RENAULT CLIO 1997 X57 / 1.G Petrol Engines Service Manual

ENGINE AND PERIPHERALS
En
gine repair10
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
En
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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
En
gine repair10
92317S
91803G1 FITTING THE PISTON RINGS
Mount on the piston:
- the scraper ring (3),
- the taper compression piston ring (2), with the
"To
p" mark facing upwards,
- the upper piston ring (1), with the
"To
p" mark
facing upwards.
Once the seating of all the piston rings has been
adjusted, never alter this seating.
Oil and bed in the piston rings, seating the scrape
r
ring onto a solid part of the groove.Fit the "connecting rods - pistons - piston rings"
assemblies into the liners using the piston ring
compressor.
Before fitting the "liners - pistons - connecting
rods" assemblies into the cylinder block, do no
t
forget to fit the O-ring on each liner, ensuring
that it is not twisted.
Fit the assembly into the cylinder block in the pre-
established order, checking that a
0.1 mm shim
will pass freely between the liners.
92316S 918038630786314
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ENGINE AND PERIPHERALS
En
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Immobilise the liners using tool
Mot. 588.
92062R
Shims of the following thicknesses (mm) are avai-
lable from the Parts Department:
2.80; 2.85; 2.90;
2.95.
Refit the connecting rod shells and tighten the
nuts to a torque value of
4.2 daN.m.
Check:
- the end float of the connecting rods,
- that the assembly is able to rotate properly. Fit the crankshaft and the end float shims.
Lubricate the crankpins and the main bearing
journals with engine oil.
Refit the crankshaft bearing shells.
Apply a thin layer of
RHODORSEAL 5661 on bea-
ring
N°
1 zone (K) and tighten the bolts to
2.5 daN.m , then angle tighten to
43°

± 6°.
Check the end floatof the crankshaft, which
should be between:
-
0.045 and 0.852 mmwith wear,
-
0.045 and 0.252 mmwithout wear.
92314S MOUNTING THE BEARING SHELLS
The connecting rod bearing shells are identical.
The crankshaft bearing shells are grooved on the
cylinder block side.
92315R
The upper shell of bearing
No. 5 is a special one
and is also grooved.
10-42
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ENGINE AND PERIPHERALS
En
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Fit:
- the oil pump, checking that the centring dowls
are present, and tighten to a torque value of
2.5 daN.m,
- the two sprockets and chain of the oil pump,
and tighten the three bolts mounting the
sprocket to the hub to
1 daN.m,
- the crankshaft end cover, 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 be-
low. - the crankshaft seal (bearing No.1), using tool
Mot. 1129-01; this tool is designed to ensure an
offset seal bearing surface. Lubricate the lip
and the outside of the seal.
92319R
92067R
-the crankshaft end seal, using tool
Mot. 1128-
01; lubricate the lip and the outside diamete
r
of the seal.
Turn over the s
pacer if the old seal has marked
the bearin
g surface.
92318R
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ENGINE AND PERIPHERALS
En
gine repair10
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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Method of tightening the cylinder head
90775S
Preseating of the gasket:
Initial tightening to
2 daN, followed by angula
r
tightening to
97°
± 2° in the recommended or-
der:
- tighten bolts
1-2,
- tighten bolts
3-4-5-6,
- tighten bolts
7-8-9-10.
Seatin
g of the gasket:
Wait
3 minutes (settling time).
Ti
ghtening:
- Slacken bolts
1-2.
Retighten bolts
1-2 to
2 daN.m, then angle
tighten to
97
° ±
2°.
- Slacken bolts
3-4-5-6.
Retighten bolts
3-4-5-6 to
2 daN.m, then angle
tighten to
97
° ±
2°.
- Slacken bolts
7-8-9-10.
Retighten bolts
7-8-9-10 to
2 daN.m, then angle
tighten to
97
° ±
2°.
There is no cylinder head retightening operation.Refit the rocker shaft, positioning the mark (1) on
the timing side and the bolts (A) at (B).
92063R
NOTE :
There are two sizes of bolts (A) :
M8×
100
and M8×
125.
Refit:
- the rocker shaft mounting bolts (2), tightening
them to a torque of
2.3 daN.m and not forge
t-
ting to lubricate the threads and underneath
the bolt heads with engine oil,
- the cylinder head cover without tightening i
t
in order to facilitate the setting of the timing,
- the crankshaft sprocket.
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ENGINE AND PERIPHERALS
En
gine repair10
Setting the timing
DI1101R4
(
1) Direction of tensioning of the tension wheel.
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ENGINE AND PERIPHERALS
En
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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
gine repair10
SETTING THE VALVE ROCKER CLEARANCES
Setting values (cold) (in mm):
- inle
t0.10
- exhaus
t0.25
Engine fitted with a CAMSHAFT SPROCKET WITH
NO MARKS
"Tilt" method
Set the valves of the
cylinder concerned to the
end-of-exhaust / start-
of- inlet positionSet the clearance of the
valve rockers of the
cylinder concerned
1
3
4
24
2
1
3Full
y open exhaust valve method
Leave the exhaust valve of cylinder
n
° 1 fully open
and set the clearance of the inlet valve of cylinde
r
n°3and the clearance of the exhaust valve of
cylinder
n
°4.
Proceed similarly for the other cylinders,
following the order shown in the table.
Inlet valve to be se
tExhaust valve to be setExhaust valve to be left fully open
78373R
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