Front cylinder head (Renault Espace III)

On the engine installed in the vehicle. Only the front cylinder head can be removed. In this case, it is necessary to keep the camshaft drive chains taut. If for any reason the chain tension is loose, it is necessary to remove the timing cover and refit the chain tensioner. To keep the chain taut, use tool Mot. 589.







To remove the rear cylinder head, you must first remove the engine and gearbox from the vehicle.

Removal

When removing the cylinder head, it is necessary to use the following special tools:

• powertrain support Mot. 1390;
• cylinder head centering bushing puller Mot. 587;
• cylinder liner retainers Mot. 588;
• camshaft sprocket lock Mot. 589-01;
• key with protractor for tightening cylinder head bolts Mot 591-02, Mot 591-04;
• clamp removal pliers Mot. 1202;
• compression clamp Mot. 1209;
• belt tension tester Mot. 1273;
• centering fork of pendulum suspension travel limiter Mot. 1289-02.

Also, when removing the cylinder head, it is necessary to use anti-tilt devices.

• Place the vehicle on a two-post lift equipped with wheel chocks.
• Disconnect the wires from the battery terminals and remove the battery.
• Remove:

protective covers under the engine;

front wheels;

front right and left wheel arches

• Remove the right and left side bumper mounting bolts, disconnect the connectors from the fog lights and remove the bumper.
• Remove the radiator grille and grille cover.
• Drain the coolant from the cooling system by disconnecting the lower hose from the radiator.
• Remove the cooling system components kit.
• Disconnect the exhaust pipe at two points.
• Install a universal stand to support the engine.
• Remove:

pendulum suspension bracket and travel limiter;

air filter with air intake pipe;

filter bracket.

• Remove the intake manifold cover.
• Using a screwdriver, disconnect the accelerator rod from the accelerator cable.
• Turn the throttle sector and remove the cable boss and cable from the sector groove.
• Remove the cable together with the sheath.
• Disconnect:

vacuum hoses from the intake manifold;



high voltage wires from their holders;

fuel injector connectors;

connectors from the ignition power module;

wires from the pressure switch and oil temperature sensor;

connectors from the throttle body;

fuel supply and return lines.

• Between the two sections of the cylinder block, remove the 4 bolts securing the wire harness support bracket and the 5 bolts securing the wire harness support. On the rear cylinder head side, release the wire harness support.
• Remove the injection system control unit and move it to the right together with the electrical wiring.
• Unscrew the bolts securing the fuel distribution line and the pressure damper-regulator unit and remove the unit.

Attention. There are heat-insulating spacers at each attachment point of the fuel distribution line - damper-regulator unit. Do not forget to remove them during disassembly.

• Remove:

the plate connecting the intake manifold to the pendulum suspension bracket,

intake manifold with throttle body;

valve cover.

• Remove the four bolts securing the connecting channel between the cylinder heads
• Remove the rigid tube mounting bolt.
• Disconnect the connecting channel tube between the cylinder heads and the thermostat block tube.
• Remove the exhaust manifold heat shields.
• Remove the heat shield bracket.
• Remove the upper generator mounting bolt.
• Remove the dipstick guide tube.
• Remove the alternator drive belt
• Remove the four upper bolts securing the timing cover to the cylinder head.
• Align the timing marks on the pulleys
• Fit tool Mot. 1209 to the balancing chain tensioner (Fig. 2.5).
• Loosen the balance shaft sprocket mounting bolt, then the camshaft sprocket mounting bolt.
• Remove the balancing chain.
• Remove the balancer sprockets.
• Slide the shaft to remove the counterweight together with the key.
• Fit tool Mot. 589-01 to the timing cover.
• Install the bolt on the camshaft sprocket (2, Fig. 2.19) and the device (3) passing the bolt through the hole in the gear.
• Remove the camshaft sprocket plug.
• Using an Allen key, remove the sprocket mounting bolt
• Loosen the mounting bolt (V) of the camshaft axial stop, remove the stop from the socket and move the camshaft.
• Using a steel rod, push down the cylinder head centering sleeve (Fig. 2.20).

• Remove the cylinder head. To avoid displacing the cylinder liners, remove the head by turning it around the remaining guide bushing.
• Use a syringe to remove the coolant remaining in the cylinder block.
• Using puller Mot. 587, remove the centering bushings from the cylinder block (Fig. 2.21).

• Remove the cylinder head gasket.
• Using a 3 mm diameter punch, ensure the required protrusion of the centering bushings from the cylinder block.
• Use Decapjoint 77 01 405 952 to clean the mating surfaces of the cylinder head and block.
• Do not allow foreign particles to enter the oil supply and return channels: this may lead to blockage of the oil supply holes to the rocker arm shaft and, accordingly, to accelerated wear of the camshaft cams and rocker arm heels.
• Using a ruler and a set of feeler gauges, check for deformation of the cylinder head mating surface. The maximum permissible non-flatness is 0.05 mm. Any processing of the cylinder head mating surface is not allowed.
• In cases where it is necessary to rotate the crankshaft with the cylinder head removed, for example, when replacing the cylinder-piston group to maintain the valve timing, use the special bracket Mot.589 and bolt it to the front cover (Fig. 2.22).

Note: Remove any slack in the timing chain. If the timing is out of phase, you will have to remove the timing cover and reinstall the tensioner.

Installation

• Installation is carried out in the reverse order of removal.
• Apply Autojoint AJ66 (7701 422 751) on the mating surfaces of the timing cover.
• Insert 3mm diameter pins into each of the centering bushing holes and press the bushings into the pins until they stop, to prevent the bushings from shifting during cylinder head installation.
• Remove the bracket of the Mot. 589 tool.
• Install the gaskets on the front cover.
• Install a new cylinder head gasket (without using sealant). The gaskets for the left and right sides of the engine are different. When installing the gasket, make sure that the bolt holes and oil holes are aligned.
• Loosen the camshaft longitudinal movement locking bolt and remove the locking device from the camshaft groove.
• Gently move the camshaft
• Install the cylinder head and install the timing cover mounting bolts and tighten them by hand.
• Install the camshaft and connect it to the sprocket by placing it on the key, but do not tighten it completely.
• Make sure that the stop is at a sufficient distance and does not touch the camshaft flange (Fig. 2.25). Lightly tighten the camshaft sprocket mounting bolt.
• Remove tool Mot. 589-01.
• Move the camshaft towards the sprocket until it stops and tighten the sprocket mounting bolt to the specified torque.
• Remove the 3mm diameter pins from under the centering bushings.
• Install the valve drive with balancing mechanism.

Caution: The balancer shaft key may fall out, so cover the timing gear housing with a rag.

• Tighten the cylinder head mounting bolts in several stages in the sequence shown in Figure 2.26.

step 1 - Tighten all bolts to 60 Nm.

step 2 - Loosen all bolts.

step 3 - Tighten all bolts to 40 Nm.

step 4 - tighten all bolts by 180°.

• No further tightening of the bolts is required. Install the sprocket (A. Fig. 2.27) together with the chain, then the sprocket (B), aligning marks (1) and (2).

• Apply a drop of Loctite FRENETANCH to the threads of the balancer sprocket mounting bolts and tighten them to the specified torque.
• Release the balancer chain tensioner by removing tool Mot. 1209.
• Install the pendulum suspension bracket, the centering fork Mot. 1289-02 for centering the suspension travel limiter and remove the support from under the engine.
• Tighten the pendulum suspension and travel limiter mounting bolts and nut to the specified torque.
• Place the engine in its original position, then remove the centering fork Mot. 1289-02.
• Using tool Mot. 1273, adjust the tension of the alternator drive belt.
• Fill the cooling system with coolant and bleed air from it.
• Adjust the accelerator cable.
• Tighten the spring-loaded exhaust manifold flange mounting bolts until snug.
• Install engine attachments.