двигатель dxi12

RENAULT TRUCKS
20 661 - GB - 12/2004
ENGINE DXi 12
RANGE FAMILY VARIANT

17RD
RENAULT MAGNUM
DXi 12 17SD -
440 - 480
17TD
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.
20 661
20.6
20.6 . . . .
20.6 . . . .
50 21 014 490
20 661 1
CONTENTS
Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 → 5
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 → 6

— General features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-2 → 3
— Cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1 → 1
— Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1 → 1
— Standard tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1 → 1
— Specific tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1 → 19
— Dimensions and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-1 → 22
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 → 14
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 → 2
Stripping and mounting on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 → 10
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 → 3

— Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-2 → 10
— Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1 → 21
— Disassembly/inspection/assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1 → 17
Valve timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 → 3

— Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G1-2 → 8
— Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G2-1 → 5
— Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3-1 → 2
Reciprocating gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 → 2

— Disassembly/inspection/assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-2 → 22
— Pilot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-1 → 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 → 9
— Oil filter(s) and by-pass filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-2 → 2
— Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-1 → 1
— Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-1 → 2
— Oil cooler by-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-1 → 1
— Pistons cooling valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-1 → 2
— Oil filter horizontal by-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I6-1 → 1
— Oil filter vertical by-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I7-1 → 1
— Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I8-1 → 3
— Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I9-1 → 3
© RENAULT TRUCKS SA 12/2004 - Imprimé en France - le 12/2004 50 21 014 490

20 661 A-1
GENERALITIES
RENAULT TRUCKS 12/2004

A-2 20 661
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.

20 661 A-3
Conventional symbols
Fitting
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
Dimensioning
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
Repair
Force to be exerted in the direction shown

Smear or coat (see "Consumables" table)
(hammer - press)
Heat or cool: Temperature in degrees Fill to level (see "Technical Data" and
Celsius (e.g. + 80 °C) "Consumables" table)
Weld bead Grease or oil (see "Consumables" table)
Repair time - Heating time Mark - Assemble according to marking

A-4 20 661
Adjustment
Rotating friction torque Turn anti-clockwise
Turn anti-clockwise
Turn in alternate directions
(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)
Various information
Exhaust - Outlet Operation with a sequence
Intake - Inlet Involves
Return to numbered operation -

Weight in kg (example: 275 kg)
Connected with numbered operation
Depending on versions or options Withdraw - Delete
Direction of disassembly
Wrong
(the arrow shows the direction)
Direction of assembly
Correct
(the arrow shows the direction)
Injection ... to ...
Repair dimension Inspect - Check condition of part
Part to be replaced Danger for persons, vehicle or equipment

20 661 A-5
General instructions
Practical advice
Prior to any work:
– Clean the major unit and its surrounds (See Driving Servicing Handbook, "Vehicle washing").
– Ensure the batteries are disconnected.
– 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.
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 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.

A-6 20 661

20 661 B1-1
TECHNICAL DATA

B1-2 20 661
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
– (15): -
– (16): Engine type
– (17): Smoke index

20 661 B1-3
Engine horsepower and torque
Type designation Maximum horsepower Maximum torque

DXi 12 440 324 KW at 1800 rpm 2000 / 2200* Nm at 1200 rpm
DXi 12 480 353 KW at 1800 rpm 2200 / 2400* Nm at 1200 rpm
(*) Torque values with the "OPTIFUEL" option.
Technical data
Number of cylinders 6
Bore 131 mm
Stroke 150 mm
Cubic capacity 12.13 l
Compression ratio 18.1 / 1

N° 1 cylinder: flywheel end
Direction of rotation: clockwise seen from flywheel end
Firing order 1.5.3.6.2.4

Idling speed 550 → 650 rpm
Max. no-load speed 2120 → 2160 rpm
Max. full load speed 1800 rpm

Fuel: diesel fuel
Supercharged: by turbocharger with intercooler
Engine weight:
With turbocharger: 1155 kg

B1-4 20 661

20 661 B2-1
Cooling circuit
Thermostat
Cooling:
Circulating coolant activated by thermostat-regulated pump.
Beginning of opening: 82 °C
End of opening: 92 °C
Min. full opening dimension: 9.5 mm

B2-2 20 661

20 661 B3-1
Lubrication system
Oil pressure
Main rail oil pressure
Engine speed in rpm Temperature in °C Pressure in bar(s)

600 1.5
85
> 1100 4.3
Rocker shaft oil pressure
Engine speed in rpm Temperature in °C Pressure in bar(s)

Optibrake not
1.0
activated 85
Optibrake activated 2.0
Lubrication: forced by gear pump
Oil: specifications and operating temperatures (see Driving & Servicing handbook).
Oil capacity: (see Driving & Servicing handbook).
Oil filter
Number of full-flow filter(s) 2
Number of by-pass filter(s) 1

B3-2 20 661

20 661 B4-1
Standard tightening torques
Definitions
Tightening torques
There are several types of tightening:
– Tightening to torque (in Nm)
– Tightening to angle (in °)
– Tightening to torque-angle (in Nm + °)
Torques given in Nm are nominal torques (average value calculated on the basis of the minimum torque and the
maximum torque).
The tightening precision class defines the tolerance of this torque in percent as a function of the nominal torque
applied.
For standard threaded hardware, use the following table.
For other torques, see the following page(s).
"FIH" type (Nylstop) locknuts must be replaced whenever removed. "DRH" type (oval) locknuts can be
re-used. If locknuts (DRH, FIH or other) are re-used, make absolutely certain that the screw-thread of the bolt
protrudes least two threads above the top edge of the nut.
Standard nut and bolt tightening torques table
The tightening torque values given in the table are based on standard 01.50.4002 and apply to new nuts and bolts
fitted dry and re-used nuts and bolts with oil applied to the screw-threads. If any nuts and bolts are replaced, it is
absolutely essential to use nuts and bolts recommended by the RENAULT TRUCKS Spare Parts Department
(coefficient of friction in compliance with standard 01.50.4002).
Tightening torques for conventional nut and bolt hardware to "metric system" standard 01.504.002
(H: normal and HE: flanged)
Diameter and pitch of nuts and

Quality class 8.8 Quality class 10.9
bolts
6 x 1.00 10 ± 1.5 12 ± 2
8 x 1.25 24 ± 4 30 ± 5
10 x 1.50 48 ± 8 60 ± 10
12 x 1.75 85 ±15 105 ± 20
14 x 2.00 140 ± 25 175 ± 30
16 x 2.00 220 ± 35 275 ± 45
18 x 2.50 290 ± 45 360 ± 55
20 x 2.50 430 ± 70 540 ± 90
22 x 2.50 580 ± 90 730 ± 120
24 x 3.00 740 ± 120 900 ± 140

B4-2 20 661

20 661 B5-1
Specific tightening torques
Cylinder head
Tighten the bolts in the sequence shown in the illustration.
Stage 1 60±10 Nm
Stage 2 60±10 Nm
Stage 3 90±5 °
Stage 4 90±5 °
Cylinder head plugs
Plug M 10 x 1.00 15±2 Nm
Pre-coated plug M 10 x 1.00 10±2 Nm
Pre-coated plug M 14 x 1.50 30±3 Nm

Plug M 36 x 1.50 60±10 Nm

B5-2 20 661
Camshaft and rocker shaft bearing caps
Tightening the camshaft and rocker shaft bearing cap bolts
Stage 1 15±5 Nm + 90±5 °
During the 2nd stage, the bolts must be tightened progressively to ensure that the rocker shaft descends without
distorting.
Stage 2 60±5 Nm
Stage 3 15±5 Nm +120±5 °
Stage 4 Loosen the bolts

Stage 5 15±5 Nm +120±5 °
Rocker arms
Rocker arm adjusting nuts (see page F-2-19) 60±5 °
Valve yoke adjusting nuts without Optibrake (see page F-2-19) 60±5 ° after contact
Valve yoke adjusting nuts with Optibrake (see page F-2-19) 30+10/- 0 ° after contact
Unit pump injector adjusting screw locknut 52±4 Nm

20 661 B5-3
Cylinder head cover

Tightening the cylinder head cover
Cylinder head cover securing bolts (see page F-2-21) 20±2 Nm
Cylinder head cover securing studs (see page F-2-21) 30±3 Nm

B5-4 20 661
Exhaust manifold
Tightening the exhaust manifold
Engine 440 / 480
Stage 1: tighten bolts 1 ≤ 10 Nm
Stage 2: tighten bolts 2 ≤ 10 Nm

Stage 3: tighten bolts 3 52±4 Nm

Clamps (1) 10±1 Nm

20 661 B5-5
Intake manifold
Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Proceed with assembly within 20 minutes
following application of the silicone .
Use a silicone sealant "CAF 44".
Intake manifold securing bolts 24±4 Nm

B5-6 20 661
Flywheel
Tightening the flywheel bolts
Engine (440 / 480)
Stage 1 60±5 Nm
Stage 2 60±5 °
Flywheel damper
Tightening the flywheel damper bolts
Stage 1 20±3 Nm
Stage 2 90±5 °
The class 8.8 damper hub bolts must not be re-used.

20 661 B5-7
Crankshaft bearing caps

Tightening the crankshaft bearing cap bolts
Stage 1 150±20 Nm
Stage 2 120±5 °
Connecting rod caps

Tightening the connecting rod cap bolts
Connecting rod cap securing bolts 275±15 Nm
Cylinder block stiffener

Tightening the cylinder block lower stiffener bolts
Stage 1: tighten bolts (1 → 6) 48±8 Nm

Stage 2: tighten bolts (7 → 26) 15 Nm + 90±5 °

B5-8 20 661
Flywheel casing
Tightening the flywheel casing bolts
Apply the bead of silicone sealant no more than 20 minutes before

assembly.
Use a silicone sealant "CAF 44".
Flywheel casing securing bolts 140±15 Nm

20 661 B5-9
Timing
Tightening the timing plate bolts
Continuous silicone bead diameter 2 mm
Intermittent silicone bead diameter (zone A) 1 mm
Apply the bead of silicone sealant no more than 20 minutes before assembly.
Apply silicone sealant "CAF 44".
Timing plate securing bolts 33±4 Nm

B5-10 20 661
Tightening the timing gear bolts
Crankshaft pinion securing bolts 645±25 Nm

Crankshaft / water pump idler gear securing bolts 15±3 Nm + 120±5 °
Water pump pinion securing bolts 225±25 Nm
Camshaft idler gear securing bolts 15±3 Nm + 120±5 °
Camshaft pinion securing bolts (see page F-2-13) 35±3 Nm + 90±5 °

Crankshaft / PTO idler gear securing bolts 15±3 Nm + 120±5 °
Hydraulic steering pump pinion securing bolts 100±10 Nm
Oil pump idler gear securing bolts 24±4 Nm

20 661 B5-11
Tightening the crankcase bolts
Tightening
Tighten the crankcase securing bolts in diagonally opposed sequence.
Tighten to torque.
See page(s) B-4-1.

B5-12 20 661
Tightening the upper timing casing securing bolts
Upper timing casing securing bolts (see page(s) F-2-13) M8 bolts = 24±4 Nm
M10 bolts = 48±8 Nm

20 661 B5-13
Oil sump
Tightening the oil sump bolts
Oil sump securing bolts 24±5 Nm
Oil sump drain plug 60±10 Nm

B5-14 20 661
Lubrication
Tightening the oil delivery pipe bolts
Stage 1 10 Nm
Stage 2 1 fitment 180 °
Stage 2 2 fitment 60 °
Oil cooler securing bolts 27±4 Nm
Timing oil jet securing bolts 33±4 Nm
Oil pump securing bolts 24±4 Nm
Oil suction pipe securing bolts 27±4 Nm

Oil jets securing bolts 24±4 Nm
Pressure reduction valve (see page B-6-22) 50±2 Nm
Safety valve (see page B-6-22) 50±2 Nm
Oil filter(s) bracket unit securing bolts 24±4 Nm

Oil filter(s) 25±5 Nm

20 661 B5-15
Oil filter(s) bracket
Plug (1) 55±5 Nm
Plug (2) 40±2 Nm
Plug (3) 55±5 Nm
Bolt (4) dia. M6 10±2 Nm
Oil filter(s) securing sleeve(s) (5) 48±5 Nm
Turbocharger
Turbocharger securing nuts 48±5 Nm
Turbocharger / exhaust pressure regulator securing bolts 28±4 Nm

B5-16 20 661
Cooling
Tightening the water gallery cover bolts
Stage 1: tighten bolts A and B 24±4 Nm
Stage 2: tighten bolts C and D 24±4 Nm
Stage 3: tighten bolts 1 to 4 24±4 Nm
Stage 4: check tightness of bolts C and D 24±4 Nm

Thermostat casing: M8 bolts 24±4 Nm
Thermostat casing: M10 bolts 48±8 Nm
Thermostat union 30±4 Nm
Viscous coupling
Viscous coupling fan / hub securing nuts 26±2 Nm
Air compressor
Air compressor drive pinion securing nuts 704 cm3 270±20 Nm

Air compressor drive pinion securing bolt 704 cm3 85±15 Nm
Outlet union 150±15 Nm
Piloting union 25±3 Nm
Coolant union(s) 35±4 Nm

Lubrication union 25±3 Nm

20 661 B5-17
Unit pump injector securing yoke

New copper sleeves
Stage 1: 20±5 Nm + 180±5 °
Loosen the unit pump injectors securing yokes before second stage tightening.
Stage 2: 20±5 Nm + 60±5 °
Lapped copper sleeves
Stage 1: 20±5 Nm + 60±5 °
Low pressure fuel circuit
Engine ECU cooler piping banjo union 25±5 Nm
Fuel feed pump
Plug(s) (1) 45±5 Nm
Bolt (2) 8±1 Nm
Valve (3) 20±3 Nm
Union(s) (4) 45±5 Nm

Bolt (5) 8±1 Nm
Plug(s) (6) 45±5 Nm

B5-18 20 661
"Optibrake" retarder
Power supply wires securing nut 1.5±0.5 Nm

Control solenoid valve 20±3 Nm
Starter
Starter securing nuts 90±10 Nm

Starter control wire securing nut 3±0.5 Nm
Starter power supply cable M10 securing nut 18±2 Nm
Alternator and tensioner roller
Bolt dia. M10 48±8 Nm
Bolt dia. M12 60±8 Nm

20 661 B5-19
Engine brackets
Engine front bracket securing bolts 160±15 Nm
Engine rear bracket securing bolts 300±30 Nm
Sensors
Oil pressure sensor 30±5 Nm
Oil level probe 7+0/-1 Nm

B5-20 20 661

20 661 B6-1
Dimensions and tolerances
Cylinder head
Type 6 cylinders
Length 1078 mm
Width 397 mm
Height 135 mm
Weight 155 kg
Maximum flatness fault (bottom face) 0.1 mm
The lower face of the cylinder head cannot be ground.

B6-2 20 661
Valves
Valve heads diameter
Inlet / exhaust 40 mm
Valve stems diameter
Inlet / exhaust 8 mm
Facing angle
Valve end (A)
Inlet: 29.5 °
Exhaust: 44.5 °
Cylinder head end (B)
Inlet: 30 °
Exhaust: 45 °
Technical data
Valves set-back in relation to cylinder head face
Max. wear tolerance
Inlet: 0.9 → 1.4 mm 1.5 mm
Exhaust: 1.2 → 1.7 mm 1.8 mm
If the valve seats are replaced, replace the valves.
Valve clearances
Adjustment values, engine cold:
Inlet 0.2 mm
Exhaust without Optibrake 0.5 mm
Exhaust with Optibrake 1.6 mm
Inlet 0.15 → 0.25 mm
Exhaust without Optibrake 0.45 → 0.55 mm
Exhaust with Optibrake 1.55 → 1.65 mm

20 661 B6-3
Valve seats
Diameter (A)
Inlet / exhaust: 43+0.070/+0.086 mm 43.3 mm
Height (B)
Inlet: 7.25±0.1 mm
Exhaust: 8.0±0.1 mm
Valve seat housings
Diameter (C)
Inlet / Exhaust: 43+0.025 mm 43.2 mm
Depth (D)
Inlet / Exhaust: 11.2±0.13 mm
Radius (R)
Inlet / Exhaust: 0.8 mm max.

B6-4 20 661
Valve guides
Length (L)
Inlet 83.2 → 83.5 mm
Exhaust 83.2 → 83.5 mm
Inside diameter (D)
Inlet 8 → 8.015 mm
Exhaust 8 → 8.015 mm
Protrusion in relation to springs support face
Inlet 26.5 ± 0.4 mm
Exhaust 26.5 ± 0.4 mm
Max. clearance between valve stem and valve guide
Inlet < 0.2 mm
Exhaust < 0.2 mm

20 661 B6-5
Valve springs
Inlet and exhaust valves outer spring
Length uncompressed 73.8 mm

Length under a load of 590±40 N 58.4 mm
Maximum solid coil length 39.5 mm
Inlet and exhaust valves inner spring
Length uncompressed 70.5 mm

Maximum solid coil length 36.5 mm
Rocker arms
Bearing play ≤ 0.1 mm
Roller play ≤ 0.1 mm

B6-6 20 661
Timing
Timing gears
Number of teeth
(1) - Crankshaft drive pinion 38
(2) - Coolant pump idler gear 83
(3) - Coolant pump drive pinion 27
(4) - Air compressor drive pinion 29
(5) - Camshaft drive pinion 76
(6) - Idler gear (adjustable) 97
(7) - Steering pump drive pinion 23
(8) - Driver (fuel feed pump and pulley) 27
(9) - Hydraulic pump idler gear 71
(10) - Hydraulic pump drive pinion 39

(11) - Oil pump drive pinion 23
(12) - Oil pump drive idler gear 44
Play, clearances and diameters
Backlash 0.05 → 0.17 mm

Idler gear hub diameter 99.99±0.01 mm
Idler gear ring diameter 100.04±0.01 mm
Idler gear radial play ≤ 0.07 mm

Idler gear end play ≤ 0.17 mm

20 661 B6-7
Camshaft
Drive Pinion
Camshaft bearings
End float < 0.24 mm
Number of bearings 7
Main bearing journals diameter 69.97 → 70.00 mm
Run-out (with new bearings) < 0.05 mm
Permitted bearing diameter wear < 0.05 mm
Central bearing coaxiality < 0.12 mm
Repair dimensions
- 0.25 mm 69.72 → 69.75 mm
- 0.50 mm 69.47 → 69.50 mm
- 0.75 mm 69.22 → 69.25 mm
Bearing half-shells
Original thickness 1.92 mm
Repair dimensions
0.25 mm 2.04 mm
0.50 mm 2.17 mm
0.75 mm 2.29 mm

B6-8 20 661
Cams
Valve lift
Inlet 13.1 mm
Full cam profile wear ≤ 0.1 mm
Unit pump injector travel 17 mm
Checking the camshaft timing
With the engine cold and zero N° 1 cylinder valve clearance.

N° 1 cylinder inlet valve must be open by 1.6±0.3 mm when the flywheel is at 6 ° after top dead centre.
For this check, the timing gears must be turned in the correct direction (rotated clockwise, seen from the front)
in order to eliminate any backlash.

20 661 B6-9
Crankshaft
Length 1203 mm
Main bearing journals
∅)
Diameter (∅ 107.978 → 108.0 mm
Run-out < 0.08 mm
Taper < 0.05 mm
Crankshaft bearing radial play (*) 0.01 → 0.15 mm
(*) The play values apply to oiled parts.
Central bearing coaxiality < 0.15 mm
Repair dimensions
- 0.25 mm 107.728 → 107.75 mm
- 0.50 mm 107.478 → 107.50 mm
- 0.75 mm 107.228 → 107.25 mm
- 1.00 mm 106.978 → 107.00 mm
- 1.25 mm 106.728 → 106.75 mm

B6-10 20 661
Surface finish (main bearing journal) Ra 0.25
Surface finish (radius) Ra 0.4
Fillet radius (R) 3.75 → 4.00 mm
Bearing half-shells
Outside diameter (C) 113.0 mm

Thickness (D) 2.485 → 2497 mm
Repair dimensions
+ 0.25 mm 2.610 → 2.622 mm
+ 0.50 mm 2.735 → 2.747 mm
+ 0.75 mm 2.860 → 2.872 mm
+ 1.00 mm 2.985 → 2.997 mm
+ 1.25 mm 3.110 → 3.122 mm
Crankshaft end float (*) 0.10 → 0.40 mm
Central main bearing journal
Width, thrust half-ring (A) 46.97 → 47.02 mm
Repair dimensions
+ 0.2 mm (end bearing 0.1) 47.17 → 47.22 mm
+ 0.4 mm (end bearing 0.2) 47.37 → 47.42 mm
+ 0.6 mm (end bearing 0.3) 47.57 → 47.62 mm
+ 0.8 mm (end bearing 0.4) 47.77 → 47.82 mm

20 661 B6-11
Thrust half-rings
Width (B) 3.14 → 3.21 mm
Repair dimensions
+ 0.1 mm 3.24 → 3.31 mm
+ 0.2 mm 3.34 → 3.41 mm
+ 0.3 mm 3.44 → 3.51 mm
+ 0.4 mm 3.54 → 3.61 mm

B6-12 20 661
Crankpins
Width (A) 56.9 → 57.0 mm

∅)
Diameter (∅ 91.978 → 92.0 mm
Big end diameter(D) 96.835 → 96.85 mm
Run-out < 0.08 mm
Taper < 0.05 mm
Repair dimensions
- 0.25 mm → 91.75 mm
91.728→
- 0.50 mm 91.478 → 91.50 mm
- 0.75 mm 91.228 → 91.25 mm
- 1.00 mm 90.978 → 91.00 mm
- 1.25 mm 90.728 → 90.75 mm
Surface finish (crankpin) Ra 0.25
Surface finish (radius) Ra 0.4
Fillet radius (R) 3.75 → 4.00 mm

20 661 B6-13
Crankpin half-shells
Outside diameter(B) 96.835 → 96.85 mm

Thickness(C) 2.384 → 2.396 mm
Repair dimensions
+ 0.25 mm 2.509 → 2.521 mm
+ 0.50 mm 2.634 → 2.646 mm
+ 0.75 mm 2.759 → 2.771 mm
+ 1.00 mm 2.884 → 2.896 mm
+ 1.25 mm 3.009 → 3.021 mm

B6-14 20 661
Connecting rod
Between-centres length (E) 259.95 → 260.05 mm
Small end bush inside diameter (G) 55.022 → 55.028 mm

Big end diameter(D) 96.835 → 96.85 mm
Connecting rod / crankshaft end play (*) < 0.25 mm
Connecting rod / crankshaft radial play (*) < 0.10 mm
Deviation in straightness for a measured length of 100 mm < 0.06 mm
Deviation in torsion for a measured length of 100 mm < 0.15 mm

20 661 B6-15
Identification marking
The connecting rod and its cap are paired and marked with a 3-figure identification marking (*).
(*) With the identification markings opposite one another.
The marking "FRONT" must be directed towards the front of the engine (N° 1) cylinder.

B6-16 20 661
Piston
∅)
Piston skirt diameter (∅ 130.940±0.009 mm
Distance (D) 42±0.3 mm

20 661 B6-17
Gudgeon pin housing diameter(s)
∅1 at D3 = 46.5 mm 55.00+0.005/+0.13 mm
∅2 55.01±0.005 mm
∅3 at D2 = 35.5 mm 55.00+0.045/+0.065 mm
∅4 at D1 = 35.5 mm 55.016±0.005 mm
Combustion chamber diameter 89±0.1 mm

Combustion chamber depth 17.14±0.1 mm
Number of piston ring grooves 3
Front marking Arrow facing towards the front

B6-18 20 661
Piston rings
Gap clearance
Top ring Trapezoidal section
Compression ring 0.09 → 0.13 mm
Oil scraper ring 0.05 → 0.10 mm
Gap clearance
Top ring 0.4 → 0.65 mm
Compression ring 1.4 → 1.6 mm
Oil scraper ring 0.35 → 0.75 mm
Liners
Type wet / detachable
Diameter 131+0.02 mm
Height 272.8±0.18 mm
Protrusion above cylinder block surface 0.15 → 0.21 mm
Number of seals 3+1
Cylinder block
Length 1052 mm
Maximum flatness fault (top face) 0.06 mm
Flywheel
Flywheel installed
Run-out (measured radius 150 mm) < 0.2 mm
Number of ring gear teeth 153
Flywheel sensor groove(s) 3 x 18

20 661 B6-19
Flywheel casing
Flywheel casing installed
Axial run-out of contact face against clutch casing < 0.20 mm
Radial positioning play against clutch casing < 0.25 mm
Sensors
Camshaft speed sensor air gap 0.3 → 1 mm

Flywheel engine speed sensor air gap 0.7 → 2.1 mm
Fuel-injection
Low pressure fuel circuit
Supply pressure at 600 rpm ≥ 1 bar(s)
Supply pressure at 1400 rpm ≥ 3 bar(s)

Supply pressure at full load ≥ 3 bar(s)
Regulation pressure 3.6 → 4.2 bar(s)
High pressure fuel circuit

Unit pump injectors
Screw up the adjusting screw to cancel out the camshaft play, then turn through 1/2 to 2/3 of a turn.
Adjustment
Delphi: 1/2 -> 2/3 of a turn

(refer to the illustration) 0.75±0.1 mm

B6-20 20 661
Exhaust pressure regulator (ATR)
Valve flap travel (A) ≥ 29 mm

20 661 B6-21
Oil pump
Type Gear driven
Diameter
Idler gear hub 69.99±0.01 mm
Idler gear bush 70.04±0.02 mm
End play
Pump drive pinion 0.11 mm

Idler gear 0.10 mm
Distance between drive pinion and pump body fastening 1.0 → 2.4 mm

B6-22 20 661
Pressure and pressure relief valves
(1) - Safety valve Marking: Yellow
(2) - Oil cooler by-pass valve Marking: 124
Spring length
Uncompressed Under load
(3) - (5) - Oil filter by-pass valve 69 mm 40 mm for

13 → 15 N
(4) - Pistons cooling valve Marking: Orange
(6) - Pressure reduction valve Marking:Blue

20 661 C-1
TOOLS

C-2 20 661
Generalities
RENAULT TRUCKS divides tools into three categories:
– General-purpose tools: proprietary tools

• 50 00 26.... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department).
• 4-figure reference number (tools classified by RENAULT TRUCKS but available from the supplier).
– Special tools: specifically created tools distributed by the RENAULT TRUCKS Spare Parts Department
• To be ordered according to the reference numbers appearing in the list of tools on the following pages.
– Locally manufactured tools:

• 4-figure reference number (represented by a drawing): tools that are simple to make without need for
special qualification.
Three levels (or echelons) determine their assignment:

– Level 1: tools for servicing, maintenance and minor tasks
– Level 2: tools for major repairs
– Level 3: tools for refurbishment
Proprietary tools mentioned in this manual do not appear in the tools list.
These tools are identified in the standard tools manual (MO) by a 4-figure number.

20 661 C-3
LIST OF TOOLS
General-purpose tools
Manufac- Manufac-
RENAULT
Illustration Designation turer turer Level Qty
TRUCKS Ref.
reference code
5000261000 Universal stand 1 1
Dial gauge +
9661 AQ 1 1
magnetic foot
5000260843 Puller 2 1
5000260857 Puller 2 1
5000260819 Unsticker 2 1
5000260837 Puller 2 1
50002600918 Puller 2 1

C-4 20 661
5000269804 Strap 2 1
Piston ring
5000260825 2 1
clamp
Piston ring
5000260824 2 1
clamp
5000260978 Puller 2 1
AQ
BROWN SHARP ROCH
13-15 avenue Georges de la Tour

BP 45
FRANCE
54303
LUNEVILLE CEDEX
! 03 83 76 83 76 " 03 83 74 13 16

20 661 C-5
Special Tools
Manufac- Manufac-
RENAULT
TRUCKS Ref.
reference code
5000262699 RH support 2 1
5000262698 LH support 2 1
Engine
7409996956 1 1
cranking bar
7409990185 Lifting tool 1 1
Camshaft
7409998264 1 1
handling tool
7409998511 Lever 1 1
Unit injector
7409998249 protection 1 6
sleeve

C-6 20 661
Fuel injector
7409998251 1 6
blanking plug
7409998599 Cleaning kit 2 1
Cylinder head
7409998601 2 1
positioning tool
Cylinder head
7409998624 2 1
positioning tool
7409998628 Press tool 1 1
7409998602 Press tool 1 1
7409996222 Hydraulic pump 2 1
7409990176 Press tool 2 1

20 661 C-7
7409809729 Jack 2 1
7409996159 Adapter 2 1
7409998246 Mandrel 2 1
7409998263 Pusher 2 1
7409998250 Blanking plug 1 1
7409998252 Tapping tool 2 1
7409998253 Puller 2 1
7409998666 Blanking plug kit 2 1

C-8 20 661
7409998266 Bar 2 1
7409998668 Blanking plug kit 2 1
Pressure
7409996662 1 1
reducer
5000263016 Handle 1 1
5000262363 Set of pushers 1 1
7409990032 Driving cup 1 1
7409998688 Opening out tool 2 1
7409998261 Mandrel 2 1

20 661 C-9
Press fitting
7488800011 2 1
cone
7409998619 Driving cup 1 1
7409990068 Press 1 1
7409996950 Retainer 2 1
7409998267 Dowels 2 1
7409996401 Front plate arm 2 1
Rear seal puller

7409998238 2 1
/ pusher
7409992000 Mandrel 2 1

C-10 20 661
7409996400 Puller 2 1
7409990192 Puller 2 1
7409990166 Pusher 2 1
5000261207 Hook 2 1
5000261230 Puller 2 1
7409992955 Plate 2 1
Dial gauge
5000261141 2 1
support
7409996599 Pusher 2 1

20 661 C-11
7409998517 Adjuster 1 1
5000262655 Filter wrench 1 1
7409998598 Socket 1 1

C-12 20 661
Locally manufactured tools
Manufac- Manufac-
RENAULT
TRUCKS Ref.
reference code
3241 Hook 1 3
1462 Spacer 2 3
2899 Blanking plugs 2 1

20 661 C-13

C-14 20 661

20 661 D-1
CONSUMABLES

D-2 20 661
Lubricants
Consumables and oil capacity: (see Driving & Servicing Handbook).
LIST OF CONSUMABLES
Automotive reference Industrial reference
CAF 44 SILICONE SEALANT CAF 44
FRENETANCH 242 THREAD LOCKING COMPOUND 242

20 661 E-1
STRIPPING AND MOUNTING ON STAND

E-2 20 661
Mounting
Right-hand side
Disconnect flexible pipes (1).
Remove the oil filter bracket / filters assembly (2).
Left-hand side
Unscrew the fuel pipe unions.
Unplug connector (3).
Remove fuel filter bracket (4).
Unscrew the fuel pipe unions.

Disconnect and remove engine ECU (5).
Disconnect and remove electronic box (6) from the wiring harness.

20 661 E-3
Right-hand side
Mount tool 2699.
Left-hand side
Mount tool 2698.

E-4 20 661
Mount the engine to stand 1000.
Removal from stand 1000

Proceed in the reverse sequence of mounting to stand 1000.
Tighten to torque.
See page(s) B-5-17.
See page(s) B-4-1.

20 661 E-5
Fan
Removal of fan
Withdraw nuts (1).
Remove fan (2).
Fitting
To fit, proceed in the revere sequence to removal.
Tighten to torque.
See pages B-5-16.

E-6 20 661
Alternator
Removal
Using a lever, compress tensioner roller spring (2) to disengage the

drive belt.
Remove alternator (1).
Remove the tensioner roller (2) from its bracket.
Remove the alternator bracket (3).
Fitting
Tighten to torque.
See pages B-5-18.
Belt tensioner
Removal
Remove tensioner (1).
Fitting
Tighten to torque.
See page(s) B-5-18.

20 661 E-7
Fan control
Removal of fan control
Remove pulley (1).
Remove hub (2).

Tighten to torque.
See pages B-4-1.
Starter
Removal
Disconnect earth cable (1).

Unscrew nuts (2).
Remove starter motor.
Fitting
To fit, proceed in the reverse sequence to removal.
Tighten to torque.
See pages B-5-18.

E-8 20 661
Air compressor
Removal
Disconnect hose (1).
Disconnect hose (2).
Remove securing nuts and bolts (3).

20 661 E-9
Remove the compressor (4).
Fitting
Replace O-ring with a new O-ring.
Tighten to torque.
See pages B-5-16.

E-10 20 661
Water pump
Removal
Remove tube (1).
Remove securing nuts and bolts (2).
Remove water pump unit (3).
Fitting
Install a new O-ring lubricated with soapy water.
Tighten to torque.
See pages B-4-1.

20 661 F1-1
CYLINDER HEAD

F1-2 20 661
Removal
Removal of cylinder head
Disconnect and remove preheater body (1).
Remove fuel pipe fastenings (2).
Remove boost air pressure sensor (3).

20 661 F1-3
Remove cylinder head cover (4).
Disconnect the wiring harness from injectors (19).
Depending on the equipment, disconnect the Optibrake control

solenoid valve.
Remove stuffing box (16).

F1-4 20 661
Take the wiring harness out of the cylinder head.
Remove bushing (17).
Remove temperature sensor (18).

Remove tube (19).
Blank off the cylinder head fuel ports to prevent the ingress of
impurities.
Remove inlet manifold (20).
Remove the inspection plate.

Mount tool 6956.

20 661 F1-5
Line up pointer (4) with the flywheel TDC mark
The camshaft TDC mark must be positioned between the camshaft

front bearing cap marks.
Disconnect oil return pipe (6).
Disconnect and remove the exhaust pressure regulator (ATR) /

exhaust outlet assembly (7).

F1-6 20 661
Remove turbocharger (8).
Remove the wiring harness fastenings from the upper timing casing.
Remove bolt (9).
Remove sensor (10).
Remove breather (20).
Remove thermostat inlet tube (21).

20 661 F1-7
Remove tube (22).
Remove the securing bolts from the timing case (12) on the cylinder
head.
Disengage the timing upper casing without removing it.
Leave the timing upper casing in place before removing

the vibration damper, so as to not damage the breather.
Remove camshaft vibration damper (11).

Remove upper timing casing.
Remove cylinder head cover stud (13) situated in front of the control
solenoid valve.

F1-8 20 661
Remove control valve (14) and tube (15) connecting up to the rocker
shaft.
Arrange the solenoid valve in a clean area, free from dust. Blank off
the oil holes in the cylinder head.
Loosen the rocker shaft securing bolts uniformly and over the entire
length.
Mount tool 0185.
Remove the rocker assembly.
On engines equipped with the Optibrake engine-brake, tie the

pistons to the rocker arms with a fastener to prevent them from falling
out when the rocker shaft is lifted up. The pistons and rocker arms
are paired according to class, 1, 2 or 3 dots.
Before lifting up the camshaft, mark the position between the

camshaft pinion and the adjustable idler gear.
Remove the camshaft pinion (24).

Mark and remove the camshaft bearing caps.
Classify the parts in order.

20 661 F1-9
Remove the camshaft using tool 8264.
Remove the unit pump injectors using lever 8511.

Install the protective sleeves 8249 to the unit pump injectors.

Install the blanking plugs 8251 one-by-one in the cylinder head and
tighten them with the unit pump injectors yokes.
Remove camshaft central bearing (25).

F1-10 20 661
Remove the cylinder head cover securing studs.
Screw in 3 lifting rings 3241.
Remove the cylinder head securing bolts.
Immerse the cylinder head bolts in a corrosion-inhibitive product and
let them drip dry on a grating.
Remove the cylinder head.
Withdraw the cylinder head gasket.
Immobilize liners.
Use tool 1462.

20 661 F2-1
Fitting
Fitting of cylinder head
Withdraw tool 1462.
Install the cylinder head gasket.

Replace timing plate gasket (1).
If necessary, clean the copper sleeves on the unit pump injectors

before positioning the cylinder head on the cylinder block.
Use tool 8599.

F2-2 20 661
Mount tool 8601 on the cylinder block front face and tools 8624 on
the cylinder head.
These positioning tools must be used to give accurate

assembly of the cylinder head. If the cylinder head is not
assembled using the recommended tools, the engine
runs the risk of suffering serious damage.
Before mounting the tools, inspect them for flatness and clean their
contact faces with the engine.
Position the cylinder head above the cylinder block a few millimetres
away from the cylinder head gasket.
Push the cylinder head by hand against tool 8601 placed on the front face.
Fit the cylinder head.
Check that the gasket between the cylinder head and the timing plate is properly positioned.
Tighten the cylinder head to tool 8601 and check that it is correctly
flattened.
Check the distance between tool 8624 and the cylinder block using
a 0.10 mm feeler gauge.
If the cylinder head is properly positioned, the feeler gauge must not
pass between tool 8624 and the cylinder block.
Fit the cylinder head securing bolts.
Tighten the securing bolts to torque in the sequence shown.
See pages B-5-1.
After preliminary tightening, check that the position of the cylinder

head has not changed, using a 0.10 mm feeler gauge.
Withdraw the lifting tools from the cylinder head.

Fit the camshaft central bearing.
Withdraw the positioning tools from the cylinder head.

20 661 F2-3
Fitting the unit pump injectors

See pages F-2-4.
Fitting the camshaft
Fitting the camshaft pinion.
See pages F-2-5.
Fitting the rocker shaft
Fitting the engine brake control valve
See pages F-2-10.
Fitting the upper timing casing
Fitting the vibration damper
See pages F-2-13.
Fitting the inlet manifold
See pages F-2-16.
Fitting the turbocharger
See pages F-2-16.
Adjustment of the rocker arms
See pages F-2-19.
Dressing the cylinder head
See pages F-2-16.
Fitting the cylinder head cover
See pages F-2-21.

F2-4 20 661
Fitting the unit pump injectors
Take blanking plug 8251

Replace the injector seals.
Oil the seals (engine oil).
Place the unit pump injector in position and centre it between the
valve springs.
Fit bolt (1).

Tighten to torque.
See page(s) B-5-17.
Proceed in the same way for the other unit pump injectors.
Connect wiring harness (19) to the injectors.
Replacement of a unit pump injector
In case of replacement of a unit pump injector, note down

the "TRIM CODE" number of the new unit pump injector.
Using the RENAULT TRUCKS test tool, programme the
new parameters in the engine management ECU.

20 661 F2-5
Fitting the camshaft
Oil the camshaft bearing half-shells.

Fit bearing half-shells.
Fit the camshaft, without the pinion, using tool 8264.

Withdraw tool 8264.
Fit the bearing caps.
Follow the sequence of disassembly.
Do not fit the rocker shaft securing bolts.
To prevent the bearing cap from lifting up when the backlash is being
gauged, screw one bolt (M10 X 80) into the free hole to be found in
the front bearing cap and tighten it.
Turn the camshaft to line up the top dead centre (TDC) mark in the
middle of the 2 front bearing cap marks.
Tighten the bolts to torque.
See page(s) B-5-2.

F2-6 20 661
Checking the backlash between the adjustable idler gear and
the lower pinion
It is important to check the backlash in order to avoid

serious damage to the engine.
Check the backlash between the adjustable idler gear and the lower
pinion by positioning the stylus of the dial gauge with magnetic foot
9661 on the adjustable idler gear.
Hold the lower pinion while moving the adjustable idler gear to and
fro.
Check that the backlash is inside the tolerances.
See page(s) B-6-6.
In the event of non-conforming backlash readings
See page(s) F-2-8.
Checking the backlash between the adjustable idler gear and the camshaft pinion
Place the camshaft pinion, without vibration damper, in position,

lining up the marks.
Use spacers to tighten the pinion correctly.
Check the backlash between the adjustable idler gear and the
camshaft pinion by positioning the stylus of the dial gauge with
magnetic foot 9661 on the camshaft pinion.
Hold the lower pinion while moving the camshaft pinion to and fro.
See page(s) B-6-6.
In the event of non-conforming backlash readings
See page(s) F-2-8.

20 661 F2-7
Checking the positioning of the camshaft
Check that the camshaft is correctly assembled by inserting a gauge

rod dia. 7 mm into the hole in the cylinder head, between the adjust-
able idler gear and the camshaft pinion.
Check that the marks on the camshaft pinion are on both sides of
the gauge rod.

F2-8 20 661
Adjustment of the backlash
Check that the camshaft is properly positioned, with the top dead
centre (TDC) mark in the middle of the 2 front bearing cap marks.
Check that the flywheel TDC mark is in line with pointer (4).
Loosen the adjustable idler gear bolts.
Leave the bolts in contact with the pinion so as to be able to adjust
the position.
Place a 0.05 mm feeler gauge in position on both sides of the cam-

shaft pinion teeth aligned along the axis defined by the centre of the
pinions (camshaft / adjustable idler gear).
Place an M12 x 150 bolt in the axis of the adjustable idler gear to
allow it to move.
Move the adjustable idler gear by hand against the camshaft pinion
until the required play is obtained.
Tighten the adjustable idler gear bolts.
Remove the camshaft pinion.
Pay attention that the feeler gauges do not fall behind the
timing case.
Check the backlash between the adjustable idler gear and the lower pinion by positioning the stylus of the dial
gauge with magnetic foot 9661 on the adjustable idler gear.
Hold the lower pinion while moving the adjustable idler gear to and fro.
See page(s) B-6-6.
Place the camshaft pinion, without vibration damper, in position, lining up the marks.
Check the backlash.
If necessary, readjust.
Tighten the adjustable idler gear securing bolts to torque.
See page(s) B-5-10.

20 661 F2-9
Check that the backlash has not been modified after tightening to torque.
The bolts can be re-used no more than four times.

Mark the bolt head with an indentation after tightening using a centre punch.
After 4 indentation marks, the bolt must be replaced.

F2-10 20 661
Fitting the rocker shaft
Lubricate the cams and valve yokes with engine oil.

Remove the rocker shaft.
Use tool 0185.
Check the alignment of the valve yokes with the rocker arms.
Fit bolts.
Tighten all the securing bolts progressively to avoid distortion of the

rocker shaft .
Tighten the camshaft and rocker shaft securing bolts to torque,

following the tightening sequence (see page B-5-2).
Engine equipped with Optibrake retarder
On engines with Optibrake retarder, remove the fasteners to untie

the pistons from the rocker arms.
Clean the Optibrake retarder control tube.

Grease the tube port in the rocker shaft.
Install a new seal ring to the tube.
Place the tube in position in the rocker shaft using an extension and
a 12 mm socket. Check that the seal ring is properly positioned.
Install a new seal ring to the tube.

Place the Optibrake retarder control solenoid valve in position on the
tube.
Check that the cylinder head oilway plug has been removed.
Use a new seal ring between the Optibrake retarder control valve
and the cylinder head. Ensure that it is properly positioned before
fastening the control solenoid valve .
Tighten to torque.
See page(s) B-5-18.
Connect the wiring harness to the control solenoid valve Optibrake
retarder.
Tighten to torque.
See page(s) B-5-18.

20 661 F2-11
After applying FRENETANCH 242, sealant, fit stud (13) positioned

in front of the Optibrake retarder control solenoid valve.
Tighten to torque.
See page(s) B-5-3.
Connect the solenoid valve wires to the Optibrake retarder.

Tighten to torque.
See page(s) B-5-18.

F2-12 20 661
Rocker shaft in place
To check that the camshaft is properly positioned, you can check the cam lift for N°1 cylinder inlet valves.
Before adjusting, ensure that the camshaft is at top dead centre

(TDC).
Provisionally adjust the rocker arm / valve yoke clearance to zero

and place a dial gauge 9661 against N°1 cylinder valve yoke.
Set the dial gauge to zero.
Turn the engine in the normal direction of rotation through about one
revolution then an extra 6° (mark 6 after TDC on the flywheel).
Note down the dial gauge reading.
Compare the reading with the value given in the technical data.
See page(s) B-6-8.
Adjust the N° 1 cylinder inlet valves.
See page(s) B-6-2.

20 661 F2-13
Fitting the upper timing casing

Clean the upper timing casing contact faces.
Replace the lower timing casing gasket.
Apply a bead of silicone sealant CAF 44 in the corners between the

oil sump and the timing plate.
Apply a bead of silicone sealant CAF 44 to the upper timing casing.
Apply the bead of silicone sealant no more than 20 minutes before

assembly.
Place the upper timing casing in position without entering into

contact with the cylinder head.
Fit the vibration damper and the pulse wheel to the camshaft.
Tighten to torque.
See page(s) B-5-10.
Place the upper timing casing in position.

Fit the securing bolts.
Bring the bolts into contact without tightening.
Mount tool 8628.

F2-14 20 661
Mount tool 8602.
Using the tools, align the timing case joint face on the cylinder head
cover with the timing case joint face on the cylinder head.
Tighten the upper timing casing bolts to torque in the sequence
shown.
See page(s) B-5-12.
Leave the tools in place for around 30 minutes to give time for the
sealant to cure.

20 661 F2-15
Adjustment of the camshaft speed sensor

Turn the engine to position a camshaft pulse wheel magnetic pole opposite the speed sensor housing.
Fit the camshaft speed sensor and check the distance between the
tip of the sensor and the pulse wheel magnetic pole.
Check that the distance is inside the tolerances.
See page(s) B-6-19.
Adjust the distance with the help of shims (see table below).
– A = Clearance (mm)
– B = Adjusting shim
– C = Pulse wheel
– D = Camshaft speed sensor
A B
Measured clearance Adjusting shim
N° Part number
0.2 → 1.0 mm - -
-0.3 → 0.3 mm 1 7401677894
-0.6 → 0.3 mm 2 7401677894

F2-16 20 661
Dressing the cylinder head
Fitting the breather
Clean the breather support face on the upper timing casing.
Fit and tighten the breather. If necessary, replace the seal.
Assembly of the inlet manifold
Carefully clean the bearing surface.
Apply a bead of silicone sealant CAF 44 to the inlet manifold joint face.
Place the inlet manifold in position on the cylinder head.

Tighten to torque.
See page(s) B-4-1.
Fit and tighten boost air pressure sensor (3).
Withdraw tool 8628 for positioning the upper timing casing.
Withdraw tool 8602 for positioning the upper timing casing.

Check the alignment of the cylinder head cover joint face on the
timing case with the joint face on the cylinder head.
Fit the cylinder head cover securing studs.
Do not fit the stud to be found in front of the engine brake control
valve.
Remove the FRENETANCH 242 sealant from the screw-threads of

the studs.
Tighten to torque.
See page(s) B-5-3.

20 661 F2-17
Fit and connect preheater body (1).
Fit the fuel pipe to the cylinder head and to the inlet manifold with
securing bolts (2).
Fit pipes (17).

Pass the injectors control and Optibrake retarder control solenoid
valve wiring harness wiring harness into the cylinder head and
fasten stuffing box (16).
Connect the injectors .
See page(s) F-2-4.
Connect the Optibrake retarder control solenoid valve.
See page(s) F-2-10.
Fit temperature sensor (18).
Install a new gasket.

Fit turbocharger (8).
Tighten to torque.
See page(s) B-5-1.

F2-18 20 661
Replace seal.
Fit turbocharger oil return pipe (6).
Do not tighten oil return pipe (6) to the turbocharger - it will serve to
check lubrication of the turbocharger on the starter motor once the
engine is installed in the vehicle.
Fit exhaust brake (7) to the turbocharger.

Tighten to torque.
See page(s) B-5-15.
Replace seals.
Fit and tighten lube tube (5).

20 661 F2-19
Using tool 6956, position the camshaft marks (A), indicating the
cylinder number to be adjusted, between the camshaft front bearing
cap marks.
Adjustment of inlet valve clearances

Loosen the locknut and the adjuster (2).
Adjust the clearance between the rocker arm and the valve yoke by
means of screw (2).
Tighten the locknut to torque while holding the adjuster (2).
See page(s) B-5-2.
Make a mark on the rocker arm when adjustment is finished.
Valve clearances
Inlet 0.2 mm
Adjustment of exhaust valve clearances(without Optibrake retarder)

Adjustment method identical to that for inlet valves.
Valve clearances

F2-20 20 661
Adjustment of unit pump injectors rocker arms (Delphi)
Loosen the locknut and the adjuster.
Screw up the adjuster by hand until it makes contact with the unit
pump injector.
Tighten the adjuster through 1/2 → 2/3 of a turn to obtain a unit
pump injector preload .
Tighten the locknut to torque while holding the adjuster.
See page(s) B-5-2.
Adjustment of exhaust valve clearances (with Optibrake retarder)
Bend a piece of steel wire (see illustration).
Use a piece of steel wire or similar tool to check there is no oil left in
the rocker arm, preventing the piston from reaching the "down"
position.
If there is still oil, empty it out and check that the rocker arm does not
spring back when it is pushed in.
Use a feeler gauge corresponding to the recommended clearance.

See page(s) B-6-2.
Check the clearance between the valve yoke and the exhaust rocker
arm piston. Turn the piston to ensure that it is properly seated in its
housing.
In the event of rocker arm play or sticking, make the check with a
thicker or thinner feeler gauge in order to determine the thickness of
the new adjusting shim.

20 661 F2-21
Valve clearances
In the event of non-conforming clearance, take out the adjusting

shim.
Measure its thickness.
Calculate the difference in thickness according to the clearance
measured during checking.
Insert and tighten the corresponding adjusting shim.
Again check the clearance between the valve yoke and the arm
piston.
Proceed in the same way for the rocker arms of the other
cylinders.
Withdraw tool 6956.
Fit the inspection panel.
Fitting the cylinder head cover

Place the cylinder head cover in position.
So as not to damage the cylinder head cover, ensure that the securing bolt spacers are properly
positioned in their housings.
Tighten to torque.
See page(s) B-5-1.

F2-22 20 661

20 661 F3-1
Disassembly/inspection/assembly
Detailed view

F3-2 20 661
Disassembly
Thermostat casing
Remove exhaust manifold (1).
Without hydraulic retarder

Remove thermostat casing (2).
With hydraulic retarder

Remove tube (1).
Remove hose (2).
Remove tubes (3).
Remove thermostat casing (4).
Remove the thermostat.
Remove gasket (3) from the thermostat.

Carefully clean the bearing surface.
The item numbers indicated in the text refer to the drawing on
page F-3-1.
Remove camshaft bearings (1).

20 661 F3-3
Valves
WEAR SAFETY GOGGLES FOR PROTECTION.
Compress springs (2).
Use tool 6222 + 0176 + 9729 + 6159 + 8246.

Save valve cotters (3).
Decompress springs (2).
Withdraw cups (4).
Take out springs (2).
Withdraw cups (5).
Remove lower plate (A) of tool 0176.

Remove valves (6).
Take out seals (8).
Valve guides
Classify the parts in order (9).
Use tool 6222 + 0176 + 9729 + 6159 + 8263.

F3-4 20 661
Valve seats
Grind an old valve.
Weld the valve to the seat.
Place a sleeve in position on the guide corresponding to the valve

seat to be removed.
Drive out valve seats (10).

20 661 F3-5
Injector sleeves
Insert blanking plugs 8250 into the fuel circuit ports.
Tap injector sleeve (12) ∅ M9 over a length of 20 mm .

Use tool 8252.
Withdraw the tap and the tool from injector sleeve (12).
Mount tool (M9) on tool 8253.

Screw the tool end into injector sleeve (12).
Withdraw injector sleeve (12) by screwing up the nut while holding
the screw of tool 8253.
Take out blanking plugs 8250.

F3-6 20 661
Cleaning the injector sleeve housing
Clean the injector sleeve housing in the cylinder head using tools
8580 + 8607 + 8613 + 8614 + 8615 + 8616 from cleaning kit 8599.
Clean the cylinder head walls for the injector sleeve using tools 8580
+ 8607 + 8618 from cleaning kit 8599.
Clean the bore in the cylinder head using tools 8580 + 8607 + 8617
from cleaning kit 8599.
Front face core plug

Remove core plug (11) by pushing it from the inside of the
thermostat housing .
Clean the core plug port (11).

20 661 F3-7
Core plug
Drill a hole in the core plug (17) to be replaced.
Screw a bolt into the core plug port (17).
Extract core plug (17) using tool 8511.
Clean the core plug port (17).

F3-8 20 661
Remove iron filings using a magnet.
Screw-in core plug(s)

If necessary
Remove core plugs (13 - 14 - 15 - 16).

20 661 F3-9
Inspection
Wash the cylinder head.
Inspect the joint face.
See page(s) B-6-1.
Cylinder head leak test
Clean the cylinder head joint faces.
Fit seal plates 9696 from kit 8666 together with seal plates 8266.
Use 13 cylinder head bolts with 13 nuts M 16 to fasten the plates.
Fit seal plate 9699 from kit 8666 in the temperature sensor housing.
Fit blanking plug 9701 from kit 8668 in the thermostat housing fastened with seal plate 9697 from kit 8666.
Fit seal plate 9698 from kit 8668.
Fit blanking plug 9700 from kit 8668.
Remove 2 elbow unions from the thermostat casing and fit 2 plugs (A - B).
Connect up the flexible pipe of tool 6662 to the connecting plate

9697.

F3-10 20 661
Place the cylinder head in a water bath heated to 70°C.
Adjust the test pressure to 0.5 bar(s).
Hold the pressure for 1 minutes.
Check that the pressure does not drop and that there are no air
bubbles.
Adjust the test pressure to 1.5 bar(s).
Hold the pressure for 2 minutes.
Check that the pressure does not drop and that there are no air
bubbles.
Drop the air pressure in the cylinder head.
Testing the thermostat housing

Transfer the test equipment to union 9698 fitted to the thermostat
housing.
Proceed in the same way as for the cylinder head leak test.
Take the cylinder head out of the water bath.
Remove all the test tools.
Dry the cylinder head and in particular the fuel conduits.
Valves
Check the calibration of the springs.
See page(s) B-6-5.
Inspect the valve yokes.
Valve guides
Check the radial play of the valves in their guides.
See page(s) B-6-2.
Use tool 9661.
Valve seats
Check the valves set-back or protrusion.
See page(s) B-6-2.
Rocker arms
Check that the roller rotates freely.

20 661 F3-11
Check the roller play.

Use tool 9661.
See page(s) B-6-5.
Check the rocker arm bearing play.
See page(s) B-6-5.

F3-12 20 661
Assembly
The item numbers indicated in the text correspond to the figure on page F-3-1.
Fit core plugs (17).
Use tool 3016 + 2363 ∅ 35 mm.
Fit core plug (11).

Use tool 0032.
Injector sleeves
Insert blanking plugs 8250 into the fuel circuit ports.
Install a new O-ring lubricated with soapy water.

Place sleeve (12) in position on tool 8688.
Oil the end of the sleeve on the tool 8688.

20 661 F3-13
Place tool 8688 with sleeve (12) in position in the cylinder head.
Use the unit pump injector yoke to hold the tool in place.
Ensure that the sleeve is properly positioned in the bottom of the

cylinder head well.
Tighten the nut while holding the shank of the tool.

Withdraw tool 8688.
Take out blanking plugs 8250.
Valve seats
Heat the cylinder head.
Contract the valve seats in liquid nitrogen.

F3-14 20 661
Shrink fit valve seats (10).
Valve guides
Lubricate the new valve guides.
Press fit valve guides (9).
Use tool 6222 + 0176 + 9729 + 6159 + 8261.
Check the protrusion.
See page(s) B-6-4.
Valves
Place valves (6) in position in the guides used for assembling
gaskets and springs with tool 0176.
Fit plate (A).
Valve guide seals

Place tool 0011 in position on the valve.
Fit seals (8) on the valve guides .
Use a suitable tube.

20 661 F3-15
Valve springs
WEAR SAFETY GOGGLES FOR PROTECTION.
Fit cups (5).

Fit springs (2).
Fit cups (4).
Tension springs (2).
Use tool 6222 + 0176 + 9729 + 6159 + 8246.

Fit valve cotters (3).
Decompress springs (2).
Check the positioning of valve cotters (3).
Withdraw the tool.
Exhaust manifold
Fit new gaskets to the exhaust manifold with the inscription
"MANIFOLD SIDE" on the manifold side.
Place the exhaust manifold in position.
Do not fit the 2 bolts on the thermostat casing side.

F3-16 20 661
Thermostat casing
Place a new gasket in position on tool 8619.
Wide end of gasket against the shoulder of the tool.
Using tool 8511, drive tool 8619 into the thermostat housing until it
makes contact with the cylinder head .
Withdraw tool 8619.
Check for proper positioning of the gasket (3).
Fit thermostat.
Without hydraulic retarder

Fit the thermostat casing.
Place a bolt (1) (M8 x 20) complete with nut, washer and spacer in
position between the exhaust manifold and the machined face of the
thermostat casing.
Screw up the nut so that the spacer pushes the thermostat casing
into its housing against the gasket.
Tighten to torque.
See page(s) B-5-16.
Remove bolt (1).

Fit the 2 bolts for securing the exhaust manifold.
Tighten to torque.
See page(s) B-5-4.

20 661 F3-17
With hydraulic retarder

Place tool 0068 in position on the cylinder head.
Fit the thermostat casing.
Tighten the screw of tool 0068 to bring the thermostat casing into
contact with the cylinder head.
Tighten bolts (B) to torque.

See page(s) B-5-16.
Fit the 2 bolts for securing the exhaust manifold (A).
Tighten to torque.
See page(s) B-5-4.
Withdraw tool 0068.
Fit pipes (3).

Fit hose (2).
Fit pipe (1).
Camshaft bearings
Fit the camshaft bearings in the order of classification made when dismantling.

F3-18 20 661

20 661 G1-1
VALVE TIMING

G1-2 20 661
Removal
Detailed view

20 661 G1-3
Removal
The item numbers indicated in the text refer to the drawing on page G-1-2.
Remove the cylinder head cover.
Remove the compressor.
See page(s) E-8.
Timing casings
Remove camshaft vibration damper (1).
Remove upper timing casing (2).
See page(s) F-1-7.
Remove the oil sump.
Remove engine bracket (A).
Remove steering pump (B).

Remove the tensioner roller from its bracket.
Remove the alternator bracket.
See page(s) E-6.
Remove securing nuts and bolts (C).

G1-4 20 661
Remove fuel feed pump (D).
Remove lower timing casing (3).
Timing gears and pinions

Mount tool 6956.
Line up pointer (H) with the flywheel TDC mark
The camshaft TDC mark must be positioned between the camshaft

front bearing cap marks.
Remove camshaft pinion (4).

20 661 G1-5
Withdraw tool 6956.

Mount tool 6950.
Remove crankshaft vibration damper (E).
Remove hub (F).

Use tool 0843.
Withdraw tool 6950.
Remove adjustable idling gear (5).
Place locating 2 tools 8267 in position and tighten them to 60 Nm.

Remove pinions (6).

G1-6 20 661
Remove oil pump (G).
Remove crankshaft pinion (7).

Use tool 0843.
Remove oil jet (8).

Remove timing plate (9).
Clean the front face of the cylinder block, timing plate (9) and timing
casings (2 - 3).

20 661 G1-7
Inspection
Inspect the oil jet orifices and channel.
Inspect the crankshaft keyway.
Check the state of the pinions.
See page(s) B-6-6.
On the camshaft, inspect:
– Coaxiality,
– Cam lift,
– Bearing surface diameter,
– Bushes.
See page(s) B-6-7.
Inspect the rocker arms.
See page(s) B-6-5.

G1-8 20 661
Disassembly
Air compressor pinion

Unscrew the pinion securing nut.
Remove pinion.
Use tool 0857.
Steering pump pinion

In a vice.
Use a protective device (A).
Remove the nut.
Extract the pinion.
Use tool 0819 + 0837
Oil pump pinion

Remove the oil pump idler gear.
Insert a bolt (M12 x 30) into the centre of the oil pump driving pinion.
Extract the pinion.
Use tool 0857.

20 661 G2-1
Fitting
Assembly
Air compressor pinion
Shrink fit pinion.
Screw up the nut.
Tighten to torque.
See page(s) B-5-16.
Steering pump pinion
Shrink fit pinion.
Screw up the nut.
Tighten to torque.
See page(s) B-5-10.
Oil pump pinion
Fit the idler gear.
Tighten to torque.
See page(s) B-5-10.
Heat the pinion to 180±20 °C for around 60 minutes.
shrink fit pinion (1) to the oil pump shaft using a press.
Ensure dimension (A) between pinion (1) and pump body (2).
See page(s) B-6-21.

G2-2 20 661
Fitting
The item numbers indicated in the text refer to the drawing on page G-1-2.
Timing plate (9)
Make sure the timing plate and the cylinder block joint face are impeccably clean.
Apply a bead of silicone sealant CAF 44 to the joint face of the cylinder block.
See page(s) B-5-9.
Fit a new gasket (10).
Place timing plate (9) in position on locating tools 8267.

Fit bolts.
Tighten to torque.
See page(s) B-5-9.
Withdraw the locating tools 8267.
Fit oil jet (8).

Tighten to torque.
See page(s) B-5-14.
Timing gears and pinions

Check that pointer (H) is in line with the flywheel TDC mark.
Correct, if necessary.

20 661 G2-3
Crankshaft pinion (7)

Check for the presence of the keyway.
Heat the pinion to 200 °C for around 60 minutes.
Shrink fit pinion (7).
WEAR HEAT-RESISTANT GLOVES FOR PROTECTION.
Let cool.
Idler gears (6)

Oil the bearings of the idler gear (6).
Fit idler gears (6).
Tighten to torque.
Follow the tightening sequence.
See page(s) B-5-9.
Check the play of idler gear (6).
See page(s) G-3-2.
In the event of non-conforming play, adjust timing plate (9).
See page(s) G-3-1.
Adjustable idler gear (5)

Fit adjustable idler gear (5).
Tighten the bolts by hand.
Camshaft pinion (4)

Check that the camshaft is properly positioned, with the top dead
centre (TDC) mark in the middle of the 2 front bearing cap marks.
Place the camshaft pinion (4), without vibration damper, in position,
lining up the marks.
See page(s) F-2-7.
Adjustment of the backlash
See page(s) F-2-8.
Oil pump
Assemble the oil pump.
Tighten to torque.
See page(s) B-5-14.

G2-4 20 661
Vibration damper
Heat the hub of vibration damper (F) to 200 °C for around
60 minutes.
Shrink fit the hub (F).
WEAR HEAT-RESISTANT GLOVES FOR PROTECTION.
Mount tool 6950.
Fit the securing bolts to hub (F).

Tighten to torque.
See page(s) B-5-10.
Fit the vibration damper.

Tighten to torque.
See page(s) B-5-6.
Withdraw tool 6950.

20 661 G2-5
Upper timing casing (3)
Make sure the lower timing casing and the timing plate joint face are impeccably clean.
Place a new gasket (11) in position on the lower timing casing (3).
Apply a bead of silicone sealant CAF 44 to the joint face of lower timing casing (3).
See page(s) B-5-9.
Fit lower timing casing (3).
Tighten to torque.
See page(s) B-5-11.
See page(s) F-2-19.
Adjustment of the camshaft speed sensor
See page(s) F-2-15.
Engine front bracket
Fit engine bracket (A).
Tighten to torque.
See page(s) B-5-19.
Upper timing casing (2)
See page(s) F-2-13.
Air compressor
See page(s) E-8.
Steering pump
Tighten to torque.
See page(s) B-4-1.
Alternator bracket
Fit the alternator bracket.
Tighten to torque.
See page(s) B-4-1.
Tensioner roller
Fit the tensioner roller to its bracket.
Tighten to torque.
See page(s) B-5-18.
Fuel feed pump
Replace seal.
Replace the O-ring on the drive shaft with a new O-ring.
Fit fuel feed pump (D).
Tighten to torque.
See page(s) B-4-1.
Oil sump
Replace seal.
Tighten to torque.
See page(s) B-5-13.
Cylinder head cover
See page(s) F-2-21.

G2-6 20 661

20 661 G3-1
Adjustment
Adjustment of the timing plate
It is necessary to adjust the timing plate if the timing idler gears backlash is incorrect.
Mount positioning tools 6401 on the cylinder block seating face .
Ensure that tools 6401 are smooth and free from burrs so
as to not damage the oil sump face on the cylinder block.
The joint faces of the timing plate and of the cylinder block must be
meticulously cleaned of all traces of sealing compound.
Place timing plate (9) in position on tools 6401.

Fit 3 timing plate securing bolts: 2 on the bottom edge and 1 on the
top edge of the timing plate.
Think of choosing tapped holes that are not covered by the idler
gears.
Fit the pinions (6)
Check that the idler gear thrust washers are fitted correctly.

Check that the timing plate can always be moved sideways.

G3-2 20 661
Insert two 0.10 mm feeler gauges between the teeth of the idler
gears and the teeth of the crankshaft pinion.
Using a plastic mallet, tap on the side of the timing plate until the
feeler gauges are a tight fit between the gear teeth.
Both feeler gauges must be as tight a fit as one another.
Tighten the 3 timing plate securing bolts (9).

Tighten 2 diagonally opposed bolts for each idler gear (6).
Tighten the bolts with enough torque to prevent the position of the timing plate (9) from being modified.
Take out the feeler gauges.

Place dial gauge 9661 in position and measure the backlash of the
idler gears. Check that the readings are inside the tolerances.
See page(s) B-6-6.
Withdraw dial gauge 9661.
Place locating tools 8267 in position and tighten them to 60 Nm.

Withdraw positioning tools 6401.
Remove idler gears (6).
Remove timing plate.
Take out timing plate in a straight line, so as to not damage locating

tools 8267.
Fitting the timing components

See page(s) G-2-2.

20 661 H1-1
RECIPROCATING GEAR

H1-2 20 661
Disassembly/inspection/assembly
Exploded view

20 661 H1-3
Replacement of crankshaft seal N° 74 01 543 896

The item numbers indicated in the text correspond to the figure on page H-1-2.
Remove flywheel (8).
See page(s) H-1-7.
Removal
Mount tool 8238.
Drill two holes dia. 4 mm in the seal, using the guide

holes. Pay attention that the drill bit is kept properly cen-
tred during drilling so as to not damage the contact faces
of the seal. Apply grease to the drill bit to retain the swarf.
Screw two self-tapping screws (A) M5x35 mm into the seal.
Extract seal (7).

Use extraction bolts (B).

H1-4 20 661
Fitting
Clean and carefully inspect the contact faces of the seal (7).
Lubricate the seal.
Drive in seal (7) as far as abutment.
Use tool 8238 + 2000
Fit flywheel (8).
See page(s) H-1-18.

20 661 H1-5
Replacement of crankshaft seal N° 74 85 108 352

See page(s) H-1-7.
Removal
Extract seal (7).
Use tool 6400 + 0192
Take care to not damage the crankshaft contact face of

the seal during extraction.
Fitting
Clean and carefully inspect the contact faces of the seal (7).
Mount tool 0166.
Check that the tool is correctly placed on the locating

dowel before tightening the bolts.
Install protective ring to tool 0166

Match the direction of orientation.
The seal is supplied fitted to a protective ring that is

placed on the assembly tool. It is essential to hold the
seal to the ring until it is finally installed in the case.
Do not apply grease to the lips.
Any gasket that has been removed from its ring must not
be re-used.

H1-6 20 661
Drive in seal (7) as far as abutment.
Withdraw tool 0166.
Fit flywheel (8).
See page(s) H-1-18.

20 661 H1-7
Disassembly
The item numbers indicated in the text refer to the drawing on page H-1-2.
Flywheel
Remove engine speed sensor (9).
Mount tool 1207.

Loosen bolts (A).
Use a hoist.
Flywheel casing
Remove clamp (B).
Remove clamp (C).

H1-8 20 661
Tighten nuts (D).
Dislodge casing (10).

Use tool 0918.
Remove casing (10).
Connecting rods
Pistons
Remove cylinder block stiffener (16).
Check for the presence of marks on the connecting rod.

Remove connecting rod caps (19).
Remove bearing half-shells (20).
Withdraw connecting rod/piston assemblies.
Do not knock the oil jets when removing the connecting

rod/piston assemblies.


20 661 H1-9
Crankshaft
Mark central bearing cap (17).

Check for the presence of marks on the bearing caps (15).
The marks are to be found on the oil cooler side, N°1 cylinder being at the fan drive (front) end.
Remove bearing caps (15 - 17).

Remove half-rings (18).
Remove crankshaft (13).

Use tool 9804.
Use a hoist.
Remove half-rings (11).
Remove oil jets (E).
Pistons
Remove piston rings (4).
Use tool 0825.

H1-10 20 661
Connecting rods
Withdraw circlips (2).
Drive out gudgeon pins (3).
Separate the crowns from the skirts.
The mark to found on the piston crown is directed towards the front of the engine.
Liners
Withdraw liners (6).
Use tool 1230 + 2955
Take out seals (1).
Flywheel
For replacement only.
Remove the gear ring.

20 661 H1-11
Inspection
Cylinder block
Inspect:
– screw-threads for cleanliness,
– joint face,
– liner seal grooves for cleanliness,
– oil valves for free sliding.
Connecting rods
Inspect:
– straightness and true,
– bushes.
See page(s) B-6-14.
Pistons
Inspect:
– diameter,
– gudgeon pin and housing,
– piston ring grooves,
– skirt surface.
See page(s) B-6-16.
Piston rings
Inspect:
– piston groove clearance,
– joint gap.
See page(s) B-6-18.
Oil jets
Clean the oil jets.
Crankshaft
Inspect:
– coaxiality,
– crankpin diameters,
– journal diameters.
See page(s) B-6-9.

H1-12 20 661
Assembly
Flywheel
Heat the crown wheel to 180 - 200°C.
Shrink fit the crown wheel.

Let cool.
Liners
Fit undressed liners (6).
Immobilize liners (6).
Use tool 1462.

20 661 H1-13
Check the protrusion of the liners.

Use tool 9661 + 1141
If the liner protrusion is outside the tolerances, it will be necessary
to mill the liner housing in the cylinder block.
See page(s) .
– Always measure starting at the highest point of the liner.

– Mark the positioning of the liner in the cylinder bloc with a felt
pen so as to obtain the same positioning during assembly.
Withdraw tool 1462.

Withdraw liners (6).
If necessary
Use tool 1230 + 2955
Lubricate the seals with the product supplied.
The purple coloured seal is to be fitted to the lower groove.

– If the liner is fitted without shims, apply a uniform bead of seal-
ing compound 0,8 mm thick on the lower face of the liner
flange.
– If the liner is fitted with shims, apply a bead of sealing com-
pound to the liner housing in the cylinder block.
No sealing compound is to be used between the adjusting shims and the liner flange.
Fit liners (6).

Use tool 8511 + 6599
Immobilize liners (6).

H1-14 20 661
Use tool 1462.
Crankshaft
Fit bearing half-shells (12).
Apply oil.
Fit crankshaft (13).
Use tool 9804.
Install thrust half-rings (11).
Fit bearing half-shells (14).
Install thrust half-rings (18).
Apply oil.
Fit the bearing caps (15 - 17).
Line up the marks.
Fit bolts.
Tighten to torque.
See page(s) B-5-7.
Check the rotation.
Check the end float.

Use tool 9661.
See page(s) B-6-10.
Correct, if necessary.

20 661 H1-15
Connecting rods
Pistons
Lubricate gudgeon pin (3), piston (5) and small end bush (23).
Use engine oil.
When assembling connecting rod / piston assemblies, watch that the

marks are correctly positioned. The inscription "FRONT" on the
connecting rod must be on the same side as the mark on the piston
crown .
Fit gudgeon pin (3).

Install circlips (2).
Install piston rings (4).

Use tool 0825.
Installation of piston rings:

– The piston ring joint gaps must be staggered in relation to one
another.
– For the oil scraper ring, the spring gap must be diametrically
opposed to the joint gap.
– The marks on the two top rings must be facing upwards. The oil
scraper ring is symmetrical and can be fitted both ways.

H1-16 20 661
Apply oil to piston (5) (engine oil).
Install connecting rod/piston assemblies.
Use tool 0824.
Watch that the mark located on the piston crown is directed towards
the front of the engine.
Fit bearing half-shells (20 - 21).

Check that they are correctly positioned.
Apply oil.
Fit connecting rod caps (19).
Fit the nuts.
Tighten to torque.
See page(s) B-5-7.
Oil jets
Fit oil jets (E).
Ensure that the oil jet is facing the groove in the piston skirt.
Tighten to torque.
See page(s) B-5-14.
Cylinder block stiffener

Fit cylinder block stiffener (16).
Tighten bolts to torque following the tightening sequence.
See page(s) B-5-7.

20 661 H1-17
Flywheel casing
Apply sealing compound to the joint face.
See page(s) B-5-8.
Fit casing (10).
Fit bolts (D).

Tighten to torque.
See page(s) B-5-8.
Fit clamp (B).

H1-18 20 661
Flywheel
Check that the surface of the sensor magnetic pole is im-

peccably clean.
Check for the presence of locating dowels.

Fit flywheel (8) to the end of the crankshaft using locating dowel to
position it correctly.
Use tool 1207.
Use a hoist.
Immobilize flywheel (3).

Use tool 6950.
Tighten bolts (A) to torque following the tightening sequence.
See page(s) B-5-6.
Withdraw tool 6950.
Fit the inspection plate.
Fit engine speed sensor (9).
Check the air gap.
See page(s) H-1-19.
Fit clamp (C).

20 661 H1-19
Adjustment of the distance between the engine speed sensor and the flywheel

Turn the flywheel using tool 6956.
Line up pointer (1) with the flywheel TDC mark.
Centre the circlip on tool 8517.

Place tool in position in the sensor hole.
Drive in tool until it makes contact with the pulse wheel.
Withdraw tool 8517.
Measure dimension "A".

Place the sensor in the tool.

H1-20 20 661
Measure dimension "B".
Calculate the thickness of the shim.
Determination of the measured air gap (C):

(Example)
Dimension (A) 28.2 mm
Dimension (B) 8 mm
Formula: (C) = (A) - (B+20) 28.2 - (8 + 20)
Measured air gap (C) 0.2 mm
Air gap adjustment value (C) 0.7 mm ≥ (C) ≥ 2.1 mm
– The adjusting shims have a thickness of 0.6 mm.

– Add shims so as to obtain an air gap (C) that is inside the tolerances.
See page(s) B-6-19.

Fit the shim.
Fit the sensor.
Withdraw tool 6956.
See page(s) B-4-1.

20 661 H1-21
Inspection of the distortion of the flywheel casing

Check the run-out of the flywheel casing.
See page(s) H-1-22.
Clean the flywheel casing.

Place the dial gauge stylus on the outer face of the flywheel.
Use tool 9661.
Note down the value.
Place the magnetic foot on the opposite side.
Check that the readings are inside the tolerances.
See page(s) B-6-19.
Repeat the reading at 4 points.

Mount tool 6956.
Place the dial gauge stylus on the inner face of the flywheel.
Use tool 9661.
Note down the value.
If one or several readings are outside the tolerances, check the

contact face between the flywheel and the cylinder block before
replacing the casing.
Withdraw tool 6956.

See page(s) B-4-1.

H1-22 20 661
Inspection of the flywheel run-out
Clean the flywheel.
Mount tool 9661.

Bring the dial gauge stylus into contact with the flywheel while
applying a preload.
Set the dial gauge to zero.

Inspect the flywheel run-out. The gauging point is located about 150
mm from the centre of the crankshaft.
See page(s) B-6-18.
If the reading is outside the tolerances, check the contact face

between the flywheel and the crankshaft before replacing the
flywheel.
Withdraw tool 6956.

See page(s) B-4-1.

20 661 H2-1
Pilot bearing
Removal / Fitting
Removal
Remove pilot bearing (1).

Use tool 0978.
Fitting
Fit pilot bearing (1).
Use tool 2363 + 3016

H2-2 20 661

20 661 I1-1
LUBRICATION

I1-2 20 661
Oil filter(s) and by-pass filter
Assembly
Fill the oil cartridge(s) with oil.

Oil the gasket(s).
Screw up the cartridge(s) until contact is made with the bracket.
Tighten to torque.
See page(s) B-5-14.
Use tool 2655.
Run the engine and check for leaks.
In the event of leakage, remove the cartridge(s), inspect the joint
face and repeat the fitting operations.

20 661 I2-1
Pressure relief valve
Replacement
Removal
Clean the area around plug (1).

Remove plug (1).
Use tool 8598.
Remove the pressure relief valve.
Clean the pressure relief valve seat.
Check the state of the pressure relief valve seat in the

cylinder block and the state of the old gasket that has
been removed.
Fitting
Check that the coloured mark on the new pressure relief valve is
correct.
See page(s) B-6-22.
Place the new valve in position in the plug.
Screw the plug complete with valve into the cylinder block.
Tighten to torque.
See page(s) B-5-14.
Rotate the engine and test for leaks.

I2-2 20 661

20 661 I3-1
Safety valve
Replacement
Removal
Remove the oil filter front cartridge (1).

Use tool 2655.

Remove plug (2).
Use tool 8598.
Remove the safety valve (2).
Clean the safety valve seat.
Check the state of the safety valve seat in the cylinder

block and the state of the old gasket that has been
removed.

I3-2 20 661
Fitting
Check that the coloured mark on the new pressure relief valve is
correct.
See page(s) B-6-22.
Place the new valve in position in the plug.

Screw the plug complete with valve into the cylinder block.
Tighten to torque.
See page(s) B-5-14.
Fill the oil cartridge with fresh oil.
Oil the gasket(s).
Screw up the cartridge(s) until contact is made with the bracket.
Tighten to torque.
See page(s) B-5-14.
Use tool 2655.
Run the engine and check for leaks.
In the event of leakage, remove the cartridge(s), inspect the joint
face and repeat the fitting operations.

20 661 I4-1
Oil cooler by-pass valve
Replacement
Removal
Clean the area around valve cover (1).
Remove securing nuts and bolts.

Take the cover (2) and the valve off the oil filters bracket.
Fitting
Replace seal.
Place the valve and the cover in position in the oil filters bracket.
Tighten to torque.
See page(s) B-5-15.

I4-2 20 661

20 661 I5-1
Pistons cooling valve
Replacement
Removal
Clean the area around valve cover (1).
Remove securing nuts and bolts.

Take off cover (1) and pistons cooling valve (2).
Clean the valve seat.
Check the state of the valve seat in the oil filters bracket
and the state of the old gasket that has been removed.

I5-2 20 661
Fitting
Check that the coloured mark on the new cooling valve is correct.
See page(s) B-6-22.
Replace O-ring (3) with a new O-ring.

Place the new valve (2) in position in the cover (1).
Replace cover gasket (1).
Tighten to torque.
See page(s) B-5-15.

20 661 I6-1
Oil filter horizontal by-pass valve
Replacement
Removal
Remove plug (1) complete with seal (2).

Remove valve (3).
Remove spring (4).
Check the state of the valve seat in the oil filters bracket.
Fitting
Fit a new spring (4) to the new valve (3).

Place the unit in plug (1).
Replace seal (2).
Screw plug (1) into the filters bracket.
Tighten to torque.
See page(s) B-5-15.

I6-2 20 661

20 661 I7-1
Oil filter vertical by-pass valve
Replacement
Removal
Remove plug (1) complete with seal (2).

Remove valve (3).
Remove spring (4).
Check the state of the valve seat in the oil filters bracket.
Fitting
Fit a new spring (4) to the new valve (3).

Place the unit in plug (1).
Replace seal (2).
Screw plug (1) into the filters bracket.
Tighten to torque.
See page(s) B-5-15.

I7-2 20 661

20 661 I8-1
Oil cooler
Removal
Remove union (1) connecting to the water pump.
Remove adapter plate (2).
Remove oil cooler (3).

I8-2 20 661
Inspection
Cleaning
Oil circuit: Use a degreasing product.
Water circuit: Use a degreasing product soluble in water.
Mount tool 2899 to the oil cooler.
Connect up the flexible pipe of tool 6662 to the connecting plate.

Test for leaks in a water bath at ambient temperature, air pressure:
2.5 bar(s) for at least 1 minute. Check there are no air bubbles.
Take the oil cooler out of the water bath.
Withdraw tool 2899.

20 661 I8-3
Fitting
Fit 2 new gaskets (4) to the cylinder block.
Place oil cooler (3) in position.

Tighten to torque.
See page(s) B-5-14.
Replace plate gasket (2).

Fit plate (2).
Tighten to torque.
See page(s) B-5-16.
Fit union connecting to the water pump.

I8-4 20 661

20 661 I9-1
Turbocharger
Operating trouble
Each turbocharged engine possesses its own characteristic sound. Owing to this, many defects can be detected
merely by noticing a change in the customary noise signature.
If the sound level becomes sharper, it may be due to leaking charge air (between turbocharger and intake
manifold) or exhaust gas, or a drive shaft defect.
An intermittent change in noise level may be due to turbocharger fouling or use of the engine at underspeed in
relation to load.
The appearance of vibration may indicate a drive shaft defect.
A sudden reduction in noise, accompanied by the appearance of black or blue exhaust smoke is the sign of total
break-up of the turbocharger.
In all cases, immediately stop the engine to avoid more serious damage to the turbocharger and to the engine.
On-vehicle checks
Engine stopped:
Refer to technical document "DT 357".
Engine idling:
Check the air pipes between air filter and turbocharger for leaks by spraying Start Pilote fluid. Leakage will be
indicated by an increase in engine speed.
Engine running at 1 200 rpm.:
Check for leaks between turbocharger and engine using a leak detector. Check for exhaust gas leaks (actuate
the exhaust brake). Replace gaskets, if necessary. A gas leak can be detected by a change in colour at the place
of the leak.
Removal / fitting of turbocharger
These operations do not present any difficulty. Clean all the air conduits and make sure there is no foreign matter
left. Before tightening the exhaust manifold bolts, smear the screw-threads with high temperature-resistant
grease (Renault Trucks Oils Gripcott NF grease) or equivalent.
Tighten to torque (see page B-5-15).
Any turbocharger replacement, where the cause of damage has not been defined, may lead to new
incidents and serious engine damage.
Do not use jointing compound on the turbocharger lubrication pipe fastening flanges. Before
installing the turbocharger, pour fresh oil through the oil inlet port and turn the rotor by hand to
lubricate the journals and the thrust bearing.
After installing the turbocharger, run the engine and wait for 30 seconds before accelerating.

I9-2 20 661
Incidents and probable causes
Before implicating the turbocharger, ensure that the engine and its surrounds are in perfect
condition.
Lack of engine power

– Air filter clogged
– Aftercooler air/air heat exchanger (tube stack fouled)
– Air inlet pipe blockage or crushing (between air filter and turbocharger)
– Boost air pipe blockage or crushing (between turbocharger and engine)
– Foreign matter between air filter and turbocharger
– Exhaust pipe blockage or crushing
– Air or gas leak between turbocharger and engine
– Turbine casing damaged or fouled
– Turbo impeller vane(s) damaged
Black exhaust smoke
– Turbocharger damaged or fouled
Blue exhaust smoke
– Engine breather clogged
– Oil consumption
– Oil return pipe clogged or crushed
– Prolonged running at idling speed
– Air compressor defective
Strange noise
– Air filter / turbocharger link leakage
– Foreign matter between air filter and turbocharger
– Exhaust pipe blockage or crushing
– Turbocharger lubrication fault
– Engine used at underspeed in relation to load

20 661 I9-3
Incidents and probable causes (cont.)

Excessive oil consumption
– Turbocharger lubrication fault
Oil in air pipes before turbocharger
Oil in air pipes after turbocharger

Oil in exhaust manifold
Oil in exhaust pipes after turbocharger

I9-4 20 661

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RENAULT TRUCKS

RANGE FAMILY VARIANT

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 → 6

Stripping and mounting on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 → 10

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 → 3

Valve timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 → 3

Reciprocating gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 → 2

© RENAULT TRUCKS SA 12/2004 - Imprimé en France - le 12/2004 50 21 014 490

RENAULT TRUCKS 12/2004

NOTE! Draws attention to particular or important points of the method.

RENAULT TRUCKS 12/2004

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

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

Weld bead Grease or oil (see "Consumables" table)

Repair time - Heating time Mark - Assemble according to marking

RENAULT TRUCKS 12/2004

Rotating friction torque Turn anti-clockwise

Place in contact Move in the direction shown

Dimension to be assured (mm)

Exhaust - Outlet Operation with a sequence

Intake - Inlet Involves

Return to numbered operation -

Depending on versions or options Withdraw - Delete

Injection ... to ...

Repair dimension Inspect - Check condition of part

Part to be replaced Danger for persons, vehicle or equipment

RENAULT TRUCKS 12/2004

Fastening, locking, sealing and adhesive products:

RENAULT TRUCKS 12/2004

RENAULT TRUCKS 12/2004

RENAULT TRUCKS 12/2004

– (1): Engine model

RENAULT TRUCKS 12/2004

Engine horsepower and torque

Type designation Maximum horsepower Maximum torque

DXi 12 480 353 KW at 1800 rpm 2200 / 2400* Nm at 1200 rpm

(*) Torque values with the "OPTIFUEL" option.

Cubic capacity 12.13 l

Compression ratio 18.1 / 1

Direction of rotation: clockwise seen from flywheel end

Firing order 1.5.3.6.2.4

Max. no-load speed 2120 → 2160 rpm

Max. full load speed 1800 rpm

Supercharged: by turbocharger with intercooler

With turbocharger: 1155 kg

RENAULT TRUCKS 12/2004

RENAULT TRUCKS 12/2004

Min. full opening dimension: 9.5 mm

RENAULT TRUCKS 12/2004

RENAULT TRUCKS 12/2004

Engine speed in rpm Temperature in °C Pressure in bar(s)

Rocker shaft oil pressure