n.t. 3264a - Clio II : Xb0

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"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The methods may be mod ified as a result of changes introduced by themanufacturer in the p roduction of the various component units and accessoriesfrom which his vehicles are constructed."

C RENAULT 1999

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 w ithout the pr ior written authority of Renault.

77 11 205 875 JULY 1999 Edition Anglaise

N.T. 3264A

- CLIO II : XB0 H K4M 748XB0 L K4J 712

K4J 713XB0 T K4M 748

- MEGANE : XA0 B K4M 700K4M 701

XA0 W K4J 750

XA0 4 K4M 700K4M 701

- LAGUNA : X56 1 K4M 720X56 8 K4M 720

K4M 724

SPECIAL FEATURES OF

K4M - K4J ENGINES

Addition to section K4M of APRIL 1998

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Contents

Page

Engine identification

Tightening torques

Specifications

10-1

10-2

10-4

ENGINE AND PERIPHERALS10

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This Technical Note covers the internal specifications of K4M and K4J engines

following the suppression of the lugs on the crankshaft bearing shells and

the connecting rod bearing shells.

There are two new tools:

- Mot. 1492 : tool for fitting the connecting rod bearing shells,

- Mot. 1493-01 : tool for fitting the crankshaft bearing shells.

Introduction to tool Mot. 1511 for fitting the valve stem seals.

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ENGINE AND PERIPHERALS

Engine identification 10

IDENTIFICATION OF THE ENGINE

The engine is iden tified by a p late riveted on to

the cylinder block.

10034G1

Engine SuffixCapacity

(cm3)

Bore

(mm)

Stroke

(mm)Ratio

K4M

700-701

704-720

724-748

1598 79.5 80.5 10/ 1

K4J712-713

7501390 79.5 70 10/ 1

It shows:

A: The engine type

B: The engine homologation letter

C: The identity of Renault

D: The engine suffixE: The assembled engine factory reference

F: The engine fabrication number

10-1

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Tightening torques (in daN.m or in degrees) 10

* See t ightening procedure page 10-4.

** See section Mot. K4M - page 10-72

*** IMPORTANT: Self tapp ing bolts must be tightened to the correct torque using a torqu e wrench.

Top of engine:

Description Tightening

Air filter unit mounting bolt 0.9

Inlet air d istributor bolt (see tightening order) 0.9

Inlet lower d istributor 2

Throttle body bolt *** 1.3

Oil decanter bolt (see tightening order) *** 1.3

Camshaft bearing block bolt (see tightening order)

Cylinder head coolant pipe housing outlet bolt 1

Camshaft pulley nut 3 plus an angle of 84°

Cylinder head bolt *

Cylinder head suspended mounting nuts and bolts 4.1

Spark p lugs 2.1

Coil bolt*** 1.3

Power assisted steering pump bolt 2.1

Alternator bolt 2.1

Air cond itioning compressor bolt 2.1

Multifunction mounting bolt **

Exhaust manifold nuts (see tightening order) 1.8

10-2

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Tightening torques (in daN.m or in degrees) 10

Peripherals:

Description Tightening torque

Sump bolt (see tightening order) 0.8 and final tightening 1.4

Crankshaft pulley bolt 2 plus an angle of 135 ± 15°

Crankshaft closure plate (see tightening order) 1.1

Flywheel bolt 5 to 5.5

Clutch bolt 1.8

Oil pump bolt 2.2 to 2.7

Big end bolt 4.3

Crankshaft bearing cap bolt 2.5 plus an angle of 47 ± 5°

Water pu mp bolt:

- M6

- M8

1.1

2.2

Timing pulley bolt 4.5

Timing tension wheel nut 2.7

10-3

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Specifications 10

CYLINDER HEAD

The bolts may be re-used i f the l ength under the head does not exceed 117.7 mm (otherwise replace all the

bolts).

Method for tightening the cylinder head

REMINDER: to ensur e correct tighten ing of the bolts, use a syringe to rem ove any oil in the cylind er head

moun ting holes.

Do not lubricate new bolts. If the old bolts are re-used, how ever, they must be lubricated us ing engine o il.

Tighten all the bolts to 2 daN.m in the order recommend ed below.

14500R

Check that all the bolts are tightened correctly to 2 daN.m, then a ngle tighten (bolt by bolt ) by 240° ± 6°.

The cylinder head bolts are not retightened after this procedure has been applied.

10-4

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Specifications 10

Cylinder head gasket thickness

The cylinder head gasket thickness is measu red at

(A) :

- new gasket thickness: 0.96 ± 0.06 mm

- compressed gasket thickness: 0.93±

0.06 mm

14521R

Firing order

1 - 3 - 4 - 2.

Height of cylinder head

H = 137 mm .

14520R

Gasket face bow : 0.05 mm.

No regrinding is permitted.

Check the cyl inder head for any cracks.

Spark p lug tightening torque : 2.5 to 3 daN.m .

10-5

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Specifications 10

Hydraulic tappets

This engine is fitted w ith hyd rau lic tapp ets (A) and

roller va lve rockers (B).

14499R

VALVES

Valve lift (in mm)

Inlet : 9.22

Exhaust: 8.075

Valve stem diameter (in mm)

Inlet : 5.484 ± 0.01

Exhaust: 5.473 ± 0.01

Valve head diameter (in mm)

Inlet : 32.7 ± 0.12

Exhaust: 27.96 ± 0.12

Seat angle

Inlet and exhaust : 90°15’

Valve length (in mm)

Inlet : 109.32

Exhaust: 107.64

VALVE SEATS

Seat angle α

Inlet and exhaust : 89°

Seat width X (in mm)

Inlet : 1.3

Exhaust: 1.4

External diameter D (in mm)

Inlet : 33.542 ± 0.006

Exhaust: 28.792 ± 0.006

87428R

+1.4

0

+1.30

10-6

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Specifications 10

VALVE GUIDES

Length (in mm)

Inlet and exhaust : 40.5±

0.15

External guide diameter (in mm)

Inlet and exhaust : 11

Internal guide diameter (in mm)

Inlet and exhaust

Non machined: 5

Machined * : 5.5

* This dimension is measured with the guide

fitted into the cylinder head .

The inlet and exhau st guides are fitted w ith valve

stem steals which also act as a lower thru st washer

for the valve spring .

Valve stem seals MUST be fitted with tool Mot.

1511.

15771S

Fitting the valve stem seals

Fit the valve into the cylinder head.

Fit the barrel of tool Mot. 1511 over the valve

stem (the internal diameter of the barrel must be

identical to that of the valve stem).

15771-1S

+ 0.0180

+ 0.075

0

15737R

NOTE : do not lubricate the valve stem seals be-

fore f itting them.

+0.068+0.05

10-7

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Specifications 10

Hold the valve against its seat.

Place the valve stem seal (not lu bricated) on the

barrel.

Position the pu shrod (1) over the valve stem seal.

NOTE : the internal diameter of the pushrod must

be identical to that of the valve stem. Also, the

bottom of the pushrod must rest on the part of

the valve stem seal which acts as the low er thrustwasher for the valve spring.

15771-2S

Push th e valve stem seal over the barrel then re-

move the barrel.

15771-3S

15771-5R

10-8

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Specifications 10

Press on the valve stem seal by using the palm of

your hand to tap on the top of the pushrod, un til

the valve stem seal touches the cylinder head .

14563S

Inlet and exhaust guide angle (in degrees)

Inlet : 63° 30’

Exhaust: 66°

14564S

15771-6S

Repeat th e operations above for all the other

valves.

15770S

10-9

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Specifications 10

Position of the inlet and exhaust valve guides (in

mm)

Inlet and exhaust : A = 11 ± 0.15

14518R

CAMSHAFTS

Camshafts are identified by a marking (A).

Details of the m arking (A) :

- references (B) and (C) are for the supp lier only,

- reference (D) is for camshaft identification:

AM = Inlet

EM = Exhaust

14564-1R

Valve springs (in mm)

Free length : 41.30

Length un der load:

19 daN 34.50

59 daN 24.50

Coils touching: 23.30

Internal diameter: 18.80

External d iameter: 27

Oval type wire section.

XXX XXX XX

DB C

10-10

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Specifications 10

End play (in mm)

Between 0.08 an d 0.178.

Nu mber of bearings: 6

Cylinder head camshaft bearing diameter (in mm)

Timing diagram (cannot be checked)

* Since the Inlet Opening Retard is negative,

the op ening of the valve is located after TDC.

** Since the Exhaust Closing Ad vance is negative,the closing of the valve is located before TDC.

14515S

Flywheel side

1

2

3

4

5

6

Timing side

28

25

Camshaft bearing diameter (in mm)

Flywheel side

1

2

3

4

5

6

Timing side

28

25

Inlet

camshaft

Cam 1 Cam 2

Exhaust

camshaft

Cam 1 Cam 2

Inlet

opening

retard*

- 1 - 5 - -

Inlet

closing

retard

18 22 - -

Exhaustopening

advance

- - 18 14

Exhaust

closing

advance**

- - - 8 - 4

A 4 - 1 = Inlet for cylinder 4 and cam n° 1.

E 4 - 1 = Exhau st for cylinder 4 and cam n° 1.

+ 0.061+ 0.04

+ 0.061+ 0.04

0- 0.021

0- 0.021

10-11

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Specifications 10

11953R

1 - Fixed mark for TDC on the cylinder block

2 - Mobile mark on the flywheel for TDC

3 - Mobile mark on the flywheel for BDC

4 - Inle t Opening Retard (IOR)

5 - Exhaust Closing Advance (ECA)

6 - Inlet Closing Retard (ICR)

7 - Exhaust Opening Advance (EOA)

14562R

1 Piston d ir ection Λ flywheel side

2 Supp lier m ar king on ly

3 Piston class (A-B-C)

4 Supp lier m ar king on ly

5 Supp lier m ar king on ly6 Pis ton axis of symmetry

7 Gudgeon pin hole axis

8 Offset between gudgeon pin hole axis (7) and

piston axis of symm etry (6) is:

- 0.9 mm for K4M engines

- 0.8 mm for K4J engines

PISTONS

SMP Piston

The gudgeon pin is fitted using tools A13, C13 and

B10.

The pin is press fitted in the connecting rod an d

fully floating in the p iston.

K4J engine

14562-1R

Piston marking

K4M engine

10-12

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Specifications 10

Marking of the piston diameter in relation to the

cylinder block diameter

Cylinder block barrel class

IMPORTAN T : it is vital to observe matching of

diameters for the pistons and barrels in the cylin-

der block. To do this:the p osition of the holes "T", in relation to the cy-

linder block gasket face, allows identification of

the original nominal barrel dim ension, and conse-

quently the correspond ing piston diameter (see

table below).

Piston mark

Piston

diameter (mm)

Cylinder

diameter (mm)

A

79.470

inclusive

to

79.480

exclusive

79.500

inclusive

to

79.510

exclusive

B

79.480

inclusive

to

79.490

exclusive

79.510

inclusive

to

79.520

exclusive

C

79.490

inclusive

to

79.500

inclusive

79.520

inclusive

to

79.530

inclusive

Position of holes T Class marking

1 = 17 mm A

2 = 27 mm B

3 = 37 mm C

14527R

NOTE : the marking comprises:- 1 gives the d iameter class reference (A-B or C),

- D gives the p osition of the class for each cylin-

der

10-13

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14514R1


Specifications 10

Measurement of piston diameter

The diameter mu st be measured at dimension :

E = 42 ± 0.01 mm for K4M engines

E = 45.7±

0.01 mm for K4J engines .

PISTON RINGS

Three piston rings (thickness in mm)

- Upper p iston ring: 1.2

- Sea ling ring: 1.5- Scraper ring, with 3 parts: 2.5

• two steel rails (1),

• one spr ing r ing (2).

Play at the opening

Piston ringsPlay at the opening

(in mm)

Upper p iston ring 0.225 ± 0.075

Sealing ring 0.5 ± 0.1

Scraper ring 0.9 ± 0.5

10027-1R

Gudgeon pin (in mm)

Length: 61.7 to 62

External d iameter: 19.986 to 19.991

Internal diameter: 11.6 (max.)

10-14

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Specifications 10

Fitting the piston rings

The piston rings, wh ich are set in the factory, mu st

fit freely in their grooves.

Ensure they are fitted the correct way rou nd .

CONNECTING RODS

Big end end play (in mm)

0.31 to 0.604

Distance between big and little end centres (in

mm)

128 ± 0.035

Big end d iameter (in mm)

48.5 ± 0.25

Little end d iameter (in mm)

19.945 to 19.958

IMPORTAN T: never use a punch to mark the big

end caps in relation to their bodies, to preventstarting any cracking in the connecting rod.

Use an indelible pencil.

The maximu m difference in w eight for connecting

rods in the same engine is 6 grammes.

Fitting direction for the connecting rod in relation

to the piston

Position th e "Λ" (1) engraved on the p iston crown

at the top an d p osition the bearing shell stop (2)

on the big end at the bottom (as shown in the

diagram below).

14514S

14513R

10-15

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Specifications 10

CRANKSHAFT

Nu mber of bearings: 5

Roll hardened journals:- nominal d iameter (in mm) see table below.

Roll hardened crankpins:

- nominal d iameter (in mm) : 43.97 ± 0.01

Crankshaft end play (in mm)

- without lateral shim wear: 0.045 to 0.252

- with lateral shim wear: 0.852

Lateral shims ar e fitted to bearing n° 3.

NOTE : the crankshaft stroke is:- 40.25 mm for K4M engines

- 35 mm for K4J engines

Determining the crankshaft bearing shell class

(1st fitting - original size)

Crankshaft marking

There are two dif ferent markings:

Crankshaft journ al diam eter marking (1) and (2):

1st marking (K4M only)

14512R

2nd marking (K4M - K4J)

14512-1R

10-16

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EngineClass marking on

crankshaft

Journal d iameter

(mm)

A = D1

47.990 inclusive

to

47.997 exclusive

B = D2

47.997 inclusive

to

48.003 exclusive

C = D3

48.003 inclusive

to

48.010 inclusive

D = D4

47.990 inclusive

to

47.997 exclusive

E = D5

47.997 inclusive

to

48.003 exclusive

F = D6

48.003 inclusive

to

48.010 inclusive

K4M

K4J

Number of journals

1* 2 3 4 5


Specifications 10

Detail of the first (1) and second marking (2) :

B B C C BDiameter

classes

A = D1

B = D2

C = D3

E F E E EDiameter

classes

D = D4

E = D5

F = D6

* Flywheel end

Table of various journal diameter classes

10-17

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Specifications 10

CYLINDER BLOCK

The diam eters of the bearings (5) on th e cylinder

block are m arked (drilling) on th e block (6) above

the oil filter.

10021R

14527R1

Table of cylinder block bearing diameters

Position of

holes (6)Class mark

Cylinder block

bearing

diameter(in mm)

A = 17 mm 1 or blue

51.936 inclusive

to

51.942 exclusive

B = 27 mm 2 or red

51.942 inclusive

to

51.949 inclusive

NOTE : the marking comprises:

- A - B : gives the d iameter class 1 or 2

Matching of crankshaft bearing shells

D1 or D4 D2 or D5 D3 or D6

C1 =Yellow

1.949 to 1.955

C2 = Blue

1.946 to 1.952

C3 =Black

1.943 to 1.949

C4 =Red

1.953 to 1.959

C1 =Yellow

1.949 to 1.955

C2 = Blue

1.946 to 1.952

1*

2*

Journal diameter class

Bearing shell thickness and class

* Cylind er block crankshaft bearing d iameter class

NOTE : the Parts Departm ent only sup plies class

C2 (blue).

10-18

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Specifications 10

BEARING SHELLS

Crankshaft bearing shells

The engine is fitted with bearing shells which donot have foolproofing .

15197S

10-19

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Specifications 10

Fitting direction

- on the cylinder block, fit grooved bearing shells to all the bearings,

- on the bearing caps, fit grooved bearing shells to bearing caps 2 - 4 an d non-grooved bearing shells to

bearing caps 1 - 3 - 5.

14508S1

10-20

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Specifications 10

Cylinder block

Fit tool Mot. 1493-01 to the cylinder block.

16359R

16359-1S

Fit the bearing shell in tool Mot. 1493-01, then

press at (A)to bring the bearing shell into contactwith tool Mot. 1493-01 at (B).

Bearings

Fit tool Mot. 1493-01 to the bearing.

16357R

16358S

Fit the bearing shell in tool Mot. 1493-01, then

pr ess at (A)to bring th e bearing shell into contact

with tool Mot. 1493-01 at (B).

10-21

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