Renault Diesel Engine G9T G9U Workshop Service & Repair Manual Master Espace Laguna Vel Satis Avantime Trafic # 1

Workshop Repair Manual Technical Note 3736A Diesel Engine G9T - G9U High Pressure - Common Rail 4 cast iron cylinders Vehicle Type Engine Master XDXG XDXN XDXN XDXM XDXU - XDXM XDXM XDXU XDXV G9T 720 G9T 722 G9T 750 G9U 720 G9U 724 G9U 750 G9U 754 Espace (JE0X) XE0K - XE0S G9T 710 Espace IV JK0H G9T 742, 743 Laguna II XG0F G9T 700, 702, 703 Vel Satis BJ0E - BJ0F - BJ0G - BJ0M BJ0F - BJ0G BJ0F G9T 702 G9T 700, 701 G9T 703 Avantime DE01 G9T 712 Trafic XLXD G9U 730 Supersedes Workshop Repair Manual MOT. G9T 77 11 321 202 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." APRIL 2003 All copyrights reserved by RENAULT. EDITION ANGLAISE Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of RENAULT. © RENAULT 2002

Contents Page 10A ENGINE AND PERIPHERALS Preface 10A-1 Cleanliness - Safety 10A-2 Engine identification 10A-10 Tightening torques (in daNm or degrees) 10A-13 Specifications Cylinder head 10A-17 Pistons 10A-26 Con rods 10A-29 Crankshaft 10A-31 Bearing shells 10A-32 Piston base cooling jets 10A-33 Preparing the engine to be mounted on the support 10A-34 Consumables 10A-38 Precaution 10A-38 Parts to be replaced after removal 10A-38 Standard replacement 10A-39 Special tooling required 10A-40 Equipment required 10A-45 Page Overhauling the engine Removing the upper engine 10A-47 Adjusting the timing 10A-50 Removing the injector holders 10A-61 Dismantling the cylinder head 10A-64 Cleaning 10A-66 Checking the gasket face 10A-66 Checking the camshaft longitudinal clearance 10A-67 Reassembling the cylinder head 10A-68 Removing the peripherals 10A-72 Extracting the gudgeon pins 10A-75 Fitting con rod bearing shells 10A-75 Refitting the peripherals 10A-79 Con rods/piston assembly 10A-88 Fitting the piston rings 10A-95 Replacing the oil pump drive pin oil deflector 10A-96 Fitting the flywheel end crankshaft seal 10A-96 Special notes concerning engines equipped with balance shafts 10A-100 Special notes concerning engines not equipped with balance shafts 10A-107 Fitting the intermediate shaft roll pins 10A-111 Replacing the play compensation sprockets 10A-114 Method for replacing the high pressure pump sprocket 10A-116 Fitting intermediate shaft No. 2 seal and the timing end crankshaft seal 10A-119 Fitting the flywheel end crankshaft seal 10A-123 Refitting the upper engine 10A-123 Inlet rocker shaft 10A-124 Exhaust rocker shaft 10A-124 Fitting the camshaft seals 10A-138 Timing adjustment method 10A-147 Timing belt tension 10A-149 Checking the tension and timing 10A-151

ENGINE AND PERIPHERALS Foreword 10A 10A-1 110A ENGINE AND PERIPHERALS Foreword USING THE MANUAL There are two main sections in this manual: – technical specifications, – overhauling the engine. For repairing vehicle components, refer to the Workshop Repair Manual and Technical Notes for the vehicle. UNITS OF MEASUREMENT – All dimensions are given in millimetres (mm) (unless stated otherwise). – Tightening torques are expressed in decaNewtonmetres ( daNm). Reminder: 1 daNm = 1.02 m.kg. – Pressures in bar Reminder: 1 bar = 100,000 Pa . TOLERANCES Tightening torques given without a tolerance must be accurate to within: – in Degrees (±3°) . – in daNm (±10 %).

ENGINE AND PERIPHERALS Cleanliness - Safety 10A 10A-2 Cleanliness - Safety OPERATION The " Common Rail" high pressure direct injection system is a sequential diesel fuel injection system (based on the petrol engine multipoint injection system). This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and produces high engine torque at low engine speeds thanks to a pre-injection process. The low pressure pump (also called the booster pump) supplies the high pressure pump via the pressure regulator filter then the fuel filter during the starting phase only , at a pressure of between 2 and 4 bar. The high pressure pump generates the high pressure, which is transmitted to the injector rail. The pressure regulator located on the pump modulates the high pressure pump supply flow. The rail supplies each injector through a steel pipe. The computer: – determines the injection pressure value necessary for the engine to run correctly and then controls the pressure regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure sensor located on the rail, – determines the injection timing necessary to deliver the right quantity of diesel fuel and the moment when injection should start, – electrically controls each injector individually after determining these two values. The flow injected into the engine is determined by: – the duration of injector control, – the injector opening and closing speed, – the needle stroke (determined by the type of injector), – the injector nominal hydraulic flow (determined by the type of injector), – the high pressure rail pressure, regulated by the computer. THE CLEANLINESS AND SAFETY ADVICE SPECIFIED IN THIS DOCUMENT MUST BE FOLLOWED DURING ANY WORK CARRIED OUT ON THE HIGH PRESSURE INJECTION SYSTEM.

ENGINE AND PERIPHERALS Cleanliness - Safety 10A 10A-3 OPERATING DIAGRAM DESCRIPTION The circuit comprises: – a "pump-sender" supply unit (1) (located in the fuel tank), – a fuel filter ( 2), – a high pressure regulator ( 3) mounted on the pump, – a high pressure pump (4), – an injector rail ( 5) fitted with a diesel fuel pressure sensor and a pressure limiter ( 6), – four solenoid injectors, – various sensors, – an injection computer. Dismantling the interior of the high pressure pump and the injectors is prohibited.

ENGINE AND PERIPHERALS Cleanliness - Safety 10A 10A-4 CLEANLINESS ADVICE THAT MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM Risks relating to contamination The system is highly sensitive to contamination. The risks caused by contamination are: – damage to or destruction of the high pressure injection system, – a component seizing up or leaking. All After Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) should penetrate the system during dismantling or get into the circuits via the fuel unions. The cleanliness guidelines must be applied from the filter through to the injectors. WHAT ARE THE SOURCES OF CONTAMINATION? Contamination is caused by: – metal or plastic chips, – paint, – fibres; ● cardboard, ● from brushes, ● from paper, ● from clothing, ● from cloths. – foreign bodies such as hair, – ambient air, – etc. ADVICE TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM ● Protect the accessories and timing belts, the electrical accessories (starter, alternator, electric power assisted steering pump) and the mating face to prevent diesel fuel spilling onto the clutch friction plate. ● Ensure that you have the caps for the unions to be opened (bag of caps sold by the Parts Department - part no. 77 01 206 381). Caps are to be used once only. After use, they must be discarded (once used they are soiled and cleaning is not sufficient to make them reusable). Unused caps must be discarded. ● Ensure that you have resealable plastic bags for storing removed parts. Parts store in these will be less prone to contamination. These bags are single use; after use they must be discarded. ● Ensure that you have lint-free cleaning cloths (part no. 77 11 211 707). Using a normal cloth or paper for cleaning purposes is prohibited. These are not lint-free and may contaminate the system fuel circuit. Each cloth must be used once only. WARNING Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections. Furthermore, moisture may collect in connectors and cause electrical connection problems.

ENGINE AND PERIPHERALS Cleanliness - Safety 10A 10A-5 CLEANING ADVICE TO BE FOLLOWED BEFORE CARR YING OUT ANY WORK ON THE FUEL CIRCUIT ● Use fresh thinner for each operation (used thinner is contaminated). Pour it into an uncontaminated container. ● For each operation, use a clean brush which is in good condition (the brush must not lose any hairs). ● Use a brush and thinner to clean the unions to be opened. ● Blow compressed air over the cleaned parts (tool and workbench, and the parts, unions and injection system area). Check that no bristles have been left behind. ● Wash your hands before and during the operation if necessary. ● When wearing leather protective gloves, cover them with latex gloves. ADVICE TO BE FOLLOWED DURING THE OPERA TION ● As soon as the circuit is open, all openings must be plugged to prevent system contamination. The caps to be used are available from the Parts Department (part no. 77 01 206 381). They must not be reused under any circumstances. ● Close the resealable bag, even if it has to be reopened shortly afterwards. The ambient atmosphere carries impurities. ● All components removed from the injection system must be stored in a hermetically sealed plastic bag once they have been plugged. ● Using a brush, thinner, air gun, swab or normal cloth is strictly prohibited once the circuit has been opened. These items could allow contamination to enter the system. ● If a component is being replaced, the new component must not be removed from its packaging until it is ready to be fitted on the vehicle.

ENGINE AND PERIPHERALS Cleanliness - Safety 10A 10A-6 CAP FITTING INSTRUCTIONS (part no. 77 01 206 381)

ENGINE AND PERIPHERALS Cleanliness - Safety 10A 10A-7 RAIL PROTECTOR Model 1 General information The rail protector isolates the high pressure injection system from the engine compartment. To fulfil its safety function, the rail protector must consist of: – two soundproofing pads ( 1), to be replaced if they are damaged or soaked with diesel fuel, – a lower metal protector (2) mounted between the rail and the cylinder head, – a diesel fuel drain pipe (3), to be replaced if damaged or soaked with diesel fuel, – a rubber flap ( 4) mounted on the metal protector and the rocker cover, – two side partitions (5), – a partition (6) mounted on the rocker cover (on some versions), – two clips for fixing the side partitions to the rubber flap. Whenever working on the rail protector, make sure the system components are fitted properly after refitting. IMPORTANT This rail protector ensures safe operation and requires special attention when being fitted. IMPORTANT Failure to comply with these instructions may have serious safety-related consequences.

ENGINE AND PERIPHERALS Cleanliness - Safety 10A 10A-8 Model 2 General information The model two rail protector fulfils the same function as model one. This protector is a development which optimises the protection function of the high pressure injection system. To fulfil its safety function, the rail protector must consist of: – two soundproofing pads ( 1) to be replaced if they are damaged or soaked with diesel fuel, – a lower aluminium protector (2) mounted between the rail and the cylinder head, – a diesel fuel drain pipe (3), to be replaced if damaged or soaked with diesel fuel, – a plastic cover (4) mounted on the aluminium protector, – a seal (5) to prevent leaks between the cover and rail protector. Whenever working on the rail protector, make sure the system components are fitted properly after refitting. IMPORTANT The rail protector ensures safe operation and requires special attention when being fitted. IMPORTANT Failure to comply with these instructions may have serious safety-related consequences.

Renault Diesel Engine G9T G9U Workshop Service & Repair Manual Master Espace Laguna Vel Satis Avantime Trafic # 1

You're Reading a Preview

Recently Viewed