Renault 199777 11 197 366 DECEMBER 1997 Edition AnglaiseCEngine and PeripheralsENGINE AND PERIPHERALSTOP AND FRONT OF ENGINEFUEL MIXTUREFUEL SUPPLY -DIESEL EQUIPMENTANTIPOLLUTIONSTARTING - CHARGINGIGNITION - INJECTIONCOOLING - EXHAUST - FUEL TANK -SUSPENDED ENGINE MOUNTINGSBB0A - BB0C - BB0D - BB0E - CB0A - CB0C - CB0D - CB0E"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.The methods may be modified as a result of changes introduced by themanufacturer in the production of the various component units and accessoriesfrom 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 partreference numbering system is forbidden without the prior written authority ofRenault.EXPLODED VIEWPRH1001ContentsConsumablesIdentificationOil consumptionOil pressureEngine - GearboxEngine and transmission assemblySumpCrankshaft seal, timing endOil pump10-110-110-210-310-410-910-2410-2810-29TOPANDFRONTOFENGINETiming beltCylinder head gasketReplacement of valve adjustersPage Page11Engine andperipherals11-111-1111-29ENGINEANDPERIPHERALS10FUELSUPPLY-DIESELEQUIPMENTFuel supplyFuel cut out on impactFuel galleryFuel filterPump flowFuel pressureAntipercolation deviceDiesel equipmentGeneralSpecificationsLocation of componentsAdvance solenoid valveAltimetric correctorFast idle LDACoded solenoid valveLoad potentiometerComputer configurationInjector with sensor (needlelift)Injection warning lightPre-postheating controlFast idle controlInjection/air conditioningprogrammingComputerDefect modesMicrometric pulleyPumpPump - TimingPump - Checking the timingPump - Adjusting the timingAdjusting the idle speedUnions13-113-213-613-713-813-1113-1213-1313-1513-1813-2113-2413-2513-2713-3113-3313-3413-3513-3713-3813-3913-4013-4113-4313-4513-4613-4813-5213-5313FUELMIXTURESpecificationsThrottle bodyInlet manifoldExhaust manifoldInlet-exhaust manifolds12-112-1012-1212-1512-1712PageCoolingSpecificationsFilling and bleedingTestingWater pumpDiagramExhaustGeneralExhaust pipe assemblyFuel tankFuel tankSender unitPump and sender unit assemblyEngine mountingsSuspended engine mountings19-119-219-319-419-619-1019-1219-1419-2319-2419-26COOLING-EXHAUST-FUELTANK-ENGINESUSPENSION1916-116-9STARTING-CHARGINGAlternatorStarter motor16IGNITION-INJECTIONIgnitionStatic ignitionSpark plugsInjectionGeneralLocation of componentsCentralised coolant temperaturemanagementInjection fault warning lightImmobiliser functionComputer configuration depending on gearbox type1714-114-214-714-11ANTIPOLLUTIONTest for the presence of leadFuel vapour rebreathingOil vapour rebreathingExhaust gas recirculation(EGR)1417-1617-1717-1817-1917-21IGNITION-INJECTION(continued)Injection/air conditioningprogrammingIdle speed correctionAdaptive idle speedcorrectionRichness regulationAdaptive richness correction17Page17-117-317-417-817-1217-1317-1417-15ContentsIdentificationENGINE AND ENGINE PERIPHERALSConsumables10Type Quantity ComponentsRHODORSEAL 5661 Coat Driveshaft roll pin holesLoctite FRENBLOCLocking and sealing resinCoat Brake caliper mounting boltsLoctite FRENETANCHLocking and sealing resinCoat Crankshaft pulley mounting boltsExhaust pipe paste Coat For sealing the exhaustVehicle type EngineManualgearboxCapacity(cm3)Bore(mm)Stroke(mm) RatioB/C B0A D7F 720 JB1 1 149 69 76.8 9.65/1B/C B0C E7J 780 JB1 1 390 75.8 77 9.5 /1B/C B0D K7M 744 JB1 1 598 79.5 80.5 9.5 /1B/C B0E F8Q 630 JB1 1 870 80 93 21.5 /1Engine Workshop Repair Manuals to be consulted depending on the type of engine:D7F E7J K7M F8QMot. D XMot. E XMot. K XMot. F (D) XEngineDocument10-1ENGINE AND ENGINE PERIPHERALSOil consumption10OIL CONSUMPTION MEASUREMENT PROCEDUREa) Filling to the maximum levelThe operation must be carried out with the engine hot (cooling fan cutting in once) and after settling for15 minutes to allow all the oil to drain into the sump.Check visually using the dipstick.Top up to the maximum level.Seal the drain plug (with a paint mark on both the filler plug and the sumps drain plug) in order to beable to check later that it has not been removed.b) Customer drivingAsk the customer to drive the vehicle for a period corresponding to about 1250 miles (2,000 km) or beforethe minimum level is reached.c) Refilling to the maximum levelThe operation must be carried out with the engine hot (cooling fan cutting in once) and after a settlingtime of 15 minutes.Check visually using the dipstick.Top up to the maximum level.Note the quantity of oil and the mileage covered since the last filling to the maximum level.d) Measurement of the oil consumptionQuantity of topping up oil (in litres)OIL CONSUMPTION = ----------------------------------------km (in thousands)10-287363R1ENGINE AND ENGINE PERIPHERALSOil pressure10SPECIAL TOOLING REQUIREDMot. 836-05 Oil pressure measuring kit EQUIPMENT REQUIRED22 mm long socketCHECKINGThe oil pressure should be checked when the en-gine is warm (approximately 80C).Contents of kit Mot. 836-05.USEENGINE CHECKING D7F engineIdling 0.8 bar4 000rpm. 3.5 barsE7J / K7M enginesIdling 1 bar3 000rpm. 3 barsF8Q engine1 000rpm. 1.2 bar3 000rpm. 3.5 barsD engine E engine F engine C + F C + E + F B + F10-3ENGINE AND ENGINE PERIPHERALSEngine -Gearbox10REMOVALPut the vehicle on a two post lift.Remove the battery and the engine undertray.Drain:- the cooling circuit (bottom hose of theradiator),- the gearbox and engine oil (if necessary),- the air conditioning circuit (if fitted) using afilling station.Remove:- the wheels,- the air intake pipe,- the expansion bottle and fix it to the engine.Brake caliper guide bolt 4Shock absorber base bolts 18Driveshaft gaiter mounting bolt 2.5Left-hand suspended engine mounting bolton gearbox 6.2Left hand suspended engine mounting bolt on body 2.1Right hand suspended engine mounting bolt on engine 6.2Right hand suspended engine mounting bolt on body 6.2Wheel bolt 9TIGHTENING TORQUES (in daN.m)SPECIAL TOOLING REQUIREDB. Vi. 31-01 Set of three punches for rollpinsMot. 1202 Hose clip pliersMot. 1448Hose clip pliers extensionMot. 1273 Tool for checking belt tensionMot. 1311-06 Tool for removal of fuel pipeMot. 1379 Tool for retaining engine onsub-frameT. Av. 476 Ball joint extractorEQUIPMENT REQUIREDLoad positionerD7F engine10-4ENGINE AND ENGINE PERIPHERALSEngine -GearboxLeft-hand side of the vehicleRemove:- the brake caliper mounting bolt then fix it tothe shock absorber spring,- the three driveshaft gaiter mounting bolts,- the track rod end using tool T. Av. 476,- the shock absorber base bolts.Tilt the hub to disconnect the driveshaft from thegearbox.Right-hand side of the vehicleRemove:- the driveshaft roll pins with the punchesB. Vi. 31-01,- the brake caliper mounting bolt then fix it tothe shock absorber spring,- the track rod end using tool T. Av. 476,- the shock absorber base bolts.Tilt the hub to disconnect the driveshaft from thegearbox.Remove the earth strap mounting bolt (gearboxside).10D7F ENGINE10-5ENGINE AND ENGINE PERIPHERALSEngine -Gearbox- the relay board (4), the connector (5) and thefuse mounting (6) by removing the fuse hol-ders (7),10Disconnect the gear selector rod at the gearbox,after releasing the gaiter.93912R1Slacken bolt (A) without removing it and removebolt (B) from the engine tie-bar. 92661R1Disconnect:- the accelerator cable,- the canister pipe,- the brake servo vacuum pipe,- the upper hose on the radiator,13034R13085R- the heater hose (there are two types of assem-bly to be disconnected as shown in the dia-grams below),D7F ENGINE10-6ENGINE AND ENGINE PERIPHERALSEngine -Gearbox1013084R- the connectors of the oxygen sensor and fan,- the fuel pipes.Remove:- the injection computer support plate havingdisconnected the 55 track connector and theimpact switch connector,13088R2- the AC pipe mountings (if fitted), and theflange (8) and rest the assembly on the en-gine,14174R- the power assisted steering pipe mountingson the engine,- the power assisted steering pump belt,- the power assisted steering pulley,- the power assisted steering pump bolts.Release the power assisted steering pump unit.Attach the load positioner to the engine liftingrings.99893SD7F ENGINE10-7ENGINE AND ENGINE PERIPHERALSEngine -Gearbox10- the mounting bolts(2) of the engine rubbermounting pad (1).Note the position of the engine mountingpad(1)in relation to the body.REFITTING (Special notes)Refitting is the reverse of removal.Tighten the suspended engine mounting bolts tothe recommended torque (see section 19"Suspended engine mounting").Put RHODORSEAL 5661 on the driveshaft roll pinhole.Press the brake pedal several times to bring thepistons into contact with the brake pads.Refit the power assisted steering pump belt (seesection07 "Accessories belt tension").Carry out the following operations:- fill the gearbox with oil,- top up the engine oil level (if necessary),- fill and bleed the coolant circuit (see section19 "Filling and bleeding").12924R212924R1Remove:- the gearbox side support,Remove the engine and transmission assemblyafter taking the power assisted steering unit outof the engine compartment and protecting theradiator.D7F engine10-8ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10REMOVALPut the vehicle on a two post lift.Remove the battery and the engine undertray.Drain:- the coolant circuit(disconnect the lowerradiator hose ),- the gearbox oil (if necessary),- the engine oil(if necessary).Remove:- the wheels,- the air intake pipe,- the upper radiator mountings,- the expansion bottle and fix it to the engine,- the power assisted steering fluid reservoir,and secure it onto the engine.Shock absorber base bolts 18Track rod end3.7Front sub-frame mounting bolt 6.2Rear sub-frame mounting bolt 10.5Driveshaft gaiter mounting bolt 2.5Mounting nut for rubber engine mounting padon left suspended engine mounting 6.2Mounting bolt for front right suspended engine mounting on the engine 6.2Mounting bolt for front right suspended engine mounting on the body 6.2Steering shaft yoke bolt 2.5Wheel bolt9TIGHTENING TORQUES (in daN.m)SPECIAL TOOLING REQUIREDB. Vi. 31-01 Set of punches for roll pinsMot. 1040-01 Dummy sub-frame forremoving and refitting engineand transmission assemblyMot. 1202 Hose clip pliersMot. 1448Hoseclip pliers extensionMot. 1311-06 Tool for removing the fuelpipe Mot. 1379 Tool for retaining engine onsub-frameT. Av. 476 Ball joint extractorT. Av. 1233-01 Tool for sub-frame and axleassemblyD7F engine10-9ENGINE AND ENGINE PERIPHERALSEngine and transmission assemblyDisconnect:- the accelerator,- the canister pipe,- the brake servo pipe,- the oxygen sensor connector,- the fuel pipes,- the relay board (4), the connector(5) and thefuse mounting (6) by removing the fuseholders (7),1013034R- the heater hoses (there are two types of as-sembly which must be disconnected as shownin the diagrams below),13085R13084RRemove:- the shock absorber base bolts ,- the steering shaft yoke bolt.SPECIAL NOTES FOR VEHICLES FITTED WITHDRIVERS AIR BAGRemove:- the tie-rods between sub-frame and body,- the earth strap mounting bolt on the bodyside,- the exhaust downpipe mountings.D7F ENGINEWARNINGIn order to avoid any risk of damage to the rotaryswitch beneath the steering wheel, the followinginstructions should be followed: Before disconnecting the steering column fromthe rack, the steering wheel MUST be immobi-lised with the wheels straight with the aid of a"steering wheel lock" throughout the opera-tion. If there is any doubt about the rotary switchbeing properly centred, the steering wheelmust be removed in order to apply the centringmethod described in the Technical Note cove-ring the 2nd generation air bag.REMINDER: this kind of work must only be carriedout by properly trained and qualified staff.10-10ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly1014174R- the AC pipe mountings (if fitted) and theflange (8) andrest the assembly on the en-gine,14215R2- the heat shield (A) and the gearbox selectorrod.Fit tool Mot. 1379 onto the sub-frame and takethe weight off the right-hand engine mounting,usingthe threaded rod (1).10267R1Fit tool Mot. 1040-01 under the sub-frame havingalready fitted theshims Mot. 1379 onto this tool.Insert a wooden block between the gearbox andthe sub-frame.Diagram showing the holes drilled in tool Mot.1040-01 (dimensions in mm).10621RD7F ENGINE10-11ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly1092442-1R2Remove:- the gearbox suspended engine mounting nut,then tap it with a copper hammer to releasethe suspended engine mounting stud,- the suspended engine mounting bolts on theengine.Lower the lift until the tool touches the ground.Remove the four mounting bolts of the sub-frame.Take out the engine and transmission assembly bylifting the body.98755RREFITTING (Special notes)Use tool T. Av. 1233-01 to position the engine andtransmission assembly in relation to the body.Refitting is the reverse of removal.Correctly refit the heat shields.Tighten the suspended engine mounting nuts andbolts to the correct torque (see section 19"Suspended engine mounting").Apply Rhodorseal 5661 to the driveshaft roll pinhole.Press the brake pedal several times to bring thepistons into contact with the brake pads. Fill:- the gearbox withoil (if necessary),- the engine withoil (if necessary),- the cooling circuit and bleed it (see section 19"Filling and bleeding").D7F ENGINE10-12ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10Front sub-frame mounting bolt 6.2Rear sub-frame mounting bolt 10.5Mounting bolt for front right suspended engine mounting cover on engine 6.2Mounting nut for front right suspended engine mounting cover 4.4Mounting nut for rubber engine mounting padon front left-handside member support 6.2Shock absorber base bolts 18Brake caliper guide bolt 4Steering shaft yoke bolt 3Wheel bolt 9TIGHTENING TORQUES (in daN.m)REMOVALPut the vehicle on a two post lift.Remove the battery and the engine undertray.Drain:- the cooling circuit through the lower hose onthe radiator,- the gearbox and the engine (if necessary),- the air conditioning circuit (if fitted) using afilling station.Remove:- the front wheels and the wheel arch protec-tors,- the radiator grille,- the front bumper,- the tie-rods between sub-frame and body,- the brake calipers (and the ABS sensors if fit-ted) and attach them to the suspensionsprings,- the shock absorber base bolts,- the heat shield (A) and the geabox selectorrod,14215R3- the exhaust pipe clamp(B) between the cata-lytic converter and the expansion chamber,- the earth strap on the gearbox,- the front bumper,- the air intake pipe from the air filter,SPECIAL TOOLING REQUIREDMot. 1040-01 Dummy sub-frame for removingand refitting engine andtransmission assemblyMot. 1159 Tool forretaining engine on sub-frameMot. 1202 Hose clip pliersE7J and K7M ENGINES10-13ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10- the injection computer support after dis-connecting the 55 track connector and that ofthe impact switch.13088R2Disconnect:- the hoses on the expansion bottle,- the brake servo pipe,- the heater hoses (there are two types of as-sembly which must be disconnected as shownin the diagrams below),13084R13085R- the fuse mounting (4) by removing the moun-ting (5) and the relay board (6) and theconnector(7),14176R- the canister pipe on the solenoid valve,- the accelerator and clutch cables.Unclip the power assisted steering reservoir andplace it on the engine.E7J and K7M ENGINES10-14ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly1014174RRemove:- the air filter assembly and disconnect fuel in-jection pipes on the gallery ,- the accelerator and clutch cables,- the upper mountings of the radiator and at-tach it to the engine,- the AC pipe mountings (if fitted) and theflange (8) andrest the assembly on the en-gine,- the nut and the eccentric bolt of the steeringshaft yoke, after pushing back the guard.SPECIAL NOTES FOR VEHICLES FITTED WITHDRIVERS AIR BAG99024R2Fit tool Mot. 1159 between the sub-frame and thecylinder block.Insert a shim between the multi-function supportand the sub-frame.14172SE7J and K7M ENGINESWARNINGIn order to prevent any risk of damage to the ro-tary switch beneath the steering wheel, the follo-wing instructions should be observed: Before disconnecting the steering column andthe rack, the steering wheel MUST be immobi-lised with the wheels straight, using a "stee-ring wheel lock", throughout the operation. If there is any doubt that the rotary switch isproperly centred, the steering wheel must beremoved in order to apply the centring methoddescribed in section 88 "Air bag".REMINDER: this kind of work must only be carriedout by properly trained and qualified staff.10-15ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10Remove the suspended engine mounting cover.13359RInsert a shim between the gearbox and the sub-frame.Remove:- the nut (1), then tap it with a copper hammerto release the suspended engine mountingstud,13086R- the tie rods (3).14175RFix tool Mot. 1040-01 underneath the sub-frame.98755R1Lower the lift until the tool touches the ground.Remove the sub-frame mounting bolts and takeout the engine and transmission assembly by lif-ting the body.NOTE : for any operation requiring separation ofthe engine, gearbox and sub-frame assembly,take care to mark the position of Mot. 1159 on thesub-frame.E7J and K7M ENGINES10-16ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10REFITTINGThe alignment of the sub-frame with the bodywill be made easier by positioning two threadedrods Mot. 1233-01 in the two frontmountings ofthe sub-frame on the body. Tighten the sub-frame mounting bolts to a torqueof:- 6.2 daN.m at the front,- 10.5 daN.m at the rear.Refitting is the reverse of removal.Fit the heat shields correctly.Apply Loctite FRENBLOC to the caliper mountingbolts and tighten them to the recommended tor-que.Press the brake pedal several times to bring thepistons into contact with the brake pads.Fill:- the engine and gearbox with oil, if necessary,-the cooling circuit and bleed it (see section 19"Filling and bleeding").E7J and K7M ENGINES10-17ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10SPECIAL TOOLING REQUIREDMot. 1040-01 Dummy sub-frame for removingand refitting engine andtransmission assemblyMot. 1159 Tool for retaining engine on sub-frameMot. 1202 Hose clip pliersMot. 1448 Hoseclip pliers extension Mot. 1311-06 Tool for removing fuel pipeFront sub-frame mounting bolt 6.2Rear sub-frame mounting bolt 10.5Mounting bolt for front right suspended engine mounting cover on engine 6.2Mounting nut for front right suspended engine mounting cover 4.4Mounting nut for rubber engine mounting padon front left-handside member support 6.2Shock absorber base bolt 18Brake caliper guide bolt 4Steering shaft yoke bolt 3Wheel bolt 9TIGHTENING TORQUES (in daN.m)- the heat shield (A) and the gearbox selectorrod,REMOVALPut the vehicle on a two post lift.Remove the battery and the engine undertray.Drain:- the cooling circuit through the lower hose onthe radiator,- the gearbox and the engine (if necessary),- the air conditioning circuit (if fitted) using afilling station.Remove:- the front wheels,- the tie-rods between sub-frame and body,- the brake calipers (and the ABS sensorsif fit-ted) and attach them to the suspensionsprings,- the shock absorber base bolts,14215R2F8Q ENGINE10-18ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10- the exhaust downpipe,- the earth strap on the gearbox,- the front bumper,- the air intake pipe from the air filter,- the fuel supply and return unions (A) and (B),- the connectors (2), (3), (4) and (5).Unclip the fuel pipes from the air filter unit and the timing cover and unclip the die-sel filter from itssupport and move the assembly to one side.13083-1RF8Q ENGINE10-19ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10Remove the computer support.13088R1Disconnect:- the hoses on the expansion bottle,- the brake servo pipe,- the heater hoses (there are two types of as-sembly to be disconnected, as shown in thediagrams below),13085R11734RFor the locking of the quick release unions, referto the diagrams below:11733RF8Q ENGINE10-20ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10Remove:- the upper mountings of the radiator and at-tach it to the engine,- the nut and the eccentric bolt of the steeringshaft yoke, after pushing back the guard,- the AC pipe mountings (if fitted) and theflange (8) andrest the assembly on the en-gine.14174RSPECIAL NOTES FOR VEHICLES FITTED WITHDRIVERS AIR BAG13084R14176R- the fuse mounting (4) by removing the nut (5)and the relay board (6) and the connector(7),- the accelerator and clutch cables.Unclip the power assisted steering reservoir andplace it on the engine.F8Q ENGINEWARNINGIn order to prevent any risk of damage to the ro-tary switch beneath the steering wheel, the follo-wing instructions should be observed: Before disconnecting the steering column andthe rack, the steering wheel MUST be immobi-lised with the wheels straight, using a "stee-ring wheel lock", throughout the operation. If there is any doubt that the rotary switch isproperly centred, the steering wheel must beremoved in order to apply the centring methoddescribed in section 88 "Air bag".REMINDER: this kind of work must only be carriedout by properly trained and qualified staff.10-21ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10Remove the suspended engine mounting cover.13086R113086RInsert a shim between the gearbox and the sub-frame.Remove the nut (1), then tap it with a copperhammer, to release the suspended engine moun-ting stud.99024R2Fit tool Mot. 1159 between the sub-frame and thecylinder block.Fit tool Mot. 1159 in place of the coolant pipemounting on the cylinder block.99310RF8Q ENGINE10-22ENGINE AND ENGINE PERIPHERALSEngine and transmission assembly10REFITTINGThe alignment of the sub-frame with the bodywill be made easier by positioning two threadedrods Mot. 1233-01 in the two frontmountings ofthe sub-frame on the body. Tighten the sub-frame mounting bolts to a torqueof:- 6.2 daN.m at the front,- 10.5 daN.m at the rear.Refitting is the reverse of removal.Fit the heat shields correctly.Apply Loctite FRENBLOC to the caliper mountingbolts and tighten them to the recommended tor-que.Press the brake pedal several times to bring thepistons into contact with the brake pads.Fill :- the air conditioning circuit (if fitted),- the engine and gearbox (if necessary),- the cooling circuit and bleed it (see section 19"Filling and bleeding"),- the power assisted steering circuit (if fitted).Fit tool Mot. 1040-01 under the sub-frame.98755R1Lower the lift until the tool touches the ground.Remove the sub-frame mounting bolts and takeout the engine and transmission assembly by lif-ting the body.NOTE : for any operation requiring separation ofthe engine, gearbox and sub-frame assembly,take care to mark the position of Mot. 1159 on thesub-frame.Remove the tie rods (3).F8Q engine14175R10-23ENGINE AND ENGINE PERIPHERALSSump10Sump bolt 1TIGHTENING TORQUES (in daN.m)Put the vehicle on a 2 post lift.Disconnect the battery and remove the engine un-dertray.Drain the engine.Remove:- the oil level sensor using a 19 mm half-moonwrench,- the gearbox - engine guard,99900S- the sump bolts.Rotate the sump towards the rear of the vehicle inorder to release the oil pump strainer from thesump partitioning.Clean the sealing surfaces without scratching thealuminium.REFITTINGProceed in the reverse order of removal and fit anew gasket.D7F ENGINE10-24ENGINE AND ENGINE PERIPHERALSSump10Front sub-frame mounting bolt 6.2Rear sub-frame mounting bolt 10.5E7J and K7M sump bolt 1F8Q sump bolt 1.5Steering shaft yoke bolt 3Engine tie-bar bolt 6.2 Wheel bolt 9TIGHTENING TORQUES (in daN.m)REMOVALPut the vehicle on a two post lift.Disconnect the battery and remove the engine un-dertray.Drain the engine.Remove:- the front right hand wheel and thewheel archprotector,- the nut and the eccentric bolt of the steeringshaft yoke, after pushing back the guard,- the lower ball joint mountings and the trackrod ends for the E7J and K7M engines,- the tie-rods between sub-frame and body,- the gear control on the gearbox side,- bolt (1), and slacken engine tie-barbolt (2), without removing it,SPECIAL TOOLING REQUIREDMot. 1233-01 Threaded rods for lowering thesub-frame13359R1- the bumper lower mountings,- the exhaust downpipe for the F8Q engine.Special notes for the E7J and K7M enginesRemove:- the exhaust manifold heat shield,- the catalytic converter,- the power assisted steering pipe mountingson the cylinder block and the multifunctionmounting.All engine typesRemove:- the tie rods (3),- the sub-frame mounting bolts, inserting thethreaded rods Mot. 1233-01 as you go.E7J/K7M & F8QENGINES14175R10-25ENGINE AND ENGINE PERIPHERALSSump1013507R1 E7J and K7M enginesX1 = 9 cm X2 = 13 cmRemove the sump.F8Q engineX1 = 7 cm X2 = 9 cmGradually lower the sub-frame with the aid of the threaded rods Mot. 1233-01 untildimensions X1 and X2. are reached approximately.E7J/K7M & F8QENGINES10-26ENGINE AND ENGINE PERIPHERALSSump10REFITTINGClean the sump.E7J and K7M enginesApply an approximately 3 mm wide bead ofRHODORSEAL 5661 asshown in the diagram be-low. 99179SE7J/K7M & F8QENGINESDo not forget to replace the two half-moon gas-kets on each side of the sump.F8Q engine Fit a new after-sales gasket.Refitting is the reverse of removal.10-27ENGINE AND ENGINE PERIPHERALSCrankshaft seal, timing end10Crankshaft output mounting bolt 2 + 90Mounting bolt for front right suspended engine mounting on the engine 6.2Mounting bolt for front right suspended engine mounting on the body 6.2Timing belt tension wheel nut 5TIGHTENING TORQUES (in daN.m and/or )REPLACEMENTREMOVALRemove the timing belt (see section 11 "Timingbelt").Use tool Mot. 1374 to remove the crankshaft seal.99787RScrew the body of the tool into theseal using nut(1), then use bolt (2) to extract the seal.SPECIAL TOOLING REQUIREDMot. 1054 TDC pinMot. 1273 Tool for checking belt tensionMot. 1355 Tool for fitting pump sealMot. 1374 Pump seal extractorMot. 1379 Tool for retaining engine on sub-frame99788RRefit the new timing belt (see the method descri-bed in section 11 "Timing belt").D7F ENGINEREFITTINGRefit the new seal onto the crankshaft output wi-thout damaging it when passing the timingsprocket drive groove.Position it using tool Mot. 1355. 10-28ENGINE AND ENGINE PERIPHERALSOil pump10Crankshaft output mounting bolt 2 + 90Mounting bolt for front right suspended engine mounting on the engine 6.2Mounting bolt for front right suspended engine mounting on the body 6.2Timing belt tension wheel nut 5TIGHTENING TORQUES (in daN.m and/or )REMOVALRemove:- the timing belt (see method described insection 11 "Timing belt"),- the oil level sensor using a 19 mm half-moonwrench,- the oil dipstick,- the crankshaft pulley and sprocket,- the engine flywheel guard.Lift the engine and gearbox assembly with the aidof tool Mot. 1379.Remove the sump bolts.Rotate the sump towards the rear of the vehicle inorder to release the oil pump strainer from thesump partitioning.Remove:- the oil pump strainer,- the oil pump.Clean the sealing surfaces without scratching thealuminium.SPECIAL TOOLING REQUIREDMot. 1054 TDC pinMot. 1273 Tool for checking belt tensionMot. 1355 Tool for fitting oil pumpMot. 1379 Tool for retaining engine on sub-frameREFITTINGReplace the oil pressure seal(3).99790RD7F ENGINE10-29ENGINE AND ENGINE PERIPHERALSOil pump1099788RApply a bead of RHODORSEAL 5661 to the sealingsurface.98964SIMPORTANT: the oil pump is driven by two studslocated on the crankshaft.D7F ENGINERefit:- the oil pump onto the engine and tighten it toa torque of 0.9 daN.m,- the new seal onto the crankshaft output wi-thout damaging it when passing the timingsprocket drive groove.Position it with the aid of tool Mot. 1355.Refit the strainer with a new O-ring.Clean the sealing surfaces (cylinder block, sump).Refit the sump.Tighten the bolts to a torque of 1 daN.m.Refit:- the timing belt (see method described insection 11 "Timing belt"),- the new alternator and power assisted stee-ring pump belts (see tension values in section07 "Accessories belt tension").10-30TIGHTENING TORQUES (in daN.m and/or )TOP AND FRONT OF ENGINETiming beltREMOVALPut the vehicle on a two post lift.Disconnect the battery.Remove :- the front right hand wheel,- the accessories belts,- the crankshaft pulley.1110267RSPECIAL TOOLING REQUIREDCrankshaft accessories pulley mounting bolt 2 + 90Mountingbolt for front right suspended engine mounting onengine 6.2 Mounting bolt for the right hand suspendedengine mounting on the body 6.2Timing belt tension wheel nut 5Mot. 1054 TDC pinMot. 1135-01 Tool for tensioning timingbeltMot. 1273 Tool for checking belt tensionMot. 1379 Tool for securingengine tosub-frameMot. 1386 Tool for pre-tensioning thetiming beltFit tool Mot. 1379.D7F ENGINE11-1TOP AND FRONT OF ENGINETiming belt11Remove the suspended engine mounting.Use tool Mot. 1054 to pin the engine at TDC by ali-gning the crankshaft and camshaftsprocket mar-kings with the fixed markings.12924S199795R11463SRemove the timing cover and the timing belt.IMPORTANT: The camshaft sprocket bears fivemarkings, of which only the rectangular one onthe surface of one of the teeth represents TDC;the other markings are intended as an aid for ad-justing the valve rockers.10072SD7F ENGINE11-2TOP AND FRONT OF ENGINETiming belt1110881R10479R1REFITTINGLine upthe markings of the timing beltwiththose of the camshaft and crankshaft sprockets.PROCEDURE FOR TENSIONING TIMING BELTRemovepinMot. 1054.Fit the spacer (1)of tool Mot. 1386 and tightenthe crankshaft sprocket bolt. Tighten the tension wheel nut.Turn the engineat least twice(never in the oppo-site direction to normal operation).Pin the engine at TDC,then remove the pin .Check that the timing is correctly adjusted on thecrankshaft and camshaft side.Slackenthe tension wheel nut and turn it slightlyclockwise using tool Mot. 1135-01 until the twoholes of the tension wheel arelined uphorizontally.Retighten the tension wheel nut.D7F ENGINEa) Fit tool Mot. 1273 and, using toolMot. 1135-01,turn the tension wheel anti-clockwise until the value of 20 US is obtained(turn the sensor wheeluntil it isreleased,asindicated by three clicks).11-3TOP AND FRONT OF ENGINETiming belt11b) Turn the engineat least twice(never in theopposite direction to normal operation).Pin the engine at TDC,then remove the pin .Using tool Mot. 1386 and a torque wrench,apply a pretensioning torque of 1 daN.m bet-ween the crankshaft sprocket and the waterpump.IMPORTANT Followingeachvariation of the tension wheelposition,turn the engine at least twice beforeproceeding to measure the tension .Apply the pretensioning of 1 daN.mwhich allowsall belt play to be eliminated.Refitting is the reverse of removal.Fit the suspended engine mounting .12924S110881RRefit the accessories belts(see section 07"Accessories belt tension").Fit tool Mot. 1273 and note the tension value,which should be 203 US (fitting tension), orsimply adjustby varying the position of the ten-sion wheel using Mot. 1135-01 and repeat the ten-sioning process in (b).Tighten the tension wheel nut to a torque of5 daN.m.D7F ENGINE11-4TOP AND FRONT OF ENGINETiming beltREMOVALPut the vehicle on a two post lift.Disconnect the battery.Fit the engine support tool.1114279SSPECIAL TOOLING REQUIREDMot. 591-02 IndexMot. 591-04 Angle tightening wrenchMot. 1135-01 Tool for tensioning timingbeltMot. 1273 Tool for checking belt tensionWheel bolts 9Crankshaft pulley bolt 2+ 68 6Tension wheel nut5Bolt for suspended engine mounting cover 6.2Nut for suspended engine mounting cover 4.413359RRemove :- the front right hand wheel and thewhel archprotector,- the suspended engine mounting cover,EQUIPMENT REQUIREDEngine support toolAngulartightening wrench- the alternator and power assisted steeringpump belts,TIGHTENING TORQUES(in daN.m and/or )E7J and K7M ENGINES11-5TOP AND FRONT OF ENGINETiming belt1113362SBring the engine to the setting point.The markings (N) and (M) on the camshaft andcrankshaft sprockets must be vertical, as shownbelow. Slacken the nut(O) andand release the tensionwheel , then remove the belt.(1) Tensioner direction of rotation.- the crankshaft pulleysand hub,- the timing covers.13506-1R10072SIMPORTANT: The camshaft sprocket has five mar-kings, of which only the rectangular one on thesurface of one of the teeth represents TDC;theother markings are intended as an aid for adjus-ting the valve rockers.E7J and K7M ENGINES11-6TOP AND FRONT OF ENGINETiming belt11REFITTINGAn arrow indicating the direction of rotation andtwo dashes for setting are marked on the surfaceof the belt.Check that the engine is at the setting point.Bring the belt markings in line with thesprocketmarkings .Observe the mounting direction for the belt andbegin to position it on the crankshaftsprocket.Carry out the tensioning of the belt using toolMot. 1135-01, until the fitting value is obtained(see section 07 "Timing belt tension").Tighten the nut(O) of the tension wheel to a tor-que of 5 daN.m.It is essential to tighten the nut of the tensionwheel to atorque of5 daN. to avoid any slacke-ning which may damage the engine .Refitting is the reverse of removal.Refit the crankshaft pulley, being sure to tightenthe bolt to a torque of 2 daN.mthen apply an an-gle of 68 6.Refit and tension the accessories belts (see section07 "Accessories belt tension").Never refit a belt once it has been removed.Replace it.E7J and K7M ENGINES11-7TOP AND FRONT OF ENGINETiming belt11REMOVALPut the vehicle on a two post lift.Disconnect the battery.Remove :- the front right hand wheel and thewheel archprotector,- the protective plastic covering over thesus-pended engine mounting cover.Fit the engine support tool.SPECIAL TOOLING REQUIREDMot. 1054 TDC pinMot. 1273 Tool for checking belt tensionEQUIPMENT REQUIREDEngine support tool14mm torx socket14279SRemove :- the accessories belt,- the suspended engine mounting cover.13086R1Wheel bolts 9Crankshaft pulley bolts 2+ 115 15Tension wheel nut5Bolt for suspended engine mounting cover 6.2Nut for suspended engine mounting cover 4.4TIGHTENING TORQUES(in daN.m and/or )F8QENGINE11-8TOP AND FRONT OF ENGINETiming belt1113095SAdjusting the timingTurn the crankshaft so that the camshaft timingreference mark is visible through the timing win-dow .Remove the TDC pin plug.Fit the TDC pin, tool Mot. 1054.12419RRemove :- the timing covers,12518R- the crankshaft pulley.Slacken the tension wheel and remove the belt.NOTE : Slackening the tension wheel nut by morethan oneturnmay cause the tensioner to be-comedisengaged.F8QENGINE11-9TOP AND FRONT OF ENGINETiming belt11REFITTINGCheck that the pin Mot. 1054 is inplace.Fit the timing belt by aligning the belt markingswith those of the camshaft,injection pump andcrankshaft sprockets.13096RTension the timing belt by tightening a bolt( A )on the inner timing housing.Fit tool Mot. 1273 and tension the belt until thefitting value is reached (see section07 "Timingbelt tension").13094RTighten the tension wheel nut to 5 daN.m.NOTE : It is essential to tighten the tension wheelnut to a torque of 5 daN.m to avoid any slacke-ning which may damage the engine.Check the injection pump timing (see section 13"Pump- Checking the timing").Replace the crankshaft pulley bolts.Refit the crankshaft pulley , being sure to tightenthe bolt to a torque of 2 daN.mthen apply an an-gle of 115 15.Refitting is the reverse of removal.Refit the accessories belt(see section 07"Accessories belt tension").NOTE : Never refit a belt once removed, but re-place it.F8QENGINE11-1012mm torxsocketAngulartightening wrenchTOP AND FRONT OF ENGINECylinder head gasket11SPECIAL TOOLING REQUIREDMot. 591-02 IndexMot. 591-04 Angle wrench fortighteningcylinder headand indexMot. 1054 TDC pinMot. 1202 Hose clip pliersMot. 1448 Hose clip pliers extensionMot. 1273 Tool for checking belt tensionMot. 1379 Tool for securingengine tosub-frameEQUIPMENT REQUIREDTIGHTENING TORQUES(in daN.m and/or )Crankshaft output mounting bolt 2 + 90Mounting bolt for front right suspended engine mounting on engine 6.2Mounting bolt for the right hand suspendedengine mounting on the body 6.2Timing belt tension wheel nut 5Wheel bolts 9REMOVALPut the vehicle on a two post lift.Disconnect the battery and remove the engine un-dertray.Drain the cooling circuit.Fit the engine support tool Mot. 1379.Remove :- the timing belt(see method describedinsection 11 "Timing belt"),- the dipstick,- the brake servo pipe,- the air filter,- the accelerator cable,- the fuel supply and return pipeslevel with thetiming belt cover on thecylinder head.Slacken the compressor mounting bolts forvehicles fitted withAC.D7F ENGINE11-11TOP AND FRONT OF ENGINECylinder head gasket1199940RDisconnect:- the spark plug leads using tool (3)which is in-tegrated tothe plastic cover (4),99894R1D7F ENGINE- the canister pipe along with the fuel vapourrebreathing hoses on the solenoid valve,- the connectors : of the ignition module, of the injectors, of the idle speed regulation steppingmotor, of the throttle position potentiometer, of the air temperature sensor.Extract the hose connecting the water pump tothe heater matrix, and the electrical wiring loomfrom the heat shield on the rocker cover.11-12TOP AND FRONT OF ENGINECylinder head gasket1199937R1D7F ENGINERemove :- the mounting bolts (5) for the throttle bodyretaining bracket on thecylinder head,- themountingnuts (3) forthe manifold on the cylinder head - the mounting bolts(4) ofthe manifoldon the valve rocker cover- the inlet manifold,throttle bodyand fuel galleryassembly.- the thermostat hoses,- the valve rocker covers,- the cylinder head mounting bolts,- the cylinder head.11-13TOP AND FRONT OF ENGINECylinder head gasket1192076SUse a syringe to remove any oil which may haveentered the cylinder head mounting bolt holes.This is necessary, in order to obtain the correcttightening of the bolts.Care must be taken whilstcarrying out thisope-ration in order to avoid any foreign bodies ente-ring the oil supply pipes in the cylinder head.Failure to follow to this advice could lead to theblocking of the jets and thus cause damage tothe camshaft.CLEANINGIt is very important not to scratch the gasket facesof the aluminium components.Use the Dcapjointproduct to dissolve any part ofthegasket which remains attached.Apply the product to the parts to be cleaned; waitabout ten minutes, then remove it using awooden spatula.Gloves should be worn during this operation.CHECKING THE GASKET FACECheck for gasket face bow using a straight edgeand a set of feeler gauges.Maximum deformation : 0.05 mm.Regrinding of the cylinder head is not permitted.Check the cylinder head for any possible cracks.REFITTINGThe cylinder head is centred by two dowels at therear of the engine.REMINDER: in order to obtain the correct tighte-ningof the bolts, use a syringe to remove any oilwhich may have entered thecylinder head moun-ting bolt holes .Lubricate the threads and under the bolt headswith engine oil.Adjustment of the valve rockers and tighteningof thecylinder head should be carried out whenthe engine is cold.D7F ENGINE11-14TOP AND FRONT OF ENGINECylinder head gasket11Tighten the cylinder head using an angular tighte-ning wrench (see section 07 "Tightening the cy-linder head").Remove the TDC pin (Mot. 1054).Refit:- the timing belt (see method described in sec-tion 11 "Timing belt"),- the accessories belt (see section 07"Accessories belt tension").IMPORTANT: The camshaft sprocket has five mar-kings, of which only the rectangular one on thesurface of one of the teeth represents TDC;theother markings are intended as an aid for adjus-ting the valve rockers.10072SADJUSTING THE VALVE ROCKERS IF NECESSARYAdjustment values(cold engine) (in mm) :- Inlet 0.10- Exhaust 0.20"Tilt" methodPlace the valves for thecylinder concerned inthe "end of exhaust-beginning ofinlet"positionAdjust thevalve rockerclearance for thecylinder concerned 13424213D7F ENGINE11-15TOP AND FRONT OF ENGINECylinder head gasket1178373ROpen exhaust valve methodBring the exhaust valve of cylinder n 1 to the fully open position,then adjust the inlet valve clearance forcy-linder n 3 and the exhaust valve clearance for cylinder n 4.Follow the same method for the other cylinders, in the order shown by the table below.Exhaust valve to be opened.Inlet valve to be adjusted Exhaust valve to be adjusted.Proceed with re-assembly in the reverse order to removal.Remove the tool for securing theengine to thesub-frame Mot. 1379.NOTE : tightening the inlet manifold :- progressively hand tighten the six nuts until the inlet manifold comes into contact with the cylinder head,thentighten them to a torque of 1.5 daN.m,- fit the upper bolts and tighten them to a torque of 0.9 daN.m.Fill and bleed the cooling circuit (see section 19 "Filling and bleeding").Adjust the accelerator cable.D7F ENGINE11-16TOP AND FRONT OF ENGINECylinder head gasket11SPECIAL TOOLING REQUIREDREMOVALPut the vehicle on a two post lift.Disconnect the battery.Remove :- the bonnet,- the timing belt (see method described insection 11, "Timing belt").Drain the cooling circuit through the lowerradia-tor hose.99024R2Engine support tool55mm torx socketAngulartightening wrenchMot. 588 Retaining bracketMot. 591-02 IndexMot. 591-04 Angle wrench fortighteningcylinder headand indexMot.1159 Tool for securingengine tosub-frameMot.1202 Hose clip pliersMot. 1273 Tool for checking belt tensionTension wheel nut 5Crankshaft pulley bolt 2 + 68 15Bolt for suspended engine mounting cover 6.2Nut for suspended engine mounting cover 4.4Wheel bolts 9TIGHTENING TORQUES(in daN.m and/or )Fit tool Mot. 1159 between the sub-frame and thecylinder block then remove the engine supporttool.E7J and K7M ENGINES11-17- the heat shield and the exhaust downpipemountings,TOP AND FRONT OF ENGINECylinder head gasket1113339S- the cover on the air filter assembly,- the air filter assembly,- the throttle position potentiometerconnector,- the accelerator cable,- the air intake pipe,having disconnected theair temperature sensor connector,13338SRemove :- the connector and the pipe on the absolutepressure sensor,- the stepping motor connector,13360R- the connectors and the hoses on the thermo-stat support,- the connectors of the ignition coils,alongwiththeconnector at (1),- the coil (2),- the pipes(3) and the connector (4),- the pipe (5),- the lifting bracket(6),- the fuel supply and return pipes (7),- the injector connectors,- the cylinder head cover,13365SE7J and K7M ENGINES11-18- the power assisted steering pump mountingbolts and move it to one side,- the compressor mounting bolts and move it toone side,TOP AND FRONT OF ENGINECylinder head gasket1114280R13364R1Vehicles without air conditioningRemove :- the alternator ,- the pressostat mounting (8) and connector (9),- the power assisted steering mounting boltsand move it to one side,- the multi-function support mounting boltsand move it to one side,Vehicles fitted with air conditioningRemove :- the radiator grille,- the left hand wheel arch protector,- the front bumper,- the upper cross member (by slackening thetwo lower mounting bolts) and put it on theengine,- the multi-function support mounting boltsand move it to one side,E7J and K7M ENGINES13995-1R11-1992106R- the cylinder head.Fitthe cylinder liner retaining brackets, toolMot. 588 (E7J engine).TOP AND FRONT OF ENGINECylinder head gasket1114177RAll vehicle typesRemove :- the mounting (10),- the bolt of the strut (11)and slacken thenut (12),- the mounting nut (13) of the dipstick guidetube.92062R- the intermediary support(A),13336-1R1Unhook the wiring loom at (14).Remove :- the cylinder head bolts, except for bolt (F)which must simply be released, then pivot thecylinder head around the bolt,E7J and K7M ENGINES11-20TOP AND FRONT OF ENGINECylinder head gasket11Use a syringe to remove any oil which may be inthe cylinder head mounting holes.This is necessary, in order to obtain the correcttightening of the bolts.Care must be taken whilstcarrying out thisope-ration in order to avoid any foreign bodies ente-ring theoil supply pipes in the cylinder head.Failure to follow to this advice could lead to theblocking of the jets and thus causerapiddeterioration of the camshaft.CLEANINGIt is very important not to scratchthe gasketfaces of the aluminium components.Use the Dcapjointproduct to dissolve any part ofthegasket which remains attached.Apply the product to the parts to be cleaned; waitabout ten minutes, then remove it using awooden spatula.Gloves should be worn during this operation.CHECKING THE GASKET FACECheck for gasket face bow using a straight edgeand a set of feeler gauges.Maximum deformation: 0.05 mm.Regrinding of the cylinder head is not permitted.Check the cylinder head for any possible cracks.REFITTING (Special notes)Remove the cylinder liner brackets Mot. 588 (E7Jengine). Check forthe presence of the centring dowel(G).98713R1Position the cylinder head gasket.Lubricate the threads and under the bolt headswith engine oil.Refit the cylinder head (shortestbolts on the inletside ).Tighten the cylinder head (seesection 07"Tightening the cylinder head").Refitting is the reverse of removal.Correctly refit the heat shields.Refit the timing belt , (see section 11 "Timingbelt").Fill and bleed the cooling circuit, (see section 19"Filling and Bleeding").E7J and K7M ENGINES11-21TOP AND FRONT OF ENGINECylinder head gasket11ADJUSTING THEVALVE ROCKERS IF NECESSARY Adjustment values(cold engine) (in mm) :- Inlet 0.10- Exhaust 0.25"Tilt" method78373RPlace the valves of thecylinder concerned inthe "end of exhaust-beginning ofinlet"positionAdjust the valve rockerclearancefor thecylinder concerned13424213Open exhaust valve methodBring the exhaust valve of cylinder n 1 to the fully open position,then adjust the inlet valve clearance forcy-linder n 3 and the exhaust valve clearance for cylinder n 4.Follow the same method for the other cylinders, in the order shown bythe table below.Exhaust valve to be opened.Inlet valve to be adjusted. Exhaust valve to be adjusted.E7J and K7M ENGINES11-22TOP AND FRONT OF ENGINECylinder head gasket11SPECIAL TOOLING REQUIREDREMOVALPut the vehicle on a two post lift.Disconnect the battery and remove the engine un-dertray.Remove the timing belt (see method described insection 11 "Timing belt").Drain the cooling circuit through the lowerradia-tor hose.Engine support tool55mm torx socketAngulartightening wrenchMot. 251-01 Dial gauge support toolMot. 252-01 Plate for measuring pistonprotrusionMot. 591-02 IndexMot. 591-04 Angle wrench fortighteningcylinder headand indexMot. 1054 TDC pinMot. 1159 Tool for securingengine to sub-frameMot.1202 Hose clip pliersMot. 1273 Tool for checking belt tensionMot. 1311-06 Tool for removing fuel pipeTension wheel nut 5Crankshaft pulley bolt 2 + 115 15Bolt for suspended engine mounting cover 6.2Nut for suspended engine mounting cover 4.4Wheel bolts 9TIGHTENING TORQUES(in daN.m and/or )99024R2Fit tool Mot. 1159between the sub-frame andthe cylinder block.F8QENGINE11-23TOP AND FRONT OF ENGINECylinder head gasket11Remove :- the exhaust downpipe,- the hoses and connectors of the cylinder headcoolant pipe housing outlet,- the connection at (1) using tool Mot. 1311-06,13097R99461R- the air filter assembly by disconnectingtheEGR solenoid valve and the air temperaturesensor connectors (unclip the fuel supply pipesfrom the air filter housing),- the air inlet pipe,- the accelerator cable,- thefeeds for theheater plugs,- the connector of the injector with sensor,along with the fast idle solenoid valve connec-tor (5),- the fuel supply and return unions at (A) and(B).Disconnect connector (6) from the diesel fuel fil-ter, remove it from its support and move thedie-sel fuel filter pipe assembly to one side.Place bracket Mot. 1159 at the mounting of thecoolant pipe on thecylinder block,then removethe engine support tool.99310RF8QENGINE11-24TOP AND FRONT OF ENGINECylinder head gasket1113083-1R1F8QENGINE11-25TOP AND FRONT OF ENGINECylinder head gasket1111733RRemove the fuel pipe support (7).Slacken, but do not remove, the lower timingcover mounting bolts.99173-1R13093RRemove :- the accessories belt tensioning system,- the cylinder head bolts.Release the cylinder headby separating the lowerpart of the inner camshaft housing.Do thiswithout pivoting the cylinder head, as this iscentred by the two dowels at ( C ).To release the quick release unions, refer to thefollowing diagrams.11734RF8QENGINE11-26TOP AND FRONT OF ENGINECylinder head gasket11CHECKING THE GASKET FACECheck for gasket face bow using a straight edgeand a set of feeler gauges.Maximum deformation: 0.05 mm.Regrinding of the cylinder head is not permitted.Check the cylinder head for any possible cracks.99180SUsing a syringe,extract any oil which may haveentered thecylinder head mounting holes.This is necessary, in order to obtain the correcttightening of the bolts.Care must be taken whilstcarrying out thisoperation in order to avoid any foreign bodiesentering theoil supply pipes in the cylinder head.Failure to take this advice could lead to theblocking of the oilways, resulting in damage tothe camshaft.CLEANINGIt is very important not to scratchthe gasketfaces of the aluminium components.Use the Dcapjointproduct to dissolve any part ofthegasket which remains attached.Apply the product to the parts to be cleaned; waitabout ten minutes, then remove it using awooden spatula.F8QENGINEGloves should be worn during this operation.11-27TOP AND FRONT OF ENGINECylinder head gasket11REFITTING(special notes)Refit the cylinder head gasketselectedprevious-ly.This is centred by two dowels at(C).99173-1RBring the pistons to mid-stroke position toprevent them from coming into contact with thevalves during the tightening of the cylinder head .Centre the cylinder head on the dowels.Lubricate the threads and under the heads of themounting bolts.Tighten the cylinder head (see section 07"Tightening the cylinder head").Refitting is the reverse of removal.Refit the timing belt, (see method described insection 11 "Timing belt").Fill and bleed the cooling circuit , (see section 9"Fillingand bleeding").DETERMINING THE THICKNESS OF THE CYLINDERHEAD GASKETChecking piston protrusionClean the piston crowns in order to eliminate anytraces of deposits.Turn the crankshaft in its direction of rotationonce,to bring piston n 1close to TDC .Fit tool Mot. 252-01 on the piston.Fit tool Mot. 251-01, complete with dial gaugeMot. 252-01. on the plate. Ensure that the dialgauge measuring pin is in contact with the cylin-der block;then locate the piston TDC.NOTE :All measurements are to be carried out inthelongitudinal axis of the engine, in order to eli-minate any errors due to tilting of the piston.99173RMeasure the piston protrusion.ONLY TAKE INTO CONSIDERATION THEDIMENSIONS OF THE PISTON WITH THEGREATEST PROTRUSION.For a maximum piston protrusion:- lower than 0.868 mm, use a gasket marked by a tab with two holes ,- included between 0.868 mm and 1mm, useagasket marked by a tab with one hole,- greater than1mm, use a gasket marked by atab with three holes.F8QENGINE11-28TOP AND FRONT OF ENGINEReplacing the tappet shims11SPECIAL TOOLING REQUIREDMot. 1366-01 Tool for removing valve adjusters(additional item toMot. 1366)TIGHTENING TORQUES(in daN.m)Studs for mounting manifolds on cylinder head 1Nut for mountingmanifolds on cylinder head 2.7Mounting bolt forstrut oninlet manifold 2.5Mounting bolt forstrut oncylinder block 2.5Put the vehicle on a two post lift.Disconnect the battery.CHECKING THE VALVE CLEARANCERemove the air filter housing along with thecy-linder head cover.Placer the valves of the cylinder concerned at the"end of exhaust - beginning of inlet" position andcheck theclearance .86911-1S13424213Compare the two dimensions noted to there-commended dimensions, and replace the shimsconcerned.Clearance ( in mm ),when the engine is cold :-Inlet: 0.10- Exhaust : 0.25F8QENGINE11-29TOP AND FRONT OF ENGINEReplacing the tappet shims11REPLACING THETAPPET SHIMSIn order to carry out this operation it is necessaryto remove the inlet and exhaust manifolds (seesection 12 Inlet/Exhaust Manifolds) .Fully open the valve concerned(by turning theengine in its operating direction).Insert tool Mot. 1366-01 into the port concerned .11231RFor inlet valvesTurn the engine in the operating direction,inorder to bring the valve into contact with toolMot. 1366-01 (rotate the camshaft by 90 inrelation to the fully open position).For the exhaust valvesIt is vital to turn the engine in the opposite direc-tion to normal operation (in order to avoid thelocking of the engine), until the valve comes intocontact with tool Mot. 1366-01 (rotate camshaftby 90 in the relation to the fully open position).Extract the tappet shim using a screwdriver and amagnetictool.11232-1RNOTE : during the refitting of the tappet shim,extract any oilwhich may be in the bottom of thepushrod bore( C ) .98895R1REFITTINGRefitting is the reverse of removal.F8QENGINE11-30FUEL MIXTURESpecifications12Vehicle GearboxEngineType SuffixBore(mm)Stroke(mm)Capacity(cm3)RatioCatalyticconverterDepollut-ionstandardXB0A JB1 D7F 720 69 76.8 1 149 9.65/1C53 EU 96Temperature in C ( 1) 0 20 40 80 90Air temperature sensorCTN typeResistance in Ohms5000 to 70001 700 to 3300800 to 1550 - -Coolant temperature sensorCTN typeResistance in Ohms6700 to 80002 600 to3 0001 100 to 1 300270 to300 200 to215EngineType SuffixTests at idle speed*Enginespeed[rpm]Pollutant emission **CO (%) (1) CO2 (%) HC (ppm) Lambda ()Fuel***[minimum octanerating]D7F 720 740 50 0.5max 14.5 min 100max 0.97