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ENGINE AND PERIPHERALS
En
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Remove:
- the coolant pipe and the dipstick guide (these
pipes are made water-tight by means of O-rings
which must be replaced after each removal
operation),
- the clutch mechanism and disc,
- the flywheel, immobilising it with the aid of
tool
Mot. 582-01,
- the sump,
- the crankshaft sprocket.
If necessary, use the locally manufactured tool
with the shaft protector end protector
Rou. 15-01.
NOTE :
The crankshaft sprocket can be fitted in one of
two ways:
- sprocket with keyway mounted on the cranks-
haf
t
- sprocket with keyway integral with it.
The two fittings are not interchangeable.
Remove:
- the crankshaft cover plate,
87069R
92311R
92171R
- the pulley, A 12 mm diameter, 1.75 mm thread pitch
B 1 hole, 13 mm diameter
C 2 holes, 6.5 mm diameter
D 12 mm diameter nut, 1.75 mm thread pitch,
welde
d
10-35
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ENGINE AND PERIPHERALS
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The amount of protrusion (X) must be checked as
follows:
- place the cylinder liner,
without its O-ring (J), in
the cylinder block,
- check the protrusion with tools
Mot. 251-01
and
Mot. 252-01.
The protrusion (X) should be between
0.02 and
0.09 mm.
Position the liners so that:
- the difference in protrusion between two adja-
cent liners does not exceed
0.05 mm (within the
tolerance),
- the amount of protrusion reduces from cylin-
der No.
1 to cylinder No.
4 or vice-versa.
85404R1
92278S
When the correct protrusion has been obtained,
re-form assemblies
A, B, C and D, then number the
liners, the pistons and the gudgeon pins from
1 to
4 (No.1 on the flywheel side) in order to match up
with the corresponding connecting rod.
If the protrusion is incorrect, check with a set of
new liners in order to find out whether the faul
t
lies in the cylinder block or in the liners; other-
wise, check the theoretical dimensions (see
"Specifications" section).
FITTING THE GUDGEON PINS
The gudgeon pins are press fitted on the
connecting rods and are fully floating in the
pistons. Use tool
Mot. 574-2 supplied in a kit
containing:
- a piston support base (S),
- an extraction mandrel (M),
- piston support rings (B),
- mounting pins (A) with their centring devices
(C).
76554R2
10-38
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ENGINE AND PERIPHERALS
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PREPARATION OF THE GUDGEON PINS
Check that the gudgeon pins are able to slide
freely in the corresponding new pistons.
Use centring device
C13 and mounting tools
A13
or
A13-01 for the shouldered gudgeon pins.
Mount the gudgeon pin (E) on the mounting tool
(A), tighten the centring device (C)
until contact is
made, then slacken b
y a quarter turn.
76716R PREPARATION OF THE CONNECTING RODS
Visually check:
- the condition of the connecting rod (twisting -
straightness),
- the bearing surface between the shells and the
connecting rod bodies (if necessary, remove
any burrs with a grinding wheel to obtain a co
r-
rect bearing surface).
Use a
1500 W heating plate.
Put the little ends on the heating plate.
Ensure that the whole surface of the little end is in
contact with the plate.
Put a piece of self-pickling tin solder with a mel-
ting point of about
250
° onto each little end at (a)
to act as a temperature check.
Heat the little end until the piece of self-pickling
solder melts.
DI1038
12367R
10-39
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ENGINE AND PERIPHERALS
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ASSEMBLING THE CONNECTING RODS AND
PISTONS
The pistons are marked with an arrow stamped
onto their heads indicating the
flywheel end.
The connecting rods have no particular mounting
direction, but nevertheless the
bearin
g stop lugs
should be
positioned on the same side.
Follow the instructions below when assembling
the piston and the connecting rod:
- place the bush
B13 on the support and fix the
piston (with the arrow pointing upwards) onto
the bush with the clip,
92310R
- lubricate the centring device and the gudgeon
pin with engine oil,
- push the gudgeon pin into the mounting to
check that it slides freely, and re-centre the pis-
ton if necessary,The followin
g operations must be carried out qui-
ckl
y in order to reduce the heat loss to a mini-
mum.
When the piece of solder reaches its melting poin
t
(turns into a droplet):
- wipe off the droplet of solder,
- engage the centring guide in the piston,
- fit the connecting rod into the piston,
- quickly push in the gudgeon pin until the guide
reaches the bottom of the support base.
Check that the gudgeon pin remains within the
piston diameter for any connecting rod position in
the piston.
10-40
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ENGINE AND PERIPHERALS
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99179R1
Refit the sump and tighten to a torque value of
1 daN.m.
NOTE : A tight seal for the sump can only be ob-
tained using the special seal supplied by the afte
r-
sales service, except for engine
E7J 764 in which a
tight seal is achieved by using
RHODOR-SEAL
5661. Bead (D) should be
3 mm wide.
Do not forget to replace the two "half-moon"
seals at (A) with new ones.
Coat the flywheel bearing surface on the cranks-
haft with
AUTOFORM Loctite.
Fit the flywheel or the converter plate and immo-
bilise it with the toothed segment
Mot. 582-01.
Apply a drop of
FRENETANCH Loctite to the
bolts and tighten them to
5 - 5.5 daN.m.
Centre the clutch disc and secure the mechanism.
92068R
Refit the water pump, sealing it with
Loctite 518.
The bead (H) should be
0.6 to 1 mm wide and
should be applied as shown in the diagram below.
REFITTING THE CYLINDER HEAD
Remove the liner tool
Mot. 588.
Clean the gasket surfaces of the cylinder bloc
k
and the cylinder head.
Refit the cylinder head centring dowl.
The new cylinder head gasket.
The cylinder head (lubricate the threads and
underneath the bolt heads).
All the cylinder head bolts must be replaced
systematically after any removal.
10-44
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ENGINE AND PERIPHERALS
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Setting the timing
DI1101R4
(
1) Direction of tensioning of the tension wheel.
10-46
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ENGINE AND PERIPHERALS
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There is an arrow painted on the back of the belt
showing the direction of rotation and two marks
for the setting.
Line up the marks (N) on the belt with those on
the sprockets (L) and the housings (M).
Respect the direction of mounting of the belt and
begin to position it on the crankshaft sprocket.
Fit the sensor of
Mot. 1273.
98708R
Turn the knurled wheel of the sensor until it re-
leases (three "clicks").
Tension the belt using tool
Mot. 1135-01 until
the display of the
Mot. 1273 shows the re-
commended fitting value
.
Belt tension (in SEEM units)
Fitting value: 30 U.S.
Lock the tension wheel, carry out a check and ad-
just the value.
Rotate the crankshaft at least
three turns.
Check that the tension value is within the fitting
tension tolerance (
±10 %), and if not readjust it.
NOTE : Never refit a belt which has been remo-
ved.
Tighten nut (O) of the tension wheel to 5 daN.m.
It is essential to tighten the tension wheel nut to
a tor
que value of 5 daN.m to prevent any risk of
working loose which might damage the engine.
WARNING: Certain camshaft s
prockets have five
marks, but onl
y the rectangular mark on the face
of a tooth shows the TDC. The other marks are
used for ad
justing the valve rockers.
10072S
Only the camshaft sprockets with marks will be
available in future from the Parts De
partment.
10-47
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ENGINE AND PERIPHERALS
En
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Refit:
- the cylinder head cover fitted with a new gas-
ket,
- the coolant pipe and the dipstick guide tube
with new seals,
- the timing cover,
- the crankshaft pulley tightening the bolt to
2 daN.m, then angle tighten to
68°
±6°,
- the inlet and exhaust manifolds, tightening the
nuts to
2.5 daN.m,
- the accessories belt or belts.
Tensionin
g process
Engine cold (ambient temperature).
Fit the new belt.
Position the sensor of the
Mot. 1273.
Turn the knurled wheel of the sensor until it re-
leases (three "clicks").
Tension the belt until the fitting value recommen-
ded on the next page is shown on the display of
the
Mot. 1273.
Lock the tension wheel, carry out a check and ad-
just the value.
Rotate the crankshaft
three turns.
Check that the tension value is within the fitting
tension tolerance, and if not readjust it.
NOTE : Never refit a belt which has been remo-
ved.
10-50
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