PAGE 1 - b1ba03p0 - presentation : ES9J4 enginepresentation : ES9J4 engine INJECTION ES9J4 - Fig. : 1 Principal structural features of the ES9J4 engine : • petrol engine with 6 cylinders in 60° Vee formation • 24 valve engine with 4 overhead camshafts driven by a toothed belt 1 Cylinder block PAGE 2 - b1ba03p0 - presentation : ES9J4 engine 1 2 - Fig. : 2 - (1) cylinder block. (2) crankshaft main bearing cap casing. The light alloy cylinder block is fitted with cast iron liners on assembly. The light alloy crankshaft bearing cap casing incorporates the 4 cast iron bearing caps. 2 Reciprocating gear Fig.b1ba03p0 . 2. . (7) piston. : 3 - (3) crankshaft. (6) bearing shell on bearing no.PAGE 3 . (10) connecting rod. (4) upper bearing shells. (9) circlip.presentation : ES9J4 engine 9 7 3 8 9 4 6 4 10 11 5 6 5 . (5) lower bearing shells. (8) gudgeon pin. 1 Crankshaft 4 bearing steel crankshaft. The crankshaft and main bearings (cylinder block and bearing cap casing) are matched from markings on both the block and crankshaft.2 Crankshaft bearing shells Plain shell bearings bearing cap casing side. 2. The matching is achieved by 4 different thicknesses of plain shell bearings. The gudgeon pins are free in the connecting rod small ends.3 Connecting rods / pistons New connecting rods with a dimension of 154 mm between centres. grooved bearing shells.presentation : ES9J4 engine (11) big-end bearing shells. 2. for the upper. Grooved shell bearings (cylinder block side).b1ba03p0 . 2. 2 main bearing shells.PAGE 4 . New light alloy pistons with valve recesses. N. Crankshaft endfloat is controlled by the integral thrust washers of the no. : There is one only class.B. 3 Cylinder head assembly . : 4 - (12) cylinder head cover. .Fig.presentation : ES9J4 engine 12 12 12 13 13 12 13 13 14 14 . (14) cylinder head.b1ba03p0 .PAGE 5 . (13) camshaft bearing cap casing. The front cylinder head houses the ( BBC 3.3 Camshafts The new cast iron camshafts comprise 6 lobes and 4 bearings.b1ba03p0 . 3. The rear cylinder head houses the ignition HT harness cassette.1 Camshaft bearing cap casings The camshaft bearing cap casings house the 4 bearings of the 2 shafts of 6 lobes. 4 valves per cylinder ( 2 for inlet. : The cylinder head houses the valve gear. The sparking plugs are offset by 3 mm towards the exhaust side of the combustion chambers. The camshaft bearing cap casings are in light alloy. The camshaft bearings are lubricated under pressure and the cams by oil baths.2 ) ignition coil assembly (Compact Coil Unit).presentation : ES9J4 engine N. 4 Timing .PAGE 6 . 3. The cylinder heads are attached to the cylinder block by 8 bolts.B. 2 for exhaust) with automatically adjusted hydraulic cam followers.2 Cylinder head New light alloy cylinder heads. The 4 camshafts are specific and act directly on the hydraulic cam followers. 3. XFZ. (17) water pump drive pinion. Supplier. 32 mm.Fig. 259. : 5 - (15) camshaft gear wheel. (18) dynamic tensioner. DAYCO. HSN quality.1 Timing belt Engine code. (16) guide roller. . Number of teeth.presentation : ES9J4 engine 15 16 15 19 18 16 17 . Width. (19) roller tensioner. Material. 4. None.b1ba03p0 . Engraving enabling the identification. The valve gear comprises 4 direct operation camshafts.PAGE 7 . (21) camshaft hub. (22) locating peg notch.presentation : ES9J4 engine Replacement intervals. 150 000 km.b1ba03p0 .2 Camshaft gear wheel 21 a 21 a 22 20 23 20 . : 6 - 22 (20) camshaft gear wheel.Fig. 120 000 km.PAGE 8 . 4. The locating of the camshafts is achieved by using the hubs ( 21 ) keyed to the shafts. Severe driving conditions. Normal conditions of use. (23) elongated hole. the pinions are free to rotate within the bounds of the elongated holes. When the 4 pinion fixing bolts are slackened. This method of fitting of the pinions allows : . The pinions are fixed to the camshaft hubs by the bolts 4. The camshaft pinions are all identical.presentation : ES9J4 engine • a more precise setting of the valve timing • a more evenly distributed tension of the camshaft drive belt between the various belt pulleys The hubs of the camshafts are identical.PAGE 9 .8 litres. Direction of fitting of the camshaft pulleys : • inlet camshaft : flange " a " towards the outside • exhaust camshaft : flange " a " towards the inside 5 Lubrication 5.1 Oil capacity Engine legislation type. 5. 2 litres. and max. 4.2 Lubrication circuit 3 b 24 .Fig. Capacity of the gauge between the min. 5. XFZ.5 litres. marks. No oil filter change.b1ba03p0 . : 7 - 25 . Oil filter change. which enables a tube to be connected to a suction draining device. (24) oil pump outer rotor. 5.Fig. immediately after the engine has been switched off. : Engines can still be drained by taking out the oil sump drain plug. It is possible to drain the engines via a suction device.b1ba03p0 . The oil pump is driven by the end of the crankshaft by two flats " b ". .presentation : ES9J4 engine (3) crankshaft. The pressure-fed lubrication is provided by a dual eccentric gear type oil pump (inner and outer rotors).3 Engine draining The draining operation should be carried out when hot. 26 27 26 . N. : 8 - ( 26 ) dipstick guide tube extremity.PAGE 10 . (25) oil pump inner rotor. The end of the dipstick guide tube has been enlarged.B. b1ba03p0 . 30 31 28 29 32 . (31) air filter/throttle butterfly housing duct. . 6 Air supply circuit The air induction system also serves as an induction silencer. union.Fig. (29) air inlet elbow/air filter duct.PAGE 11 .presentation : ES9J4 engine ( 27 ) 14 mm dia. (32) additionnal air duct. : 9 - (28) air inlet elbow. (30) air filter unit. 0. 7 Injection system Supplier : BOSCH. Type : MP7.Fig. The interior gas flow of the inlet manifold enables high engine torque to be achieved at low engine speed and a smooth progressive torque curve (a volume for each cylinder bank with an interconnection between these 2 volumes for a long induction link " c " and a short induction link " d ").1 Injection ECU The ECU also controls the following functions : • air fuel mixture • ignition system • autodiagnosis • richness adjustment • adjustment of idling speed • anti-knock adjustment .presentation : ES9J4 engine d c .b1ba03p0 .PAGE 12 . 7. : 10 - Light alloy inlet manifold. b1ba03p0 . in the case of a change in calibration. using an appropriate after sales tool. through the diagnostic socket : " ELIT " test unit.2 Fuel supply system 33 . This type of memory permits.presentation : ES9J4 engine This ignition injection ECU is equipped with a "FLASH-EPROM" memory. the memory of the ECU to be modified without remove or replacing the ECU. : 11 The left hand injector rail is equipped with SCHRADER (33) valve to enable the following checks to be carried out : • fuel pressure • flow of injected fuel .Fig.PAGE 13 . 7. Instead of replacing the ECU or the eprom. the operation consists in "downloading" the ECU program into its memory. 5 m.5 m.daN • tighten the studs ( 8 ) to 1.data : tightening torques data : tightening torques INJECTION ES9J4 1 Engine/gearbox mountings 11 15 12 13 14 8 10 9 8 6 4 3 2 1 7 9 16 17 5 7 3 1 .daN . : 1 Left hand engine mounting : • tighten the screws ( 1 ) to 2 m.b1bb30p0 .daN • tighten the screws ( 5 ) to 4.daN • tighten the screw ( 12 ) to 3.3 m.daN • tighten nut ( 10 ) to 4.daN : coat with threadlock LOCTITE FRENETANCH • tighten the nuts ( 9 ) to 4.daN • tighten the shaft ( 4 ) to 5 m.daN : coat with threadlock LOCTITE FRENETANCH • tighten the screws ( 3 ) to 3 m.Fig.5 m.daN Right hand upper engine mounting : • tighten the screws ( 6 ) to 6 m.daN • tighten the screw ( 13 ) to 5 m.daN • tighten the screws ( 7 ) to 4.daN • tighten the mounting ( 14 ) to 4 m.daN • tighten the screws ( 11 ) to 5 m.daN • tighten nut ( 2 ) to 6.PAGE 1 .5 m.5 m.5 m. daN • tighten the screw ( 17 ) to 5 m.daN • tighten the screw ( 16 ) to 5 m.b1bb30p0 .PAGE 2 .daN 2 Motor .data : tightening torques Right hand lower engine mounting : • tighten the nuts ( 15 ) to 1 m. b1bb30p0 . : 2 - ( 18 ) compact coil unit : tighten to 1 m.daN .5 m.te) : • 0.PAGE 3 .data : tightening torques 22 18 19 23 20 30 29 21 24 28 26 25 27 .daN. (19) cylinder head cover (refer to the No.daN pre-tightening • tightening torque = 1 m.Fig. daN • finish with an angular tightening of 225 ° (22) air inlet manifold (refer to the No.te) : • 1 m.2 m.daN (21) cylinder head (refer to the No. 9 5 2 3 6 10 8 1 4 .B.5 m. Working one bolt at a time : • pre-tightening to 2 m.te) : • 1 m.8 m.daN • slacken the bolts • tighten to 1.te).5 m.Fig.daN pre-tightening • tightening torque = 2 m.daN (23) inlet manifold (equipped with new seals) (refer to the No. : Respect the tightening order.data : tightening torques (20) camshaft bearing cap casing (refer to the No.te) : • 0. : 3 - 7 .daN pre-tightening • tightening torque = 2.PAGE 4 .daN N.b1bb30p0 .daN pre-tightening • tightening torque = 0. data : tightening torques (24) exhaust manifold (equipped with a new seal) (refer to the No. : 4 - (25) crankshaft main bearings.b1bb30p0 . lubricate the threads and below the heads of the bolts and refit them • check that the 8 locating dowels are in place • pre-tighten screws ( M11 ) to 3 m.daN (in order from 1 to 8 ) • tighten the screws ( M8 ) to 1 m.PAGE 5 .daN (in order from a to m ) • loosen screws ( M11 ) and ( M8 ) Working one bolt at a time : • tighten the screws ( M11 ) to 3 m. bolt length below head = M1 : 131. The following operations should be carried out : • brush clean the threads of the bolts • using grease " MOLYKOTE G RAPID PLUS ".te) : • 1 m.daN (in order from A to H ) Max.daN (in order from 1 to 8 ) • pre-tighten screws ( M8 ) to 1 m.daN pre-tightening • tightening torque = 3 m.daN (in order from A to H ) • tighten the screws ( M6 ) to 1 m.daN 1 i E 5 6 F e j f A a B b 2 d c D C h m H 8 4 7 G K 3 g .Fig.5 mm. . : 5 - 13 3 (27) sump : • 0.daN • angular tightening of 80 ° (30) crankshaft pulley : tighten to 2.5 m.daN pre-tightening • tightening torque = 0. (26) flywheel : • tightening torque = 1 m.b1bb30p0 .Fig.5 m.daN (28) connecting rod caps : • tightening torque = 2 m.daN • angular tightening of 74 ° (29) crankshaft pulley hub : • tightening torque = 4 m.8 m.data : tightening torques Max.PAGE 6 .daN. bolt length below head = M8 : 119 mm.daN • angular tightening of 60 ° 8 18 9 19 10 20 17 1 7 11 16 2 6 12 15 5 14 4 . . data : tightening torques 36 36 35 31 33 32 35 37 34 33 33 .daN pre-tightening • tightening torque = 0.Fig.8 m.daN. (34) timing belt tensioner roller : tighten to 8 m.daN.daN.daN pre-tightening • tightening torque = 0. (35) camshaft hubs.daN ( 32 ) oil pump coolant pump (refer to the No.b1bb30p0 .8 m.5 m.PAGE 7 .daN • angular tightening of 57 ° 2nd method : tightening torque = 8 m.5 m.daN N.te) : • 0.daN.B. (36) camshaft pulleys : tighten to 1 m. : Respect the tightening order. 1st method (recommended method) : • tightening torque = 2 m. : 6 (31) coolant pump (refer to the No. (33) guide roller : tighten to 8 m.te) : • 0. . b1bb30p0 .5 m.data : tightening torques 2 3 4 .PAGE 8 . : 7 (37) oil vapour recovery housing (in order from 1 to 4 ) : • 0.daN 1 .Fig.daN pre-tightening • tightening torque = 1 m.