Renault Master Engine User manual

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

19-8

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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Renault Master Engine User manual

Renault Master Engine User manual

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