General

SPECIFICATIONS LIFTING EQUIPMENT TOWING LUBRICANTS - CONSUMABLES DRAINING - REFILLING VALUES AND SETTINGS

77 11 190 814

OCTOBER 1996
All copyrights reserved by Renault.

Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed".

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

Rgie Nationale des Usines Renault S.A. 1996

EXPLODED VIEW

PRC0001

General
Contents

Pages

Pages

01 SPECIFICATIONS
Engine - Clutch - Gearbox Vehicle identification 01-1 01-2

05 DRAINING - REFILLING
Engine Gearbox Power assisted steering 05-1 05-3 05-4

02 LIFTING EQUIPMENT
Trolley jack - Axle stands 02-1

07 VALUES AND SETTINGS

Dimensions Capacities - Grades Belt tension Accessories belt tension Timing belt tension Cylinder head tightening Main brake components and dimensions Front axle setting values Front axle checking values Rear axle checking values Underbody heights Brake compensator 07-1 07-4 07-7 07-9 07-15 07-17 07-21 07-22 07-24 07-25 07-27 07-28

03 TOWING
All types 03-1

04 LUBRICANTS - CONSUMABLES
Packaging 04-1

SPECIFICATIONS Engine - Clutch - Gearbox

01
Type of manual and automatic gearbox

Engine Vehicle type Type Cubic capacity (cm 3) 1237 1397 1397 1390 1390 1390 1390 1171 1721 Clutch type

B530 - C530 - L530 S530 B531 - C531 - L531 B53H - B53P - C53P
L53H - L53P

C1G C1J C2J C3J E6J E7J E7J E7F F2N

180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 180 CP 3300 200 CP 4000

JB0 - JB1 - JB4 - JB5 JB0 - JB1 - JB4 - JB5 JB0 - JB1 - JB4 - JB5 JB0 - JB1 JB0 - JB1 - MB1 JB1 - MB1 JB1 - MB1 JB0 - JB1 - JB3

B532 - C532 - L532 B53G - B537 - C537 L53G - L537 - S537 B53A - C53A - L53A B535 - C535 - L535 B53W - C53W - L53W B53E - B53M - B533 B536 - C53E - C53M C533 - L533 - L536 B53B - B53C - B53F C53B - C53C - C53F D53C - L53B - L53C L53F B53V - B53Y - B538 C53V - C53Y - C538 D53V - D53Y - L53V L53Y - L538 - 353A 353C - 353D - 353F 453A - 453C - 453D 453F - 453H - 553A 553C - 553D - 553F 553H - 853A - 853C 853F B53D - B539 - C53D C539 - D53D - L53D L539 B53I - B53J - B53K B53T - B53Z - B534 C53I - C53J - C53K C53T - C53Z - C534 L53I - L53J - L53K L53T - L53Z - L534 S53I - S53J - S53K S534

JB0 - JB1 - JB3 - AD4

F3N

1721

200 CP 4000

AD4 - JB3 - MB3

F3P

1794

200 CP 4000

AD4 - JB3 - JC5

F7P

1764

200 CP 4400

JB3 - JC5

200 CPV 4600 F8Q 1870 200 CPV 3500

JB1 - JB3 - JC5

01-1

SPECIFICATIONS Vehicle identification

IDENTIFICATION OF F3P ENGINES WITH REDUCED CUBIC CAPACITY APPROVAL LETTER VEHICLE TYPE

01

ENGINE

NUMBER

E H E H

704 706 X53 Y 708 760

H F3P H

706 053 A 760

053 B - F - H J 765 X53 V

053 C - D - H A 682 X53 8 Definition of identification X and 0 X53 Y = B53 Y, C53 Y, L53 Y 053A = 353 A, 453 A Vehicle type code starting with a letter. Vehicle type code starting with a number.

The reduced cubic capacity can be identified using the type approval letter (B) on the engine plate.

C D
A B C D E F : : : : : : the engine type the vehicle type approval letter the identity of RENAULT SA the engine number the engine manufacturing number letter indicating the factory at which the engine was manufactured (e.g.: C for Clon)

000 0 000 / 0000000

F E
90775

01-2

SPECIFICATIONS Vehicle identification

LOCATION OF THE VEHICLE IDENTIFICATION PLATE

01

Position n 1

Position n 3

95890-1R

Adhesive plate (D) is attached to the chassis on the side of the right front door.
92025R

Plates (A) and (B) may be separate or on a single plate (according to specification).

Position n 2

94946R

Plate (C) is located on the front panel.

01-3

SPECIFICATIONS Vehicle identification

METAL PLATE (Position n 1)

01

Rectangular plate

Oval plate

REGIE NATIONALE DES USINES RENAULT B1 X*0* 0000 XX0000 000

A B2 B C D E F G H J

00000000 0000 kg 0000 kg

00000 00 000 000 X 0000000 0000

1 - 0000 kg 2 - 0000 kg
0000
This consists of; At A : the manufacturers name, At B : the EU official approval number, including: At B1 : the number of the country granting the EU approval At B2 : the approval number for the vehicle type. At C : the official type number preceded by the manufacturers worldwide identification code (for example VF1 is the code for RENAULT France), At D : the chassis number At E : the gross vehicle weight, At F : the gross train weight, At G : the maximum permissible front axle weight, At H : the maximum permissible rear axle weight, At J* : the vehicle model year or paint identification code.
* NOTE: some of these items of information are

not required for certain export markets. The plates described above are shown in their most complete form.

This consists of: At 1 : the vehicle type At 2 : special features of the vehicle* At 3 : the basic equipment * (see table), At 4 : options, At 5 : the manufacturing number, At 6 : the vehicle model year* or paint identification code*, At 7 : the factory at which the vehicle was assembled: A : Portugal B : Batilly C : Creil D : Douai E : Spain F : Flins G : Grand Couronne H : Haren J : Billancourt K : Dieppe N : Mexico P : Mexico Q : A.M.C. S : Sandouville T : Matra Romorantin U : Maubeuge W : Spain Valladolid X : Heuliez Y : Yugoslavia Z : U.S.A.
* DEPENDING ON COUNTRY OR SPECIFICATION

01-4

SPECIFICATIONS VEHICLE IDENTIFICATION

METAL PLATE (Position n 2)

01
1 3 4 7 6 8 5 2

A B C D E F G H

REGIE NATIONALE DES USINES RENAULT AU 0000-00-00 VF1000000 00000000 0000 kg 0000 kg 1 - 0000 kg 2 - 0000 kg 0000 00 000 000 00 000 000 0000000

This consists of: : the manufacturers name, : the EU official approval number : the official type number preceded by the manufacturers worldwide identification code (for example : VF1 for RENAULT France), At D : the chassis number, At E : the gross vehicle weight, At F : the gross train weight, At G : the maximum permissible front axle weight, At H : the maximum permissible rear axle weight,
At A At B At C

At 1 : the vehicle type, At 2 : the first number indicates the gearbox or the factory options the second number indicates the level of equipment, At 3 : the technical equipment number, At 4 : the factory option additional equipment, At 5 : the trim identification code, At 6 : the paint identification code, At 7 : the level of equipment, At 8 : a letter indicating the factory of manufacture, followed by the manufacturing number.
WARNING: The 7 characters of the manufacturing number must not be separated. For vehicles manufactured

before that date, the manufacturing number is 7 numbers.

NOTE: some of these items of information are not required for certain export markets. The plates described above are shown in their most complete form.

01-5

SPECIFICATIONS Vehicle identification

METAL PLATE (Position n 3)

01

REGIE NATIONALE DES A B 1 2 3 4 5 6 USINES RENAULT S.A. e000-00/00000-0000-00 VF0000000 00000000 0000 kg 0000 kg 1 - 0000 kg 2 - 0000 kg
Renault

0000 00 000 000 00 000 000 0000000

8 9 10 11 12 13 14 7

1 2 8 7 14 13

VF0000000 00000000 0000 00 000 000 00 000 000 0000000 10 11 12 9

01-6

SPECIFICATIONS Vehicle identification

01

This consists of: At A : the manufacturers name, At B : the EU official approval number At 1 : the official type number preceded by the manufacturers worldwide identification code (for example : VF1 for RENAULT France), At 2 : the chassis number, At 3 : the gross vehicle weight, At 4 : the gross train weight, At 5 : the maximum permissible front axle weight, At 6 : the maximum permissible rear axle weight, At 7 : the first number indicates the gearbox or the factory options the second number indicates the level of equipment, At 8 : the vehicle type At 9 : the technical equipment number, At 10 : the factory option additional equipment, At 11 : the level of equipment, At 12 : the paint identification code, At 13 : a letter indicating the factory of manufacture, followed by the manufacturing number, At 14 : the trim identification code.
NOTE: some of these items of information are not required for certain export markets. The plates described

above are shown in their most complete form.

ALLOCATION OF THE TECHNICAL EQUIPMENT CODES

The equipment code, three letters at (9), must be documented when vehicle identification is required (ordering of replacement parts, warranty form, etc).

01-7

SPECIFICATIONS Vehicle identification

01

Due to the European depollution standards, the "ABCD" coding of some vehicles has become saturated following the introduction of new engines (letter "D"), the body code "A" therefore becomes "A".

A 3 door hatchback 5 door hatchback 4 door saloon Utility Cabriolet Renault 19 all models C B L S D X

A 3 5 4 6 7 0

"ABCD"

"ABCD"

C53A B53A L53A S53A D53A X53A or

353A 553A 453A 653A 853A 053A

The engine letter"D" at A in both cases corresponds: to engine E7J 700 when the body type is B, C, D, L, and S X covers B, C, D, L, and S to motor F3P 706 when the body type is 3, 4, 5, 6 and 8 0 covers 3, 4, 5, 6 and 8. Therefore
B53A :

553A : C53A : 353A :

Renault 19 5 door hatchback with engine E7J 700 Renault 19 5 door hatchback with engine F3P 706 Renault 19 3 door hatchback with engine E7J 700 Renault 19 3 door hatchback with engine F3P 706

REMINDER:

"A" or "A" "BC" "D"

= body type = N of project (example 53) = Engine number

01-8

LIFTING EQUIPMENT Trolley jack - Axle stands

Safety symbol (special precautions to be taken when carrying out work).

02

ESSENTIAL SPECIAL TOOLS

Cha. Cha.

280 -02 408 -02

Trolley jack pad Trolley jack socket

Suitable axle stands must be used when using a trolley jack. It is forbidden to lift the vehicle by taking the load under the front suspension arms. Use whichever of the sockets Cha. 408-02 that suits the trolley jack to fit pad Cha. 280-02.

LIFTING WITH THE TROLLEY JACK FROM THE FRONT

LIFTING WITH THE TROLLEY JACK FROM THE REAR

Apply the handbrake or place chocks under the rear wheels. Use pad Cha. 280-02. Take the load under the front sub-frame. Avoid the pad touching the gearbox or the exhaust down-pipe.

It is FORBIDDEN to lift the rear of the vehicle taking the load under the rear axle. Lift each wheel separately taking the load under the vehicle jacking points.

92556R

For some vehicles, make a notch in tool Cha. 28002 to prevent it touching the exhaust.

91936G2

85679-1G13

02-1

LIFTING EQUIPMENT Trolley jack - Axle stands

LIFTING WITH THE TROLLEY JACK FROM THE SIDE AXLE STANDS

02

Use pad Cha. 280-02. Take the load on the body sill, under the front door. Ensure that the body sill flange locates correctly in the groove in the pad.

When taking the weight of the vehicle on the axle stands ensure that the stands are under the vehicle jacking points (1). Stands are to be placed under the rear end by lifting the vehicle from the side.

87709R

91936G3

85679-1G14

02-2

TOWING All models

FOR TOWING, REFER TO THE LEGISLATION IN FORCE IN THE COUNTRY CONCERNED. NEVER USE THE DRIVESHAFT TUBES AS ATTACHMENT POINTS.

03

The towing points are only to be used for towing the vehicle on the road. In no circumstances are they to be used for pulling the vehicle out of a ditch, or for any other similar operation nor are they to be used for lifting the vehicle either directly or indirectly.

FRONT

REAR

92020S

92019S

03-1

LUBRICANTS - CONSUMABLES Packaging

DESCRIPTION PACK SIZE

04
PART NUMBER

GREASES MOLYKOTE "BR2" for bushing surfaces, thrust pad guide tube, clutch fork pads, lower suspension arm bearings, torsion bar splines, steering box, driveshaft splines. MOLYKOTE "33 Medium" bushes on tubular rear axles anti-roll bar bushes ANTI-SEIZE (high temperature grease) Turbo etc. "MOBIL CVJ" 825 Black star
or MOBIL EXF57C

1 kg tin

77 01 421 145

100 g tube

77 01 028 179

80 ml tube

77 01 422 307

180 g sachet

77 01 366 100

for driveshaft seals MULTIPURPOSE GREASE wheel sensor

Aerosol

77 01 422 308

MECHANICAL SEALING COMPOUNDS Perfect-seal "LOWAC" liquid jointing compound Mastic for sealing exhaust pipe joints RHODORSEAL 5661 100 g tube 77 01 417 404

1.5 kg tin

77 01 421 161

100 g tube

77 01 421 042 77 01 404 452 77 01 421 080

HARDENER KIT (Rhodorseal 5661) for sealing the sides of bearing caps AUTO joint blue jointing paste AUTO joint or sealing compound for the timing cover of V6 engines

Kit

100 g tube 45 g tube 100 g tube

77 01 396 227 77 01 397 027 77 01 422 751

04-1

LUBRICANTS - CONSUMABLES Packaging

DESCRIPTION PACK SIZE

04
PART NUMBER

MECHANICAL SEALING COMPOUNDS AUTO joint grey sealing compound LOCTITE 518 for sealing gearbox housings Leak detector 100 g tube 77 01 422 750

24 ml syringe

77 01 421 162

Aerosol

77 11 143 071

ADHESIVES "LOCTITE - FRENETANCH" to prevent bolts coming loose but still permit their release "LOCTITE - FRENBLOC" for locking bolts "LOCTITE SCELBLOC" for bonding bearings "LOCTITE AUTOFORM" for bonding the flywheel to the crankshaft 24 cc bottle 77 01 394 070

24 cc bottle

77 01 394 071

24 cc bottle

77 01 394 072

50 cc bottle

77 01 400 309

CLEANERS - LUBRICANTS "NETELEC" release, lubricating agent Cleaner NC1 electrical contact cleaner Carburettor cleaner 250 g aerosol 77 01 408 464

Aerosol

77 01 422 379

250 ml can 300 ml aerosol 355 ml can 420 ml aerosol Aerosol

77 01 393 112 77 01 393 111 77 01 423 189 77 01 407 689 77 01 405 952

Injector cleaner Super concentrated release agent "DECAPJOINT " for cleaning aluminium cylinder head gasket faces

04-2

LUBRICANTS - CONSUMABLES Packaging

DESCRIPTION PACK SIZE

04
PART NUMBER

VARNISH "CIRCUIT PLUS" Varnish for the repair of heated rear screens "CONTACT PLUS" Varnish for the repair of heated rear screen supply tabs Bottle 77 01 421 135

Kit

77 01 422 752

AIR CONDITIONING Compressor oil ELF RIMA 100 Fixed cubic capacity compressor oil SANDEN SP 20 Variable cubic capacity compressor oil SP10 250 ml (R12) 250 ml (R134a) 77 01 417 655 77 11 143 700

250 ml (R134a)

77 01 419 313

04-3

DRAINING - REFILLING Engine

05

ESSENTIAL SPECIAL TOOLS

Engine drain plug spanner

DRAINING: plug (1)

REFILLING:

plug (2) dipstick (3)

ENGINES C - F

ENGINES C1G - C1J - C2J - C3J

98486R

92179R

ENGINE E

ENGINES E6J - E7J - E7F

98701R

92178R

05-1

DRAINING - REFILLING Engine

REFILLING:

05

plug (2) dipstick (3)

ENGINES F2N - F3P

ENGINE F7P

92035R

92715R

ENGINE F3N

ENGINE F8Q

95748R

95747R

05-2

DRAINING - REFILLING Gearbox

MANUAL DRAINING: plug (1) REFILLING: plug (2)

05

ENGINES C - E - F

98486R1

Plug (A) with no dipstick

Plug (A) with dipstick

92081R

DI0522

Fill to the level of the opening.

Wipe the dipstick section. Refit the plug without tightening it, dipstick downwards. Remove the plug, the level should be on the boss (2).

For automatic transmission, refer to the relevant section.

05-3

DRAINING - REFILLING Power assisted steering

CHECKING THE LEVEL POWER ASSISTED STEERING PUMP LEVEL

05

Use ELF RENAULTMATIC D2 or MOBIL ATF 220 for topping up or refilling. The level is correct when the fluid is visible between the MINIMUM and MAXIMUM levels on the reservoir (1).

92030R

05-4

VALUES AND SETTINGS Dimensions

Phase 1

07

91936R1

Marks A B C

Dimensions in metres 2.545 4.155 1.418

Marks D E F

Dimensions in metres 1.416 unladen from 1.406 to 1.417 1.676 or 1.694

07-1

VALUES AND SETTINGS Dimensions

Phase 2

07

95890R

Marks A B C D E F G H I

Dimensions in metres 0.813 from 2.540 to 2.544 (1) from 0.805 to 0.809 (1) from 4.158 to 4.166 (1) 0.120 (2) 1.426 from 1.684 to 1.696 (1) from 1.400 to 1.420 (1) - (3) 1.406 or 1.417 (1)

Turning circle (in metres) Between kerbs : 10.4 (10.8 model with F7P engine) Between walls : 11.0 (11,4 model with F7P) engine (1) According to model with option (2) Laden (3) Unladen

07-2

VALUES AND SETTINGS Dimensions

Models D and L

07

95888R4

Marks A B C D E

Dimensions in metres 0.813 from 2.540 to 2.544 from 0.805 to 0.809 4.162 0.120 (*)

Marks F G H I (*) Laden

Dimensions in metres 1.426 from 1.684 to (1.696 with moulding) from 1.395 to 1.410 1.406 or 1.417

07-3

VALUES AND SETTINGS Capacities - Grades

Capacity in litres For oil drain

07

Units Petrol engine (oil)

Grade

EU countries
PETROL

- 15 C - 30 C - 20 C - 10 C

+ 25 C 0C + 10 C + 20 C + 30 C 15W40-15W50 15W40-15W50

CCMC-G4 ACEA A2-96/A3-96 CCMC-G5 ACEA A2-96/A3-96 CCMC-G5 ACEA A2-96/A3-96

10W30-10W40-10W50 10W30-10W40-10W50 5W30 5W30 5W40-5W50 5W40-5W50

C E
F2N - F3N - F3P

3 3.5 4.8 6

CCMC-G5 ACEA A2-96/A3-96

Other countries
PETROL

F7P

- 15 C - 30 C - 20 C - 10 C 0C + 10 C + 20 C + 30 C

API SH 15W40

API SH 10W40

API SH 10W30

(plus 0.5 litre for oil filter)

API SH 5W30

07-4

VALUES AND SETTING Capacities - Grades

Capacity in litres For oil drain

07

Units Diesel engine (oil)

Grade

EU countries DIESEL (All models) - 15 C - 30 C - 20 C - 10 C 0 C + 10 C + 25 C + 20 C + 30 C

CCMC-PD2 ACEA B2-96/B3-96 CCMC-PD2 ACEA B2-96/B3-96 CCMC-PD2 ACEA B2-96/B3-96 CCMC-PD2 ACEA B2-96/B3-96

15W40 15W40

10W40 10W40 5W30 5W30 5W40 5W40

F8Q

5 Other countries
DIESEL

- 15 C - 30 C - 20 C - 10 C 0 C

+ 15 + 10 C + 20 C + 30 C

API CF 15W40

API CF 10W40

(plus 0.5 litre for oil filter)

API CF 10W30

07-5

VALUES AND SETTINGS Capacities - Grades

Capacity in litres

07
Special points

Units Manual gearbox JB0 JB1 JB3 JB4 JB5 JC5 Automatic transmission MB1 MB3 AD4 Final drive AD4 Braking system Fuel tank Power assisted steering Engine cooling system
C1G - C1J - C2J

Grade All countries: TRANSELF TRX 75 W 80 W (Standards API GL5 or MIL-L 2105 C or D)

3.25 3.40 3.40 2.80 2.90 3.10

4.5 4.5 4.6 1 Normal : 0.7

ABS : 1

ELF RENAULT MATIC D2 (D20104)

or if not available use:

MOBIL ATF 220 (D20104 or D21412)

TEXAMATIC 4011

SAE J 1703

and DOT 4 Unleaded petrol/diesel

ELF RENAULT MATIC

The brake fluid must be of a type approved by our Design office. -

55 Separate reservoir 1.1

D2 or
MOBIL ATF 220

C3J E6J
E7F - E7J F2N - F3N

F3P F7P F8Q

5.4 6 5.2 5,2 6 6.1 or 6.5 7 6.8

07-6

VALUES AND SETTINGS Belt tension

07

ESSENTIAL SPECIAL TOOLS

Mot.

1273

Belt tension checking tool

96601R

A B C D

: : : :

Sensor Display Connecting lead Calibration checking blade

Calibration of the equipment The equipment is calibrated at the factory, however, this calibration must be checked every six months. Procedure Setting zero: - switch on the equipment (button E) with the pressure piece button (1) head down, - if 0 is displayed, do not adjust anything, - if there is no display, check the charge of the equipments 9 volt battery, - if a value other than 0 is displayed, operate screw (F) until 0 is obtained .

Principle Via the pressure piece button (1), the pressure piece (2) and the external pads (3), the sensor applies a constant slack to the belt. The reactive force of the belt is measured using a test unit (4) fitted with stress gauges. The pulling of the gauges creates a variation in their electrical resistances. Once converted by the equipment, this variation is displayed in SEEM units (US).

07-7

VALUES AND SETTINGS Belt tension

Checking the calibration Switch on the equipment (button E).

07

Position the standard spring blade (Z) on the sensor as shown on the diagram (checking value etched towards the top , (A) minimum value, (B) maximum value). Tighten the pressure piece button (1) until it clicks (three "CLICKS"). Check that the display shows a value X between values (A and B) (A X B).
COMMENT: It may be necessary to carry out a few preliminary test in order to obtain the correct value.

If the values are incorrect after several tests, contact your local After Sales Head Office.
NOTE: Each apparatus has its own standard spring blade which is not interchangeable.

96602R

1 Knurled button (pressure piece) A Standard blade checking value B Z Standard blade

GENERAL RECOMMENDATIONS:

- Never refit a belt which has been removed, always fit a new one. - Never retighten a belt the tension value of which is between the fitting value and the minimum required for operation. - When carrying out a check, if the tension is below the minimum operating tension, change the belt.

SEEM

Please contact your local After Sales Head Office for details.

07-8

VALUES AND SETTINGS Accessories belt tension

RECOMMENDATIONS FOR FITTING BELTS: V-BELT

07

Procedure for tensioning a new belt: With the engine cold (ambient temperature). Fit the new belt. Fit the sensor of Mot. 1273. Turn the sensor wheel until it clicks (three CLICKS"). Tension the belt until the recommended fitting value is displayed on Mot. 1273. Lock the tensioner, carry out a check, adjust the value. Turn the crankshaft through three revolutions. Check that the tension is within the fitting tension tolerance, adjust it if it is not.

Procedure for tensioning a belt which has been operated: With the engine cold (ambient temperature). Fit the belt. Fit the sensor of Mot. 1273. Turn the sensor knob until it clicks (three CLICKS"). Tension the belt until 80% of the recommended fitting value is displayed on Mot. 1273. Lock the tensioner, carry out a check, adjust the value. Turn the crankshaft through three revolutions. Check that the tension is within the tolerance of 80% of the fitting tension. If it is not, adjust it to 80% of the fitting value.
NOTE:

The V-belt is changed depending on its condition or the noise which it makes. For the measuring point, fit the sensor of Mot. 1273 in place of El. 346-04.

07-9

VALUES AND SETTINGS Accessories belt tension

Toothed BELT

07

Tensioning procedure With the engine cold (ambient temperature). Fit the new belt. Fit the sensor of Mot. 1273. Turn the sensor wheel until it clicks (three "CLICKS"). Tension the belt until the recommended fitting value is displayed on Mot. 1273. Lock the tensioner, carry out a check, adjust the value. Turn the crankshaft through three revolutions. Check that the tension is within the fitting tension tolerance, adjust it if it is not.

NOTE :

Never refit a belt which has been removed. Change the belt if the tension is below the minimum operating tension. Small cuts or cracks are not criteria for changing the belt. For the measuring point, fit the sensor of Mot. 1273 in place of El. 346-04.

07-10

C
ENGINE

VALUES AND SETTINGS Accessories belt tension

ALTERNATOR AND COOLANT PUMP

07

92648R1

A B C

Coolant pump Crankshaft pump Alternator pump Tension checking point

Tension (US=SEEM unit)

Coolant pump Alternator Belt 90 6 89 5 (*) 64 68 (*)

Air conditioning belt 105 6 (*)

Fitting Minimum operating tension (*) = C2J 776

75 (*)

07-11

E
ENGINE

VALUES AND SETTINGS Accessories belt tension

ALTERNATOR

07

92320R2

B Crankshaft pulley C Alternator pulley Tension checking point

E6J engine Toothed alternator belt (three teeth) 84 6 52 Air conditioning and power assisted steering belt (four teeth) 106 59

Tension (US=SEEM unit)

Alternator V-belt

Air conditioning V-belt

Fitting Minimum operating tension E7J engine

83 7 70

90 72

Tension (US=SEEM unit)

Toothed alternator belt (three teeth)

Toothed power assisted steering belt (three teeth)

Alternator V-belt

Air conditioning V-belt

Air conditioning and power assisted steering belt (four teeth) 106 59

Fitting Minimum operating tension

84 6 52

84 5 46

83 7 70

90 72

07-12

F
ENGINE

VALUES AND SETTINGS Accessories belt tension

07
Toothed belt (six dents teeth) Alternator and coolant pump 83 6 57

F2N, F3N engines Toothed belt (six teeth) Alternator Air conditioning and power assisted steering 106 6 71 Toothed belt (six teeth) Alternator Power assisted steering 98 6 73

Tension (US=SEEM unit)

Fitting Minimum operating tension

F7P engine Toothed belt (six teeth) Alternator Air conditioning 91 5 58 Toothed belt (six teeth) Alternator Power assisted steering 95 5 57

Tension (US=SEEM unit)

Fitting Minimum operating tension F8Q engine Toothed belt (six teeth) Alternator Air conditioning and power assisted steering 112 4 116 7* 67

Tension (US=SEEM unit)

Toothed belt (six dents teeth) Alternator Air conditioning

Toothed belt (six teeth) Alternator Power assisted steering 99 5 68

Toothed belt (six teeth) Alternator

Fitting Minimum operating tension *

101 5 67

97 3 67

only for belt Part number : 77 00 272 741

07-13

F
ENGINE

VALUES AND SETTINGS Accessories belt tension

07

ALTERNATOR AND COOLANT PUMP

87413R1

86979R1

A B C E

Coolant pump Crankshaft Alternator Air conditioning compressor

91136R3

92290R2

A B C D E F

Coolant pump pulley Crankshaft pulley Alternator pulley Assistance pump pulley Compressor pulley Tensioner roller Tension checking point

07-14

VALUES AND SETTINGS Timing belt tension

Tensioning procedure With the engine cold (ambient temperature). Fit the new belt Fit the sensor of Mot. 1273. Turn the sensor knob until it clicks (three
"CLICKS").

07
E engine

Tension the belt until the recommended fitting value is displayed on the Mot. 1273. Lock the tensioner, carry out a check, adjust the value. Turn the crankshaft through a minimum of three revolutions. Check that the tension is within the fitting tension tolerance ( 10%). If it is not, adjust it.

98708R

Belt tension (in SEEM units)

NOTE :

Fitting : 30 U.S. Do not refit a belt which has been removed. Minimum operating tension: 26 U.S. Change the belt if the tension is below the minimum operating tension.

07-15

VALUES AND SETTINGS Timing belt tension

F engine (petrol) except F7P F8Q engine

07

96528R1

99175R

Belt tension (in SEEM units) Fitting: 25 U.S. Minimum operating tension: 22 U.S.

Belt tension (in SEEM units) Fitting: 38 U.S. Minimum operating tension: 36 U.S.

07-16

VALUES AND SETTINGS Cylinder head tightening

E ENGINE CYLINDER HEAD TIGHTENING PROCEDURE C ENGINE CYLINDER HEAD TIGHTENING PROCEDURE

07

Grease the bolt threads and underneath the bolt heads with engine oil.
REMINDER: In order to tighten the bolts correctly,

Grease the bolt threads and underneath the bolt heads with engine oil.
REMINDER: In order to tighten the bolts correctly, remove any oil from the cylinder head securing holes using a syringe.

remove any oil from the cylinder head securing holes using a syringe. Tighten the cylinder head in the order shown below:

Tighten the cylinder head in the order shown below:

10

90775S

81528-1S

1st tightening to 2 daN.m. 2nd tightening (angle) : 97 2.

1st tightening from 5.5 to 6.5 daN.m.

Adjusting the clearance at the valves Wait for at least three minutes. Run the engine for 20 minutes. Slacken bolts 1 and 2 then tighten to 2 daN.m. 2nd tightening (angle) : 97 2. Repeat the slackening and retightening operation for bolts 3, 4, 5, 6 then 7, 8, 9, 10. The cylinder head is not retightened. Adjust the clearance at the valves. The cylinder head is not retightened. After 2 hours 30 minutes with the engine stopped, retighten the cylinder head: - slacken bolt number 1 by 180 and retighten it to the recommended torque, - repeat for the other mounting bolts following the tightening order.

07-17

VALUES AND SETTINGS Cylinder head tightening

For engines F2N - F3N - F3P, refer to the "F ENGINE" section.

07

F ENGINE (petrol) ALL TYPES EXCEPT F7P

CYLINDER HEAD GASKET WITH ASBESTOS CYLINDER HEAD TIGHTENING PROCEDURE

CYLINDER HEAD GASKET WITH NO ASBESTOS CYLINDER HEAD TIGHTENING PROCEDURE

Grease the bolt threads and underneath the bolt heads with engine oil.
REMINDER: In order to tighten the bolts correctly,

All of the bolts must be changed automatically after removal. Grease the bolt threads and underneath the bolt heads with engine oil.
REMINDER: In order to tighten the bolts correctly, remove any oil from the cylinder head securing holes using a syringe.

remove any oil from the cylinder head securing holes using a syringe. Tighten the cylinder head in the order shown below:

Tighten the cylinder head in the order shown below:

9 8 4 1 5 9

10

10

90775S

1st tightening to 3 daN.m.

90775S

2nd tightening (angle) : 7 daN.m. Wait for at least three minutes. Slacken bolts 1 and 2 then tighten to 2 daN.m. 2nd assembly (angle) : 123 2. Repeat the slackening and retightening operation for bolts 3, 4, 5, 6 then 7, 8, 9, 10. The cylinder head is not retightened.

1st tightening to 3 daN.m. 2nd tightening (angle) : 50 4 . Wait for at least three minutes. Slacken bolt by bolt by 180, then tighten to 2.5 daN.m. : 2nd tightening (angle) : 123 7. Repeat the slackening and retightening operation for bolts 3, 4, 5, 6 then 7, 8, 9, 10. The cylinder head is not retightened.

07-18

VALUES AND SETTINGS Cylinder head tightening

F7P ENGINE CYLINDER HEAD GASKET WITH NO ASBESTOS CYLINDER HEAD TIGHTENING PROCEDURE

07

Grease the threads and underneath the heads of the new bolts.

1) Pre-seating the gasket: - tighten all of the bolts to 3 daN.m then carry out an angular tightening of 51 3 in the order recommended below. Wait for at least 3 minutes to allow the gasket to settle.

2) Cylinder head tightening: - slacken bolt by bolt until they are completely free then tighten all of the bolts to 2.5 daN.m, then carry out an angular tightening of 108 3 .

10

90775S

The cylinder head is not retightened.

07-19

VALUES AND SETTINGS Cylinder head tightening

F ENGINE (diesel)

07

CYLINDER HEAD GASKET WITH ASBESTOS CYLINDER HEAD TIGHTENING PROCEDURE

CYLINDER HEAD GASKET WITHOUT ASBESTOS CYLINDER HEAD TIGHTENING PROCEDURE

This operation is carried out when cold, when the cylinder head is refitted, and there is no other reason for it to be carried out. Grease the bolt threads and underneath the bolt heads with engine oil.
REMINDER: In order to tighten the bolts correctly,

All of the bolts must be changed automatically after removal. Grease the bolt threads and underneath the bolt heads with engine oil.
REMINDER: In order to tighten the bolts correctly, remove any oil from the cylinder head securing holes using a syringe.

remove any oil from the cylinder head securing holes using a syringe. Tighten the cylinder head in the order shown below:

Tighten the cylinder head in the order shown below:

81528-1S

81528-1S

1st tightening to 3 daN.m. 2nd tightening (angle) : 7 daN.m. Wait for at least three minutes. Slacken bolt by bolt until they are completely free, then tighten to 2 daN,m. 2nd tightening (angle) : 123 2.

1st tightening to 3 daN.m. 2nd tightening (angle) : 50 4 . Wait for at least three minutes. Slacken bolt by bolt until they are completely free, then tighten to 2.5 daN,m. 2nd tightening (angle) : 213 7. The cylinder head is not retightened except on the F8Q Turbo. - Special features of engines F8Q 610, 740, 744, 768. - Following an increase in engine temperature (operation of the fan). - Wait until the engine returns to ambient temperature. - In the recommended order, again tighten bolts 1-2, 3-4, 5-6, 7-8, 9-10, angle 120 7.

07-20

VALUES AND SETTINGS Main brake components and dimensions

B/C/L/S B/C/D/L/S B/C/L/S

07
B/C/D/L

530, 531 532, 534 535, 537 53A, 53B 53G, 53H 53J, 53W

533, 536 538, 53C 53F, 53K 53T, 53V 53Y, 53Z 3/4/5/8 53A, 53F 53H

538, 53F 53K, 53T 3/4/5 53C, 53D 53H

539, 53D
X53 ABS*

FRONT BRAKE (dimensions in mm) Diameter of slave cylinders Diameter of discs Thickness of discs Minimum thickness of discs (1) Thickness of linings (including mounting) Minimum thickness of linings (including mounting) Maximum run-out of discs 48 238 12 10.5 18 6 0.07 48 238 20 18.3 18 6 0.07 48 259 20.7 17.7 18 6 0.07 48 259 238 20.7 20 17.7 18 18 6 0.07

REAR BRAKE (dimensions in mm) Diameter of slave cylinders Diameter of drums Maximum diameter of drums after grinding Width of linings Thickness of linings (including mounting) Minimum thickness of linings (including mounting) Diameter of discs Thickness of discs Minimum thickness of discs (1) Thickness of linings (including mounting) Minimum thickness of linings (including mounting) Maximum run-out of discs 20.6 (2) 180.25 181.25 40 6.5 2.5 20.6 (2) 180.25 181.25 40 6.5 2.5 19 203.20 204.40 38 6.5 2.5 30 238 8 7 11 5 0.07

MASTER CYLINDER (dimensions in mm)

Diameter

20.6

20.6

20.6

20.6

(*) Except sport version (1) The brake discs cannot be ground. The discs must be changed if they are excessively scratched or worn. (2) Wheel cylinder with integral fixed compensator: in the event of a wheel cylinder or compensator function fault: change the assembly, repair is forbidden.

07-21

VALUES AND SETTINGS Front axle setting values

MANUAL STEERING ALL TYPES EXCEPT B539 - C539 - L539 - B53D - C53D - D53D - L53D POSITION OF FRONT AXLE CASTOR

07
ADJUSTMENT

ANGLES

VALUES

255 225 155 125 055 Maximum left/ right difference= 1

H5-H2= H5-H2= H5-H2= H5-H2= H5-H2=

21 mm 40 mm 59 mm 78 mm 97 mm

NOT ADJUSTABLE

78423S3

CAMBER

135 030 05 030 045

30

H1-H2= H1-H2= H1-H2= H1-H2= H1-H2=

22 mm 59 mm 86 mm 115 mm 149 mm

NOT ADJUSTABLE

Maximum left/right difference = 1

78423S1

KING PIN INCLINATION

1045 125 1255 1340 1415

30

H1-H2= H1-H2= H1-H2= H1-H2= H1-H2=

22 mm 59 mm 86 mm 115 mm 149 mm

NOT ADJUSTABLE

78423S2

Maximum left/right difference = 1 (Toe-out) Adjusted by rotating track rod sleeves 1 turn= 30 (3 mm)

PARALLELISM

For two wheels 010 10 (1 1 mm)

78423S

UNLADEN

POSITION FOR TIGHTENING RUBBER BUSHES UNLADEN

81603S1

07-22

VALUES AND SETTINGS Front axle setting values

POWER ASSISTED STEERING ALL TYPES EXCEPT B539 - C539 - L539 - B53D - C53D - D53D - L53D POSITION OF FRONT AXLE CASTOR

07
ADJUSTMENT

ANGLES

VALUES

5 430 4 330 3 Maximum left/right difference= 1

H5-H2= H5-H2= H5-H2= H5-H2= H5-H2=

21 mm 40 mm 59 mm 78 mm 97 mm

NOT ADJUSTABLE

78423S3

CAMBER

135 030 05 030 045

30

H1-H2= H1-H2= H1-H2= H1-H2= H1-H2=

22 mm 59 mm 86 mm 115 mm 149 mm

NOT ADJUSTABLE

Maximum left/right difference= 1

78423S1

KING PIN INCLINATION

1045 125 1255 1340 1415

30

H1-H2= H1-H2= H1-H2= H1-H2= H1-H2=

22 mm 59 mm 86 mm 115 mm 149 mm

NOT ADJUSTABLE

78423S2

Maximum left/right difference= 1 (Toe-out) Adjusted by rotating track rod sleeves 1 turn= 30 (3 mm)

PARALLELISM

For two wheels 010 10 (1 1 mm)

78423S

UNLADEN

POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN

81603S1

07-23

VALUES AND SETTINGS Front axle checking values

POWER ASSISTED STEERING B/C/L 539 - B/C/D/L 53D POSITION OF FRONT AXLE CASTOR

07
ADJUSTMENT

ANGLES

VALUES

530 5 430 4 330 Maximum left/right difference= 1

H5-H2= H5-H2= H5-H2= H5-H2= H5-H2=

32 mm 51 mm 70 mm 89 mm 108 mm

NOT ADJUSTABLE

93012-1S

CAMBER

018 015 000 102

30

H1-H2= H1-H2= H1-H2= H1-H2=

41 mm 120 mm 141 mm 185 mm

NOT ADJUSTABLE

Maximum left/right difference= 1

93013-1S

KING PIN INCLINATION

840 1040 1100 1106

30

H1-H2= H1-H2= H1-H2= H1-H2=

41 mm 120 mm 141 mm 185 mm

NOT ADJUSTABLE

93014-1S

Maximum left/right difference= 1 (Toe-out) Adjusted by rotating track rod sleeves 1 turn= 30 (3 mm)

PARALLELISM

Foe two wheels 010 10 (1 1 mm)

93011-1S

UNLADEN

POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN

81603S1

07-24

VALUES AND SETTINGS Rear axle checking values

ALL TYPES EXCEPT B/C/L 539 - B/C/D/L 53D VALUES ANGLES POSITION OF THE REAR AXLE

07
ADJUSTMENT

Rear axle Tubular

CAMBER

Rear axle 4 bars

Rear axle Rear axle Tubular 4 bars

Rear axle Rear axle Tubular 4 bars

- 050 30 (negative)

UNLADEN

NOT ADJUSTABLE

78423S1

PARALLELISM

- 20 to 40 (Toe-in) or

- 30 to - 50 (Toe-in) or - 3 to - 5 mm
UNLADEN NOT ADJUSTABLE

- 2 to - 4 mm
78423S

POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN

81603S1

07-25

VALUES AND SETTINGS Rear axle checking values

B/C/L 539 - B/C/D/L 53D ANGLES CAMBER VALUES POSITION OF THE REAR AXLE

07
ADJUSTMENT

- 050 30 (negative)

UNLADEN

NOT ADJUSTABLE

93013-2S

PARALLELISM

Per wheel - 10 to 30 (Toe-in) or - 1 to - 3 mm

93011-2S

UNLADEN

NOT ADJUSTABLE

POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN

81603S1

07-26

VALUES AND SETTINGS Underbody heights

UNDERBODY HEIGHTS (1) (mm)

07
Dimension X (mm)
RH and LH

Type B530 C530 L530 S530 B531 C531 L531 S531 B532 C532 L532 S532 B534 C534 L534 S534 B533 C533 L533 B538 C538 L538 B53C C53C D53C L53C S53C B53F C53F L53F B53K C53K L53K S53K
X53 ABS*

At the front H1 - H2 = ... mm B53I C53I L53I S53I B53J C53J L53J S53J B53W C53W L53W S53W

At the rear H4 - H5 = ... mm

B535 C535 L535 B537 C537 L537 S537 B53A C53A L53A B53B C53B L53B B53G L53G B53T C53T L53T S53T B53V C53V D53V L53V B53Y C53Y D53Y L53Y S53Y B53Z C53Z L53Z

87

10

590

353A 453A 553A 853A 353B 353C 453C 553C 353D 453D 553D 353F 453F 553F 853F 453H 553H

93

25

645

B536 L536 B539 C539 L539

B53H L53H B53D C53D D53D L53D

86

580

120

54

580

Tolerances : 7.5 mm The differences between the right hand side and the left hand side on the same axle must not exceed 5 mm, with the drivers side always being the higher. Any alteration to the underbody height must be followed by resetting of the headlight beams and the braking compensator. (1) If there is a minus sign in front of a value, this represents a floor position which is higher than that of the wheel centreline in relation to the ground. * As an option.

07-27

VALUES AND SETTINGS Brake compensator

07
Checking pressure (Bar) Front Rear

Type

Amount of fuel in tank (driver on board)

All types with fixed compensator incorporated in the wheel cylinder

60

34 +0
-4

B/C/L

533 53C 53Y 534 53J 53K With ABS (after 05/92)

B/C/L

53T 53V 53Z

With ABS

90966S

100

40

3/4/5

53A 53B 53F

+0 -8

With ABS

B/C/L/S

53F 538 53K 53T 53Z Without ABS (before 11/94)

3/4/5

53C 53D 53H

Without ABS (before 11/94)

07-28

VALUES AND SETTINGS Brake compensator

07
Checking pressure (Bar) Front Rear
+0 -8

Type

Amount of fuel in tank (driver on board)

B/C/D/L

539 53D

(before 05/92)

100

47

B/C/L

53A 535 53B 538 with ABS (after 05/92) 100 with ABS

B/C/L

53F

52 -8

+0

3/4/5

53C 53D 53H with ABS

90966S

D53D (after 05/92) 853C

B/C/L/S

53F 538 53K 53T 53Z With ABS (after 11/94) 100 49
+0 -8

3/4/5

53C 53D 53H

Without ABS (after 11/94)

07-29

VALUES AND SETTINGS Brake compensator

07
Checking pressure (Bar) Front Rear

Type

Amount of fuel in tank (driver on board)

B/C/D/L/S

533 53C 53F 534 53J 53K 53Y With ABS (before 05/92) 100 43

+0 -8

B/C

53M ABS

B/C/L

53D

(after 05/92)
90966S

53C 53Y

With ABS (after 05/92)

100

52

+0 -8

D 8

53V 53A 53F With ABS

07-30