Renault Premium Dxi 11 Euro 3 Truck Engine Workshop Manual

20 664 - GB - 07/2005 20 664 20.6 . . . . 20.6 . . . . 50 21 022 130 20.6 RENAULT TRUCKS ENGINE - DXi 11 The above information may change in the course of time. Only the "Consult" section of the workshop manuals repertory in standard N° 10320 serves as reference. RANGE FAMILY VARIANT RENAULT PREMIUM DXi 11 EURO 3 27BC - TR 4X2 LC 120AR+13103 27JC - TR 6X2 Pusher 27RC - PR 6x2 27SC - PR 4x2 27TC - TR 4x2

1 20 664 50 21 022 130 © RENAULT TRUCKS SAS 07/2005 - Imprimé en France - le 08/2005 CONTENTS Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 → 5 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 → 6 — General features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-2 → 3 — Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1 → 1 — Engine lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1 → 1 — Standard tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1 → 1 — Specific tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1 → 27 — Dimensions and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-1 → 23 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 → 13 Consumable products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 → 2 Stripping and mounting on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 → 7 — Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-2 → 2 — Drive belt(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1 → 2 — Stand 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-1 → 5 — Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4-1 → 2 — Air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E5-1 → 1 — Steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6-1 → 1 — Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7-1 → 1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 → 4 — Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-2 → 11 — Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1 → 5 — Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1 → 4 — Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1 → 19 Valve timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 → 8 Reciprocating gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 → 25 Engine cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 → 4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1 → 10 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1 → 4

A-1 20 664 RENAULT TRUCKS 07/2005 GENERALITIES

A-2 20 664 RENAULT TRUCKS 07/2005 Warnings In this document, safety instructions are symbolized as follows: DANGER! NON-OBSERVANCE OF THE PROCEDURE DESCRIBED OR LACK OF CARE OR ATTENTION, RISK CAUSING SERIOUS INJURY OR EVEN DEATH. WARNING! Any different or inappropriate working method risks causing damage to the product. NOTE! Draws attention to particular or important points of the method. Comply without fail with the regulations in force relative to the recovery and treatment of used parts and waste.

A-3 20 664 RENAULT TRUCKS 07/2005 Conventional symbols Fitting Dimensioning Repair Tighten to torque (Nm) (left-hand thread) Tighten by indicated value Tighten to torque (Nm) (right-hand thread) Loosen by indicated value Tightening torque with lubricated threaded hardware Tightening ... Greater than or equal to ... Equal to Wear limit ... Less than ... Machining limit or dimension ... Greater than ... Maximum out-of-true ... Less than or equal to ... Maximum parallelism error Force to be exerted in the direction shown (hammer - press) Smear or coat (see "Consumables" table) Heat or cool: Temperature in degrees Celsius (e.g. + 80 °C) Fill to level (see "Technical Data" and "Consumables" table) Weld bead Grease or oil (see "Consumables" table) Repair time - Heating time Mark - Assemble according to marking

A-4 20 664 RENAULT TRUCKS 07/2005 Adjustment Various information Rotating friction torque Turn anti-clockwise Turn in alternate directions Turn anti-clockwise (the figure shows the number of turns) Turn clockwise Turn clockwise (the figure shows the number of turns) Place in contact Move in the direction shown Dimension to be assured (mm) Exhaust - Outlet Operation with a sequence Intake - Inlet Involves Weight in kg (example: 275 kg) Return to numbered operation - Connected with numbered operation Depending on versions or options Withdraw - Delete Wrong Direction of disassembly (the arrow shows the direction) Correct Direction of assembly (the arrow shows the direction) Injection ... to ... Repair dimension Inspect - Check condition of part Part to be replaced Danger for persons, vehicle or equipment

A-5 20 664 RENAULT TRUCKS 07/2005 General instructions Practical advice Prior to any work: – Clean the major unit and its surrounds (See Driving Servicing Handbook, "Vehicle washing"). – Disconnect the batteries, starting with the negative terminal. – Mark the pipes and wiring harnesses, if necessary. – Protect all ports to prevent the ingress of foreign matter. – Before disconnecting an air pipe, drop the circuit pressure. – If liquid is splashed onto the bodywork, clean quickly with a cleaning product recommended by RENAULT TRUCKS. Raising a vehicle on lifts or elevators – For tyres with size less than or equal to 16 inches, place fork reducers on each lift column. – Position and centre the lift columns. – Release the parking brake. – Raise the vehicle and put safety trestles into place. Preparation prior to assembly: Carefully clean and check all the parts. Do not unpack a new bearing until you are ready to install it. Do not clean off the protective grease on new bearings. Old seals, circlips and lock-plates must be discarded and new ones fitted. Never force fit parts with copper or brass punches or drifts. Always use a specially adapted driver to prevent ingress of metal particles into the casings and bearings. Always oil parts prior to force fitting. Always apply grease on the inside of seal ring lips. Shrink fitted parts are to be heated with a hot air blower or in an oven. etc. Flame heating is strictly forbidden. When using a torque multiplier, calibrate the torque wrench/multiplier unit at the required torque loading. Fastening, locking, sealing and adhesive products: Prior to assembly, carefully clean the product application surfaces of the parts. Old product residue is to be removed. Threaded portions are to be brushed, tapped and, if necessary, cleaned with a suitable product. Using the product: Always adapt the recommended product while observing the utilization conditions appearing on the pack: – Surface finish, – Working temperature, – Reaction, drying, etc. time, – Shelf life. Stick to the assembly method so as to guarantee the quality of the repair. Fuel system Recommendations Observe maximum cleanliness when working on the fuel supply system. Always wash the engine before you start any work. The Spare Parts Department supplies appropriate disposable blanking plugs and storage bags. To avoid the ingress of impurities into the system, blank off all ports with these plugs as soon as you start to dismantle any pipes and store the dismantled parts in these bags. All these recommendations guarantee reliability of the fuel-injection system.

A-6 20 664 RENAULT TRUCKS 07/2005

B1-1 20 664 RENAULT TRUCKS 07/2005 GENERAL DATA

B1-2 20 664 RENAULT TRUCKS 07/2005 General features Identification plate – (1): Engine model – (2): Engine part number – (3): Maximum torque – (4): Engine horsepower – (5): Maximum full load engine speed – (6): Cubic capacity – (7): Idling speed – (8): Fuel injectors type – (9): Exhaust brake – (10): Optifuel option – (11): Engine type approval country – (12): Type approval number – (13): Type approval number – (14): Type approval number – (15): - – (16): Engine type – (17): Smoke index

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Renault Premium Dxi 11 Euro 3 Truck Engine Workshop Manual

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