- air conditioning compressor;
- power steering pump;
- generator assembly with mounting bracket;
- starter;
- engine management system;
- wiring harnesses;
- intake and exhaust manifolds;
- oil dipstick;
- engine mounts;
- flywheel or faceplate (with automatic transmission).
For overhaul from the engine are removed:
- cylinder head;
- engine oil pan;
- oil pump;
- water pump;
- pistons assembled with connecting rods;
- crankshaft.
Engine assembly is carried out in the reverse order of the above.
The processes of disassembly and assembly of complex engine components will be discussed in the relevant subsections.
Before disassembly, prepare small boxes or containers to hold the small parts to be removed. This will help save them for later assembly. After removing the next part, install the fasteners in their places (bolts, nuts, washers), to speed up the assembly process and preserve the threads on the parts. Keep replacement parts for comparison with new ones. Mark the position of the parts to be removed (paint, risk or in any other way), to put them in their original place during reassembly. Before starting disassembly, thoroughly wash the outside of the engine with kerosene.
Place the clean engine on a disassembly stand.
1. Remove: - the plugs at the ends of the camshafts; - the plug for the hole of the TDC position retainer.
![](https://www.renaultbook.ru/img/symbol/0773.jpg)
2. Install the camshafts with the grooves down as shown in the figure below.
![](https://www.renaultbook.ru/img/symbol/0774.jpg)
4. Turn the engine crankshaft counterclockwise (from the gas distribution mechanism), until the crankshaft hits the TDC lock pin.
![](https://www.renaultbook.ru/img/symbol/0775.jpg)
The grooves at the ends of the camshafts must be horizontal and offset downwards relative to the axis, as shown in the figure.
![](https://www.renaultbook.ru/img/symbol/0776.jpg)
5. Install flywheel lock (Mot. 582-01).
![](https://www.renaultbook.ru/img/symbol/0777.jpg)
6. Remove:
- crankshaft pulley to drive auxiliary equipment;
- middle cover of the timing gear (1);
- the upper cover of the gas distribution mechanism drive (2).
![](https://www.renaultbook.ru/img/symbol/0778.jpg)
7. Loosen the nut (3) on the tension roller.
![](https://www.renaultbook.ru/img/symbol/0779.jpg)
8. Remove the guide roller using tool Mot. 1368.
9. Remove: timing belt; camshaft pulleys using tool Mot. 1490.
![](https://www.renaultbook.ru/img/symbol/0780.jpg)
10. Remove the parts shown in figures 1-12.
Remove the air filter housing mounting bolts and remove the air filter housing.
![](https://www.renaultbook.ru/img/symbol/0781.jpg)
Remove the two throttle valve mounting bolts and remove the air intake manifold.
![](https://www.renaultbook.ru/img/symbol/0782.jpg)
Remove ignition coils.
![]() Figure 3 | ![]() Figure 4 |
Remove the 24 bolts securing the cylinder head cover and then, tapping with a copper hammer on the tabs (1), remove the cylinder head cover vertically upwards.
![](https://www.renaultbook.ru/img/symbol/0785.jpg)
Figure 5
Remove the intake and exhaust camshafts.
![](https://www.renaultbook.ru/img/symbol/0786.jpg)
Remove rocker arms and hydraulic pushers.
Caution: Place the hydraulic tappets in a vertical position to prevent oil leakage from them.
![](https://www.renaultbook.ru/img/symbol/0787.jpg)
Figure 7
Remove the two catalytic converter strut mounting bolts and remove the catalytic converter strut (see fig. 8).- Using tool Mot. 1495 remove the oxygen sensor; remove the exhaust manifold heat shields and the inner timing case spacer (see fig. 8).
![](https://www.renaultbook.ru/img/symbol/0788.jpg)
![](https://www.renaultbook.ru/img/symbol/0789.jpg)
Figure 9
Remove the removable part of the cooling jacket at the end of the cylinder head.
![](https://www.renaultbook.ru/img/symbol/0790.jpg)
Remove the fuel rail.
![](https://www.renaultbook.ru/img/symbol/0791.jpg)
Loosen the 10 cylinder head bolts evenly, in several passes, in the sequence shown in the figure. Remove the cylinder head and cylinder head gasket.
![](https://www.renaultbook.ru/img/symbol/0792.jpg)
11. Using a valve puller, compress the valve springs.
12. Remove: crackers of valve springs; upper plates of valve springs; valve springs; valves; valve guide valve stem seals using pliers Mot. 1335.
13. Remove the casing and driven clutch disc.
![](https://www.renaultbook.ru/img/symbol/0793.jpg)
![](https://www.renaultbook.ru/img/symbol/0794.jpg)
![](https://www.renaultbook.ru/img/symbol/0795.jpg)
Picture 1.
![](https://www.renaultbook.ru/img/symbol/0796.jpg)
![](https://www.renaultbook.ru/img/symbol/0797.jpg)
![](https://www.renaultbook.ru/img/symbol/0798.jpg)
![](https://www.renaultbook.ru/img/symbol/0799.jpg)
![](https://www.renaultbook.ru/img/symbol/0800.jpg)
Caution: To avoid cracking the connecting rods, do not use a punch to mark the connecting rod caps in relation to the connecting rods. Use an indelible marker for this purpose.
![](https://www.renaultbook.ru/img/symbol/0801.jpg)
Remove the crankshaft bearing caps (they are numbered 1 to 5).
![](https://www.renaultbook.ru/img/symbol/0802.jpg)
Caution: It is very important to mark the position of the crankshaft bearings as they may be in different size groups for each bearing.
Removing nozzles for cooling the piston bottoms1. Ream nozzles to cool piston crowns (1) drill with a diameter of 7 mm.
![](https://www.renaultbook.ru/img/symbol/0803.jpg)
2. Remove: spring thrust bush (1); spring (4).
![](https://www.renaultbook.ru/img/symbol/0804.jpg)
Attention: Do not remove the ball (3), so that the chips do not get into the oil channel.
3. Remove metal filings with a brush.
![](https://www.renaultbook.ru/img/symbol/0805.jpg)
4. Wrap the jig into the nozzles (1) (Mot. 1485 or Mot. 1485-01) with a 6 mm hexagon wrench (the key must be inserted inside the device).
![](https://www.renaultbook.ru/img/symbol/0806.jpg)
5. Screw on the puller (1) (Emb. 880) on adaptation (Mot. 1485 or Mot. 1485-01).
6. Remove nozzles.
Flushing
It is very important to avoid damage (scratches, scuffs) on mating surfaces of aluminum parts.
To remove the remnants of the old gasket from the surface, use the special Decapjoint solvent.
Apply this solvent to the area to be cleaned, wait approximately 10 minutes, and then remove any remaining gasket with a wooden spatula.
Camshafts
1. Camshafts are identified by markings (A).
![](https://www.renaultbook.ru/img/symbol/0807.jpg)
Marking details (A):
- - labels (IN) And (WITH) intended for the supplier only;
- label (D) serves to identify camshafts: AM - intake camshaft; EM - exhaust camshaft.
![](https://www.renaultbook.ru/img/symbol/0808.jpg)
- Axial clearance - 0.08 - 0.178 mm
- Number of supports - 6
- Jaw height "H":
- Inlet valves - 40.661±0.03 mm
- Exhaust valves - 40.038±0.03 mm
![](https://www.renaultbook.ru/img/symbol/0809.jpg)
2. Identification by the position of the cams. - Inlet camshaft. Position groove 3 at the end of the camshaft horizontally and offset downwards. Cams 1 of cylinder No. 1 must be located to the left of the vertical axis 2.
![](https://www.renaultbook.ru/img/symbol/0810.jpg)
Exhaust camshaft. Position groove 3 at the end of the camshaft horizontally and offset downwards. Cams 2 of cylinder No. 1 must be located to the right of the vertical axis 1.
![](https://www.renaultbook.ru/img/symbol/0811.jpg)
Table. Diameter of camshaft bearings in cylinder head
flywheel side | |
1 | |
2 | |
3 | 25+0.061+0.04 mm |
4 | |
5 | |
6 | 28+0,061+0.04. mm |
Timing Drive Side |
![](https://www.renaultbook.ru/img/symbol/0812.jpg)
Checking the diameters of the camshaft bearings in the cylinder head.
Table. Diameter of necks of camshafts
flywheel side | |
1 | |
2 | |
3 | 250-0.021mm |
4 | |
5 | |
6 | 280-0.021, mm |
Timing Drive Side |
![](https://www.renaultbook.ru/img/symbol/0813.jpg)
A 4 -1 = Cylinder 4 inlet valve and cam #1.
E 4 -1 = Cylinder 4 exhaust valve and cam #1.
Checking the camshaft end play Reinstall: - the camshafts in the correct position; - the cylinder head cover; tighten the bolts of its fastening (order and tightening torques see table "The order of tightening the cylinder head cover bolts").
![](https://www.renaultbook.ru/img/symbol/0814.jpg)
Check the end play, which should be between 0.08-0.178 mm.
![](https://www.renaultbook.ru/img/symbol/0815.jpg)
Checking the diameters of the bearing journals of the camshafts.
Table. The order of tightening the cylinder head cover bolts
Stage | Bolt tightening sequence | Bolt loosening sequence | Torque (Nm) |
№1 | 22-23-20-13 | - | 8 |
№2 | 1 to 12, 14 to 19, 21 to 24 | - | 12 |
№3 | - | 22-23-20-13 | - |
№4 | 22-23-20-13 | - | 12 |
![](https://www.renaultbook.ru/img/symbol/0816.jpg)
Note: To fit the magnetic indicator holder to the cylinder head, use tool Mot. 588 and secure it with mounting bolts (1) oil sump and bushings (2) with the dimensions below:
- outer diameter 18 mm;
- bolt hole diameter (1) 9 mm;
- height 15 mm.
![](https://www.renaultbook.ru/img/symbol/0817.jpg)
Remove the cylinder head cover and camshafts again.
Cylinder Head GasketThe thickness of the cylinder head gasket is measured at (A).
Head gasket thickness:
- The thickness of the new gasket is 0.96±0.06 mm
- The thickness of the crimped gasket is 0.93±0.06 mm
![](https://www.renaultbook.ru/img/symbol/0818.jpg)
Cylinder head
Height "H" cylinder heads - 137 mm
![](https://www.renaultbook.ru/img/symbol/0819.jpg)
Permissible non-flatness of the mating surface of the cylinder head is 0.05 mm.
Regrinding of the mating surface is not allowed. Check the cylinder head for possible cracks.
Plug tightening torques - 25-30 Nm
Cylinder block
Check the flatness of the mating plane with a straightedge and a set of feelers.
![](https://www.renaultbook.ru/img/symbol/0820.jpg)
Permissible non-flatness of the mating surface of the cylinder block is 0.03 mm.
Resurfacing of the mating surface is not allowed.
Hydraulic liftersThis engine is equipped with hydraulic lifters (A) and single-arm levers with a roller (IN).
![](https://www.renaultbook.ru/img/symbol/0821.jpg)
Valves
![](https://www.renaultbook.ru/img/symbol/0822.jpg)
Valve lift:
- Intake Valve - 9.22mm
- Exhaust Valve - 8.075mm
Rod diameter "d" (measured at a distance "X1"):
- X1 (inlet valve) - 75.14±0.35 mm
- Inlet valve - 5.484±0.01 mm
- X1 (Exhaust valve) - 77.5±0.35 mm
- Exhaust valve - 5.473±0.01 mm
Plate diameter "D":
- Inlet valve - 32.7±0.12 mm
- Exhaust valve - 27.96±0.12 mm
Chamfer Angle:
- Inlet and outlet valves - 90°15'
Valve length "L":
- Inlet valve - 109.32 mm
- Exhaust Valve - 107.64mm
Head thickness "T":
- Inlet valve - 1.15mm
- Exhaust Valve - 1.27mm
Valve seats
Seat seat angle α:
- Inlet and outlet valves - 89°
Chamfer Width X:
- Inlet valve - 1.3+1,4 mm
- Exhaust valve - 1.41'3 mm
Outer diameter D:
- Inlet valve - 33.542±0.006 mm
- Exhaust valve - 28.792±0.006 mm
![](https://www.renaultbook.ru/img/symbol/0823.jpg)
Valve guides
Length:
- Inlet and outlet valves - 40.5±0.15 mm
Guide bush outer diameter:
- Inlet and outlet valves - 11+0,068+0,05mm
Guide bush inner diameter:
- Inlet and outlet valves:
- Not processed - 5+0,075 mm
- Processed* — 5.5+0,018 mm
* The hole in the guide sleeve is reamed to the specified size after the sleeve is pressed into the cylinder head. Guide bush diameter in cylinder head:
- Inlet and outlet valves - 11 mm
Oil scraper caps are installed on the guide bushings of the intake and exhaust valves (valve stem seals), which simultaneously serve as lower supports for the valve springs.
Inlet and Exhaust Valve Guide Inclination: Inlet Valve - 63°30'
![](https://www.renaultbook.ru/img/symbol/0824.jpg)
Exhaust valve - 66°
![](https://www.renaultbook.ru/img/symbol/0825.jpg)
performance "A" inlet and exhaust valve guides - 11±0.15 mm
![](https://www.renaultbook.ru/img/symbol/0826.jpg)
Checking the clearance between the stems and the valve guides There are two ways to check the clearance between the stems and the guide bushes of the caps.
Nominal clearance between valve guide and valve stem:
- Inlet valve - 0.015±0.048 mm
- Exhaust valve - 0.029±0.062 mm
1. Raise the valve head by 25 mm, then measure the movement of the valve in the direction of the arrows at an angle of 90°to the camshaft axis with the indicator. Half the value obtained will give the value of the clearance between the valve stem and the valve guide.
![](https://www.renaultbook.ru/img/symbol/0827.jpg)
2. Measure the valve stem diameter and guide bushing inside diameter.
![](https://www.renaultbook.ru/img/symbol/0828.jpg)
Valve stem seals To fit the valve stem seals, tool Mot. 1511.
![](https://www.renaultbook.ru/img/symbol/0829.jpg)
Note: Do not lubricate valve stem seals with oil prior to installation.
Installing new valve stem seals Insert the valve into the cylinder head.
![](https://www.renaultbook.ru/img/symbol/0830.jpg)
Attach tip Mot. 1511 for valve stem (the inner diameter of the tip must be different from the diameter of the rod).
![](https://www.renaultbook.ru/img/symbol/0831.jpg)
Keep the valve pressed against the seat. Install the valve stem seal (not oiled) on the tip
![](https://www.renaultbook.ru/img/symbol/0832.jpg)
Press the valve stem seal until it comes off the tip, then remove the tip.
![](https://www.renaultbook.ru/img/symbol/0833.jpg)
Install pusher (1) on the valve stem oil seal.
![](https://www.renaultbook.ru/img/symbol/0834.jpg)
Note: The inside diameter of the tappet must match the diameter of the valve stem. In addition, the bottom of the tappet should partially rest against the valve stem oil seal, which serves as the lower support washer for the valve spring.
Replace the oil seal by tapping the top of the tappet with your palm until the oil seal is in contact with the cylinder head.
![](https://www.renaultbook.ru/img/symbol/0835.jpg)
![](https://www.renaultbook.ru/img/symbol/0836.jpg)
Repeat the above steps for all valves.
Valve springs
Check spring calibration.
![](https://www.renaultbook.ru/img/symbol/0837.jpg)
Free length - 41.30 mm
Loaded length:
- 190 N - 34.50 mm
- 590 N - 24.50 mm
Fully collapsed length - 23.20 mm
Inner diameter - 18.80 mm
Outer diameter - 27 mm
Permissible deviation of the spring from the vertical - 1.2 mm
![](https://www.renaultbook.ru/img/symbol/0838.jpg)
Oval wire.
Removing the piston pins Place the piston in the V-shaped stand so that the piston pin is aligned with the hole to remove it.
Using a mandrel (1) to remove the piston pin, remove it from the piston using a press.
![](https://www.renaultbook.ru/img/symbol/0839.jpg)
Pistons
Piston height - 46.5 mm
1. Pressing in the piston pin using tools A13, C13 and B10. The pin is pressed into the connecting rod and rotated in the piston bosses.
![](https://www.renaultbook.ru/img/symbol/0840.jpg)
Piston markings. 1 - Piston orientation (label"L" must be on the flywheel side of the engine), 2 - Used by supplier only, 3 - Piston class (A-B-C), 4 - Supplier use only, 5 - Supplier use only, 6 - Piston axis of symmetry, 7 - Piston pin bore axis, 8 - Offset between axle bore (7) and the axis of symmetry of the piston (6) - 0.8 mm.
Table. Dimensional groups of pistons and cylinders of the block
Piston size designation | Piston diameter, mm | Cylinder diameter, mm |
A | 79,470 - 79,479 | 79,500 - 79,509 |
IN | 79,480 - 79,489 | 79,510 - 79,519 |
WITH | 79,490 - 79,500 | 79,520 - 79,530 |
Attention: It is necessary to comply with the diameters of the pistons and cylinders.
Hole position "T" in relation to the joint surface of the cylinder block allows you to determine the size group for each cylinder and, therefore, the diameter of the corresponding piston (see matching table below).
![](https://www.renaultbook.ru/img/symbol/0841.jpg)
The marking area includes. 1 - to indicate the size group (A, B or C), D - to correlate the size group with the cylinder number.
Table. Designation of dimensional groups of block cylinders
T hole positions | Size group |
1 = 17 mm | A |
2 = 27 mm | IN |
3 = 37mm | WITH |
2. Measurement of the piston diameter. The measurement of the diameter must be carried out at distance E.
- E - 45.7±0.01 mm
![](https://www.renaultbook.ru/img/symbol/0842.jpg)
Checking the gaps in the locks of the piston rings
1. Install the piston ring (2) into the cylinder.
![](https://www.renaultbook.ru/img/symbol/0843.jpg)
2. Move the piston ring (2) to the middle of the cylinder with a piston (1).
3. Measure the gap of the ring in the lock with a set of probes (3).
Table. Piston ring gaps
Piston rings | Gap in the castle |
Top compression ring | 0.225±0.075 mm |
Lower compression ring | 0.5±0.1mm |
Oil scraper ring | 0.9±0.5mm |
4. Replace piston rings if gaps are out of tolerance. If the gaps remain out of tolerance with new rings, replace the cylinder block.
Crankshaft
Number of supports - 5
Fillet grooved journals: Nominal diameter - see table below
![](https://www.renaultbook.ru/img/symbol/0844.jpg)
Axial clearance of the crankshaft: Without wear of the inserts of the installation bearing - 0.045-0.252 mm
Taking into account the wear of the installation bearing shells - 0.852 mm
The inserts of the installation bearing are located on the support No. 3.
Note: Crankshaft crank radius is 35mm.
Crankpins with fillet grooves: Nominal diameter - 43.97±0.01 mm
![](https://www.renaultbook.ru/img/symbol/0845.jpg)
![](https://www.renaultbook.ru/img/symbol/0846.jpg)
Marking on the crankshaft.
Table. Marking on the crankshaft
No. of the main neck | |||||
V | 2 | 3 | 4 | 5 | |
E | F | E | E | E | Size group |
D = D4 | |||||
E = D5 | |||||
F = D6 |
* From the flywheel side of the engine.
Designation of the size group on the crankshaft | Diameter of main journals, mm |
D = D4 | 47,990 - 47,996 |
E = D5 | 47,997 - 48,002 |
F = D6 | 48,003 - 48,009 |
Cylinder block
Dimensional groups of main supports (5) indicated by the position of the drillings on the cylinder block (6) above the oil filter.
![](https://www.renaultbook.ru/img/symbol/0847.jpg)
Table. Dimensional groups of main supports
Hole position (6) | Size group designation | Main bearing diameter, mm |
A = 17 mm | 1 or blue | 51,936 - 51,941 |
H = 27 mm | 2 or red | 51,942 - 51,949 |
Note: The marking area includes A B to indicate the size group, respectively, 1 or 2.
Table. Correspondence of the size groups of the liners with the size groups of the main journals and main bearings of the crankshaft
Dimensional group of main journals | |||
D1 or D4 | D2or D5 | D3 or D6 | |
1* | C1 = Yellow 1.949-1.955 | C2= Blue 1.946-1.952 | C4 = Red 1.953-1.959 |
2* | SZ = Black 1.943-1.949 | C1 = Yellow 1.949-1.955 | C2 = Blue 1.946-1.952 |
Thickness and class of liners |
* Size group of the crankshaft main bearing.
Note: The spare parts warehouse will only provide bearings in size group 02 (blue labels).