DPC R8443 B142B  
DPC R8443 B143B  
dimension "X" on  
pump  
ROTO DIESEL  
DPC R8443 A400 A to  
A409 A (A)  
DPC R8443 A401 B to  
A409 B (A)  
1.80 (A)  
dimension "x" on  
pump (B)  
ROTO DIESEL  
-
DPC R8443 B402 B to  
B409 B (B)  
DPC R8443 B403 C  
to B409 C (B)  
If this is not the case, correct the setting.  
IMPORTANT: the following operations must be carried out in this order.  
Remove TDC setting rod Mot. 861 or Mot. 1054.  
Turn the injection pump to obtain the desired setting value (see above table).  
Tighten the injection pump mounting bolts.  
Turn the engine over twice and pin the engine again.  
Check the corresponding setting value again.  
Fit sprocket locking tool Mot. 854 or use tool Mot. 799-01, then tighten the injector pump pulley to a torque of  
5 daNm.  
Remove rod Mot. 861 or Mot. 1054.  
Turn the engine over twice and check the injection pump timing again.  
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10-112  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
Refit:  
– the timing cover,  
– the high pressure pipes on the injection pump using Mot. 1383,  
– the inlet and exhaust manifolds, by tightening the nuts to a torque of  
2.8 daNm,  
– the lifting bracket at the flywheel end and the fuel pipe support plate,  
– the multifunction support, tightening the nuts and bolts to a torque of  
4.3 daNm,  
– the alternator,  
– the air conditioning compressor (if fitted),  
– the power assisted steering pump,  
– the crankshaft accessories pulley by tightening the bolt to a torque of  
2 daNm, then angle tightening to 115˚ ± 15˚.  
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10-113  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
NOTES ON FITTING ACCESSORIES BELTS  
V BELT  
Tensioning procedure for new belts  
Engine cold, ambient temperature.  
Fit the new belt.  
Bring the tension wheel into contact with the belt and tighten to obtain the recommended fitting tension.  
Tighten the tension wheel.  
Turn the crankshaft over three times.  
Position the read head of Mot. 1505 and perform the measurement. Check that it is within the fitting tension  
tolerances, otherwise readjust it.  
Tensioning procedure for used belts  
Engine cold, ambient temperature.  
Fit the belt.  
Bring the tension wheel into contact with the belt and tighten to obtain 80 % of the recommended fitting tension  
value.  
Tighten the tension wheel.  
Turn the crankshaft over three times.  
Fit the read head of Mot. 1505 and perform the measurement. Check that it is within 80 % of the tension value  
tolerances, otherwise readjust it.  
NOTE: the V belt is replaced according to condition or noise.  
RIBBED BELT  
Belt tensioning procedure  
Engine cold, ambient temperature.  
Fit the new belt.  
Bring the tension wheel into contact with the belt and tighten to obtain the recommended fitting tension.  
Tighten the tension wheel.  
Turn the crankshaft over three times.  
Fit the reading head of Mot. 1505 and perform the measurement. Check that it is within the fitting tension  
tolerances, otherwise readjust it.  
NOTE: DO NOT REFIT A BELT ONCE IT HAS BEEN REMOVED; REPLACE IT.  
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10-114  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
FITTING  
TENSION IN  
SEEM UNITS  
MINIMUM OPERATING  
TENSION IN SEEM  
UNITS  
FITTING  
TENSION  
IN HERTZ  
ENGINE  
TYPE  
DIA-  
GRAM  
BELT FUNCTION  
Alternator  
Water pump (V-belt)  
J8S - 852  
J8S  
106 ± 4  
101 ± 4  
85 ± 5  
68  
74  
60  
158 ± 5  
222 ± 7  
88 ± 4  
1
2
3
Power steering (V-belt)  
Air conditioning  
(four ribs)  
J8S  
Alternator  
Water pump  
(four ribs)  
J8S 760  
J8S 760  
98 ± 7  
58  
50  
164 ± 5  
1
4
Power steering  
(four ribs)  
99 ± 6  
234 ± 10  
Alternator  
Coolant pump  
Air conditioning  
(six ribs)  
J8S 760  
123 ± 9  
76  
164 ± 5  
5
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10-115  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
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10-116  
ENGINE AND PERIPHERALS  
Overhauling the engine  
10  
A
B
C
D
E
T
Crankshaft  
Alternator  
Power assisted steering pump  
Air conditioning compressor  
Water pump  
Tension wheel  
→
Tension test point  
Refit the engine wiring harness.  
Remove the engine from the DESVIL support.  
Refit:  
– the metal oil vapour rebreather pipe tubes for the  
bottom engine.  
– the turbocharger  
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10-117  

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