Workshop Repair Manual

Technical Note 3736A

Diesel Engine G9T - G9U
High Pressure - Common Rail
4 cast iron cylinders
Vehicle Type Engine
Master XDXG G9T 720
XDXN G9T 722
XDXN G9T 750
XDXM G9U 720
XDXU - XDXM G9U 724
XDXM G9U 750
XDXU G9U 754
XDXV
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 G9T 702
BJ0F - BJ0G G9T 700, 701
BJ0F G9T 703
Avantime DE01 G9T 712
Trafic XLXD G9U 730

Supersedes Workshop Repair Manual MOT. G9T

77 11 321 202 APRIL 2003 EDITION ANGLAISE

"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by RENAULT.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of
in the production of the various component units and accessories from which his RENAULT.
vehicles are constructed."

© RENAULT 2002
 Contents

Page Page

10A ENGINE AND PERIPHERALS Overhauling the engine

Removing the upper engine 10A-47
Preface 10A-1 Adjusting the timing 10A-50
Cleanliness - Safety 10A-2 Removing the injector holders 10A-61
Engine identification 10A-10 Dismantling the cylinder head 10A-64
Tightening torques (in daNm Cleaning 10A-66
or degrees) 10A-13 Checking the gasket face 10A-66
Specifications Checking the camshaft longitudinal
Cylinder head 10A-17 clearance 10A-67
Pistons 10A-26 Reassembling the cylinder head 10A-68
Con rods 10A-29 Removing the peripherals 10A-72
Crankshaft 10A-31 Extracting the gudgeon pins 10A-75
Bearing shells 10A-32 Fitting con rod bearing shells 10A-75
Piston base cooling jets 10A-33 Refitting the peripherals 10A-79
Preparing the engine to be mounted Con rods/piston assembly 10A-88
on the support 10A-34 Fitting the piston rings 10A-95
Consumables 10A-38 Replacing the oil pump drive pin oil
Precaution 10A-38 deflector 10A-96
Parts to be replaced after removal 10A-38 Fitting the flywheel end crankshaft
Standard replacement 10A-39 seal 10A-96
Special tooling required 10A-40 Special notes concerning engines
Equipment required 10A-45 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
 110A
ENGINE AND PERIPHERALS
Foreword 10A
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 %).

10A-1
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
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.

10A-2
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
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.

10A-3
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
CLEANLINESS ADVICE THAT MUST BE ADVICE TO BE FOLLOWED BEFORE ANY WORK
FOLLOWED WHEN WORKING ON THE HIGH IS CARRIED OUT ON THE INJECTION SYSTEM
PRESSURE DIRECT INJECTION SYSTEM
● Protect the accessories and timing belts, the
Risks relating to contamination electrical accessories (starter, alternator, electric
power assisted steering pump) and the mating face
The system is highly sensitive to contamination. The to prevent diesel fuel spilling onto the clutch friction
risks caused by contamination are: plate.
– damage to or destruction of the high pressure
injection system, ● Ensure that you have the caps for the unions to be
– a component seizing up or leaking. opened (bag of caps sold by the Parts Department -
part no. 77 01 206 381).
All After Sales operations must be performed under Caps are to be used once only. After use, they must
very clean conditions. This means that no impurities be discarded (once used they are soiled and
(particles a few microns in size) should penetrate the cleaning is not sufficient to make them reusable).
system during dismantling or get into the circuits via Unused caps must be discarded.
the fuel unions.
● Ensure that you have resealable plastic bags for
The cleanliness guidelines must be applied from storing removed parts. Parts store in these will be
the filter through to the injectors. less prone to contamination. These bags are single
use; after use they must be discarded.
WHAT ARE THE SOURCES OF CONTAMINATION?
● Ensure that you have lint-free cleaning cloths (part
Contamination is caused by: no. 77 11 211 707). Using a normal cloth or paper
– metal or plastic chips, for cleaning purposes is prohibited. These are not
– paint, lint-free and may contaminate the system fuel circuit.
– fibres; Each cloth must be used once only.
● cardboard,
● from brushes,
● from paper,
● from clothing,
● from cloths.
– foreign bodies such as hair,
– ambient air,
– etc.

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.

10A-4
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
CLEANING ADVICE TO BE FOLLOWED BEFORE
CARRYING 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

OPERATION

● 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.

10A-5
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
CAP FITTING INSTRUCTIONS (part no. 77 01 206 381)

10A-6
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
RAIL PROTECTOR

Model 1

General information

The rail protector isolates the high pressure injection system from the engine compartment.

IMPORTANT
This rail protector ensures safe operation and requires special attention when being fitted.

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
Failure to comply with these instructions may have serious safety-related consequences.

10A-7
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
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.

IMPORTANT
The rail protector ensures safe operation and requires special attention when being fitted.

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
Failure to comply with these instructions may have serious safety-related consequences.

10A-8
 ENGINE AND PERIPHERALS
Cleanliness - Safety 10A
POST-REPAIR CHECK When replacing a high pressure pipe, follow the
method below:
Re-prime the circuit. To do this, turn the low pressure – remove the high pressure pipe, holding the filter rod
pump over by switching on the ignition several times, on the injector with a lock-wrench,
or turn the low-pressure pump over using the fault – insert anti-contamination plugs,
finding tool via the "Actuator commands" menu. – loosen the high pressure rail,
– fit the new high pressure pipe,
After any operation, check that there are no diesel – manually bring the unions together until they touch,
fuel leaks. Run the engine at idling speed until the – tighten to torque:
engine cooling fan is activated, then accelerate ● the high pressure rail mountings,
several times at no load. ● the injector end union,
● the high pressure rail end union.

WARNING
The engine must not run with diesel fuel containing IMPORTANT
more than 10% diester. Dismantling the interior components of the
pump is prohibited.
The system can inject the diesel fuel into the engine at The fuel return pipe fitted to the injectors must
a pressure of up to 1350 bar. Before any operation, be replaced when it is removed.
check that the injector rail is depressurised. The diesel fuel temperature sensor cannot be
removed. It is part of the fuel return rail.
It is vital that you observe the tightening torque: Loosening a high pressure pipe union when the
– of the high pressure pipes, engine is running is prohibited.
– of the cylinder head injector,
– of the pressure sensor and pressure regulator.

When the high pressure pump, injectors and high-

pressure supply, return and output unions are
removed or repaired, all orifices should be fitted
with appropriate new blanking plugs to prevent
contamination entering.

WARNING
All pipes removed must be replaced.

10A-9
 ENGINE AND PERIPHERALS
Engine identification 10A
ENGINE IDENTIFICATION

There are two means of identification.

A) A plate (1) riveted onto the cylinder block.

10A-10
 ENGINE AND PERIPHERALS
Engine identification 10A

A label (2) stuck onto the rocker cover.

A engine type,
B the engine approval letter,
E The engine rating,
F the engine fabrication number,
G the engine assembly factory,
H the assembled engine part number.

10A-11
 ENGINE AND PERIPHERALS
Engine identification 10A
Compression Cubic capacity
Engine Rating Bore (mm) Stroke (mm)
ratio (cc)

700
701
702
703
710
G9T 712 18 / 1 87 92 2188
720
722
742
743
750

720
724
G9U 750 21.25 / 1 89 99 2463
754
730

10A-12
 ENGINE AND PERIPHERALS
Tightening torques (in daNm and/or in degrees) 10A
UPPER ENGINE

Description Tightening torque

Heater plugs 1.5

Injector flange bolt *

Common rail mounting bolt 2.5

High pressure pipe nuts:

– on injectors 2.5
– on the pump and on the rail 2.7

Camshaft bearing cap bolts *

Camshaft hub bolts 6

Camshaft sprocket bolts 0.9

Hydraulic rocker shaft bolts *

Vacuum pump mounting bolts 2.3

Inlet tract bolt on cylinder head *

Rocker cover bolt *

Exhaust manifold nuts 2.7

Cylinder head plenum chamber bolts 1

Turbocharger flange nut 2.7

Turbocharger oil return bolt 0.8

Turbocharger oil supply hollow bolt on cylinder block 2.3

Turbocharger oil supply nut on turbocharger 2.3

Exhaust gas recirculation valve bolt on venturi 1.5

Exhaust heat shield bolt 1

Cylinder head support bolt 4.4

Air conditioning compressor bolts 2.1

Alternator bolts 3

* See tightening procedure.

10A-13
 ENGINE AND PERIPHERALS
Tightening torques (in daNm and/or in degrees) 10A
UPPER ENGINE (continued)

Description Tightening torque

Power assisted steering pump bolt 2.1

Power assisted steering pulley bolt 1

Accessories tension wheel bolt 2.1

Accessories pulley bolt 4.4

Engine lifting ring bolts

– M6 1
– M8 3

Timing belt cover bolt 1

Cylinder head mounting bolts *

Timing tension wheel bolt 2.5

Timing pulley mounting bolt 3

* See tightening procedure.

RAIL PROTECTOR: Model 2

Protector bolts (M6 bolt) 1.2

(M8 bolt) 2.5

RAIL PROTECTOR: Model 1

Lower metal protector bolt (M6 bolt) 1

10A-14
 ENGINE AND PERIPHERALS
Tightening torques (in daNm and/or in degrees) 10A
PERIPHERALS

Description Tightening torque

Sump bolts **

Crankshaft pulley bolts 5 plus angle of 90° ±6°

Flywheel bolts:
– Classic 2 plus angle of 45° ±6°
– Dual mass flywheel 2.5 plus angle of 50° ±6°

Clutch bolts 1.2

Oil pump bolts:

– M6 1
– M8 2.5

Anti-emulsion plate bolts 1

Bolts for split con rod caps 2.5 plus angle of 60° ±6°

Crankshaft bearing cap bolts 2 plus angle of 150° ±10°

Crankshaft bearing cap housing seam bolts 2

Water pump bolts 1

Water pump cover bolts 1

Water pump sprocket nut 5

Piston base cooling jet mounting bolts 2*

Timing cover bolt

– M6 1.2
– M8 3

Alternator bracket mounting bolt 3

High pressure pump mounting bolt 3

High pressure pump rear support bolt 3

High pressure pump sprocket nut 9

Cylinder marking sensor mounting bolt 1

Intermediate shaft mounting bolts 2.5 plus angle of 30° ±6°

Timing belt pulley bolt 3

Oil filter holder mounting bolt 2.2

Dipstick guide mounting bolt

Lower mounting 2.5
Upper mounting 1

Oil level sensor mounting bolt 1

TDC cap mounting bolt 3.1

** See tightening order

* Important: left-hand thread.

10A-15
 ENGINE AND PERIPHERALS
Tightening torques (in daNm and/or in degrees) 10A
LOWER ENGINE (continued)

Description Tightening torque

Coolant pipe bolts 3.1

Venturi mounting bolts 2.2

Catalytic converter mounting nuts 2.1

Catalytic converter stay mounting bolts 2.1

Relay bearing mounting bolts 6.2

Balance shaft cassette mounting bolts 1.5 plus an angle of 38° ±6°

10A-16
 ENGINE AND PERIPHERALS
Specifications 10A
CYLINDER HEAD

Cylinder head bolts must always be replaced.

WARNING
Do not oil new bolts. Bolts must be oiled if reused.

Cylinder head tightening procedure

WARNING
In order to ensure that the bolts are correctly tightened, use a syringe to
remove any oil which may be in the cylinder head mounting holes.

Tighten the cylinder head bolts to torque (3 daNm) and in order.

Check that all the bolts are correctly tightened to 3 daNm then angle
tightening (bolt by bolt) by 300°° ± 6°°.

WARNING
Do not retighten the cylinder head bolts after applying this procedure.

10A-17
 ENGINE AND PERIPHERALS
Specifications 10A
Cylinder head changes

Model 1

This cylinder head has lower washers on the valve

springs.

Marking (1) is made directly on the newly cast cylinder

head.

Model 2

This cylinder head no longer has valve spring lower

washers.

Marking (1) is made after milling.

10A-18
 ENGINE AND PERIPHERALS
Specifications 10A
Cylinder head gasket thickness

There are two cylinder head gasket thicknesses:

Thickness of crushed gasket: 1.16 ± 0.05 mm

1.21 ± 0.05 mm

Cylinder head gasket thickness 1.21 ± 0.05 mm

The thickness of the cylinder head gasket is measured

at (1).

G9T engine

Cylinder head gasket thickness 1.16 ± 0.05 mm

10A-19
 ENGINE AND PERIPHERALS
Specifications 10A
G9U engine Reset the dial gauge on the front of the cylinder block.

Cylinder head gasket thickness 1.21 ± 0.05 mm Apply force to the piston to eliminate the various
clearances (between pin and piston, between pin and
con rod, etc.)

Take the protrusion value at both points (1) and (2),

then take the average of the two measurements.

Note:
All measurements must be carried out along the
longitudinal engine axis, in order to eliminate any
errors due to tilting of the piston.

WARNING
The dial gauge feeler must not be in the valve
clearance.

Note:
When replacing:
– the crankshaft,
– the cylinder block,
– the con rods,
– the pistons.
The thickness of the cylinder head gasket must
be calculated.

Checking piston protrusion

Clean the piston crowns in order to eliminate any

scaling.

Turn crankshaft by one revolution (in the operating

direction, clockwise at the timing end) to bring piston Measure the piston protrusion.
no. 1 close to the top dead centre.
The protrusion must be: 0.399 ± 0.065 mm.
Put tool (Mot. 252-01) in position.

Insert tool (Mot. 251-01) equipped with a dial gauge on

its pressure plate (Mot. 252-01), and find top dead
centre of the piston.

10A-20
 ENGINE AND PERIPHERALS
Specifications 10A
Cylinder head height (mm) H = 90.2 Hydraulic tappet

These engines are equipped with hydraulic thrust

bearings (1) and roller type rocker arms (2).

Gasket face deformation (mm)

Cylinder head 0.05

Cylinder block 0.06

Test the cylinder head to detect any cracks using

the cylinder head test tools, comprising a tray and a kit
suited to the cylinder head (cap, sealing plate,
blanking cover). The approval reference no. of the
cylinder head test tray is 664 000.

10A-21
 ENGINE AND PERIPHERALS
Specifications 10A
Valves Valve seat

Stem diameter (in mm) Seat angle ∝

Inlet: 5.9675 ± 0.0125 Inlet and exhaust: 89°°30'

Exhaust: 5.9575 ± 0.0075
External diameter D (in mm)
Head diameter (in mm)
Inlet: 32.31 ± 0.01
Inlet: 30.6 ± 0.12 Exhaust: 31.11 ± 0.01
Exhaust: 29.5 ± 0.12

Mating face angle

Inlet and exhaust: 90°°15'

Valve length (in mm)

Inlet: 123.2 ± 0.15

Exhaust: 123 ± 0.15

Max valve lift (in mm)

Inlet: 7.8
Exhaust: 7.8

No valve clearance adjustment.

Diameter of housing in the cylinder head (in mm)

Inlet: 32.228 ± 0.0125

Exhaust: 31.032 ± 0.0125

10A-22
 ENGINE AND PERIPHERALS
Specifications 10A
Valve guide The valve stem seals must be fitted using tool
Mot. 1511-01 or other suitable equipment.
Length (in mm)

Inlet and exhaust: 50 ± 0.15

Guide external diameter (in mm)

Inlet and exhaust: 11 + 0.039

+ 0.028

Diameter of guide housing in the cylinder head

(in mm)

Inlet and exhaust: 11

Guide internal diameter (in mm)

Inlet and exhaust:

+ 0.12
Not machined: 5.5 0
Machined*: 6 + 0.022
0

* This value must be obtained with the guide fitted in

the cylinder head.

The inlet and exhaust guides have valve stem seals

which must be replaced each time the valves are
removed.

Note:
Do not lubricate the valve stem seals before fitting
them.

10A-23
 ENGINE AND PERIPHERALS
Specifications 10A
Angle of the inlet and exhaust guides (in degrees) Position of inlet and exhaust valve guides (mm)

Inlet: 95°° Inlet: A = 8.7 ± 0.15

Exhaust: A = 13.3 ± 0.15

Exhaust: 94°°

Valve springs (mm)

Free length: 46.7

Length under load

18.5 daN 40.5
21.5 daN 39.5
24.5 daN 38.5
35 daN 35
45 daN 32
48.3 daN 31
51.5 daN 30

Length of joined spires: 28

Wire diameter: 3.2 ± 0.02

Internal diameter: 14.1 ± 0.2

External diameter: 20.9

10A-24
 ENGINE AND PERIPHERALS
Specifications 10A
Camshaft Longitudinal clearance (mm) 0.05 to 0.13

How to distinguish between camshafts: Number of bearings: 6

– the exhaust camshaft has the vacuum pump
drive (1), Diameter of camshaft bearings (in mm)
– the inlet camshaft has no vacuum pump drive. on the camshafts: 25 -0
- 0.021
+ 0.061
on the cylinder head: 25 + 0.040

Timing diagram
– Inlet opening retardation (ROA) * - 11
– Inlet closing retardation (RFA) 16
– Exhaust opening advance (AOE) 28
– Exhaust closing advance (AFE)** - 13

* If the inlet opening retardation is negative, the

valves open after top dead centre.

** If the exhaust closing advance is negative, the

valves close before top dead centre.

Either by a marking (2): marking details:

● (B) gives the engine type,
● (C) identifies the camshafts (A = Inlet and
E = Exhaust),
● (D) is used by the supplier only.

1 Cylinder block top dead centre fixed marking

2 Flywheel top dead centre moving mark
3 Flywheel bottom dead centre moving mark
4 Inlet Opening Retardation ROA
5 Exhaust Closing Advance AFE
6 Inlet Closing Retardation RFA
7 Exhaust Opening Advance AOE
8 Direction of engine rotation (flywheel end)

10A-25
 ENGINE AND PERIPHERALS
Specifications 10A
PISTONS Table of gudgeon pin heights

Fitting the free floating pin in the con rod and in the G9T
piston.
* Mark on Pin height H Thickness of the
The gudgeon pin is retained by circlips.
piston (in mm) associated
cylinder head
These engines are fitted with KOLBENSCHMIDT
gasket (in mm)
pistons.
E 54.48 1.16
Piston marking
F 54.52 1.16

J 54.56 1.16

K 54.60 1.16

L 54.64 1.16

These pistons have no ducting (oil circulation in the

piston crown contributing to piston cooling).

* Mark on Pin height H Thickness of the

piston (in mm) associated
cylinder head
gasket (mm)

E 54.53 1.21

F 54.57 1.21

J 54.61 1.21

K 54.65 1.21

1 Direction of fitting of the piston ("Λ" flywheel end) L 54.69 1.21

2 Piston height category
3 Used by the supplier only These pistons have no ducting (oil circulation in the
4 Used by the supplier only piston crown contributing to piston cooling).
5 Piston axis of symmetry
6 Gudgeon pin hole axis
7 Offset between axis (5) and axis (6). This offset is
0.5 mm

10A-26
 ENGINE AND PERIPHERALS
Specifications 10A
G9U
* Mark on Pin height H Thickness of the
piston (in mm) associated
cylinder head * Mark on piston Pin height H (in mm)
gasket (mm)
N 53.03
A or T 54.53 1.21
O 53.07
B or U 54.57 1.21
P 53.11
C or W 54.61 1.21
R 53.15
D or X 54.65 1.21
S 53.19
G or Y 54.69 1.21
The tolerance on the pin heights is ± 0.02 mm.
These pistons have ducting (oil circulation in the piston
crown contributing to piston cooling). * The various gudgeon pin heights are exclusively
reserved for the engine assembly factory.
Procedure for distinguishing between pistons with
an identical mark but different pin heights: The Parts Department supplies only the following
piston categories

F and K
U and X
O and R
B and D

Calculation:X = H - 31/2

Example:
– piston of category F with a pin height H = 54.52
Hence X = 54.52 - (31 / 2)
X = 39.02 mm

– piston of category F with a pin height H = 54.57

Hence X = 54.57 - (31 / 2)
X = 39.07 mm

10A-27
 ENGINE AND PERIPHERALS
Specifications 10A
Measuring the piston diameter Fitting the rings

The piston diameter should be measured with Rings are adjusted to their original fitting. They must
A = 49 mm for G9T engines, be free in their grooves.
A = 47 mm for G9U engines.
Ensure the rings' direction of fitting is correct.
Piston diameter (in mm):
86.806 ± 0.007 for G9T engines,
88.81 ± 0.007 for G9U engines.

Gudgeon pin (in mm)

Length 64.7 to 65
External diameter 30.994 to 31
Internal diameter 15.13 ± 0.1

Rings

Three rings (thickness in mm)

Compression ring: 3
- 0.01
Sealing ring 1.75 - 0.025
- 0.01
Scraper ring 2.5 - 0.03

End clearance

Rings End clearance (in mm)

Compression ring 0.2 to 0.35

Sealing ring 0.5 to 0.7

Scraper ring 0.25 to 0.5

10A-28
 ENGINE AND PERIPHERALS
Specifications 10A
CON RODS Lateral clearance of the big end
(in mm) 0.22 to 0.482
The con rods are of the "SPLIT" type.
Big end diametrical clearance
(in mm) 0.027 to 0.086

Big end - small end centre-to-centre distance:

There are four categories of big end - small end

centre-to-centre distance* (mm).

G9T

1 149.8775 ± 0.0075

2 149.8925 ± 0.0075

3 149.9075 ± 0.0075

4 149.9225 ± 0.0075

G9U

5 147.8775 ± 0.0075

WARNING 6 147.8925 ± 0.0075

– The bolts must be coated with engine oil under the 7 147.9075 ± 0.0075
heads and on the threads when the con rods are
fitted on the engine. 8 147.9225 ± 0.0075
– Positioning of the con rod caps on the body is
ensured by textured mating faces. * Marking of the rotating assembly on the original
– Impacts or a foreign body between the body-cap engine is reserved exclusively for the engine
mating faces will cause a rapid fracture of the con
assembly factory.
rod.
– It is vital that the mating faces remain clean and The Parts Department supplies only the following con
dry.
rod category: 3 for G9T engines
– Do not oil the bearing shell pressure faces (cap 7 for G9U engines
side and con rod side).
Big end diameter (mm)
(there are two big end diameters)

+ 0.019
51.587 0
+ 0.019
56.587 0

Small end diameter (mm)

+ 0.025
(without bush) 33.5 0
+ 0.025
(with bush) 31 + 0.013

Note:
The con rod small end bushes cannot be replaced.

10A-29
 ENGINE AND PERIPHERALS
Specifications 10A

WARNING
Do not use a sharp point to mark the big end caps in relation to their
bodies, to prevent incipient breakage of the con rod.

Use a permanent marker pen.

The maximum con rod weight difference for a given motor must be 25 grams.

10A-30
 ENGINE AND PERIPHERALS
Specifications 10A
Direction of fitting of the con rod in relation to the CRANKSHAFT
piston
Number of bushings 5

Crankshaft lateral clearance (mm) 0.06 to 0.232

Crankshaft diametrical clearance (mm) 0.036 to 0.071

Diameter of bushings

The bushing diameters are shown on the crankshaft

by paint marks.

Paint mark Blue Red

57.98
57.99
Bushing diameter inclusive to
inclusive to
(mm) 57.99
58 inclusive
exclusive
Position the "Λ" (1) etched on the piston crown
downwards and lubrication hole (2) on the small end to
Note:
the right of the vertical axis (as shown on the diagram
This paint mark is used only by the factory for
above). Also, the slot (3) should be positioned at the
matching bearing shells and bushings. The Parts
flywheel end.
Department supplies only a single type of bearing
Direction of fitting circlips on the piston shell.

- 0.01
Crankpin diameter (mm) 48 - 0.03
53 - 0.01
- 0.03
The lateral shims are located on bearing no. 2.

NO REGRINDING IS AUTHORISED

The lateral shims have changed: A foolproofing device

has been added. They are not interchangeable. The
foolproofing device helps fitting the lateral shims:
Model 1 (1)
Model 2 (2)

Fit the circlips on the piston as shown above.

10A-31
 ENGINE AND PERIPHERALS
Specifications 10A
BEARING SHELLS Con rod bearing shells

Crankshaft bearing shells These engines are fitted with non-foolproofed

bearing shells.
These engines are fitted with foolproofed bearing
shells.

The bearing shells are fitted using tools Mot. 1492 and
Mot. 1492-02 (with diameter 48 mm or 53 mm).
Direction of fitting:
– on the cylinder block, fit grooved bearing shells on
all the bearings,
– on the bearing caps, fit non-grooved bearing
shells.

Note:
On a given bearing, fit an upper bearing shell and a
lower bearing shell of the same colour.

The bearing caps and cylinder block bearings must be

clean and dry before the bearing shells are fitted.

10A-32
 ENGINE AND PERIPHERALS
Specifications 10A

Piston base cooling jet

WARNING
The piston base cooling jet mounting bolts have a
left-handed thread.

10A-33
 ENGINE AND PERIPHERALS
Specifications 10A
PREPARING THE ENGINE TO BE MOUNTED ON THE SUPPORT

Before the engine is mounted on the support

(Mot. 792-03), the engine's electrical harness must be
removed and the engine oil drained.

Remove the exhaust heat shield.

Remove the turbocharger retaining strut from the

cylinder block (if fitted).

10A-34
 ENGINE AND PERIPHERALS
Specifications 10A
Remove the turbocharger retaining strut and the pre-catalytic converter
retaining strut from the cylinder block (if fitted).

Remove the turbocharger oil supply pipe.

Remove the turbocharger oil return pipe.

Remove the three turbocharger mounting bolts (1).

10A-35
 ENGINE AND PERIPHERALS
Specifications 10A

Remove:
– the exhaust manifold,
– driveshaft relay bearing.

10A-36
 ENGINE AND PERIPHERALS
Specifications 10A

Note:
It is essential to remove the relay bearing centring dowel to enable stud D1
to be correctly positioned.

Position the rods (D), (D1) of tool Mot. 1574 and (T) of Mot. 1301 in the
cylinder block so that they fit into holes 19, 28 and 29 of the plate
(Mot. 792-03).

10A-37
 ENGINE AND PERIPHERALS
Specifications 10A
CONSUMABLES

Type Quantity Component concerned Part no.

Cleaner - Cleaning parts 77 01 421 513

DECAPJOINT Coat Cleaning sealing surfaces 77 01 405 952

RHODORSEAL 5661 Coat Crankshaft bearing cap housing 77 01 404 452

LOCTITE FRENETANCH 1 or 2 drops High pressure pump bolt 77 01 394 070

WARNING

WARNING
The cleanliness rules described at the start of this document must be strictly observed when working on
the fuel supply system.

PARTS TO BE REPLACED AFTER REMOVAL:

– all seals,
– flywheel bolts,
– crankshaft bearing bolts,
– crankshaft pulley bolts,
– con rod cap bolts,
– injector holder copper washers,
– diesel return pipes,
– high pressure pipes,
– pipe caps,
– belts,
– timing tension wheel,
– timing pulley,
– exhaust gas recirculation pipe.

WARNING
Excess sealant could be squeezed out when the parts are tightened; a mixture of sealant and fluid could damage
certain components (engine, radiator, etc.)

10A-38
 ENGINE AND PERIPHERALS
Standard replacement 10A
PREPARING USED ENGINE FOR RETURN

The engine must be cleaned and drained (oil and

water).

Leave on the used engine or include in the return box:

– the oil filter,
– the oil pressure switch,
– the water pump,
– the high pressure pump,
– the rail,
– the injectors
– the heater plugs,
– the diesel fuel collector on rail protector model 2,
– the oil level sensor,
– the cylinder head plenum chamber,
– the water pump coolant inlet pipe,
– the rocker cover,
– the dipstick,
– the vacuum pump,
– the flywheel,
– the clutch.
– the inlet shim assembly,
– the accessories support.

Remember to remove:
– all coolant flexible pipes,
– the exhaust manifold,
– the alternator,
– the power assisted steering pump,
– the air conditioning compressor,
– the rail protector model 1 (entire system),
– the cover of model 2.

The used engine must be secured to the base under

the same conditions as the overhauled engine:
– plastic caps and covers fitted,
– cardboard cover over the assembly.

10A-39
ENGINE AND PERIPHERALS
Special tooling required 10A
Engineering Parts Department part
Description
reference no.

Mot. 11 00 01 072 500 Crankshaft spigot bush extractor

Dial gauge support.

Mot. 251-01 00 00 025 101
Used with tool Mot. 252-01

Dial gauge support thrust plate.

Mot. 252-01 00 00 025 201
Used with tool Mot. 251-01

Magnetised flexible shaft for

Mot. 591-02 00 00 059 102 angle wrench for tightening
cylinder head

Angle wrench with index for

Mot. 591-04 00 00 059 104 tightening cylinder head
(1/2" drive)

Engine support plate for Desvil

Mot. 792-03 00 00 079 203
engine stand (with studs A to W)

Stud ref. "T" for Desvil engine

Mot. 1301 00 00 131 100
stand Used with Mot. 792-03

Flywheel end crankshaft seal

Mot. 1313 00 00 131 300
fitting tool

10A-40
 ENGINE AND PERIPHERALS
Special tooling required 10A
Engineering Parts Department part
Description
reference no.

Mot. 1316 00 00 131 600 Flywheel locking tool

Depth gauge for measuring the

Mot. 1319 00 00 131 900
height of crankpins

Pliers for removing valve stem

Mot. 1335 00 00 133 500
seals

Tool for fitting con rod bearing

Mot. 1492 00 00 149 200
shells

Tool for fitting bearing shells on

split con rods - adaptor for
Mot. 1492-02 00 00 149 202
Mot. 1492 ∅ 48 mm and
∅ 53 mm

Tool for fitting high pressure

Mot. 1503 00 00 150 300
pump nut blanking cover

Mot. 1511-01 00 00 151 101 Tool for fitting valve stem seals

Mot. 1534 00 00 153 400 Inlet camshaft setting tool

10A-41
ENGINE AND PERIPHERALS
Special tooling required 10A
Engineering Parts Department part
Description
reference no.

Mot. 1536 00 00 153 600 Top dead centre locating pin

Mot. 1537 00 00 153 700 Exhaust camshaft setting tool

High pressure pump sprocket

Mot. 1538 00 00 153 800
immobiliser pin

Intermediate sprocket
Mot. 1539 00 00 153 900
immobiliser tool

Tool for aligning the play

Mot. 1540 00 00 154 000
compensation sprocket teeth

Tool for refitting the oil deflector

Mot. 1541 00 00 154 100
on the crankshaft sprocket

Tool for refitting the roll pins on

Mot. 1542 00 00 154 200
the intermediate sprocket shafts

High pressure pump sprocket

Mot. 1548 00 00 154 800
retaining and extraction tool

10A-42
ENGINE AND PERIPHERALS
Special tooling required 10A
Engineering Parts Department part
Description
reference no.

Mot. 1549 00 00 154 900 Injector extraction tool

Tool for fitting timing end

Mot. 1560 00 00 156 000
crankshaft seal

Tool for fitting intermediate shaft

Mot. 1561 00 00 156 100
seal

Mot. 1562 00 00 156 200 Tool for fitting camshaft seal

Flywheel end crankshaft seal

Mot. 1564 00 00 156 400
fitting tool

Tool for removing high pressure

Mot. 1566 00 00 156 600
pipes

Mot. 1573 00 00 157 300 Cylinder head support

Stud ref. "D1" for Desvil engine

Mot. 1574 00 00 157 400
stand Used with Mot. 792-03

10A-43
ENGINE AND PERIPHERALS
Special tooling required 10A
Engineering Parts Department part
Description
reference no.

Lip seal extractor ∅ 28 mm to

Mot. 1577 00 00 157 700
∅ 50 mm

Lip seal extractor ∅ 50 mm to

Mot. 1578 00 00 157 800
∅ 75 mm

Lip seal extractor ∅ 80 mm to

Mot. 1579 00 00 157 900
∅ 95 mm

Set of 3 sleeves for fitting

elastomer seals. This kit is
Mot. 1628 00 00 162 800
needed for tools Mot. 1560,
Mot. 1561 and Mot. 1562

Mot. 1660 00 00 166 000 Balance shaft setting tool

Mot. 1665 00 00 166 500 Flywheel timing pin

Set of clutch disc centring

Emb. 1518 00 00 151 800
mandrels

Clutch compression tool for

Emb. 1604 00 00 160 400 resetting the play compensation
system

10A-44
 ENGINE AND PERIPHERALS
Equipment required 10A
Description

Tool for fitting piston and rings into cylinder liner

Manual extractor for removing the water pump sprocket

Standard 22 mm long "1/2" (12.7 mm square) drive socket for removing the oil pressure
checking gauge

Valve spring compressor

Cylinder head test tools from CULASSE EUROPE SERVICE comprising, for example, a
tray and the various kits for each model of cylinder head (cap, sealing plate, blanking
cover).
The approval number of the cylinder head test tray is 664000

Female torx socket 8/12/14, standard 1/2 (12.7 mm square)

Angle tightening wrench

Tool for fitting valve stem seals

10A-45
 ENGINE AND PERIPHERALS
Equipment required 10A
Description

High pressure pipe wrench

Articulated wrench for removing and refitting heater plugs

Crankshaft spigot bush extractor pliers

Dummy heater plug for measuring the pressure at end of compression

"CROWFOOT" socket for tightening high pressure pipes to torque

10A-46
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
REMOVING THE UPPER ENGINE

Remove the accessories belt by turning the spanner to the left to slacken the
belt.

Lock the tension wheel by inserting a 4 mm Allen key in the hole (1).

10A-47
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove the cylinder head suspended mounting.

10A-48
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove:
– the timing cover,
– the TDC setting rod cap (1).

10A-49
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
ADJUSTING THE TIMING Fit the TDC setting rod (Mot. 1536).

Turn the engine clockwise (timing end), while pressing

Note:
down on the TDC setting rod (Mot. 1536) until it
The camshaft grooves must be vertical as shown in
reaches the timing setting point.
the following illustration (zoom or top view).

Position the top dead centre mark (1) almost vertically

to the engine as shown in the following illustration.

10A-50
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
The inlet and exhaust camshafts are set using tools Place tools Mot. 1534 and Mot. 1537 in the camshaft
Mot. 1534 and Mot. 1537. grooves as recommended below.

For the inlet camshaft:

Fit tool Mot. 1534 SCREWING IN THE BOLT (1) BY

HAND.

Loosen the three camshaft sprocket bolts (2) by up to

one turn.

Turn the inlet camshaft clockwise by the hub mounting

bolt (3) using a 16 mm tubular hexagon box spanner,
so as to pin the tool Mot. 1534 to the cylinder head.

Then lock down the bolt (1) onto tool (Mot. 1534).

10A-51
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
For the exhaust camshaft:

Fit tool Mot. 1537 SCREWING IN THE BOLT (4) BY

HAND.

Loosen the three camshaft sprocket bolts (5) by up to

one turn.

Turn the inlet camshaft clockwise by the hub mounting

bolt (6) using a 16 mm tubular hexagon box spanner,
so as to pin tool Mot. 1537 to the cylinder head.

Then lock down the bolt (4) onto tool Mot. 1537.

10A-52
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Slacken the timing belt by loosening the tension wheel

bolt (1).

Remove the three bolts (2), then remove the exhaust

camshaft sprocket.

Remove:
– the timing belt,
– the inlet camshaft sprocket,
– the camshaft hubs by removing the bolts (3).

10A-53
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
Remove:
– the strut linking the multifunction support to the
venturi unit,
– the power assisted steering pump rear bolt,
– the power assisted steering pump pulley.

10A-54
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove:
– the power assisted steering pump,
– the accessories belt pulley,
– the accessories belt tension wheel,

10A-55
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove the alternator.

10A-56
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove the air conditioning compressor.

10A-57
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
RAIL PROTECTOR Unclip the rail protector from the rocker cover, pushing
it as far back as possible.
WARNING
Remove the sealing partition (2) attached by two nuts
Pay strict attention to the rules regarding
to the rocker cover, holding the stud in place (on some
cleanliness (see start of document).
versions).

Model 1

Unclip the rail protector side partitions (1).

Remove the absorbent soundproofing pads (3).

10A-58
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
Model 2 Remove the diesel fuel drain pipe (3).

Disconnect the oil vapour rebreathing pipe (1). Remove the heater plugs using the correct equipment.

Unclip the protector plastic cover and remove it.

WARNING
When loosening the high pressure pipe nuts (7),
hold the filter-rod retaining nuts (8) with a lock
wrench.

10A-59
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove the injector pipes using tool Mot. 1566 or other suitable equipment.

Remove the high pressure pipe between the high pressure pump and the rail
(using a "CROWFOOT" socket).

WARNING
The clip (6) is very fragile.

10A-60
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
Remove:
– the fuel return pipe (be sure to replace it),*
– the oil vapour recirculation pipe (Model 1).

Fit the anti-contamination blanking covers on the

high pressure pump, the injectors and the high
pressure pipes (set of caps available from the
Parts Department).

* To remove the return pipe, press on the clips then

pull the pipe out vertically. It is not necessary to
remove the clips. If removed, be sure to replace them.

Apply release agent around the injector.

WARNING
Never reuse injector holder mounting bolts. A
special set of studs is available from the Parts
Department.

REMOVING THE INJECTOR HOLDERS

Fit the extractor onto an injector holder.
Loosen the mounting bolts on each injector holder. Tighten the knurled ring to bring the two jaws together
on the flat surfaces without over-tightening.
A special extractor must be used to remove the
injectors.

Never attempt to remove an injector holder locked

in its cylinder head well without using the tool
described below.

Description of the extractor (Mot. 1730 and 1549).

1 Extractor support chassis (1), which is mounted on
the rocker cover mounting bolts. Check that it is
positioned correctly before use.
2 Extractor (2).
3 Extractor bolt (3).

Mount the tool (Mot. 1549 and 1730) chassis on the

rocker cover mounting bolts. Tighten the extraction
bolt until the injector is released from the cylinder
head.

10A-61
 ENGINE AND PERIPHERALS
Overhauling the engine 10A
RAIL PROTECTOR:

Model 1

Remove the washer from the bottom of each injector

well.

Remove:
– the bolt from the clamp (3) securing the rail to the
lower metal protector,
– the three common rail bolts (4), then remove the rail.

Remove:
– the two clips (2),
– the engine lifting eye at the flywheel end,

10A-62
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove: Remove:
– the side partition mounting bolt (5), – the two aluminium protector mounting bolts,
– the lower metal protector mounting bolt (6). – the rail protector.

Remove the rail protector with the side partition.

Model 2

Remove both injector rail mounting bolts, then remove

the rail.

Remove:
– the two aluminium protector mounting bolts,
– the rail protector.

10A-63
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove:
– the rocker cover bolts,
– the vacuum pump,
– the cylinder head plenum chamber.

10A-64
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove the coolant pipe.

10A-65
 ENGINE AND PERIPHERALS
Overhauling the engine 10A

Remove the rocker shafts.

10A-66