Renault 1997
77 11 195 441
AUGUST 1997
Edition Anglaise
The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes by the manufacturer in the
production of the various component units and accessories from which his vehicles
are constructed".
All copyrights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
RENAULT.
C
FD0A - FD0C - UD0A - UD0C
Engine and peripherals
ENGINE AND PERIPHERALS
TOP AND FRONT OF ENGINE
TURBOCHARGING
DIESEL EQUIPMENT
STARTING - CHARGING
COOLING - EXHAUST SYSTEM
FUEL TANK - ENGINE MOUNTING
EXPLODED VIEW
PRF1006
Contents
ENSEMBLE MOTEUR ET BAS
Oil pressure
Engine - Gearbox
10-1
10-2
TOP AND FRONT OF ENGINE
Accessories belt
Timing belt
Cylinder head gasket
PagesPages
11
Engine and
peripherals
11-1
11-2
11-5
ENGINE AND PERIPHERALS
10
DIESEL EQUIPMENT
Fuel cut-out on impact
Specifications
Bosch coded solenoid valve
Cold start device (KSB)
Inlet air heater
Inlet air heater/ Fault finding
Pre-postheating unit
Pre-postheating unit / Fault finding
Idle speed correction
Microswitch
Fuel filter
Pump
Pump timing
Adjustments
13-1
13-2
13-4
13-7
13-12
13-16
13-18
13-22
13-24
13-25
13-26
13-28
13-29
13-32
13
TURBOCHARGING
Turbocharger
Wastegate
Air-air exchanger
Exhaust manifold
Inlet manifold
12-1
12-3
12-5
12-6
12-8
12
16-1
16-3
STARTING - CHARGING
Alternator
Starter motor
16
ENSEMBLE MOTEUR ET BAS
Cooling
Specifications
Filling - bleeding
Checking
Diagram
Radiator temperature switch
Radiator
Engine cooling fan
Cooling system
Metal coolant pipe
Water pump
Exhaust system
General
Exhaust assembly
Fuel tank
General
Fuel tank
Filler neck
Gauge and sender unit
Engine mounting
Suspended engine mounting
19-1
19-2
19-3
19-4
19-6
19-7
19-7
19-8
19-9
19-11
19-13
19-14
19-16
19-17
19-20
19-21
19-24
COOLING - EXHAUST SYSTEM - FUEL
TANK - ENGINE MOUNTING
19
87363R
ENGINE AND PERIPHERALS
Oil pressure
10
ESSENTIAL SPECIAL TOOLING
Mot. 836 -05 Kit for measuring oil pressure
CHECKING
The oil pressure should be checked when the en-
gine is warm (approx. 80°C).
Contents of kit Mot. 836-05.
USE
S engines:
C + F
.
Oil pressure
MEASUREMENT USING MOT. 836-05
Remove the oil pressure sensor behind the
alternator and fit Mot. 836-05.
Engine speed in rpm Pressure in bar
Idling 0.8
4100 3.5
13456R
10-1
ENGINE AND PERIPHERALS
Engine - Gearbox
10
ESSENTIAL EQUIPMENT
Suspension spring compressor
Load positioner
Wheel nuts 15.5
Lower calliper guide bolts 3
Upper calliper guide bolts 8
Drive shaft bellows screws 2.5
Steering ball joint nut 8
Upper ball joint nut 9
Lower ball joint stud 8
Bolt for suspended engine mounting
right-hand side 4.5
Nut for suspended gearbox mounting 8
Torque reaction arm stud 10.5
TIGHTENING TORQUES (in daN.m)
REMOVING
Place the vehicle on four axle stands (see section
on "Lifting" to position the lifting jack correctly).
Disconnect the battery.
Drain the gearbox.
Remove :
- front wheels,
- cooling assembly (see section 19),
- battery,
- clutch slave cylinder,
- the expansion bottle and its mounting.
Disconnect:
- the wiring harness for the engine interconnec-
tion unit,
- the brake servo pipe,
- the accelerator cable,
- the diesel delivery and return lines,
- the gearbox control cables,
- the gearbox earthing strap,
- the wiring harness for the impact sensor and
diesel filter heater,
- the heating pipes,
- the exhaust down pipe.
Remove the front right-hand suspension spring
using a spring compressor.
12734S
NOTE:
Before decompressing the spring, mark its
position using an indelible marker on the tool.
10-2
ENGINE AND PERIPHERALS
Engine - Gearbox
10
Remove:
- the front left-hand suspension spring,
- the left-hand half axle by removing the ball
joint nuts for the upper arm and steering arm,
the stud for the lower arm ball joint, the brake
calliper (secure it to the body), the drive shaft
bellows screws and then separate the upper
and lower arms to release the half axle,
- the right-hand half axle (same operation as
for the left-hand half axle), except for the
drive shaft; the retaining flange for the inter-
mediate bearing antifriction bearing must be
taken out.
NOTE:
Use cloths to protect the drive shafts.
Take the lower radiator mountings off the body.
Disconnect the power steering pipes from the
pump.
Remove:
- the power steering reservoir and secure it to
the engine,
- its support,
- the torque reaction arm,
- the sound-damping tie bar for the suspended
engine mounting,
- the bonnet.
Fit the load positioner.
Remove the right-hand suspended engine moun-
ting (rubber pad plus cover).
Undo the nut for the rubber pad on the left-hand
suspended mounting (but do not remove it).
Use a bronze drift to tap the stud for the rubber
pin so as to separate it from the rubber pad.
NOTE:
There is a risk that the engine will tilt when
the stud and rubber pad are separated.
Remove the engine - gearbox assembly via the
front.
REFITTING
Position the engine - gearbox assembly in the bo-
dy.
Fitting the suspended engine mounting
Fit the right-hand suspended mounting support,
with the rubber pad fitted, on the water pump.
13447S1
10-3
ENGINE AND PERIPHERALS
Engine - Gearbox
10
Start by positioning the right-hand suspended engine mounting by tilting the engine
towards the rear of the vehicle (if necessary) and then tighten the mounting bolts for
the rubber pad to a torque of 4.5 daN.m.
Insert the left-hand suspended engine mounting stud into the rubber pad and then
tighten the nut to a torque of 8 daN.m.
Fit the torque reaction arm and tighten the studs to a torque of 10.5 daN.m.
Refit in reverse order to removal.
Torque tighten the studs and nuts.
Apply
Loctite FRENBLOC
to the brake calliper mounting bolts before fitting
and torque tighten them.
Press the brake pedal several times to bring the pistons into contact with the brake
pads.
Fill and bleed the engine cooling circuit (see section 19 on filling and bleeding the
system).
Top up the gearbox (see the general instructions in section 21 ).
13450S
10-4
TOP AND FRONT OF ENGINE
Accessories belt
11
ESSENTIAL SPECIAL TOOLING
Mot. 1273 Tool for checking belt tension
Drive the vehicle on to a lift (minimum of 5
tonnes) or so that it is over a pit (on axle stands).
Disconnect the battery.
REMOVING
Remove the underbody engine guard.
Undo bolt (1) and slacken off the two bolts (2).
13458R
Remove the accessories belt.
REFITTING
Refit in reverse order to removal.
Refer to section 07 on the "Accessories belt"for
information on accessories belt tensioning proce-
dure.
11-1
TOP AND FRONT OF ENGINE
Timing belt
11
ESSENTIAL SPECIAL TOOLING
Mot. 910 Pin for setting injection pump
timing gear
Mot. 1054
TDC pin
Mot. 1273 Tool for checking belt tension
Refit the crankshaft accessories pulley to make it
easier to turn the engine by hand.
Turn the engine to the timing adjustment posi-
tion.
Compress the tensioner roller spring and place an
M14 nut, cut to form a U-shape, at the back of the
push rod.
PRF1100
Drive the vehicle on to a lift (minimum of 5
tonnes) or so that it is over a pit (on axle stands).
Disconnect the battery.
REMOVING
Remove:
- the guard under the engine,
- the accessories belt,
- the panel over the cylinder head cover (1),
- the valve timing cover (2),
- the crankshaft accessories pulley,
- the lower valve timing cover (3), replace and
tighten nut (4) on the timing gear tensioner.
Crankshaft pulley bolt 20
Timing gear tensioner nut 4.5
TIGHTENING TORQUES (in daN.m)
85384-1S
11-2
TOP AND FRONT OF ENGINE
Timing belt
11
Insert setting rods Mot. 910 in the injection pump
timing gear and Mot. 1054 in the gearbox casing.
85397R1
Align the mark on the camshaft with the mark on
the cylinder head, and align the mark on the
crankshaft pulley in relation to the mark on the
crankcase.
13460R
13459R
13533R
Remove the crankshaft accessories pulley.
11-3
TOP AND FRONT OF ENGINE
Timing belt
11
Checking the timing gear setting
Turn the crankshaft one more time in the normal
direction of rotation and check the four timing
points, using setting rods Mot. 910 and Mot. 1054.
Refit in reverse order to removal.
Tighten the bolt on the crankshaft pulley to a tor-
que of 20 daN.m.
Undo the tensioner nut to release the timing belt.
REFITTING
Check that setting rods Mot. 910 and Mot. 1054
are in place.
Align the mark on the camshaft sprocket with the
mark on the cylinder head cover.
Check that there is no play or stiffness in either
the tensioner rollers or the tensioner when they
are turned by hand. If any stiffness or play can be
detected, replace them .
Fit a new timing belt.
Free the timing tensioner.
Remove setting rods Mot. 910 and Mot. 1054.
Turn the engine a quarter of a turn.
Tighten the tensioner nut.
Turn the engine three quarters of a turn.
In this position, adjust the belt tension by relea-
sing and retightening the tensioner.
13460R1
11-4
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
ESSENTIAL SPECIAL TOOLING
Emb. 880 Pin extractor
Mot. 910 Rod for setting injection pump
timing gear
Mot. 921 Tool for extracting injector holders
(to be used with pin extractor Emb.
880)
Mot. 1054
TDC rod
Mot. 1273 Tool for checking belt tension
Mot. 1383 17 mm pipe wrench to remove high
pressure pipes
Remove:
- the retaining flange for the metal coolant
pipes,
13448S
Drive the vehicle on to a lift (minimum of 5
tonnes) or so that it is over a pit (on axle stands).
Disconnect the battery.
REMOVING
Remove:
- the timing gear belt,
- the air filter unit and the intake trunking for
the air filter unit,
- the pipe for the turbo air intake,
- the bracket for the air filter unit (mounted on
the scuttle panel),
- the expansion bottle and its bracket,
- the pipes for the turbocharger,
- the upper and lower hoses for the radiator
(cylinder head side),
- the pipes on the thermostat bracket.
Disconnect the various sensors and the flamestart.
Disconnect the diesel pipes which are attached on
the inlet manifold.
Remove the oil vapour rebreathing reservoir.
Bolt for crankshaft pulley 20
Nut for timing tensioner 4.5
TIGHTENING TORQUES (in daN.m)
- the lifting bracket (flywheel side),
- the high pressure injection pipes, using Mot.
1383,
- the injector return pipe,
11-5
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
- the flanged injector holders using tool Mot.
921, secured using pin extractor Emb. 880.
84914R
13446S
Release the dipstick guide.
Remove:
- the stay between the turbocharger and the cy-
linder block,
- the accoustic damper (tie rod),
- the starter motor heat shield (if one is fitted),
13454S
- the turbocharger oil return pipe.
First take out the wastegate rod and then remove
the turbocharger oil supply pipe using Mot. 1383 .
Disconnect the exhaust down pipe from the mani-
fold or the turbocharger.
Remove:
- cylinder head cover,
- cylinder head bolts,
- cylinder head.
84592S
11-6
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
NOTE :
Two studs are used to centre the cylinder
head on the cylinder block (A). Do not pivot the
cylinder head: lift it up to release it. (No risk of li-
ners becoming detached as they are force-fitted.)
85077R
Checking the gasket face
83179S
First remove the pre-combustion chambers. Then
use a straight edge and a set of shims to check for
gasket face bow.
Maximum bow : 0.05 mm
Maximum regrinding : 0.4 mm
After the cylinder head has been ground, the
valves must be recessed according to the amount
ground from the cylinder head.
Stripping down cylinder head
(see S engine workshop repair manual)
Check the cylinder head for cracks.
Fit a new cylinder head gasket and refit the cylin-
der head.
Tighten the cylinder head bolts (see section 07).
Refit in reverse order to removal.
See section 11 for information on refitting the ti-
ming gear.
Fill up and bleed the cooling system (see section
on"Filling and bleeding cooling system").
CLEANING
It is very important not to scratch the gasket faces
of aluminium parts.
Use Décapjoint to dissolve any parts of the gasket
remaining on the metal.
Apply the product on the area to be cleaned; wait
approximately 10 minutes then remove using a
wooden spatula.
Gloves should be worn during this operation.
Do not allow this agent to drip on to the paint-
work.
Remember that this operation should be carried
out with extreme care to avoid the risk of foreign
bodies being introduced into the oilways brin-
ging oil under pressure to the camshaft.
11-7
TURBOCHARGING
Turbocharger
12
ESSENTIAL SPECIAL TOOLING
Mot. 1383 Pipe wrench for high pressure
diesel pipes
Turbocharger nuts on
exhaust manifold 2.5
Nuts, turbine outlet elbow 2.5
Oil inlet pipe 1.2
Screws for oil return pipe 1.2
Bracket mounting bolt for
wastegate on compressor 1.5
TIGHTENING TORQUES (in daN.m)
REMOVING
Drive the vehicle on to a lift (minimum 5 tonnes)
or so that it is over a pit (on axle stands).
Disconnect the battery.
Working from underneath the vehicle, remove
- the guard under the engine,
- the exhaust down pipe,
- the turbocharger oil return pipe.
Working from above the vehicle remove:
- the air filter unit assembly with the trunking,
- the air inlet pipe for the turbocharger,
- the starter motor protection plate,
- the oil delivery pipe on the turbocharger
using tool Mot. 1383 (to do this, disconnect
the wastegate control rod (1)),
- the wastegate assembly with its bracket (2),
- the stay holding the turbocharger (3),
13446-1R
S9W engine
- the four nuts securing the turbocharger to the
manifold.
Remove the turbocharger, taking it out under-
neath the vehicle.
12-1
TURBOCHARGING
Turbocharger
12
Special precautions
• Before refitting, make sure that the lubrica-
tion is correct for the turbocharger bearings.
To do this, first disconnect the diesel pump co-
ded solenoid valve (to stop the engine starting
up) and then operate the starter.
Plenty of oil should be supplied by the oil sup-
ply pipe. (Place a container underneath to
catch the oil.) If this is not the case, change the
lubrication pipe.
• Ensure that no foreign bodies enter the tur-
bine or compressor during the refitting opera-
tion.
• If there has been a fault in the turbocharger,
check that the air-air exchanger is not full of
oil.
If the air-air exchanger is full of oil, it must be
removed, flushed with a cleaning agent and
then left to drain properly.
• Check that the turbocharger oil return pipe is
not partially or completely blocked by scale.
Also check that it is absolutely leak-tight
(crimping). If it is not, replace it.
IMPORTANT :
Before starting the engine, ensure the connector
for the solenoid valve on the diesel injection
pump is still disconnected.
Activate the starter motor until the oil pressure
warning light extinguishes. (Keep operating it for
several seconds.)
Reconnect the diesel pump solenoid valve. Wait
for the warning light to extinguish and start the
engine.
Run the engine at idling speed and check that
there are no leaks at the connections for oil and
water.
REFITTING - Special points
Proceed in reverse order to removal. When refit-
ting the turbocharger, ensure that the self-locking
nuts securing the turbocharger on the exhaust
manifold and the nuts for the turbine outlet el-
bow are replaced with new nuts.
12-2
TURBOCHARGING
Wastegate
12
ESSENTIAL SPECIAL TOOLING
Mot. 1014 Kit for checking and adjusting
turbo pressure
Mot. 1079-02 Dial gauge
Mot. 1311-01 Pressure gauge and connectors
for measuring oil pressure
Checking calibration pressure
Fit on vehicle.
Use a dial gauge with a magnetic holder (1) which
is positioned at the end of the wastegate rod.
13494R
S9W engine
The pressure applied to the wastegate is varied
using pressure gauge Mot. 1014.
Calibration pressure values
Pressures
(mbar)
Rod movement
(mm)
1100 ± 33 1
1220 ± 66 4
12-3
TURBOCHARGING
Wastegate
12
Fitting on the vehicle
When checking the calibration pressure it may be
necessary to adjust the wastegate rod length (A)
(if it is not within tolerance).
This adjustment is made with the turbocharger in
place.
13446R
S9W engine
To do this, release clip (1) and regulator arm rod
(A).
The rod at the wastegate end (2) must be held in a
vice.
Next undo the lock nut and then slacken off or
tighten the threaded end.
Work half a turn at a time. (Tighten to increase ca-
libration pressure. )
NOTE :
The operation to replace the threaded
end on the regulator arm (A) will be easier if tool
Mot. 1014 is used and if the pressure applied is in-
creased.
REMOVING
Remove:
- the pneumatic pipe (1) on the wastegate,
- the circlip (2) on the wastegate; release the
rod on the wastegate arm,
- the two mounting screws for the wastegate
assembly with its bracket (3).
Take out the wastegate.
13446R1
REFITTING
Refit the wastegate assembly, together with its
bracket, in reverse order to removal.
NOTE:
Apply
LOCTITE FRENBLOC
to the wastegate
bracket mounting screws before refitting.
Tightening torque: 1.5 daN.m.
12-4
TURBOCHARGING
Air - air exchanger
12
REMOVING
Disconnect the battery.
Remove:
- the direction indicators,
- the radiator grille,
- the air filter unit,
- the two air hoses on the air-air exchanger,
- the bumpers,
- the upper cross member,
- the four mounting screws (1) for the air-air ex-
changer (2).
13495R
S9W engine
Take out the air-air exchanger.
REFITTING
Refit the assembly in reverse order to removal.
12-5
TURBOCHARGING
Exhaust manifold
12
ESSENTIAL SPECIAL TOOLING
Mot. 1383 Pipe wrench for high pressure
diesel pipes
Mounting nuts for exhaust
manifold 2.5
Union for oil delivery pipe 1.2
Mounting studs 1
TIGHTENING TORQUES (in daN.m)
The turbocharger and the inlet manifold do not
have to be taken out to remove the exhaust mani-
fold.
REMOVING
Drive the vehicle on to a lift (minimum of 5
tonnes) or so that it is over a pit (on axle stands).
Disconnect the battery.
Working from underneath the vehicle, remove:
- the guard under the engine,
- the exhaust down pipe,
- the turbocharger oil return pipe.
Working from above the vehicle remove:
- the air filter unit assembly with the trunking,
- the air inlet pipe for the turbocharger,
- the starter motor protection plate,
- the oil delivery pipe on the turbocharger
using tool Mot. 1383 (to do this, disconnect
the wastegate control rod (1)),
- the stay holding the turbocharger (2),
- the heat shield on the manifold (3),
- the exhaust manifold mounting bolts and
take out the manifold from underneath the
vehicle (exhaust manifold/turbocharger as-
sembly not separated).
13446-1R1
S9W engine
13451R
REFITTING
Refit in reverse order to removal.
COMMENT:
When refitting, always replace all
seals and gaskets for the manifold and for the tur-
bocharger oil return pipe with new ones.
12-6
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