Description
Workshop Repair ManualHigh Pressure Common Rail Diesel Engine 4 Cast Iron Cylinders Vehicle Type Engine Clio XB07 XB08 XB09 K9K 700 and 704 K9K 702 K9K 710 Kangoo KC07 KC09 K9K 700 K9K 710 77 11 298 922 JULY 2001 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. EDITION ANGLAISE All copyrights reserved by 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." 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. © RENAULT 2001 Contents Page 10 ENGINE AND PERIPHERALS Cleanness & Safety Foreword Engine identification Tightening torques (in daNm or degrees) Technical specifications Standard exchange Essential special tooling Essential equipment Engine overhaul 10-1 10-7 10-8 10-10 10-12 10-31 10-32 10-36 10-37 K9 ALL TYPES ENGINE 110 Cleanness & Safety 10 CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM Risks relating to contamination The system is very sensitive to contamination. The risks caused by the introduction of contamination are: – damage to or destruction of the high pressure injection system, – seizing or leaking of a component. All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) must be allowed to enter the system during dismantling or into the circuits via the fuel unions. The cleanliness principle must be applied from the filter to the injectors. WHAT ARE THE SOURCES OF CONTAMINATION? Contamination is caused by: – metal or plastic chips, – paint, – fibres, ● of cardboard, ● brushes, ● paper, ● clothing, ● cloths. – foreign bodies such as hairs, – ambient air, – etc. IMPORTANT: it is forbidden to clean the engine using a high pressure washer because of the risk of damaging connections. Also the moisture may collect in the connectors and cause electrical connection problems. 10-1 These are not lint-free and may contaminate the fuel circuit of the system. CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE CARRYING OUT ANY WORK ON THE FUEL SYSTEM ● For each operation. ● Blow compressed air over the cleaned parts (tools. use a clean brush which is in good condition (the brush must not shed its bristles). ● Ensure that you have the resealable plastic bags for storing removed parts. ● Wash your hands before and during the operation if necessary.K9 ALL TYPES ENGINE Cleanness & Safety 10 INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM ● Ensure that you have the plugs for the unions to be opened (bag of plugs sold by the Parts Stores . cover these with latex gloves. they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). ● When wearing leather protective gloves. Plugs are to be used once only. After use. ● Use a brush and thinners to clean the connections to be opened. Pour it into a clean receptacle. There is less risk of parts stored in this way being exposed to contamination. Each lint-free cloth should only be used once. use new thinner (used thinner contains impurities). Unused plugs must be thrown away. connections and injection system zone).: 77 01 206 804).Part no. The use of conventional cloth or paper is prohibited. 10-2 . The bags must be used only once. and after use they must be thrown away. Check that no bristles remain adhered. ● Make sure that lint-free cleaning cloths are available (cleaning cloths part number 77 11 211 707). bench and parts. ● For each operation. K9 ALL TYPES ENGINE Cleanness & Safety 10 INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION ● As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores (part number 77 01 206 804). They must not, under any circumstances, be reused . ● Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries contamination. ● All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once the plugs have been inserted. ● The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened. In fact, these items are likely to result in impurities entering the system. ● A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle. 10-3 K9 ALL TYPES ENGINE Cleanness & Safety INSTRUCTIONS FOR FITTING THE PLUGS (part number 77 01 206 804) 10-4 10 K9 ALL TYPES ENGINE Cleanness & Safety 10 IMPORTANT ● The engine must not run with: – diesel containing more than 10% diester, – petrol, even in very small amounts. ● The system can inject the diesel into the engine at a pressure of up to 1400 bars. Before carrying out any work, check that the injector rail is no longer pressurised and that the fuel temperature is not too high. ● You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system. ● Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the diesel temperature sensor and the venturi may be changed on the pump. ● For safety reasons, it is strictly forbidden to undo a high pressure pipe union when the engine is running. ● It is forbidden to remove the pressure sensor from the fuel rail because this may cause contamination problems. If the pressure sensor develops a fault, the pressure sensor, fuel rail and the five high pressure pipes must be replaced. ● It is strictly forbidden to remove any high pressure pump pulley bearing the part no. 070 575. The pulley must be replaced when the high pressure pump is replaced. ● It is forbidden to repair the wiring connecting the accelerometer and the engine speed sensor. If the wiring should fail, it has to be replaced with new wiring. ● Applying 12 volts directly to any component in the system is prohibited. ● Ultrasonic decoking and cleaning are prohibited. ● Never start the engine if the battery is not connected correctly. ● Disconnect the injection system computer when carrying out any welding work on the vehicle. ● All disconnected plastic air inlet hoses must be replaced. 10-5 – download the data from the diagnostic tool to the computer. – Using the diagnostic tool. ● If it is not possible to communicate with the computer: – Change the computer. ensure that the computer has not detected faults relating to the injector codes and check that the instrument panel warning light is off. takes into account any manufacturing variations and specifies the flow injected by each injector. specific to each injector.K9 ALL TYPES ENGINE Cleanness & Safety 10 A 16 character code called C2I (Individual Injector Corrector) is marked on the injectors. The code of the four injectors must be programmed into the computer when the computer is replaced. This code. – read the data on the injectors. 10-6 . ensure that the computer has not detected faults relating to the injector codes and check that the instrument panel warning light is off. The code of the new injector must be programmed into the computer when injector is replaced. – Using the diagnostic tool. – store the data in the computer using the diagnostic tool. There are two possibilities: ● If it is possible to communicate with the computer: – Upload the data from the computer into the diagnostic tool. – change the computer. UNITS OF MEASUREMENT – All dimensions are expressed in millimetres mm (unless otherwise stated). 10-7 10 . – overhauling the engine. – Pressures are expressed in bar (reminder: 1 bar = 100 000 Pa). – Tightening torques are expressed in decanewtonmetres daNm (reminder: 1 daNm = 1. TOLERANCES Tightening torques given without a tolerance must be accurate to within: – in degrees (± 3º).02 kgm). – in daNm (± 10 %). To repair a component on the vehicle.ENGINE Foreword K9 ALL TYPES USING THE MANUAL There are two main sections in this manual: – technical specifications. refer to the vehicle's Workshop Repair Manual and Technical Notes. K9 ALL TYPES ENGINE Engine identification Identification is by means of an engraved plate on the cylinder block which carries: – A: engine type. – D: Renault code. – B: engine type approval letter. – F: engine fabrication number. 10-8 10 . – E: engine suffix. – G: engine assembly plant. 5 1461 10-9 .710 18.ENGINE Engine identification K9 ALL TYPES 10 Engine Suffix Compression ratio Bore (mm) Stroke (mm) Cubic capacity (cc) K9K 700 .702 704 .25/1 76 80. 6 0. 10-10 10 .8 3.6 2.manifold mounting Turbo oil return pipe Turbo oil delivery pipe Timing tension wheel Top dead centre cap Cylinder head suspended mounting support * See tightening procedure.3 2.1 1.1 Cylinder head Camshaft bearings Camshaft pulley Vacuum pump Cylinder head coolant outlet unit Exhaust manifold Exhaust gas recirculation valve Pre-heater plugs High pressure pump Injector flanges High pressure rail High pressure pipe Cylinder head cover Turbo .8 1 2.9 2.8 2.1 1 2.5 2 2.5 2.K9 ALL TYPES ENGINE Tightening torques (in daNm or degrees) UPPER ENGINE Description Tightening torques * 1 3 + 84° 2.1 2. 7 + 47° ± 5° 2 + 45° ± 6° 2 2.8 2 + 130° ± 15° 2 4 2.5 2.5.5 4.1 Heat exchanger connector Oil filter unit bracket Crankshaft bearing caps Con rods Pinking sensor Oil level sensor Oil pump Engine oil sump Water pump Flywheel Clutch mechanism Crankshaft accessories pulley Water pump inlet pipe Multifunction support Alternator Power steering pump Air conditioning compressor * See tightening procedure.5 0. 10-11 .K9 ALL TYPES ENGINE Tightening torques (in daNm or degrees) 10 BOTTOM ENGINE: Description Tightening torques 4.1 2.2 2.1 2.1 5 .5 * 1. 78 ± 0. All bolts must always be changed after removal.K9 ALL TYPES ENGINE Specifications 10 CYLINDER HEAD Thickness of the cylinder head gasket Cylinder head tightening procedure The thickness of the cylinder head gasket is measured at (A): – thickness of the gasket when tightened: 0.m. Tighten all the bolts to a torque of 2.5 daN.m then tighten to an angle. Do not retighten the cylinder head bolts after performing this procedure. Check that all the bolts are correctly tightened to 2. bolt by bolt. Do not oil the new bolts. 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. 10-12 . of 255° ± 10°.5 daN.3 mm. 192 ± 0.: All measurements must be carried out along the longitudinal axis of the engine. in order to eliminate any errors due to tilting of the piston. and find top dead centre of the piston.B. Turn the crankshaft one turn in its operating direction to bring piston no. Measure the piston protrusion.093 mm.1 close to Top Dead Centre. WARNING: the gauge follower must not be in the valve clearance. Fit tool Mot. N. 252-01.K9 ALL TYPES ENGINE Specifications Checking piston protrusion Clean the piston heads in order to eliminate any traces of deposits. 251-01 equipped with a gauge on its base plate Mot. The protrusion must be: 0. 10-13 10 . 03 Inlet and exhaust NO REGRINDING IS AUTHORISED Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit suited to the cylinder head. blanking plate).05 0. sealing plate. 10-14 0 ± 0.95 ± 0.12 29 ± 0. plug. valve lift (in mm) Inlet Exhaust: Gasket face bow (in mm): Cylinder head Cylinder block 8.008 Face angle Inlet and exhaust: 90º Head diameter (in mm) Inlet Exhaust 33.22 100.977 ± 0.K9 ALL TYPES ENGINE Specifications Height of the cylinder head (in mm) Valves H = 127 Stem diameter (in mm) Inlet Exhaust 10 5.008 5.963 ± 0.5 ± 0.015 8.22 Max.07 .595 Protrusion of valves in relation to the cylinder head gasket face (in mm) 0.12 Valve length (in mm) Inlet Exhaust 100.75 ± 0. The approval number of the cylinder head test container is 664 000. 044 +0.12 0 Guide internal diameter (in mm) Inlet 34.008 Not machined 5.062 +0.459 ± 0.008 Inlet and exhaust Exhaust 30.5 Machined* 6.009 ± 0.ENGINE Specifications K9 ALL TYPES Valve seats Valve guides Seat angle (α) Length (in mm) Inlet and exhaust: Inlet and exhaust: 89º 30' Mating surface width (X) (in mm) Inlet and exhaust: 10 40.015 Exhaust 29.0075 The inlet and exhaust guides have valve stem seals which must be changed each time the valves are removed.5 ± 0.542 ± 0. Diameter of the housing in the cylinder head (in mm) Inlet 34.97 ± 0. Diameter of the housing in the cylinder head (in mm) Normal 11 ± 0.015 10-15 .009 * This dimension is measured with the guide fitted in the cylinder head.8 Normal: Seat external diameter (D) (in mm) 11 +0.15 Guide external diameter (in mm) 1.042 ± 0. α = 90 Inlet and exhaust: 19675 Position of the inlet and exhaust valve guides (in mm) Inlet: Exhaust NOTE: do not lubricate the valve stem seals before fitting them.2 . 1511-01 or other suitable equipment.K9 ALL TYPES ENGINE Specifications 10 Angle of the inlet and exhaust guides (in degrees) It is imperative to fit the valve stem seals using tool Mot. 10-16 A = 14 A = 14. then replace the tappets which are not within tolerance.45 Internal diameter (in mm) Bottom Top 18.10 ± 0.02 Checking the valve clearance Place the valves of the cylinder concerned at the "end of exhaust .40 + 0.2 21 ± 0.05 -0.80 Joined spires (in mm): 23. Free length (in mm) 43.075 .05 -0.01 Diameter of the housing in the cylinder head (in mm) 35.beginning of inlet" position and check the clearance (X).80 24.40 Wire diameter (in mm) 3.075 Exhaust: 0.02 ± 0.70 ± 0.2 External diameter (in mm): Bottom Top 25. when the engine is cold: 10-17 Inlet 0. WARNING: THIS ENGINE DOES NOT HAVE ANY VALVE SPRING LOWER WASHERS.20 + 0.80 ± 0.2 14.975 ± 0. Piston external diameter (in mm) 34. Clearance (in mm).ENGINE Specifications K9 ALL TYPES 10 Valve springs Pistons The valve springs are tapered (ensure the correct direction of fitting).2 1 4 3 2 4 1 2 3 Compare the values recorded with the values specified.31 Length under a load of (in mm) 23 daN 50 daN 33. NOTE: dimension (Y) corresponds to the tappet thickness class (there are 25 classes at the Parts Store). K9 ALL TYPES ENGINE Specifications The camshaft must be removed to replace the tappets. 5 ● bearing 6 25.989 ± 0. the valve is closed before Top Dead Centre. 3.178 Number of bearings 6 Diameter of the camshaft bearings (in mm) – on the camshaft: ● bearings 1. then slide in the tappet to be measured.05 ± 0. 2.01 Timing diagram Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly). 4.01 27.05 ± 0. 5 ● bearing 6 24.01 – on the cylinder head: ● bearings 1. 10-18 . Determining dimension "Y". 3. 856-02. then calibrate the gauge. 10 Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance.01 28. ** As the exhaust closing advance is negative. 2.08 to 0. The Parts Stores supplies 25 classes of single-piece tappets. – – – – Inlet opening retard * Inlet closing retard Exhaust opening advance Exhaust closing advance ** -9 20 27 -7 * As the inlet opening retard is negative.989 ± 0. Set up the following assembly using Mot. Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s) . 252-01 and Mot. the valve is opened after Top Dead Centre. Camshaft End play (in mm) 0. 4. Piston marking 1 2 3 4 5 6 7 8 Cylinder block top dead centre fixed mark Flywheel top dead centre moving mark Flywheel bottom dead centre moving mark Inlet Opening Retard Exhaust Closing Advance Inlet Closing Retard Exhaust Opening Advance Direction of engine rotation (flywheel end). 3 Used by the supplier only 4 Used by the supplier only 5 Used by the supplier only 6 Piston axis of symmetry 7 Gudgeon pin hole axis 8 Offset between the hole axis (7) and the piston's axis of symmetry (6) is 0.3 mm 10-19 . 1 Direction of fitting of the piston Λ towards the flywheel 2 Height between the gudgeon pin and the top of the piston (see table below). These engines are fitted with FEDERAL MOGUL pistons. The gudgeon pin is retained by circlips.K9 ALL TYPES ENGINE Specifications 10 PISTONS Fitting the gudgeon pin in the con rod and in the piston. Piston diameter (in mm): 75.ENGINE Specifications K9 ALL TYPES 10 Measuring the piston diameter Table of gudgeon pin heights * Mark on piston Pin height (mm) K 41. N.55 .751 N 41.3 External diameter 24. NOTE: ● if the engine is fitted with a K class piston.02 mm. Gudgeon pin (in mm) 10-20 Length 59. * The different gudgeon pin heights are exclusively reserved for the engine assembly plant.95 .2 Internal diameter: 13.667 L 41.007 The tolerance on the pin heights is ± 0.8 . M. The Parts Stores will only supply piston classes (height) L.60.7 .793 P 41.835 The piston diameter must be measured at height A = 56 mm.94± 0.709 M 41.13. ● if the engine is fitted with a P class piston. an L class piston must be fitted as a replacement. an N class piston must be fitted as a replacement.25. 9 Scraper 0.7 to 0.5 -0.01 -0.5 .2 to 0.25 to 0.35 Sealing 0. T = Top 10-21 Rings Clearance at the gap (in mm) Compression 0.03 Sealing 2 -0.03 Scraper 2.03 The rings are supplied ready adjusted.01 -0.01 -0.ENGINE Specifications K9 ALL TYPES Rings 10 Clearance at the gap Three rings (thickness in mm): Compression 2 -0. 619 ± 0. Use a permanent marker pen.009 CON RODS Diameter of the big end (in mm) The connecting rods are of the "DETACHABLE CAP" type.25 ± 0. Diameter of the small end (in mm) (without ring) 27.019 ± 0. WARNING: ● The bolts must be coated with engine oil under the heads and on the threads when the con rods are fitted in the engine. ● The big end caps are positioned on the con rod by irregularities on the parting line. to avoid initiating a crack in the rod.205 to 0.006 NOTE: the con rod small end rings cannot be replaced. Lateral big end play (in mm) 0.045 Centre distance between the big end and small end (in mm) 133.cap mating surfaces will lead to rapid rupture of the con rod. WARNING: do not use a sharp point to mark the big end caps in relation to their con rod. The maximum weight difference for the con rod.K9 ALL TYPES ENGINE Specifications 10 47.467 Diametrical big end play (in mm) 0.75 10-22 . ● The occurrence of impacts or a foreign body between the body . piston and gudgeon pin assemblies for the same engine must be 25 grams.035 to 0.010 (with ring) 25. 045 .0.252 – with wear on the lateral shims: 0.027 .035 .0.852 Crankshaft diametrical clearance (in mm): – journals 0.01 43.045 . 5 Crankshaft lateral clearance (in mm): – without wear on lateral shims: 0. Direction for fitting the circlips on the piston Position the opening (3) of the spring rings opposite the removal and fitting channel (4).0.97 ± 0. NO RECTIFICATIONS ARE ALLOWED. 10-23 .01 The lateral shims are located on bearing Nº 3.045 Journal diameter (in mm): Crankpin diameter (in mm): 48 ± 0.054 – crankpins 0.0.K9 ALL TYPES ENGINE Specifications 10 CRANKSHAFT Direction of fitting of the con rod in relation to the piston Number of main journals Point the "Λ" (1) engraved on the top of the piston downwards and the machined flat (2) of the big end as shown on the diagram below. ENGINE Specifications K9 ALL TYPES Working out the class of crankshaft bearing shells (Original fitment) Marking (5) on the crankshaft Detail of the marking (5): Number of journals 1* 2 3 4 5 B B C C B Classes of journal diameters A = D1 B = D2 C = D3 * Flywheel end.990 to 47.004 to 48.996 B = D2 47.997 to 48.010 . 10-24 10 Table of journal diameter classes Journal class mark on the crankshaft Journal diameter (in mm) A = D1 47.003 C = D3 48. 943 to 1.952 1.959 1.949 to 1.936 .955 1.K9 ALL TYPES ENGINE Specifications CYLINDER BLOCK 10 Table of cylinder block bearing diameters The diameters of the bearings (6) of the cylinder block are marked by a hole on the block (7) located above the oil filter. Matching the crankshaft bearing shells Journal diameter class 1* 2* D1 D2 D3 C1 C2 C3 1.949 yellow blue black C4 C1 C2 1.B gives the diameter class of bearings 1 or 2.51. Hole position (7) Class reference Cylinder block bearing diameter (in mm) A = 33 mm 1 or blue 51. NOTE: the parts stores will only supply class C2 (blue).953 to 1.942 exclusive B = 43 mm 2 or red 51.942 inclusive 51.952 red yellow blue Bearing shell thickness and class * Cylinder block crankshaft bearing diameter class.949 NOTE: the marking zone includes: – A .946 to 1. 10-25 .949 to 1.955 1.946 to 1. The crankshaft bearing shells are fitted on the cylinder block and on the bearings using Mot. fit grooved bearing shells on all the bearings. 1493-01. fit non grooved bearing shells. Crankshaft bearing shells The engine is fitted with bearing shells without a locator notch.K9 ALL TYPES ENGINE Specifications BEARING SHELLS 10 Direction of fitting: – on the cylinder block. 10-26 . – on the bearing caps. 1492-03. 1492 and Mot.625 10-27 . Bearing shell width (in mm): – upper – lower 10 20. NOTE: the upper and lower con rod bearing shells are not the same width. Con rod bearing shells The engine is fitted with bearing shells without a locator notch.K9 ALL TYPES ENGINE Specifications The bearing shells are fitted using Mot.625 17. 10-28 . – the air conditioning compressor or the powerassisted steering pump. – the multifunction support.K9 ALL TYPES ENGINE Specifications 10 – the alternator. 792-03. PREPARING THE ENGINE TO BE SET ON THE STAND Before the engine is mounted on the stand Mot. the engine's electrical harness must be removed and the engine oil drained. Remove: – the accessories belt. (X). Place the rods (A). 10-29 10 . (Y) of Mot.K9 ALL TYPES ENGINE Specifications – the coolant inlet pipe on the water pump. 1378 on the cylinder block so that they fit into the holes (20. 32. 33) on the plate of Mot. 792-03. – Camshaft pulley bolt. Cleaning parts 77 01 421 513 Cleaning gasket faces 77 01 405 952 Crankshaft bearing cap Sealing paste Bead Camshaft bearings - Crankshaft closure plate Loctite FRENETANCH 1 . PARTS TO BE REPLACED AFTER REMOVAL: – All gaskets. – Turbo plastic pipes. – Injector holder copper washers. – High pressure injection pipes. WARNING: when working on the fuel supply system. – Crankshaft pulley bolts. – Piston base cooling jets. – Big end cap bolts. – Belts. 10-30 . – Crankshaft bearing bolts. – Flywheel bolts. – Pipe plugs.ENGINE Specifications K9 ALL TYPES 10 CONSUMABLES Type Cleaner DECAPJOINT Quantity Coat Component concerned Part no.2 drops RHODORSEAL 5661 Coat Water pump bolts 77 01 394 070 Top Dead Centre pin plug 77 00 404 452 FITTING THREAD INSERTS WARNING Threaded holes on all engine component parts can be repaired by using thread inserts. the cleanliness rules described in this document must be strictly complied with. – Timing belt tension wheel. – the injectors – the heater plugs. – the high pressure pump. – the clutch Remember to remove: – all coolant pipes. – the multifunction support. – the oil level sensor. Leave on the used engine or include in the return box: – the oil filter. – the alternator. 10-31 10 .K9 ALL TYPES ENGINE Standard replacement PREPARING THE USED ENGINE FOR RETURN The engine should be cleaned and drained (oil and water). – the power-assisted steering pump. The used engine should be secured to the base under the same conditions as the overhauled engine: – plastic plugs and covers fitted. – the oil pressure switch. – the cylinder head coolant outlet unit. – the rail. – cardboard cover over the assembly. – the flywheel. – the water pump. – the dipstick. – the vacuum pump. – the exhaust manifold. – the air conditioning compressor. K9 ALL TYPES Illustration ENGINE Essential special tooling 10 Method part number Parts stores number Emb. 11 00 01 072 500 Crankshaft bearing extractor Mot. 252-01 Mot. 445 00 00 044 500 Oil filter wrench Mot. 252-01 00 00 025 201 Thrust plate for measuring the protrusion of cylinder liners used with Mot. Mot. 591-02 00 00 059 102 Magnetic flexible shaft for angular wrench for tightening cylinder head. 588 00 00 058 800 Liner retaining strap Mot. 251-01 00 00 025 101 Gauge stand used with Mot. Mot. 591-04 00 00 059 104 Angular wrench for tightening cylinder head. 1/2" drive with index 10-32 Description . 251-01. 880 00 00 088 000 Inertia extractor Mot. Mot. 582-01 00 00 058 201 Flywheel immobilising tool. K9 ALL TYPES Illustration ENGINE Essential special tooling 10 Method part number Parts stores number Mot. 1489 00 00 148 900 TDC setting pin Mot. 1335 00 00 113 500 Tool for removing valve stem seals Mot. 1329 00 00 132 900 Oil filter cap Mot. 792-03 00 00 079 203 Engine mounting plate for Desvil stand Mot. 1430 00 00 143 000 Set of top dead centre pins Mot. 799-01 00 00 079 901 Tool for locking sprockets for toothed timing belt Mot. 1485-01 00 00 0148 501 Tool for removing the piston bottom cooling jets Mot. 1492 00 00 149 200 Tool for fitting con rod bearing shells 10-33 Description . 1378 00 00 137 800 X and Y engine pins Mot. K9 ALL TYPES Illustration ENGINE Essential special tooling 10 Method part number Parts stores number Mot. 1493-01 00 00 149 301 Tool for fitting crankshaft bearing shells Mot. 1585 00 00 158 500 Tool for fitting crankshaft seals. 1492-03 00 00 149 203 Adaptation kit for fitting the detachable cap con rod bearing shells Mot. 1511-01 00 00 151 101 Tool for fitting valve stem seals Mot. 1494 00 00 149 400 Tool for removing the piston bottom jets Mot. 1567 00 00 156 700 Pliers for exhaust gas recycling pipe clips Mot. flywheel end 10-34 Description . 1573 00 00 157 300 Cylinder head support Mot. 1505 00 00 150 500 Belt tension setting tool Mot. 1566 00 00 156 600 Spanner for fitting and removing high pressure pipes Mot. timing end Mot. 1586 00 00 158 600 Tool for fitting crankshaft seals. 1638 00 00 163 800 Tool for tensioning accessories belt for engines with a mechanical tension wheel Rou. 1632 00 00 163 200 Tool for fitting inlet camshaft seals Mot. 15-01 00 00 001 501 Internal shaft protector ∅ 16 mm 10-35 Description .K9 ALL TYPES Illustration ENGINE Essential special tooling 10 Method part number Parts stores number Mot. g. including: a tray and the various kits suited for each model of cylinder head (plug.g. e. e. – e. blanking plate). FACOM part number B10R10A.g. FACOM part number DM 19 Crowfoot adapter for tightening high pressure pipe Articulated wrench for removing and refitting the heater plugs. The approval number of the cylinder head test container is 664000 Standard 1/2" (12.7 mm) square drive socket for removing the oil pressure checking gauge Tooling for testing the cylinder head. e. FACOM part number DM6J4. e.K9 ALL TYPES ENGINE Essential equipment 10 Description Ring for fitting pistons in the cylinder block Standard 22 mm long 1/2" (12.7 mm) square drive 8/12 /14 female torx socket . Angular tightening tool from: – e. FACOM part number DM360.g. – e.g. sealing plate. Angled nippers Wrench for removing high pressure pipes. Tool for fitting valve stem seals. STAHL WILLE part number 540 100 03.g. FACOM U49 A D5 Valve spring compressor 10-36 .g. SAM part number 1 SA. Wrench for removing crankshaft bearings. K9 ALL TYPES ENGINE Overhauling the engine Removing the upper engine Remove: – the upper timing cover by unclipping the two tabs (1), – the lower timing cover by unclipping the three tabs (2) and pulling out the plastic bolt (3), 10-37 10 K9 ALL TYPES ENGINE Overhauling the engine – the cylinder head suspended mounting support, – the TDC pin cap. 10-38 10 K9 ALL TYPES ENGINE Overhauling the engine 10 Turn the engine clockwise (timing side) until the crankshaft touches the TDC pin Mot. 1489. Positioning the belt at the timing point Position the hole (4) of the camshaft pulley almost opposite the hole (5) of the cylinder head. The pin Mot. 1430 must engage in the camshaft pulley and cylinder head holes. Screw in the TDC pin Mot. 1489. Remove Mot. 1430 and Mot. 1489. 10-39 K9 ALL TYPES ENGINE Overhauling the engine Fit flywheel block Mot. 10-40 10 . 582-01. Remove the crankshaft accessories pulley. K9 ALL TYPES ENGINE Overhauling the engine Slacken the timing belt by loosening the bolt (6) of the tension wheel. Remove: – the timing belt tension wheel. 10-41 10 . then remove the timing belt. – the inner timing cover. Unclip the fuel return pipe from the cylinder head cover at (7). – the clamp (3). the nuts (4) of the turbo flange. – the oil vapour rebreathing pipe. 10-42 . then remove the cylinder head cover. 10 the turbo oil supply pipe on the turbo side. by removing the clamp (1) and the bolt (2). – the turbo oil supply pipe on the cylinder head side.K9 ALL TYPES ENGINE Overhauling the engine – – – – – the air filter unit. the turbo oil return pipe (6). the bolts (5) of the catalytic converter bracket. Pay strict attention to the rules regarding cleanliness (see start of document). 10-43 . – the cylinder head. it is essential to secure the intermediate union (10) of the injector. 10 STRIPPING THE CYLINDER HEAD Place the cylinder head on cylinder head support Mot.K9 ALL TYPES ENGINE Overhauling the engine Remove: – the dipstick guide. 1573. WARNING: when undoing the high pressure pipes. 10-44 . – the pre-heater plugs using an angled spanner. – the ring for lifting the engine (flywheel end). – the high pressure pump. – the vacuum pump.K9 ALL TYPES ENGINE Overhauling the engine 10 – the injectors (by marking them in relation to their cylinder). – the rail. 1566 or a pipe wrench. – the cylinder head coolant outlet unit. the rail and the injectors. fit the protective blanking plugs to the high pressure pump. Remove: – the high pressure pipes using Mot. the exhaust gas recirculation valve. the ring for lifting the engine (timing end).K9 ALL TYPES – – – – – ENGINE Overhauling the engine 10 – the camshaft bearings. 20064-2 – the tappets. – the camshaft pulley using Mot. 799-01. noting their position. the exhaust manifold. 10-45 . the exhaust gas recirculation pipe. the inlet pipe. – the upper cups. it is vital to measure position H of one of the old seals in relation to the cylinder head using Mot.: before removing the valves and the valve stem seals. 10-46 . Remove: – the keys. 1511 -01 or other suitable equipment.K9 ALL TYPES ENGINE Overhauling the engine Compress the valve springs using the valve lifter. 10 N.B. – the springs. 1335 pliers. – the valve guide seals using the Mot. NOTE: the internal diameter of the pushrod must be identical to that of the valve. In addition. Fit the pushrod (1) of Mot.K9 ALL TYPES ENGINE Overhauling the engine 10 Fit the guide tube (2) over the pushrod until the guide tube comes into contact with the cylinder head. Remove: – the valves. 1511-01 on the valve stem seal. Remove the guide tube assembly plus pushrod. being careful not to loosen the knurled wheel. locking the pushrod with the knurled wheel. 10-47 . the bottom of the pushrod must come into contact with the metal upper section of the valve stem seal. K9 ALL TYPES ENGINE Overhauling the engine 10 CLEANING CHECKING THE GASKET FACE It is very important not to scratch the gasket faces of any aluminium components. The approval number of the cylinder head test container is 664000 Apply the product to the part to be cleaned. wait approximately 10 minutes. resulting in rapid and serious damage to the engine. Use DECAPJOINT to dissolve any part of the seal which remains stuck to the metal surface. Check for mating surface bow using a ruler and a set of shims. sealing plate. Failure to follow this instruction could lead to the blocking of the oilways. Maximum bow 0. then remove it using a wooden spatula.05 mm Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit suited to the cylinder head. plug. to prevent foreign objects entering the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover) and the oil return pipes. 10-48 . Great care should be taken when performing this operation. Wear gloves whilst carrying out this operation. blanking plate). Do not allow this product to drip on to the paintwork. 1511-01 or other suitable equipment. It is imperative to fit the valve stem seals using tool Mot. Clean all the parts thoroughly.m. then carry out the refitting operation. which must be between 0. Fitting new valve stem seals Place the valve in the cylinder head. 588 must be used and secured using the oil filler attachment bolt (1) of the cylinder head cover and a spacer with the following dimensions: – external diameter 18 mm.K9 ALL TYPES ENGINE Overhauling the engine 10 CHECKING THE CAMSHAFT END PLAY REBUILDING THE CYLINDER HEAD NOTE: to attach the magnetic gauge to the cylinder head. 10-49 . NOTE: do not lubricate the valve stem seals before fitting them.178 mm. – diameter of bolt (1) hole 9 mm. Lubricate the inside of the valve guide. grind them gently into their respective seats. Remove the camshaft bearings and the camshaft. – the camshaft bearings (positioning them correctly with bearing 1 on the flywheel end). clamp Mot. mark them for identification purposes.08 and 0. Check the end play. then tighten the bolts to a torque of 1 daN. Fit new valves. Refit: – the camshaft. – height 15 mm. Keep the valve pressed against its seat. then withdraw the barrel. Place the barrel of tool Mot.K9 ALL TYPES ENGINE Overhauling the engine 10 Push the valve stem seal past the tool barrel. 1511-01 over the valve stem (the internal diameter of the barrel must be identical to the diameter of the valve stem). 10-50 . Place the valve stem seal (not lubricated) over the tool barrel. Fit: – the springs. Compress the springs.07 mm.K9 ALL TYPES ENGINE Overhauling the engine Place the guide tube plus pushrod assembly on the valve stem seal. Refit the keys using tweezers. Repeat these operations for all the valves. 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. Check the valve protrusion which should be 0 ± 0. 10-51 10 . – the upper cups. 1 4 3 2 4 1 2 3 Compare the values recorded with the values specified. – the tappet(s) not within tolerance. when the engine is cold. 856-02. Set up the following assembly using Mot.05 -0.m. Determining dimension Y.40 + 0.075 10 10-52 . Clearance. in mm: Inlet 0. Place the valves of the cylinder concerned at the "end of exhaust . – the camshaft bearings.075 Exhaust: 0. NOTE: dimension (Y) corresponds to the tappet thickness class (there are 25 classes at the Parts Store). tightening the bolts to a torque of 1 daN. CHECKING AND ADJUSTING THE VALVE CLEARANCE Refit: – the tappets. – the camshaft.beginning of inlet" position and check the clearance (X).20 + 0.ENGINE Overhauling the engine K9 ALL TYPES Remove: – the camshaft bearings. 252-01 and Mot. then calibrate the gauge. then replace the tappets which are not within tolerance.05 -0. – the camshaft. 10 Grease the underside of the tappets and the camshaft bearings. Lay four beads (3) of Loctite 5181 with a width of 1 mm on bearings 1 and 6 of the cylinder head. They should be clean. Degrease the gasket faces (of the cylinder head and bearings numbers 1 and 6). – the camshaft. remove finger marks). Check the valve clearance again. – the tappet(s) not within tolerance. 10-53 Refit: – the camshaft.m. Remove: – the camshaft bearings.K9 ALL TYPES ENGINE Overhauling the engine Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly). – the camshaft bearings (these are numbered from 1 to 6 and bearing (1) should be positioned on the flywheel end) tightening the bolts to a torque of 1 daN. then slide in the tappet to be measured. . Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s) . dry and free from grease (in particular. 14678-1S Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance. K9 ALL TYPES ENGINE Overhauling the engine 10 The new rubber seal has a flat sealing lip (4) and a protector (5) which also assists in fitting the seal to the engine. Fitting the camshaft seal This engine can be fitted with two different types of seal. 10-54 . The old rubber seal is fitted with a spring (2) and has a "V"-shaped sealing lip (3). Old and new seals are easily recognised. 10-55 . Fit the cover (7) and the collar nut (8) of Mot. Fit the old seal on the camshaft. For the new seal. taking care not to touch the seal.K9 ALL TYPES ENGINE Overhauling the engine 10 Screw the shouldered rod (6) of Mot. 1632 onto the stud of the camshaft. put the protector with the seal on the camshaft. 1632. 10 Remove the nut.K9 ALL TYPES ENGINE Overhauling the engine Screw the collar nut until the cover touches the cylinder head. tightening the new nut to a torque of 3 daN. the protector and the shouldered rod. 10-56 . Refit the camshaft pulley. the cover.m plus an angle of 84°. 6 daNm in the recommended order. – the ring for lifting the engine (timing end). – the inlet pipe fitted with a new seal. then tighten the clips of the pipe using pliers Mot. 10-57 10 – the exhaust manifold fitted with new seals. – the cylinder head coolant outlet unit fitted with a new seal. tightening the bolts to a torque of 2. Tighten the mounting bolts of the valve to a torque of 2.1 daN. .1 daNm.K9 ALL TYPES ENGINE Overhauling the engine Refit: – the vacuum pump fitted with a new seal. 1567. – the exhaust gas recycling valve and the exhaust gas recycling pipe fitted with new clips.m. tightening the bolts to a torque of 2. tightening the bolts to a torque of 1 daNm. Replace the compression washer with a new washer. – the pre-heater plugs. Method for refitting the injector pipes WARNING: all removed high pressure pipes must be systematically replaced. Refit: – the injectors (using the marks made during removal). part no. Dry off using a different new wipe. – the high pressure rail without locking its mounting nuts.m. tightening the mounting flanges to a torque of 2. 10-58 . 77 11 211 707) dipped in clean solvent.8 daN. lubricate the threads of the nuts with the applicator supplied with the kit of new parts. as well as their brackets using a lint-free cloth (use the wipes recommended for this purpose. Clean the injector sockets and the injector bodies. tightening the bolts to a torque of 2. Before fitting the new high pressure pipes. tightening them to a torque of 1. – the ring for lifting the engine (flywheel end).1 daNm.5 daNm.K9 ALL TYPES ENGINE Overhauling the engine 10 – the high pressure pump. – put the high pressure pipe nuts in position by hand beginning with the one located on the rail side. it is essential to secure the intermediate union (10) of the injector. WARNING: when tightening the high pressure pipes. IMPORTANT: Pay attention to the direction of fitting of the second half of the clip. The tabs located in the centre of the clip will only fit together in one position. Fit the rail-high pressure pump pipe: – remove the protective plugs from the pump high pressure outlet and the rail high pressure inlet. 10-59 .K9 ALL TYPES ENGINE Overhauling the engine 10 – remove the protective plugs from the rail high pressure rail outlet and the injector high pressure inlet. – insert the olive of the high pressure pipe into the taper of the pump high pressure outlet. Fit the injector-high pressure rail pipe: Fit the clips supplied with the new pipes onto the high pressure pipes: – Insert the first half of the clip using adjustable pliers. – insert the olive of the high pressure pipe into the taper of the injector high pressure inlet. – put the high pressure pipe nuts in position by hand beginning with the one located on the injector side. – Insert the second half of the clip using adjustable pliers. – insert the olive of the high pressure pipe into the taper of the rail high pressure outlet. Fit the remaining high pressure pipes as before. – insert the olive of the high pressure pipe into the taper of the rail high pressure inlet. m. 10 Tighten the nuts of the injector-rail high pressure pipes using the recommended tool: – tighten the nut on the injector side to a torque of 3.8 daN.m. Tighten the nuts of the pump-rail high pressure pipe using the recommended tool: – tighten the nut on the rail side to a torque of 3. NOTE: Tighten one pipe fully before moving on to the next pipe.8 daN.m. WARNING: the correct order and tightening torque must be used for the high pressure pipes. – tighten the nut on the pump side to a torque of 3.8 daN.8 daN. IMPORTANT: do not touch the pipes with the wrench when torque tightening. – tighten the nut on the rail side to a torque of 3.K9 ALL TYPES ENGINE Overhauling the engine Tighten the rail nuts to a torque of 2.8 daNm. 10-60 .m. – the anti-emulsion plate.K9 ALL TYPES ENGINE Overhauling the engine – the sump. 582-01. REMOVING THE BOTTOM ENGINE Fit flywheel block Mot. – the flywheel. 10-61 10 . Remove: – the clutch mechanism. NOTE: It is essential to mark the position of the crankshaft shells. – the crankshaft closure plate. – the oil pump chain.K9 ALL TYPES ENGINE Overhauling the engine 10 – the oil level sensor. Use a permanent marker pen. Remove: – the crankshaft bearing caps. – the oil pump. 10-62 . Remove the big end cap bolts and the connecting rod/ piston assemblies. WARNING: do not use a sharp point to mark the bearing caps in relation to their con rods to avoid starting a crack in the rod. – the oil pump drive sprocket. as the category may be different for each bearing. – the water pump. – the crankshaft. 10 Replacement of the piston base cooling jets REMOVAL To remove the piston base cooling jets (1).K9 ALL TYPES ENGINE Overhauling the engine Remove: – the oil pressure sensor. – the pinking sensor. – the bolt of the oil filter unit bracket. 10-63 . NOTE: do not remove the ball (4) to prevent swarf entering the cooling circuit. – the heat exchanger connector. they must be drilled with a 7 mm diameter drill. This is necessary in order to remove the spring stop (2) and the spring (3). 880 onto Mot. 10-64 . Remove the swarf using a brush. 1485-01 and remove the jet.K9 ALL TYPES ENGINE Overhauling the engine 10 – the inertia extractor Emb. Screw: – tool Mot. 1485-01 in the drilled out jets using a 6 mm Allen key which must slide into the tool. Fitting piston base cooling jets The jets must be fitted using tool Mot. With a hammer. NOTE: check that the jet is correctly oriented with the end of the jet (4) directed towards the centre of the cylinder.K9 ALL TYPES ENGINE Overhauling the engine 10 Fit the pushrod instead and in place of the guide rod. Fitting the jets for cylinders 1 and 3 Fit plate (3) of tool Mot. Remove the guide rod. 1494 onto the cylinder block (as shown on the diagram below) without tightening the two bolts (1). 10-65 . tap the pushrod until the shoulder (5) of the pushrod comes into contact with the plate (3). then insert the jet into the pushrod. Position the guide rod (2) in the plate (3) and the end of the guide rod in the hole of the jet to centre the plate (3). Tighten the two bolts (1). 1494. Tighten the two bolts (1). 10-66 . Position the guide rod (2) in the plate (3) and the end of the guide rod in the hole of the jet to centre the plate (3). tap the pushrod until the shoulder (5) of the pushrod comes into contact with the plate (3). NOTE: check that the jet is correctly oriented with the end of the jet (4) directed towards the centre of the cylinder. 1494 onto the cylinder block (as shown on the diagram below) without tightening the two bolts (1).K9 ALL TYPES ENGINE Overhauling the engine 10 Position the pushrod instead and in place of the guide rod. Fitting the jets for cylinders 2 and 4 Fit plate (3) of tool Mot. Remove the guide rod. With a hammer. then insert the jet into the pushrod. 792-03. positioning the lip (2) of the seal behind the lugs (3) of the exchanger. Replace the seal (1) of the exchanger. 10 Method for refitting the heat exchanger Remove the cylinder block from engine stand Mot.K9 ALL TYPES ENGINE Overhauling the engine Orientation of the piston cooling jets (see diagram below). – the crankshaft by passing a wire through the lubrication channels. 10-67 . A: Orientation of the jets of cylinders 2 and 4 B: Orientation of the jets of cylinders 1 and 3 Clean: – the cylinder block. Hold the exchanger by hand whilst tightening the connector (5) to a torque of 4. Refit the cylinder block on engine stand Mot. Fit the exchanger (with its coolant pipes) on the cylinder block using the connector (5) without locking the connector.m. securing using the bolt (4). Insert the two coolant hoses (6) onto the ends of the coolant pipe. Refit the inlet pipe of the water pump.K9 ALL TYPES ENGINE Overhauling the engine Proceed as follows to ensure the exchanger is correctly refitted.5 daN. 10 Remove the water pump inlet pipe. 792-03. 10-68 . then release the pin. to a torque of 4. Then tighten the bolt (10) fitted with new seals. To extract the gudgeon pin. 10-69 . because the piston height classes in the same engine may be different (see Technical Specifications section).m.: it is imperative to mark the connecting rod to match it to its piston.K9 ALL TYPES ENGINE Overhauling the engine 10 Fit the oil filter support (complete with a new seal (7)). EXTRACTING THE GUDGEON PINS N.B.5 daN. positioning the lug (8) in the hole (9) of the exchanger. remove the spring ring using a screwdriver. K9 ALL TYPES ENGINE Overhauling the engine 10 FITTING THE CON ROD BEARING SHELLS On the con rod body The bearing shells are fitted using Mot. 1492-03. 1492-03 onto the base (as shown in the diagram). Fit the guide (4) of Mot. Slide the bearing shell support (1) of Mot. 10-70 . 1492 and Mot. 1492. 1492-03 (positioning the engraved mark (3) "A" as shown on the diagram below) into the groove (2) of the base of Mot. Lay the bearing shell (with a width of 20. Check that the lower part (5) of the small end is touching the centring pin and push the guide (7) in the direction of the arrow.625 mm) (6) on the bearing shell support. then push it in the direction of the arrow (as shown on the diagram). 10-71 . 10 Bring the shell support up against the base of the con rod body.K9 ALL TYPES ENGINE Overhauling the engine Lay the body of the con rod on the base of the tool (as shown in the diagram). Remove the con rod body support and repeat the operation for the remaining con rod bodies. 625 mm. – the engraved mark (4) "B" if the width of the bearing shell is equal to 17. 10-72 . then push it in the direction of the arrow (as shown in the diagram). Fit the shell (8) on the shell support.K9 ALL TYPES ENGINE Overhauling the engine On the con rod cap Position the bearing shell support either on: – the engraved mark (3) "A" if the width of the bearing shell is equal to 20.625 mm. 10 Push the guide (in the direction of the arrow) until the con rod cap is in contact with the pins (9) on the base of the tool. Fit the con rod cap as shown in the diagram. Remove the con rod cap support and repeat the operation for the remaining con rod caps.K9 ALL TYPES ENGINE Overhauling the engine Bring the shell support up against the base of the con rod cap. 10 REFITTING THE BOTTOM ENGINE Fitting the crankshaft bearing shells Direction of fitting. Fit the smooth bearing shells on the bearings. 10-73 . Position the grooved bearing shells on the cylinder block. 1493-01. 1493-01. 1493-01. 1493-01.K9 ALL TYPES ENGINE Overhauling the engine 10 On the cylinder block On the bearings Position tool Mot. 1493-01 on the cylinder block. 10-74 . then press at (A) until the bearing shell is touching at (B) with Mot. Fit the bearing shell in Mot. Fit the bearing shell in Mot. then press at (A) until the bearing shell is touching at (B) with Mot. 1493-01 on the bearing. Position Mot. 045 .252 – with wear on the lateral shims: 0. – the crankshaft bearing caps on bearing cap no.m plus an angle of 47° ± 5°.1 (these are numbered from 1 . – the lateral shims on bearing no.045 .7 daN.0.0.5 and these numbers should be positioned opposite the water pump). Refit: – the crankshaft. putting the grooves on the crankshaft side.K9 ALL TYPES ENGINE Overhauling the engine Oil the crankshaft bearing shells. 10-75 10 Check the lateral clearance of the crankshaft (in mm) which should be: – without wear on lateral shims: 0.3. Then tighten the bolts to a torque of 2.852 . They should be clean. remove finger marks).K9 ALL TYPES ENGINE Overhauling the engine Fitting bearing number 1 Degrease the gasket faces (of the cylinder block and bearing number 1).m plus an angle of 47° ± 5°. 10-76 10 . Tighten the bolts of bearing cap no. 1 to a torque of 2. Lay two beads (3) of Threebond silicon with a width of 1 mm on bearing no.1 of the cylinder block.7 daN. dry and free from grease (in particular. Oil the gudgeon pin. Position the opening (3) of the spring rings opposite the removal and fitting channel (4). Direction of fitting of the con rod in relation to the piston Point the "Λ" (1) engraved on the top of the piston downwards and the flat (2) of the big end as shown on the diagram below.K9 ALL TYPES ENGINE Overhauling the engine 10 "CON RODS / PISTON" ASSEMBLY Direction for fitting the circlips on the piston The pistons have a "Λ" mark engraved on their heads indicating the flywheel side. Check that the gudgeon pins rotate correctly in the new piston and in the matching connecting rod. 10-77 . Tighten the big end cap bolts to a torque of 2 daNm.467 mm. being careful to fit them the right way round ("Λ" towards the flywheel). plus an angle of 45° ± 6°. Ensure the rings are fitted the correct way round with the word TOP pointing upwards. Fit the con rod/piston assemblies into the cylinder block using the ring (e. Orientation of the rings in the piston Fit the con rods onto the oiled crankpins of the crankshaft.205 to 0.K9 ALL TYPES ENGINE Overhauling the engine 10 FITTING THE RINGS Oil the pistons. Ensure the break in each ring is correctly oriented as shown in the diagram below. Fit the con rod caps. Check that the big ends have the correct lateral clearance of 0.g.: FACOM 750 TB). ensuring they are correctly matched. Rings set to their original adjustment must be free within their channels. T = Top 10-78 . Fit tool Mot.m. and find top dead centre.2 daN.1 close to Top Dead Centre. Turn the crankshaft one turn in its operating direction to bring piston no.m.192 ± 0. in order to eliminate any errors due to tilting of the piston.: All measurements must be carried out along the longitudinal axis of the engine. 252-01 on the piston. Check the piston protrusion which must be 0.5 daN.093 mm.K9 ALL TYPES ENGINE Overhauling the engine 10 Checking piston protrusion Clean the piston head. WARNING: the gauge follower must not be in the valve clearance.m. 10-79 . 252-01. N. Refit: – the pinking sensor to a torque of 2 daN. 251-01 equipped with a gauge on support plate Mot. – the oil pressure sensor to a torque of 2. Fit tool Mot. – the oil pump sprocket and chain to a torque of 2.B. 1 daN. The crankshaft closure plate is sealed with THREEBOND silicon.K9 ALL TYPES ENGINE Overhauling the engine NOTE: the gasket faces (cylinder block. crankshaft closure plate and water pump) must be clean. remove finger marks).2 daN. The bead (A) must be 1.5 2 mm wide and be applied in accordance with the diagram below.2 daN.m.m. Put a drop of LOCTITE FRENETANCH on the bolts. 10-80 . 10 Refit: – the crankshaft closure plate by: ● pre-tightening bolts 1 and 6 to a torque of 0. ● tightening bolts 1 and 6 to a torque of 1. dry and free from grease (in particular. 4 and 5 to a torque of 1. – the water pump fitted with a new seal. then tighten them to a torque of 1.m in the recommended order. ● tightening bolts 2. 3.m.8 daN. with a diameter of 7 mm at the intersection of the crankshaft closure plate and the cylinder block.K9 ALL TYPES ENGINE Overhauling the engine NOTE: the gasket faces (cylinder block and crankshaft closure plate) must be clean. 10-81 10 . – two drops (C) of THREEBOND silicon. remove finger marks). dry and free from grease (in particular. Apply: – four beads (B) of THREEBOND silicon. with a diameter of 5 mm. 8 daN. 13. 3. 14.m. 1. 10-82 . 2 to a torque of 0.K9 ALL TYPES ENGINE Overhauling the engine 10 Refit: – the anti-emulsion plate. 17. ● tighten the bolts in the recommended order of 1. 20. 16.m. – the cylinder block and the oil sump are correctly aligned on the flywheel side. 15. 6. to prevent the clutch housing from being damaged when fitting the gearbox. 10. 12. 5. 19. – the oil sump.m. ● pretighten the bolts in the recommended order of 9. 2 to a torque of 1. 11. 8 to a torque of 0. 7. When refitting the oil sump. 5. 18. 20. 19. ● tighten the bolts in the recommended order of 9. 8 to a torque of 1. 12. 1. 4. 3. 7. 10. ensure that: – the tabs (D) of the anti-emulsion plate are correctly positioned in the slots (E). 15. 18. 17.8 daN. 11.m.5 daN. 4. 13. 16. tightening the bolts as follows: ● pretighten the bolts in the recommended order of 1. 14. 2. 2. 6.5 daN. 1586. Fit the cover (15) and the nut (16) (putting the threaded part (17) of the nut on the side away from the engine) of tool Mot. 1586 into the crankshaft. Screw the threaded rod (13) of Mot. Position the spacer (14) of tool Mot.K9 ALL TYPES ENGINE Overhauling the engine 10 Fit the protector complete with the seal onto the spacer. 10-83 . timing side. Fitting the crankshaft seal gaskets Crankshaft elastomer seal. taking care not to touch the seal. 1586 on the crankshaft. the cover. 10-84 .K9 ALL TYPES ENGINE Overhauling the engine Tighten the nut until the cover touches the spacer. 10 Remove the nut. the protector and the threaded rod. flywheel side. 10 Fit the cover (19) and nut (20) (putting the threaded part (21) of the nut on the side away from the engine) of Mot. 1585. 1585.K9 ALL TYPES ENGINE Overhauling the engine Crankshaft elastomer seal. being careful not to touch the seal. Put the protector complete with the seal on tool Mot. securing it with bolts (18). 1585 on the crankshaft. Fit tool Mot. 10-85 . the cover.5 daN.K9 ALL TYPES ENGINE Overhauling the engine Tighten the nut until the cover touches the cylinder block. 10-86 . 10 Remove the nut. Refit: – the flywheel.m (blocking the flywheel using Mot. tightening the new bolts to a torque of 5 . the protector and the threaded rod. 582-01).5. NOTE: the gasket faces (cylinder head and cylinder head cover) must be clean. tightening the bolts to a torque of 0.8 daN.m. Remove flywheel block Mot. 582-01. Lay four beads (B) of THREEBOND silicon. Fit the cylinder head gasket using the centring dowels of the cylinder block. Tighten the cylinder head (see the section "Cylinder head specifications"). dry and free from grease (in particular. 10-87 .K9 ALL TYPES ENGINE Overhauling the engine – the clutch and mechanism. remove finger marks). with a diameter of 2 mm. 10 REFITTING THE UPPER ENGINE Refitting the cylinder head Position the pistons at mid-stroke. – the turbo. – the turbo oil return pipe fitted with new seals.9 daN.6 daN. tightening the bolts to a torque of 1 daN. – the catalytic converter bracket. tightening the nuts to a torque of 2. – the air filter unit.m.K9 ALL TYPES ENGINE Overhauling the engine 10 Tighten: – the bolts of the turbo oil return pipe to a torque of 0. 10-88 . – the nut and the bolt of the turbo oil supply pipe to a torque of 2. Refit: – the oil vapour rebreathing pipe. – the turbo oil supply pipe.m in the recommended order. Refit: – the cylinder head.m.3 daN.m. – the new turbo air ducts. – the timing tension wheel. 10-89 10 .K9 ALL TYPES ENGINE Overhauling the engine Refit: – the inner timing cover. Insert pin Mot. Ensure that the peg (7) of the tension wheel is correctly positioned in the groove (8). 1489 (the crankshaft groove (11) must be facing upwards). the bore of the crankshaft sprocket and the bearing faces of the accessories pulley to prevent any slip between the timing and the crankshaft which would risk destroying the engine. Check that: – the mark on the high pressure pump pulley (9) is opposite the bolt head (10).K9 ALL TYPES ENGINE Overhauling the engine Timing adjustment IMPORTANT: it is essential to degrease the end of the crankshaft. – the crankshaft is touching the Top Dead Centre pin Mot. 10-90 10 . 1430 in the camshaft and cylinder head pulley holes. by turning the key anticlockwise. Remove the Top Dead Centre pin Mot. Then move the crankshaft slowly and without jolting it until it is resting on the pin. screw pin Mot. tightening the bolt to a torque of 2 daNm. then angle tighten to 130° ± 15° (crankshaft touching the Top Dead Centre pin). aligning the marks on the belt with those on the camshaft and high pressure pump sprockets (19 teeth spaces on the belt between the marks on the camshaft and pump sprockets). move the movable index (1) of the tension wheel into the position shown below.5 daNm. 1489 into the cylinder block. Refit the crankshaft accessories pulley. Just before the hole (4) of the camshaft pulley is opposite the cylinder head hole (5).K9 ALL TYPES ENGINE Overhauling the engine 10 Tighten the tension wheel bolts to a torque of 2. Using a 6 mm Allen key. Turn the crankshaft two full turns in a clockwise direction (timing side). 10-91 . 1489 and the camshaft pulley timing pin Mot. Fit the timing belt. 1430. then gradually bring the movable index (1) (by turning the key clockwise) to the centre of the timing window (2) and tighten the nut to a torque of 2. 1489 and the camshaft pulley timing pin Mot.5 daNm. Undo the tension wheel bolt by a maximum of one turn while holding it using a 6 mm Allen key. 1430 is correctly inserted in the holes of the camshaft and cylinder head pulleys and that there are 19 teeth spaces between the marks on the camshaft (3) and the high pressure pump (4) sprockets. Remove the Top Dead Centre pin Mot. 10-92 . Refit the cap of the Top Dead Centre pin. 1430.K9 ALL TYPES ENGINE Overhauling the engine 10 Check that pin Mot. applying RHODORSEAL 5661 to the thread and tightening to a torque of 2 daNm. 10-93 10 .K9 ALL TYPES ENGINE Overhauling the engine Refit: – the cylinder head suspended mounting.1 daNm. tightening the bolts to a torque of 2. 10-94 10 .K9 ALL TYPES ENGINE Overhauling the engine – the lower timing cover by positioning the tab (1) into the hole (2) on the inner timing cover. – the two heat exchanger pipes. Remove the engine from the engine stand Mot. 10-95 10 .2 daN. 792-03.m. tightening the bolt to a torque of 2. Refit: – the coolant pipe.K9 ALL TYPES ENGINE Overhauling the engine – the upper timing cover. tightening the bolts to a torque of 4 daN. 10-96 NOTE: the engine must be turned through two revolutions in order to position the belt correctly. tightening the bolts to a torque of 2. – the air conditioning compressor. tightening the bolts to a torque of 2.1 daN.m.K9 ALL TYPES ENGINE Overhauling the engine 10 – the accessories belt.1 daN. – the power-assisted steering pump or the washer which replaces the pulley (if the engine has one). – the multifunction support. – the alternator. NOTE: the accessories belt has five teeth as opposed to the pulleys which have six.m. tightening the bolts to a torque of 2. It is therefore essential to ensure that tooth "E" remains free when fitting the belt.m.1 daNm. Version with air conditioning. . 10 Crankshaft: Power-assisted steering pump Alternator Tension wheel: Tension checking point NOTE: the engine must be turned through two revolutions in order to position the belt correctly. 1638 (with the two mounting bolts of the tensioner undone).K9 ALL TYPES ENGINE Overhauling the engine A: B: C: T: →: Version without air conditioning. 10-97 . The tension value is 233 ± 5 Hz. The belt is tensioned using tool Mot.
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