12 pin RENAULT CLIO 1997 X57 / 1.G Petrol Engines Workshop Manual

ENGINE AND PERIPHERALS
S
pecifications10
PISTONS
The gudgeon pin is press fitted in the connecting
rod and fully floating in the piston.
Direction of mounting: arrow pointing towards
flywheel end.
Gud
geon pins (mm)
Length60
Outside diamete
r19
Inside diamete
r11
Piston markin
g
SMP piston
12618R
Direction of piston: arrow (1) pointing towards
the flywheel end.
The piston class is at (2) (piston class
A - B - C).
The marks (3) are intended for the supplier only.
MARKING OF THE PISTON DIAMETER IN
RELATION TO THE CYLINDER DIAMETER
Piston
markPiston
diameter
(mm)
Cylinder
diameter
(mm)
A75.765 -75.775
(exclusive)75.8 to 75.81
(exclusive)
B75.775 - 75.785
(incl.) (excl.)75.81 to 75.82
(incl.) (excl.)
C75.785 - 75,795
(inclusive)75.82 to 75.83
(inclusive)
Raised metal piston
12617R
10-15
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ENGINE AND PERIPHERALS
S
pecifications10
CRANKSHAFT
Number of bearings5
Roll hardened
journals (mm):
- nominal diameter 54.795 ± 0.01
- repair diameter 54.550 ± 0.005
Roll hardened crankpins (mm)
:
- nominal diamete
r43.98
- repair diameter43.73
End float 0.045 - 0.852 worn
0.045 - 0.252 unworn
There are shims of various thicknesses.
If grinding is carried out, the roll hardening mus
t
remain intact over an angle of 140° in the areas
shown by the arrows.
These areas are defined on sections (A) and (B) ta-
ken as an example.
0
- 0.02
0
- 0.02
79260-1G1
OIL PUMP
Minimum oil pressure at 80
°C:
- Idle spee
d1 bar
- 4000 rpm3 bars
The pump is of the gear pump type.
Remove the cover and the valve of the oil pump.
92313S
Checking the oil pump
Check the clearances:
Clearance
A(in mm) :
- minimum
0.110
- maximum0.249
80142R1
10-17
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Mot. 574-22 Fi
gurineMethod
ReferencePart
NumberDescription
ENGINE AND PERIPHERALS
S
pecial tooling required10
Rou. 15-0100 01 331 601
Mot. 251-0100 00 025 101
Mot. 252-0100 00 025 201Pressure plate for measuring cylinder liner
protrusion. Used with Mot. 251-01.
69306-1S1
83812S
83812S1
68666S
Mot. 330-0100 00 033 001
00 00 057 422Tool for replacing gudgeon pins (kit)
Tool for fitting gudgeon pins (pin with
shoulder), used in conjunction with kit
Mot.
574-22
.
99614S
Mot. 582-0100 00 058 201 Flywheel locking tool.Protector, inside diameter
16 mm
Dial gauge support. Used with Mot. 252-01
Cylinder head support.
77666S1
Mot. 58800 00 058 800 Cylinder liner retaining flange
77889S1
Mot. 591-0200 00 059 102Magnetised flexible tool for angular wrench
for tightening cylinder head.
Mot. 574-2400 00 057 424
10052S
10-21
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Mot. 792-03
Mot. 1132 Fi
gurineMethod
ReferencePart
NumberDescription
ENGINE AND PERIPHERALS
S
pecial tooling required10
Mot. 591-0400 00 059 104
Elé. 1382
00 00 138 200
78181S
10250
82919S1
80359S1
97628S
Mot. 799-0100 00 079 901
80357S
Mot. 1128-0100 00 112 801Tool for fitting crankshaft seal, timing side Angular wrench for tightening cylinder head
( 1/2" drive )
Spark plug wrench kit, limited tightening
torque
Pinion immobiliser for notched timing belt.
68658S
Mot. 1129-0100 00 112 901Tool for fitting crankshaft seal, flywheel side
92645-1S1
Mot. 1135-01
00 00 113 501Timing belt tensioning tool En
gine mounting plate for Desvil stand.
Set of 3 threaded rods for mounting engine
on the
Mot. 792-03. 00 00 079 203
00 00 113 200
Mot. 1127-01
00 00 112 701Tool for fitting camshaft seal
10-22
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ENGINE AND PERIPHERALS
En
gine repair10
Remove:
- the cylinder head cover,
- the inlet manifold,
- the hot air scoop,
- the exhaust manifold,
- the cylinder head bolts except for bolt (F) which
will only be slackened (use a Torx socket 12) in
order to pivot the cylinder head about this bol
t
by tapping it at (G) using a wooden block,Retain the liners using tool
Mot. 588.
Remove:
- the rocker shaft, noting the bolt positions:
• the 2 bolts (B) are solid,
• the 3 bolts (C) are hollow (oil passage).
92106R1
- the cylinder head.
92062R
92064R
10-28
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ENGINE AND PERIPHERALS
En
gine repair10
- the water pump,
92312R
- the three bolts mounting the oil pump sprocket
on the hub, and remove the sprocket and chain
assembly,
- the oil pump.
Carry out the marking of the big end shells with
reference to their bodies.
WARNING: Do not use a scriber tool for the mar-
kin
g, in order to avoid starting any cracks in the
connectin
g rods .
Use an indelible
pencil instead.
Remove:
- the big end shells and the bearings,
- the liner clamps
(Mot. 588),
- the "liners - pistons - connecting rods" assem-
blies,
- the bearing shells with their bearings (mar
k
them),
- the crankshaft (recover the side clearance
shims),
- the crankshaft bearings in the cylinder block.
EXTRACTING THE GUDGEON PINS
Place the piston on the "V" of the support with
the pin lined up with the clearance hole (two
marks (T) showing the centre of the hole assist this
alignment).
Use the extraction mandrel (E) to remove the
gudgeon pin on the press.
76555R
10-36
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ENGINE AND PERIPHERALS
En
gine repair10
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
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
gine repair10
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
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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