Figure 3.35. hole plug (arrow) for screwing the retainer into the cylinder block
To carry out these operations, it is required to install the piston of the first cylinder (flywheel side) to top dead center (TDC) end of the compression stroke. In order to determine this position, Renault uses a special retainer that is screwed into a hole closed by a screw plug in the front of the cylinder block (Figure 3.35).
Operating procedure:
- remove the air filter housing and resonator box from the left side of the engine;
- use a screwdriver to remove the plastic plugs on the left side of the cylinder head that cover the ends of the camshafts;
- remove the right front wheel and plastic fender liner to access the crankshaft pulley;
Figure 3.36. The position of the grooves on the ends of the camshafts: a=30°
- turn the crankshaft using the pulley bolt in the direction of engine rotation until the grooves on the ends of the camshafts are in the position shown in Figure 3.36, and tilt it at an angle of approximately 30°to the horizontal;
- remove the plug from the cylinder block (see Figure 3.35) and screw the latch in completely. In the absence of a retainer, TDC can be determined using a dial indicator screwed into the hole of the spark plug of the first cylinder;
- screw in the TDC lock, then slowly, without jerking, turn the crankshaft by the pulley bolt one turn clockwise (when viewed from the drive side of the gas distribution mechanism) until the shaft rests against the retainer.
This position of the crankshaft corresponds to the presence of the piston of the first cylinder at TDC at the end of the compression stroke.
Figure 3.37. The location of the grooves on the ends of the camshafts when installing the piston of the first cylinder at the end of the TDC of the compression stroke
Make sure that the position of the camshaft grooves corresponds to the position shown in Figure 3.37.
To fix the position of the camshafts, Renault uses a special metal plate that is installed in the grooves of the shafts and attached to the cylinder head. Such a tool is easy to make yourself.
Removing
- disconnect the wire from the negative terminal of the battery;
- apply the parking brake, jack up the front of the car and install safety supports under the body;
- remove the accessory drive belts as described in section 2 (subsection «Check of a condition of driving belts of auxiliary units»);
- set the crankshaft to the TDC position of the piston of the first cylinder of the end of the compression stroke, as described above;
- hang out the power unit by placing a piece of board under the head of the jack;
- remove upper right engine swing arm and travel stop (see Figure 3.09);
Figure 3.38. Removing electrical connectors from the engine (1), hose (2), fastening foot (3), fastening bolt (4) wiring harness bracket
- disconnect (Figure 3.38) electrical connectors 1, disconnect the hose 2, remove the mounting tab 3 and the bolt of the wiring harness bracket 4;
- disconnect the wiring harness from the top cover of the timing gear drive and take it to the side;
- disconnect the fuel lines from the bottom cover of the timing gear drive;
- fix the flywheel with a wide screwdriver and unscrew the crankshaft pulley bolt;
Attention! The bolt is tightened to a very high torque. Be careful.
- remove the crankshaft pulley;
Figure 3.39. Timing belt covers: 1 - lower; 2 - top
- remove the timing belt covers by unscrewing their fastening bolts (Figure 3.39);
- loosen the timing belt by unscrewing the nut securing the tension roller axle;
Attention! The crankshaft toothed pulley is mounted without a key; make sure that it does not fall when removing the timing belt. The keyway on the nose of the crankshaft must be in position «12 hours», if the piston of the first cylinder is at TDC of the compression stroke.
Figure 3.40. Timing belt: 1 - tension roller; 2 - bypass roller; 3 - Tool Mot. 1368 to remove the bypass roller
- remove the bypass roller using the tool (Figure 3.40);
- remove the timing belt;
- inspect the removed belt. When oiling, cracking, tooth wear, delamination and similar defects, the belt must be replaced. It is necessary to find out and eliminate the cause of oiling;
Note. Renault recommends replacing the timing belt every time it is removed, as well as replacing the tensioner and idler rollers.
- thoroughly clean and degrease the crankshaft nose, crankshaft pulley bearing surface, crankshaft sprocket seating surface to prevent their mutual slipping, which can lead to engine failure.
Installation
- install the camshafts as shown in Figure 3.37;
Figure 3.41. Locking the camshafts with a Renault tool
- fix the position of the camshafts using the tool from Renault Mot. 1496 (Figure 3.41) or using a self-made device;
Figure 3.42. Keyway on the toe of the crankshaft (arrow) should be in position «12 hours»
- check that the crankshaft is securely locked with the top dead center tool Mot. 1489 and the crankshaft keyway is in position «12 hours» (Figure 3.42);
Figure 3.43. Groove (A), into which the protrusion of the tension roller should enter
- when installing the tension roller, make sure that the protrusion of the roller fits correctly into groove A (Figure 3.43);
- install the belt on the crankshaft sprocket, then on the water pump pulley, idler pulley, around the camshaft sprockets and tensioner. Make sure the belt is installed in accordance with the arrows indicating its direction;
- tighten the bypass roller mounting bolt to the specified torque;
- install the pulley on the toe of the crankshaft, do not tighten it with a bolt - the gap between the bolt and the pulley should be 2–3 mm;
Attention! The crankshaft pulley bolt is reusable if the length of the bolt to the head does not exceed 49.1 mm (otherwise replace the bolt).
Attention! Do not lubricate the new bolt with engine oil. On the contrary, a reused bolt must always be lubricated with engine oil.
Figure 3.44. Tension roller: A - movable pointer; B - fixed pointer; A' - the position of the movable indicator after adjusting the belt tension; C - hexagon hole
- tighten the belt, for which turn the tension roller clockwise so that the movable pointer A (Figure 3.44) occupied position A' at a distance of 7-8 mm from the fixed pointer B. Rotate the roller with a hex key inserted into hole C. Tighten the pre-tensioning roller to 7 Nm;
- tighten the bolt securing the crankshaft pulley to a torque of 20 Nm, then tighten it by 135°± 15°, while the crankshaft must be locked with the TDC lock;
- remove the tool for fixing the camshafts and the TDC retainer;
- turn the crankshaft two turns clockwise (when viewed from the drive side of the gas distribution mechanism), screw the retainer into the cylinder block until the end of rotation and slowly, without jerking
- bring the crankshaft to the stop position in the latch;
- unscrew the retainer from the hole in the cylinder block;
- loosen the nut of the tension roller axle by no more than one turn, holding the roller from turning with a hex wrench;
- align the movable pointer A with the fixed pointer B and finally tighten the nut to 27 Nm;
- turn the crankshaft again and make sure that the alignment marks match;
Figure 3.45. Installing the camshaft pulleys: A - emblem of the company Renault
If it becomes necessary to remove the camshaft pulleys, then when installing, position them so that the Renault emblem printed on the pulley spokes is at the top in the position «12 hours» (Figure 3.45). When tightening the nuts securing the toothed pulleys, use a device that prevents them from turning.
- first install the upper, then the lower belt covers, securely tightening the bolts of their fastening;
- wrap the hole plug in the cylinder block to determine the TDC;
Figure 3.46. Installing plugs for the ends of the camshafts using a mandrel
- install new plastic camshaft end caps using suitable drifts (Figure 3.46);
- perform the remaining operations in the reverse order of removal.