service repair manual instant download

1. Celtis – 09.2007 – GB
CONTENTS
ENGINE
INLET AND EXHAUST .......................................................................................................................................3
COOLING..........................................................................................................................................................21
LUBRICATION..................................................................................................................................................30
MECHANICAL INJECTION ..............................................................................................................................42
ELECTRONIC INJECTION ...............................................................................................................................55
HYDRAULIC PART ............................................................................................................................................................66
ELECTRONIC COMPONENTS..........................................................................................................................................76
MOVING ASSEMBLY .......................................................................................................................................98
ACCESSORY GEAR TRAIN...........................................................................................................................108
VISCOUS FAN COUPLING ............................................................................................................................113

2. Celtis – 09.2007 – GB
A.2
First line (1): Serial number (13 characters)
Second line (2): Engine type
Tractor prior to May 2005 Tractor after May 2005
CD Engine built at the Saran factory CD Engine built at the Saran factory
4 4 cylinders 4 4 cylinders
O45 4,5 litres capacity O45 4,5 litres capacity
D Normally aspirated engine B Uncertified engine
T Turbo-charged engine C Tier 1 engine (will be followed by
the letter E then F when the
counter reaches 999999)
H Turbo-charged engine with
intercooler
G Tier 2 engine (will be followed by
the letter J then K when the
counter reaches 999999)
5 Tier 1 engine 123456 Number within the series
7 Tier 2 engine
12345 Number within the series
4 See above
045
T
RT RENAULT Agriculture application
52 Application issue

3. Celtis – 09.2007 – GB A.3
Inlet and exhaust
Technical description
Cylinder head
131msm00
This can be identified by: The cross-flow design.
Inlet ducts have been redesigned to increase turbulence in the cylinders SWIRL, and hence
improve air/fuel mixing.
A cast letter (H) in the inlet port identifies the model of cylinder head.
The cylinder head now incorporates a housing for the direct mounting of the thermostat.
The cylinder head gasket is specific.
It has a compressed graphite film on both surfaces.
H

4. Celtis – 09.2007 – GB
A.4
Valves
The valve guides are machined directly in the cylinder head. A helicoidal open groove improves
lubrication between the guide and valve. An "umbrella" type seal (D) allows the passage of a
controlled quantity of oil to provide lubrication for the valve stem.
Each valve is fitted with a rotator (B) ensuring a rotation of 2° each time the valve operates. The
contact surface between the valve head and the seat insert is thus always clean.
A – Collets.
B – Valve rotator.
C – Spring.
D – Umbrella seal.
131hsm10
A
B
C
D

5. Celtis – 09.2007 – GB A.5
Schematic diagram
Air circulation
141msm00
J
I
H
G
F
E
K
D
B
C
A
L
t°
t°
M

6. Celtis – 09.2007 – GB
A.6
A – Filter.
B – Filter blockage thermal switch.
C – Pneumatic compressor.
D – Turbocharger.
E – Intercooler.
F – Turbocharger pressure sensor (according
to model).
G – Air temperature thermistance.
H – Pre-heat flange.
I – Pre-heat relay.
J – Instrument panel.
K – Intake/exhaust.
L – Particulate rebreathing.
M – Check valve.

7. Celtis – 09.2007 – GB A.7
Technical specifications
Pre-heating
– Mechanical injection:
Pre-heating is activated by holding the key at position III on the master switch. The pre-heat
warning light illuminates.
Maximum pre-heat duration is 20 seconds (Instrument panel time delay).
A 1 200 W heater is fitted between the manifold and the intake pipe.
– Electronic injection:
Both the pre-heating and the illumination of the instrument panel warning light are controlled by
the engine ECU.
Particulate rebreathing
Particulate rebreathing is achieved by a duct subject to a venturi effect between the exhaust pipe
and the air filter.
DIMENSIONS
Cylinder head
130hsm00
A.
Minimum acceptable cylinder head thickness 104,87 mm
Maximum acceptable cylinder head thickness 105,13 mm
Maximum acceptable cylinder head rework
Minimum cylinder head thickness after rework
0,73 mm
104,11 mm
B.
Cylinder head flatness over entire length 0,08 mm
B
A

8. Celtis – 09.2007 – GB
A.8
Valves
131hsm00
INTAKE EXHAUST
C. G.
Minimum diameter of valve stem 7,864 mm Minimum diameter of valve stem 7,848 mm
Maximum diameter of valve stem 7,884 mm Maximum diameter of valve stem 7,874 mm
D. H.
Minimum clearance between stem
and guide
0,05 mm Minimum clearance between
stem and guide
0,05 mm
Maximum clearance between stem
and guide
0,10 mm Maximum clearance between
stem and guide
0,10 mm
Wear limit 0,15 mm Wear limit 0,15 mm
E. I.
Minimum valve withdrawal 0,61 mm Minimum valve withdrawal 1,22 mm
Maximum valve withdrawal 1,11 mm Maximum valve withdrawal 1,72 mm
Wear limit 1,63 mm Wear limit 2,26 mm
F. J.
Minimum diameter of valve head 46,47 mm Minimum diameter of valve head 42,37 mm
Minimum diameter of valve head 46,73 mm Minimum diameter of valve head 42,63 mm
H
G
I
D
E
F
C
J

9. Celtis – 09.2007 – GB A.9
Rocker shaft
313hsm01
Adm. – Intake
Ech. – Exhaust
LU. – Wear limit
A

10. Celtis – 09.2007 – GB
A.10
A.
Uncompressed length 54 mm
Length compressed to 24 daN 46 mm
Length compressed to 68 daN 34,5 mm

11. Celtis – 09.2007 – GB A.11
Turbocharger
165hsm00
Type of turbocharger CZ
Normal turbocharger pressure at full load
nominal speed
0,83 bar

12. Celtis – 09.2007 – GB
A.12
Check of valve lift
Note: Measuring valve lift enables any wear in the cam to
be detected.
– Fit the flywheel rotating tool 60 05 005 501
in (A).
– Using tool No. 60 05 005 501 turn the
flywheel in its normal direction (clockwise
when viewed from the water pump) until piston
No. (1) (at the front) is at top dead centre
(TDC) of its compression stroke.
– Fit the lock pin n° 60 05 005 576 in (B).
– Eliminate the clearance between the rocker
arm and the valve stems on exhaust valves
n° 1 - 3 and inlet valves n° 1 - 2.
– Place a dial gauge on the valve spring cup or
on the valve cap and then set to 0.
– Remove the lock pin, turn the engine, and
observe the dial gauge up to the point of
maximum valve opening.
131msm13
– Measure valve lift and compare it with the
values mentioned in "Dimensional
specifications".
– Turn the engine by a full revolution 360°. Lock
the engine at TDC on the compression stroke
for piston (4).
– Eliminate the clearance between the rocker
arm and the valve stems on exhaust valves
n° 2 - 4 and inlet valves n° 3 - 4.
– If the specifications are not followed, remove
and check the camshaft condition.
– Place a dial gauge on the valve spring cup or
on the valve cap and then set to 0.
– Measure valve lift and compare it with the
values mentioned in "Dimensional
specifications"..
– If the lift of one or several valves is not within
specifications, remove and inspect the entire
valve set and camshaft.
131msm02
B
A

13. Celtis – 09.2007 – GB A.13
Head gasket failure - investigation procedure
Preliminary checks
Three types of seal failures can occur:
– Combustion gas faulty sealing.
– Cooling system faulty sealing.
– Lubrication system faulty sealing.
A – Combustion gas sealing surface
B – Oil sealing surfaces
C – Coolant sealing surfaces
135msm03
A B C

14. Celtis – 09.2007 – GB
A.14
Visual inspection to be carried out before intervention on the cylinder head gasket:
Pressurized test of the cooling system:
– Presence of oil or coolant on the seal face or
adjacent surfaces.
– Seal displaced in respect of its normal
position.
– Discoloration or presence of soot caused by a
combustion gas leak
– Leak on the radiators (oil and water), the
tank, overflow, or pipe hoses.
– Coolant leaking at the water pump bleed
hole.
– Presence of coolant on the cylinder head
gasket.
– Presence of coolant in the crankcase.
– Insufficient coolant level.
– High oil level.
– Presence of cooling liquid in the engine
breather (A).
131hsm16
Before the test, warm the engine.
Let the engine cool down, and remove the
radiator cap cautiously.
If no leak is visible, but if pressure drops, there
may be an internal coolant leak or an internal
leak in the seal between the block and the
cylinder head.
131hsm15
A
0,7 bar

15. Celtis – 09.2007 – GB A.15
Combustion gas sealing
Symptoms:
– Loss of power.
– Irregular engine running.
– White smoke at the exhaust pipe.
– Air bubbles in the water radiator or the overflow tank.
– Cooling fluid leak from overflow pipe.
– Engine overheating.
– Loss of heating in driver's cab.
– Coolant in a cylinder.
– Coolant in the crankcase oil.
– Insufficient coolant level.
Possible causes:
– Cracks, folds in the seal surfaces.
– Damages, punctures in the elastomer ribs.
– Cracks, folds in the seal surfaces. O-ring damaged or missing at the push rod oil orifice.
– Excessive liner protrusion.
– Excessive difference in liner protrusion between the cylinders.
– Insufficient tightening torque.
– Distorted, damaged, or irregular engine block surface.
– Distorted, damaged, or irregular cylinder head surface.
– Oil or fluid overheating.
IMPORTANT: Oil cooling failures can cause the presence of oil in the cooling fluid.

16. Celtis – 09.2007 – GB
A.16
Coolant sealing
Symptoms:
– Coolant leaking through the cylinder head gasket.
– Coolant in the oil pan.
– Insufficient level in the tank.
– High oil level.
– Coolant leaking through the crankcase breather.
Possible causes:
– Excessive liner protrusion.
– Excessive difference in liner protrusion between the cylinders.
– Insufficient tightening torque.
– Deformed, damaged, or irregular engine block surface.
– Deformed, damaged or irregular cylinder head surface.
– Oil or coolant temperature too high.
– Cylinder head gasket surface deformed or cracked.
– Elastomer parts of cylinder head gasket damaged or cracked.
Lubrication system sealing
Symptoms:
– Oil leaking through the cylinder head gasket.
– Oil in the coolant.
– Insufficient oil level in the crankcase.
– Insufficient rocker lubrication (abnormal noises).
Possible causes:
– Excessive liner protrusion.
– Excessive difference in liner protrusion between the cylinders.
– Insufficient tightening torque.
– Deformed, damaged, or irregular engine block surface.
– Deformed, damaged or irregular cylinder head surface.
– Oil or coolant temperature too high.
– Cylinder head gasket surface deformed or cracked.
– Elastomer parts of cylinder head gasket damaged or cracked.
– O-rings damaged in the oil passages to the rockers.
IMPORTANT: Oil cooling failures can cause the presence of oil in the cooling fluid.

17. Celtis – 09.2007 – GB A.17
Checking the turbocharger pressure
– Observe the pressure gauge.
The lift pressure should be, when the engine is running at full load and reaches nominal speed:
If the pressure is too low, check the following points:
– Air filter clogging.
– Leak at the intake circuit, between the turbocharger and cylinder head.
– Faulty turbocharger.
– Remove the plug (1) or (2).
– Install the pressure gauge n° 60 05 005 521
– Before checking, run the engine.
101msm50
4045 TRT 77 engine 0,52 bar
4045 TRT 78 engine 0,60 bar
4045 TRT 72 engine 0,76 bar
1
2

18. Celtis – 09.2007 – GB
A.18
Turbo checks
Radial shaft play
Axial shaft play
– Fit on the turbocharger a comparator fitted
onto a support with a graduated extension,
and fit the graduated extension on the shaft of
the compressor, by passing it through the
lubrication orifice.
– Push and pull alternately the compressor
shaft.
– With equal pressure applied to both ends of
the shaft, the clearance should not exceed the
values indicated in the chapter "Dimensional
specifications".
251msm27
– Using a comparator contacting the shaft,
measure axial clearance.
– Move the shaft axially by hand in both
directions and compare the value read with
the values specified in the chapter
"Dimensional specifications".
251msm18

19. Celtis – 09.2007 – GB A.19
Reconditioning the turbocharger
IMPORTANT: It is difficult to recondition a turbocharger without the tools and training required: do not totally
disassemble a turbocharger. If a turbo is found to be faulty when checked, replace it.
Note: When refitting, use the recommended torque settings.
IMPORTANT: When refitting, oil the turbo bearings to ensure lubrication on engine start-up.
167msm00

20. Celtis – 09.2007 – GB
A.20
Cooling
Technical description
Cooling system
251msm00

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22. Celtis – 09.2007 – GB A.21
A – Water pump.
B – Coolant passage adaptor.
C – Oil cooler drain plug.
D – Oil cooler plates.
E – Cooling fluid passage.
F – Cooling fluid envelope.
G – Passages in the upper part of the block.
H – Passages.
I – Thermostat.
J – Water manifold/thermostat housing.
L – Bypass circuit.
M – Towards the radiator upper tank.
N – Drain plug.
O – Water pump suction side.
P – High temperature cooling fluid.
Q – Low temperature cooling fluid.
R – Cabin heater valve.
S – Cabin heater radiator.
T – Engine management thermistance.
U – Instrument panel thermistance (depending
on the model).
V – Heat exchanger.
W – Expansion bottle.

23. Celtis – 09.2007 – GB
A.22
Schematic diagram
Cooling system
221msm05
x – Depending on installation.
t˚
t˚
t˚
O
A D
J
E
G
I
T
R
S
M
V
X
W
U
F
L
H

24. Celtis – 09.2007 – GB A.23
Technical specifications
Thermostat
The thermostat sits within the cylinder head under the water housing. Part of the coolant flow is
diverted to the water pump via a steel tube. The temperature is regulated between 82 and 95°C.
A – Coolant temperature probe
251msm01
During filling, bleed the system by loosening the
temperature probe or the plug (depending on
installation) at position (A).
251msm02
A
A

25. Celtis – 09.2007 – GB
A.24
Water pump
Degraded modes
Coolant temperature too high
First check coolant quality and level. Check for leaks from external engine system components.
The water pump is fitted under the accessory
gear train cover and uses the cavity in the cover
as the pump body.
251msm03
1. FAULTY
Go to 2.
GOOD
Go to 4.
2. CHECK FOR THE PRESENCE OF OIL
IN THE COOLANT HEADER TANK.
YES
Check the cylinder head and the cylinder head
gasket.
See: Head gasket failure - investigation
procedure.
NO
Go to 3.
3. DRAIN THE COOLANT.
– Refill to the correct level.
Does the problem remain ?
YES
Go to 4.
NO
Problem solved.
4. CHECK THE RADIATOR:
– Dirt ;
– Leaks ;
– Blockage.
Repair or replace the defective components.
Does the problem remain ?
YES
Go to 5.
NO
Problem solved.