B1CJ0KK1 - 406D9 ES9J4 ENGINE

REASSEMBLY ENGINE (CYLINDER BLOCK) (ES9J4)

1 - SPECIAL TOOLS

[-] Stand DESVIL .

[1] Adaptors (-).0187-L .

[2] Fitting drift for crankshaft rear seal (-).0187-H .

[3] Fitting drift for crankshaft front seal (-).0187-G .

2 - REASSEMBLY

Place the cylinder block on the stand [1] .

Clean the joint faces with an approved descaling product .

Clean the threads and taps .

Do not use sharp or abrasive tools .

The joint faces must not have any trace of knocks or scores .

Fit the grooved main bearing half-shells on the cylinder block side .

NOTE : the half-shell (1) is fitted with stop thrust washers .

Check that pin (2) is present .

Always change the O-ring at (A) .

Oil the half shells and the journals .

Fit the crankshaft .

Check that the 8 centralising studs are present (3) .

Fit the new smooth main bearing shells in main bearing cap casting .

NOTE : the half-shell (4) is fitted with stop thrust washers .

Oil the main bearing shells and stop thrust washers .

2 - 1 - CHECK OF THE MAIN BEARING CAP CASTING BOLTS BEFORE RE-USE

Bolt (M11) : (X) must be less than 131,5 mm .

Bolt (M8) : (Y) must be less than 199 mm .

3 - REASSEMBLY (CONTINUED)

Brush the bolt threads .

Coat the threads and the contact area under the bolt head with (G10) grease .

Refit the main bearing cap casting .

Pre-tighten the bolts (M11) to 3 m.daN (From (1) to (8)) .

Pre-tighten the bolts (M8) to 1 m.daN (From (A) to (H)) .

Fit :

• the dial gauge extension [11] on the dial gauge
• the dial gauge [10] to the support [9]

Fit the bracket [9] to the rod [8] .

Fit rod [7] on the cylinder block, on the timing gear end .

Permissible play: 0,1 to 0,3 mm .

IMPERATIVE : if the figures read do not correspond to those indicated, identify the cause of the fault: crankshaft condition, burrs, impurities...) .

Remove the tools [7] - [8] - [9] - [10] - [11] .

Remove :

• the main bearing cap casting

Position :

• the tools [4]
• the bolts (M11)

Run up the bolts (M11) .

Piston and pin must match .

Assemble the connecting rods and the pistons positioning the oil jet hole (B) in relation to the marking identified at (C) on the piston .

Fit :

• the oiled gudgeon pins (5)
• the new retaining rings (6)

Ensure that the con rods turn freely on their pins .

Check that the new main bearing shell is fitted on the con rod big end .

Fit the rings using piston ring pliers :

• (7) scraper ring with its spring
• (8) sealing ring (fit with the TOP mark upward)
• (9) compression ring

Position the ring gaps at 120 degrees to the scraper ring gap .

IMPERATIVE : position the mark identified as (C) on the timing end .

Position :

• 2 rubber end pieces (10) on the connecting rod mountings

Oil the piston rings and cylinder jackets .

Insert the con rod/piston assembly in the corresponding cylinder using a ring compressor .

WARNING : there is a correct way round for the big end caps to be fitted ; the notches of the big end caps half-shells must be opposite the notches of the big end half-shells .

Fit the big end cap with a new oiled main bearing shell .

Clean : The bolts, The nuts .

Coat the big end nuts (thread and contact surface) with G10 .

Tightening is carried out in two stages .

Stage 1 :

• tighten the nuts to 2 da.Nm

Stage 2 :

• finally tighten by turning through 74 °, using the tool [5]

Remove the tools [4] .

IMPERATIVE : carefully degrease the joint face and fill groove (D) up to the ends (E) of the cylinder block with (E10) sealing compound .

Coat the threads and the contact area under the bolt head with (G10) grease .

Refit the main bearing cap casting .

This operation is performed in 3 stages .

Stage 1 :

• pre-tighten the bolts (M11) to 3 m.daN (from (1) to (8))
• pre-tighten the bolts (M8) to 1 m.daN (from (A) to (H))
• bolts (M6) tightening torque 1 da.Nm (from (I) to (XII))

Stage 2 :

• slacken completely, the bolt (1)
• retighten the bolt (1) : 3 da.Nm
• finally tighten by turning through 180 ° (using the tool [5])
• repeat the operation in the order indicated for the other 7 bolts

Stage 3 :

• slacken completely : the bolt (A)
• retighten the bolt (A) : 1 da.Nm
• finally tighten by turning through 180 ° (using the tool [5])
• repeat the operation in the order indicated for the other 7 bolts
• tightening of the plugs (12) fitted with new seals : 4,5 da.Nm

Fit :

• the panel (13)
• a new seal (14)
• the filter gauze (15) : tightening torque 0,8 da.Nm
• a new seal (16)
• the tube (17)
• the sump (18)
• the bolt (19) fitted with a new seal (20)
• the nipple (21), tightening torque: 1,5 da.Nm + E6

Tighten the bolts (In the order shown) (Bolts pre-coated with E3) .

Pre-tighten : 0,5 da.Nm .

Tightening torque: 0,8 da.Nm .

Check the tightening : 0,8 da.Nm .

IMPERATIVE : before fitting the crankshaft seal, ensure that the bottom of the housing is free of sealing compound ; the outer face of the lip seal must be free of all traces of oil .

Fit :

• the crankshaft lip seal using the tool [2]

5 GEARBOX

Check that the centralising pin is present (22) .

Fit :

• the flywheel (23)
• the flange (24)

Lock the flywheel with the stop [6] .

Tighten the bolts to 2 daN.m + E5 .

Finally tighten by turning through 60 ° (Using the tool [5]) .

4 AUTOMATIC GEARBOX

Check that the centralising pin is present (22) .

Fit :

• a new centralising ring (23) coated with AUTOFORM 549
• the crown-wheel carrier (24)
• the spacer washerdistance piece (24a)
• the converter securing plate 24b (sheet of plastic on the engine side)
• the flange (24c) (thickness 6 mm)

Immobilise the crown-wheel carrier using the immobilising tool [6] .

Tighten the bolts to 2 daN.m + E5 .

Finally tighten by turning through 60 ° (Using the tool [5]) .

ALL MODELS

NOTE : the oil pump is fitted with a composite gasket capable of withstanding removal several times : if the gasket is damaged, it can be partially repaired with (E10) jointing paste .

Refit the oil pump .

IMPERATIVE : finger tighten then progressively tighten the securing bolts in the order shown (from (1) to (14)) .

Pre-tighten : 0,5 da.Nm .

Tightening torque: 0,8 da.Nm .

Check the tightening : 0,8 da.Nm .

Fit a new oil seal (25) using tool [3] and the bolt (26) .

Check that the cotter pin is present .

Refit the crankshaft gear .

Tighten the bolt to 4 da.Nm .

Finally tighten by turning through 80 ° (Using the tool [5]) .

Remove the tool [6] .

Peg :

• the crankshaft with the rod [12]