Renault 19 Repair Manual 1996 Edition

77 11 190 814 OCTOBER 1996 Edition Anglaise
General
"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".
All copyrights reserved by Renault.
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.
Régie Nationale des Usines Renault S.A. 1996
SPECIFICATIONS
LIFTING EQUIPMENT
TOWING
LUBRICANTS - CONSUMABLES
DRAINING - REFILLING
C
VALUES AND SETTINGS
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EXPLODED VIEW
PRC0001
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TOWING
All types
Contents
SPECIFICATIONS
Engine - Clutch - Gearbox
Vehicle identification
01-1
01-2
LIFTING EQUIPMENT
Trolley jack - Axle stands
Pages
01
02
03
General
02-1
03-1
Packaging 04-1
Engine
Gearbox
Power assisted steering
04
05
05-1
05-3
05-4
07-1
07-4
07-7
07-9
07-15
07-17
07-21
07-22
07-24
07-25
07-27
07-28
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
Pages
07
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SPECIFICATIONS
Engine - Clutch - Gearbox 01
Vehicle type
Engine
Type
Cubic
capacity
(cm3)
Clutch type
Type of manual and automatic
gearbox
B530 - C530 - L530
S530
C1G 1237 180 CP 3300 JB0 - JB1 - JB4 - JB5
B531 - C531 - L531 C1J 1397 180 CP 3300 JB0 - JB1 - JB4 - JB5
B53H - B53P - C53P
L53H - L53P
C2J 1397 180 CP 3300 JB0 - JB1 - JB4 - JB5
B532 - C532 - L532 C3J 1390 180 CP 3300 JB0 - JB1
B53G - B537 - C537
L53G - L537 - S537
E6J 1390 180 CP 3300 JB0 - JB1 - MB1
B53A - C53A - L53A E7J 1390 180 CP 3300 JB1 - MB1
B535 - C535 - L535 E7J 1390 180 CP 3300 JB1 - MB1
B53W - C53W - L53W E7F 1171 180 CP 3300 JB0 - JB1 - JB3
B53E - B53M - B533
B536 - C53E - C53M
C533 - L533 - L536
F2N 1721 200 CP 4000 JB0 - JB1 - JB3 - AD4
B53B - B53C - B53F
C53B - C53C - C53F
D53C - L53B - L53C -
L53F
F3N 1721 200 CP 4000 AD4 - JB3 - MB3
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
F3P 1794 200 CP 4000 AD4 - JB3 - JC5
B53D - B539 - C53D
C539 - D53D - L53D
L539
F7P 1764 200 CP 4400 JB3 - JC5
B53I - B53J - B53K
B53T - B53Z - B534
C53I - C53J - C53K
C53T - C53Z - C534
L53I - L53J - L53K
L53T - L53Z - L534
S53I - S53J - S53K -
S534
F8Q 1870
200 CPV 4600
200 CPV 3500
JB1 - JB3 - JC5
01-1
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SPECIFICATIONS
Vehicle identification 01
ENGINE
APPROVAL
LETTER
NUMBER
VEHICLE
TYPE
F3P
E
H
E
H
H
H
J
A
704
706
708
760
706
760
765
682
X53 Y
053 A
053 B - F - H
X53 V
053 C - D - H
X53 8
IDENTIFICATION OF F3P ENGINES WITH REDUCED CUBIC CAPACITY
Definition of identification X and 0
X53 Y = B53 Y, C53 Y, L53 Y Vehicle type code starting with a letter.
053A = 353 A, 453 A Vehicle type code starting with a number.
The reduced cubic capacity can be identified using
the type approval letter (B) on the engine plate.
0 0 0 0 0 0 0 /
0 0 0 0 0 0 0
F E
A B C D
90775
A : the engine type
B : the vehicle type approval letter
C : the identity of RENAULT SA
D : the engine number
E : the engine manufacturing number
F : letter indicating the factory at which the en-
gine was manufactured (e.g.: C for Cléon)
01-2
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SPECIFICATIONS
LOCATION OF THE VEHICLE IDENTIFICATION PLATE
Plates (A) and (B) may be separate or on a single
plate (according to specification).
Position n° 2
Position n° 1 Position n° 3
95890-1R
94946R
Plate (C) is located on the front panel.
Adhesive plate (D) is attached to the chassis on the
side of the right front door.
92025R
01-3
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SPECIFICATIONS
METAL PLATE (Position n° 1)
Rectangular plate Oval plate
This consists of;
At A : the manufacturer’s name,
At B : the EU official approval number, inclu-
ding:
At B1 : the number of the country gran-
ting the EU approval
At B2 : the approval number for the ve-
hicle type.
At C : the official type number preceded by the
manufacturer’s 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 identifica-
tion 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.
REGIE NATIONALE
DES USINES RENAULT
X*0* 0000
XX0000 000
00000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
0000
0 0 0 0 0
0 0 0 0 0 0 0 0
X 0 0 0 0 0 0 0
0 0 0 0
567
1 432
A
B
C
D
E
F
G
H
J
B1
B2
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 identifi-
cation code*,
At 7 : the factory at which the vehicle was as-
sembled:
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
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SPECIFICATIONS
VEHICLE IDENTIFICATION 01
This consists of:
At B : the EU official approval number
At C : the official type number preceded by the manufacturer’s 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 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.
4
0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0
7
0 0 0 0 0 0 0 0
2
8
1
5
3
6
B
REGIE NATIONALE
DES USINES RENAULT
AU 0000-00-00
VF1000000
00000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
C
D
E
F
G
H
A
01-5
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SPECIFICATIONS
REGIE NATIONALE DES
USINES RENAULT S.A.
e000-00/00000-0000-00
VF0000000
00000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
10
0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0
11
0 0 0 0 0 0 0 0
7
13
8
14
9
12
Renault
1
2
3
4
5
6
VF0000000
00000000
0000
00 000 000
00 000 000
0000000
9
10
12
11
1
2
8
7
14
13
B
A
01-6
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SPECIFICATIONS
This consists of:
At B : the EU official approval number
At 1 : the official type number preceded by the manufacturer’s 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 (orde-
ring of replacement parts, warranty form, etc).
01-7
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SPECIFICATIONS
Due to the European depollution standards, the "ABCD" coding of some vehicles has become saturated follo-
wing the introduction of new engines (letter "D"), the body code "A" therefore becomes "A’".
A A’ "ABCD" "A’BCD"
3 door hatchback C 3 C53A 353A
5 door hatchback B 5 B53A 553A
4 door saloon L 4 L53A 453A
Utility S 6 S53A 653A
Cabriolet D 7 D53A 853A
Renault 19 all models X 0 X53A 053A
or
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 : Renault 19 5 door hatchback with engine E7J 700
553A : Renault 19 5 door hatchback with engine F3P 706
C53A : Renault 19 3 door hatchback with engine E7J 700
353A : Renault 19 3 door hatchback with engine F3P 706
REMINDER:
"A" or "A’" = body type
"BC" = N° of project (example 53)
"D" = Engine number
01-8
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LIFTING EQUIPMENT
Trolley jack - Axle stands
LIFTING WITH THE TROLLEY JACK FROM THE
REAR
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.
02
Safety symbol (special precautions to be taken when carrying out work).
ESSENTIAL SPECIAL TOOLS
Cha. 280 -02 Trolley jack pad
Cha. 408 -02 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
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.
85679-1G1391936G2
For some vehicles, make a notch in tool Cha. 280-
02 to prevent it touching the exhaust.
92556R
02-1
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LIFTING EQUIPMENT
Trolley jack - Axle stands 02
LIFTING WITH THE TROLLEY JACK FROM THE SIDE
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.
AXLE STANDS
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
85679-1G1491936G3
02-2
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TOWING
All models
FRONT
03
FOR TOWING, REFER TO THE LEGISLATION IN FORCE IN THE COUNTRY CONCERNED.
NEVER USE THE DRIVESHAFT TUBES AS ATTACHMENT POINTS.
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.
92020S
REAR
92019S
03-1
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DESCRIPTION PACK SIZE PART NUMBER
1 kg tin
100 g tube
80 ml tube
180 g sachet
Aerosol
77 01 421 145
77 01 028 179
77 01 422 307
77 01 366 100
77 01 422 308
GREASES
Packaging 04
• MOLYKOTE "BR2"
for bushing surfaces, thrust pad guide tube,
clutch fork pads, lower suspension arm bea-
rings, torsion bar splines, steering box, drives-
haft 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
for driveshaft seals
• MULTIPURPOSE GREASE
wheel sensor
• Perfect-seal "LOWAC"
liquid jointing compound
• Mastic
for sealing exhaust pipe joints
• RHODORSEAL 5661
• 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
100 g tube
1.5 kg tin
100 g tube
Kit
100 g tube
45 g tube
100 g tube
77 01 417 404
77 01 421 161
77 01 421 042
77 01 404 452
77 01 421 080
77 01 396 227
77 01 397 027
77 01 422 751
MECHANICAL SEALING COMPOUNDS
04-1
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24 cc bottle
24 cc bottle
24 cc bottle
50 cc bottle
77 01 394 070
77 01 394 071
77 01 394 072
77 01 400 309
ADHESIVES
Packaging 04
• "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
CLEANERS - LUBRICANTS
250 g aerosol
Aerosol
250 ml can
300 ml aerosol
355 ml can
420 ml aerosol
Aerosol
77 01 408 464
77 01 422 379
77 01 393 112
77 01 393 111
77 01 423 189
77 01 407 689
77 01 405 952
• "NETELEC"
release, lubricating agent
• Cleaner NC1
electrical contact cleaner
• Carburettor cleaner
• Injector cleaner
• Super concentrated release agent
• "DECAPJOINT "
for cleaning aluminium cylinder head gasket
faces
MECHANICAL SEALING COMPOUNDS
• AUTO joint grey
sealing compound
• LOCTITE 518
for sealing gearbox housings
• Leak detector
100 g tube
24 ml syringe
Aerosol
77 01 422 750
77 01 421 162
77 11 143 071
04-2
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Packaging 04
• "CIRCUIT PLUS"
Varnish for the repair of heated rear screens
• "CONTACT PLUS"
Varnish for the repair of heated rear screen sup-
ply tabs
Bottle
Kit
77 01 421 135
77 01 422 752
VARNISH
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)
250 ml (R134a)
77 01 417 655
77 11 143 700
77 01 419 313
04-3
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Engine
ENGINE E
05
ENGINES C - F
98486R
Engine drain plug spanner
DRAINING: plug (1)
98701R
REFILLING: plug (2)
dipstick (3)
ENGINES E6J - E7J - E7F
ENGINES C1G - C1J - C2J - C3J
92179R
92178R
05-1
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Engine 05
REFILLING: plug (2)
dipstick (3)
ENGINE F8Q
ENGINES F2N - F3P
95747R
ENGINE F3N
95748R
ENGINE F7P
92035R 92715R
05-2
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Gearbox 05
98486R1
Plug (A) with no dipstick
MANUAL
DRAINING: plug (1)
REFILLING: plug (2)
ENGINES C - E - F
92081R
Plug (A) with dipstick
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
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Power assisted steering 05
CHECKING THE LEVEL
POWER ASSISTED STEERING PUMP LEVEL
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
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VALUES AND SETTINGS
Dimensions
Phase 1
07
91936R1
Marks Dimensions in metres
A 2.545
B 4.155
C 1.418
D 1.416 unladen
E from 1.406 to 1.417
F 1.676 or 1.694
07-1
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VALUES AND SETTINGS
Dimensions
Phase 2
07
95890R
Turning circle (in metres)
Between kerbs : 10.4 (10.8 model with F7P en-
gine)
Between walls : 11.0 (11,4 model with F7P) en-
gine
(1) According to model with option
(2) Laden
(3) Unladen
A 0.813
B from 2.540 to 2.544 (1)
C from 0.805 to 0.809 (1)
D from 4.158 to 4.166 (1)
E 0.120 (2)
F 1.426
G from 1.684 to 1.696 (1)
H from 1.400 to 1.420 (1) - (3)
I 1.406 or 1.417 (1)
07-2
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VALUES AND SETTINGS
Dimensions
Models D and L
07
95888R4
(*) Laden
A 0.813
B from 2.540 to 2.544
C from 0.805 to 0.809
D 4.162
E 0.120 (*)
F 1.426
G from 1.684 to (1.696 with moulding)
H from 1.395 to 1.410
I 1.406 or 1.417
07-3
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VALUES AND SETTINGS
Capacities - Grades 07
Units
For oil
drain
3
3.5
4.8
6
(plus 0.5 litre
for oil filter)
EU countries
PETROL
Other countries
PETROL
Capacity
in litres
Grade
Petrol engine
(oil)
C
E
F2N - F3N - F3P
F7P
0°C + 30 °C- 30 °C + 10 °C + 20 °C- 20 °C - 10 °C
- 15 °C + 25 °C
CCMC-G4 15W40-15W50
ACEA A2-96/A3-96 15W40-15W50
CCMC-G5 10W30-10W40-10W50
ACEA A2-96/A3-96 10W30-10W40-10W50
CCMC-G5 5W30
ACEA A2-96/A3-96 5W30
CCMC-G5 5W40-5W50
ACEA A2-96/A3-96 5W40-5W50
API SH 10W40
API SH 10W30
0°C + 30 °C- 30 °C + 10 °C + 20 °C- 20 °C - 10 °C
- 15 °C
API SH 5W30
API SH 15W40
07-4
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VALUES AND SETTING
Units
For oil
drain
5
(plus 0.5 litre
for oil filter)
EU countries
DIESEL (All models)
Other countries
DIESEL
Capacity
in litres
Grade
Diesel engine
(oil)
F8Q
0 °C + 30 °C- 30 °C + 10 °C + 20 °C- 20 °C - 10 °C
- 15 °C + 25 °C
CCMC-PD2 15W40
ACEA B2-96/B3-96 15W40
CCMC-PD2 10W40
ACEA B2-96/B3-96 10W40
CCMC-PD2 5W30
ACEA B2-96/B3-96 5W30
CCMC-PD2 5W40
ACEA B2-96/B3-96 5W40
API CF 10W30
0 °C + 30 °C- 30 °C + 10 °C + 20 °C- 20 °C - 10 °C
- 15 °C + 15
API CF 15W40
API CF 10W40
07-5
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4.5
4.5
4.6
1
ELF RENAULT MATIC D2 (D20104)
or if not available use: MOBIL ATF 220 (D20104 or D21412)
TEXAMATIC 4011
Automatic
transmission
VALUES AND SETTINGS
Manual
gearbox
Units Capacity
in litres
Grade Special points
JB0
JB1
JB3
JB4
JB5
JC5
3.25
3.40
3.40
2.80
2.90
3.10
All countries: TRANSELF TRX 75 W 80 W
(Standards API GL5 or MIL-L 2105 C or D)
Fuel
tank
55
Unleaded
petrol/diesel
Separate
reservoir
1.1
Engine cooling
system
C1G - C1J - C2J
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
Power
assisted
steering
-
ELF RENAULT MATIC
D2 or
MOBIL ATF 220
MB1
MB3
AD4
Final drive AD4
Braking system
The brake fluid must be of a type approved by our
Design office.
SAE J 1703
and DOT 4
Normal : 0.7
ABS : 1
-
07-6
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VALUES AND SETTINGS
Belt tension 07
96601R
Mot. 1273 Belt tension checking tool
A : Sensor
B : Display
C : Connecting lead
D : Calibration checking blade
Principle
Via the pressure piece button (1), the pressure
piece (2) and the external pads (3), the sensor ap-
plies 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).
Calibration of the equipment
The equipment is calibrated at the factory, howe-
ver, 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
equipment’s 9 volt battery,
- if a value other than 0 is displayed, operate
screw (F) until 0 is obtained .
07-7
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VALUES AND SETTINGS
Belt tension 07
Checking the calibration
Switch on the equipment (button E).
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
B
Z Standard blade
Standard blade checking value
SEEM
Please contact your local After Sales Head Office
for details.
GENERAL RECOMMENDATIONS:
- Never refit a belt which has been removed, al-
ways fit a new one.
- Never retighten a belt the tension value of
which is between the fitting value and the mi-
nimum required for operation.
- When carrying out a check, if the tension is be-
low the minimum operating tension, change
the belt.
07-8
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VALUES AND SETTINGS
Accessories belt tension 07
RECOMMENDATIONS FOR FITTING BELTS:
V-BELT
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:
Fit the belt.
Turn the sensor knob until it clicks (three CLICKS").
Tension the belt until 80% of the recommended fitting value is displayed on Mot. 1273.
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 Elé. 346-04.
07-9
http://vnx.su

VALUES AND SETTINGS
Toothed BELT
Tensioning procedure
Fit the new belt.
Turn the sensor wheel until it clicks (three "CLICKS").
Tension the belt until the recommended fitting value is displayed on Mot. 1273.
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 Elé. 346-04.
07-10
http://vnx.su

VALUES AND SETTINGS
92648R1
A Coolant pump
B Crankshaft pump
C Alternator pump
→ Tension checking point
ALTERNATOR AND COOLANT PUMP
C
ENGINE
Tension
(US=SEEM unit)
Coolant pump
Alternator
Belt
Air
conditioning
belt
Fitting
90 ± 6
89 ± 5 (*)
105 ± 6 (*)
Minimum
operating
tension
64
68 (*)
75 (*)
(*) = C2J 776
07-11
http://vnx.su

VALUES AND SETTINGS
92320R2
B Crankshaft pulley
C Alternator pulley
ALTERNATOR
E
ENGINE
Tension
(US=SEEM unit)
Toothed alternator
belt
(three teeth)
Alternator V-belt
Air conditioning
V-belt
Air conditioning
and power assisted
steering belt
(four teeth)
Fitting 84 ± 6 83 ± 7 90 106
Minimum operating
tension
52 70 72 59
E6J engine
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)
Fitting 84 ± 6 84 ± 5 83 ± 7 90 106
Minimum operating
tension
52 46 70 72 59
E7J engine
07-12
http://vnx.su

VALUES AND SETTINGS
Accessories belt tension 07F
ENGINE
Tension
(US=SEEM unit)
Toothed belt
(six teeth)
Alternator
Air conditioning and
power assisted steering
Toothed belt
(six teeth)
Alternator
Power assisted steering
Toothed belt
(six dents teeth)
Alternator and
coolant pump
Fitting 106 ± 6 98 ± 6 83 ± 6
Minimum operating
tension
71 73 57
F2N, F3N engines
Tension
(US=SEEM unit)
Toothed belt
(six teeth)
Alternator
Air conditioning
and power assisted
steering
Toothed belt
(six dents teeth)
Alternator
Air conditioning
Toothed belt
(six teeth)
Alternator
Power assisted
steering
Toothed belt
(six teeth)
Alternator
Fitting
112 ± 4
116 ± 7*
101 ± 5 99 ± 5 97 ± 3
Minimum operating
tension
67 67 68 67
F8Q engine
Tension
(US=SEEM unit)
Toothed belt
(six teeth)
Alternator
Air
conditioning
Toothed belt
(six teeth)
Alternator
Power assisted
steering
Fitting 91 ± 5 95 ± 5
Minimum
operating
tension
58 57
F7P engine
* only for belt Part number : 77 00 272 741
07-13
http://vnx.su

VALUES AND SETTINGS
86979R1
ALTERNATOR AND COOLANT PUMP
F
ENGINE
91136R3
A Coolant pump pulley
B Crankshaft pulley
C Alternator pulley
D Assistance pump pulley
E Compressor pulley
F Tensioner roller
87413R1
92290R2
A Coolant pump
B Crankshaft
C Alternator
E Air conditioning compressor
07-14
http://vnx.su

VALUES AND SETTINGS
Timing belt tension 07
98708R
E engineTensioning procedure
Fit the new belt
Turn the sensor knob until it clicks (three
"CLICKS").
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.
NOTE :
Do not refit a belt which has been removed.
Change the belt if the tension is below the mini-
mum operating tension.
Belt tension (in SEEM units)
Fitting : 30 U.S.
Minimum operating tension: 26 U.S.
07-15
http://vnx.su

VALUES AND SETTINGS
Timing belt tension 07
F engine (petrol) except F7P
96528R1
Fitting: 25 U.S.
F8Q engine
99175R
Fitting: 38 U.S.
07-16
http://vnx.su

E ENGINE
CYLINDER HEAD TIGHTENING PROCEDURE
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.
Tighten the cylinder head in the order shown be-
low:
VALUES AND SETTINGS
Cylinder head tightening 07
1st tightening to 2 daN.m.
2nd tightening (angle) : 97° ± 2°.
Wait for at least three minutes.
Slacken bolts 1 and 2 then tighten to 2 daN.m.
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 from 5.5 to 6.5 daN.m.
Adjusting the clearance at the valves
Run the engine for 20 minutes.
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.
Adjust the clearance at the valves.
81528-1S
C ENGINE
low:
27 6 10
18 5 94
3
90775S
07-17
http://vnx.su

VALUES AND SETTINGS
27 6 10
18 5 94
3
2nd tightening (angle) : 7 daN.m.
Slacken bolts 1 and 2 then tighten to 2 daN.m.
2nd assembly (angle) : 123° ± 2°.
for bolts 3, 4, 5, 6 then 7, 8, 9, 10.
CYLINDER HEAD GASKET WITH ASBESTOS
low:
For engines F2N - F3N - F3P, refer to the "F ENGINE" section.
90775S
F ENGINE (petrol) ALL TYPES EXCEPT F7P
27 6 10
18 5 94
3
2nd tightening (angle) : 50° ± 4 °.
Slacken bolt by bolt by 180°, then tighten to
2.5 daN.m. :
for bolts 3, 4, 5, 6 then 7, 8, 9, 10.
CYLINDER HEAD GASKET WITH NO ASBESTOS
All of the bolts must be changed automatically af-
ter removal.
low:
90775S
07-18
http://vnx.su

VALUES AND SETTINGS
F7P ENGINE
CYLINDER HEAD GASKET WITH NO ASBESTOS
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 complete-
ly free then tighten all of the bolts to 2.5
daN.m, then carry out an angular tightening
of 108° ± 3 °.
27 6 10
18 5 94
3
90775S
07-19
http://vnx.su

VALUES AND SETTINGS
2nd tightening (angle) : 7 daN.m.
Slacken bolt by bolt until they are completely free,
then tighten to 2 daN,m.
CYLINDER HEAD GASKET WITH ASBESTOS
This operation is carried out when cold, when the
cylinder head is refitted, and there is no other rea-
son for it to be carried out.
low:
F ENGINE (diesel)
2nd tightening (angle) : 50° ± 4 °.
Slacken bolt by bolt until they are completely free,
then tighten to 2.5 daN,m.
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 tem-
perature.
- In the recommended order, again tighten bolts
1-2, 3-4, 5-6, 7-8, 9-10, angle 120° ± 7°.
CYLINDER HEAD GASKET WITHOUT ASBESTOS
All of the bolts must be changed automatically af-
ter removal.
low:
81528-1S
81528-1S
07-20
http://vnx.su

B/C/D/L/S
533, 536
538, 53C
53F, 53K
53T, 53V
53Y, 53Z
3/4/5/8
53A, 53F
53H
VALUES AND SETTINGS
Main brake components and dimensions
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
REAR BRAKE (dimensions in mm)
Diameter of slave cylinders
Diameter of drums
Maximum diameter of drums after grinding
Width of linings
Diameter of discs
Thickness of discs
Minimum thickness of discs (1)
Maximum run-out of discs
MASTER CYLINDER (dimensions in mm)
Diameter
(*) 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.
48
238
12
10.5
18
6
0.07
20.6 (2)
180.25
181.25
40
6.5
2.5
-
-
-
-
-
-
20.6
07
B/C/D/L
539, 53D
X53 ABS*
B/C/L/S
538, 53F
53K, 53T
3/4/5
53C, 53D
53H
B/C/L/S
530, 531
532, 534
535, 537
53A, 53B
53G, 53H
53J, 53W
48
238
20
18.3
18
6
0.07
20.6 (2)
180.25
181.25
40
6.5
2.5
-
-
-
-
-
-
20.6
48
259
20.7
17.7
18
6
0.07
19
203.20
204.40
38
6.5
2.5
-
-
-
-
-
-
20.6
48
259 238
20.7 20
17.7 18
18
6
0.07
30
-
-
-
-
-
238
8
7
11
5
0.07
20.6
07-21
http://vnx.su

KING PIN INCLINATION
CASTOR
POSITION FOR TIGHTENING RUBBER BUSHES
VALUES AND SETTINGS
ANGLES VALUES
2°55’
2°25
1°55’
1°25’
0°55’
Maximum left/ right
difference= 1°
1°35’
0°30’
- 0°5’ ± 30’
- 0°30’
- 0°45’
Maximum left/right
difference = 1°
H5-H2= 21 mm
H5-H2= 40 mm
H5-H2= 59 mm
H5-H2= 78 mm
H5-H2= 97 mm
NOT ADJUSTABLE
ADJUSTMENTPOSITION OF
FRONT AXLE
CAMBER
10°45’
12°5’
12°55’ ± 30’
13°40’
14°15’
Maximum left/right
difference = 1°
H1-H2= 22 mm
H1-H2= 59 mm
H1-H2= 86 mm
H1-H2= 115 mm
H1-H2= 149 mm
H1-H2= 22 mm
H1-H2= 59 mm
H1-H2= 86 mm
H1-H2= 115 mm
H1-H2= 149 mm
NOT ADJUSTABLE
NOT ADJUSTABLE
PARALLELISM
UNLADEN
UNLADEN
Adjusted by
rotating track rod
sleeves
1 turn= 30’
(3 mm)
- -
MANUAL STEERING
ALL TYPES EXCEPT B539 - C539 - L539 - B53D - C53D - D53D - L53D
07
(Toe-out)
For two wheels
0°10’ ± 10’
(1 ± 1 mm)
78423S3
78423S1
78423S2
78423S
81603S1
07-22
http://vnx.su

VALUES AND SETTINGS
POWER ASSISTED STEERING
ALL TYPES EXCEPT B539 - C539 - L539 - B53D - C53D - D53D - L53D
07
CASTOR
5°
4°30’
4°
3°30’
3°
Maximum left/right
difference= 1°
1°35’
0°30’
- 0°5’ ± 30’
- 0°30’
- 0°45’
Maximum left/right
difference= 1°
H5-H2= 21 mm
H5-H2= 40 mm
H5-H2= 59 mm
H5-H2= 78 mm
H5-H2= 97 mm
NOT ADJUSTABLE
CAMBER
10°45’
12°5’
12°55’ ± 30’
13°40’
14°15’
Maximum left/right
difference= 1°
H1-H2= 22 mm
H1-H2= 59 mm
H1-H2= 86 mm
H1-H2= 115 mm
H1-H2= 149 mm
NOT ADJUSTABLE
NOT ADJUSTABLE
PARALLELISM
UNLADEN
UNLADEN
Adjusted by
rotating track rod
sleeves
1 turn= 30’
(3 mm)
(Toe-out)
For two wheels
0°10’ ± 10’
(1 ± 1 mm)
ANGLES VALUES ADJUSTMENTPOSITION OF
FRONT AXLE
H1-H2= 22 mm
H1-H2= 59 mm
H1-H2= 86 mm
H1-H2= 115 mm
H1-H2= 149 mm
-
-
78423S3
78423S1
78423S2
78423S
81603S1
07-23
http://vnx.su

PARALLELISM
VALUES AND SETTINGS
Front axle checking values
POWER ASSISTED STEERING
B/C/L 539 - B/C/D/L 53D
07
5°30’
5°
4°30’
4°
3°30’
Maximum left/right
difference= 1°
0°18’
- 0°15’
- 0°00’
1°02’
Maximum left/right
difference= 1°
H5-H2= 32 mm
H5-H2= 51 mm
H5-H2= 70 mm
H5-H2= 89 mm
H5-H2= 108 mm
NOT ADJUSTABLE
8°40’
10°40’
11°00’
11°06’
Maximum left/right
difference= 1°
H1-H2= 41 mm
H1-H2= 120 mm
H1-H2= 141 mm
H1-H2= 185 mm
NOT ADJUSTABLE
NOT ADJUSTABLE
UNLADEN
UNLADEN
Adjusted by
rotating track rod
sleeves
1 turn= 30’
(3 mm)
(Toe-out)
Foe two wheels
0°10’ ± 10’
(1 ± 1 mm)
ANGLES VALUES ADJUSTMENTPOSITION OF
FRONT AXLE
H1-H2= 41 mm
H1-H2= 120 mm
H1-H2= 141 mm
H1-H2= 185 mm
-
-
CASTOR
CAMBER
± 30’
± 30’
93012-1S
93013-1S
93014-1S
93011-1S
81603S1
07-24
http://vnx.su

VALUES AND SETTINGS
ALL TYPES EXCEPT B/C/L 539 - B/C/D/L 53D
07
UNLADEN
ANGLES
VALUES
- 0°50’ ± 30’
(negative)
ADJUSTMENT
POSITION OF THE
REAR AXLE
CAMBER
- 20’ to -
40’
(Toe-in)
or
- 2 to - 4
mm
PARALLELISM
POSITION FOR TIGHTENING
RUBBER BUSHES
UNLADEN
Rear axle
Tubular
Rear axle
4 bars
Rear axle
Tubular
Rear axle
4 bars
Rear axle
Tubular
Rear axle
4 bars
- 30’ to - 50’
(Toe-in)
or
- 3 to - 5 mm
UNLADEN
NOT ADJUSTABLE
NOT ADJUSTABLE
- -
78423S1
78423S
81603S1
07-25
http://vnx.su

PARALLELISM
CAMBER
VALUES AND SETTINGS
B/C/L 539 - B/C/D/L 53D
07
- 0°50’ ± 30’
(negative)
UNLADEN NOT ADJUSTABLE
UNLADEN
UNLADEN
NOT ADJUSTABLE
Per wheel
- 10’ to 30’
(Toe-in)
or
- 1 to - 3 mm
ANGLES VALUES ADJUSTMENTPOSITION OF THE
REAR AXLE
-
-
93013-2S
81603S1
93011-2S
07-26
http://vnx.su

VALUES AND SETTINGS
Underbody heights
UNDERBODY HEIGHTS (1) (mm)
07
Type
At the front
H1 - H2 = ... mm
At the rear
H4 - H5 = ... mm
Dimension X (mm)
RH and LH
B530 B535 B53I
C530 C535 C53I
L530 L535 L53I
S530 B537 S53I
B531 C537 B53J
C531 L537 C53J
L531 S537 L53J
S531 B53A S53J
B532 C53A B53W
C532 L53A C53W
L532 B53B L53W
S532 C53B S53W
B534 L53B
C534 B53G
L534 L53G
S534
87 10 590
B533 B53T 353A
C533 C53T 453A
L533 L53T 553A
B538 S53T 853A
C538 B53V 353B
L538 C53V 353C
B53C D53V 453C
C53C L53V 553C
D53C B53Y 353D
L53C C53Y 453D
S53C D53Y 553D
B53F L53Y 353F
C53F S53Y 453F
L53F B53Z 553F
B53K C53Z 853F
C53K L53Z 453H
L53K 553H
S53K
X53 ABS*
93 25 645
B536 B53H
L536 L53H 86 4 580
B539 B53D
C539 C53D
L539 D53D
L53D
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 driver’s 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
http://vnx.su

Type
Amount of fuel in tank
(driver on board)
Checking pressure (Bar)
Front Rear
All types with fixed compensator
incorporated in the wheel cylinder
- 60 34
B/C/L 533
53C
53Y
534
53J
53K
B/C/L 53T
53V
53Z
3/4/5 53A
53B
53F
B/C/L/S 53F
538
53K
53T
53Z
3/4/5 53C
53D
53H
100 40
VALUES AND SETTINGS
Brake compensator 07
+0
-4
With ABS
(after 05/92)
With
ABS
With
ABS
Without ABS
(before 11/94)
Without ABS
(before 11/94)
+0
-8
90966S
07-28
http://vnx.su

Type
(driver on board)
Front Rear
B/C/D/L 539
53D
100 47
B/C/L 53A
535
53B
538
B/C/L 53F
3/4/5 53C
53D
53H
D53D (after 05/92)
853C
100 52
B/C/L/S 53F
538
53K
53T
53Z
3/4/5 53C
53D
53H
100 49
VALUES AND SETTINGS
With ABS
(after 11/94)
with ABS
(after 05/92)
+0
-8
+0
-8
(before 05/92)
90966S
Without ABS
(after 11/94)
with ABS
with ABS
+0
-8
07-29
http://vnx.su

Type
(driver on board)
Front Rear
B/C/D/L/S 533
53C
53F
534
53J
53K
53Y
B/C 53M ABS
B/C/L 53D
D 53C
53Y
D 53V
8 53A
53F
100
100
43
52
VALUES AND SETTINGS
With ABS
(before 05/92)
(after 05/92)
With ABS
(after 05/92)
+0
-8
90966S
+0
-8
With ABS
07-30
http://vnx.su

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UUUUPPPPPPPPEEEERRRR RRRREEEEAAAARRRR SSSSTTTTRRRRUUUUCCCCTTTTUUUURRRREEEE
RRRReeeeaaaarrrr wwwwiiiinnnngggg ppppaaaannnneeeellll ((((AAAA))))
http://vnx.su

44
PPPPaaaarrrrtttt ooooffff rrrreeeeaaaarrrr wwwwiiiinnnngggg ppppaaaannnneeeellll ((((BBBB))))
http://vnx.su

44
WWWWiiiinnnngggg ppppaaaannnneeeellll aaaasssssssseeeemmmmbbbbllllyyyy lllliiiinnnniiiinnnngggg ((((CCCC))))
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44
WWWWiiiinnnngggg ppppaaaannnneeeellll ffffrrrroooonnnntttt lllloooowwwweeeerrrr lllliiiinnnniiiinnnngggg ((((DDDD))))
http://vnx.su

44
WWWWiiiinnnngggg ppppaaaannnneeeellll ffffrrrroooonnnntttt uuuuppppppppeeeerrrr lllliiiinnnniiiinnnngggg ((((EEEE))))
http://vnx.su

44
WWWWiiiinnnngggg ppppaaaannnneeeellll rrrreeeeaaaarrrr lllliiiinnnniiiinnnngggg ((((FFFF))))
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44
OOOOuuuutttteeeerrrr wwwwhhhheeeeeeeellll aaaarrrrcccchhhh ((((GGGG))))
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44
OOOOuuuutttteeeerrrr wwwwhhhheeeeeeeellll aaaarrrrcccchhhh SSSSttttiiiiffffffffeeeennnneeeerrrr ((((HHHH))))
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UUUUppppppppeeeerrrr ccccrrrroooossssssss mmmmeeeemmmmbbbbeeeerrrr bbbbeeeettttwwwweeeeeeeennnn wwwwhhhheeeeeeeellll aaaarrrrcccchhhheeeessss ((((IIII))))
http://vnx.su

44
HHHHoooooooodddd ccccoooommmmppppaaaarrrrttttmmmmeeeennnntttt fffflllloooooooorrrr ((((JJJJ))))
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HHHHoooooooodddd ccccoooommmmppppaaaarrrrttttmmmmeeeennnntttt rrrreeeeaaaarrrr ccccrrrroooossssssss mmmmeeeemmmmbbbbeeeerrrr ((((KKKK))))
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44
BBBBooooooootttt lllliiiidddd cccchhhhaaaannnnnnnneeeellll ((((LLLL))))
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RRRReeeeaaaarrrr lllliiiigggghhhhtttt ssssuuuuppppppppoooorrrrtttt ppppaaaannnneeeellll ((((MMMM))))
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45
UUUUPPPPPPPPEEEERRRR BBBBOOOODDDDYYYY
WWWWiiiinnnnddddssssccccrrrreeeeeeeennnn ffffrrrraaaammmmeeee ((((AAAA))))
http://vnx.su

45
WWWWiiiinnnnddddssssccccrrrreeeeeeeennnn ppppiiiillllllllaaaarrrr lllliiiinnnniiiinnnngggg ((((BBBB))))
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WWWWiiiinnnnddddssssccccrrrreeeeeeeennnn uuuuppppppppeeeerrrr ccccrrrroooossssssss mmmmeeeemmmmbbbbeeeerrrr ((((CCCC))))
http://vnx.su

48
NNNNOOOONNNN----SSSSIIIIDDDDEEEE DDDDOOOOOOOORRRRSSSS AAAANNNNDDDD LLLLIIIIDDDDSSSS
BBBBooooooootttt lllliiiidddd
http://vnx.su

48
SSSShhhheeeeeeeetttt mmmmeeeettttaaaallll hhhhoooooooodddd ccccoooovvvveeeerrrr
http://vnx.su

51
SSSSIIIIDDDDEEEE DDDDOOOOOOOORRRR AAAANNNNDDDD LLLLIIIIDDDD MMMMEEEECCCCHHHHAAAANNNNIIIISSSSMMMMSSSS
FFFFrrrroooonnnntttt wwwwiiiinnnnddddoooowwww wwwwiiiinnnnddddeeeerrrr
http://vnx.su

51
SSSSIIIIDDDDEEEE DDDDOOOOOOOORRRR AAAANNNNDDDD LLLLIIIIDDDD MMMMEEEECCCCHHHHAAAANNNNIIIISSSSMMMMSSSS
QQQQuuuuaaaarrrrtttteeeerrrr wwwwiiiinnnnddddoooowwww wwwwiiiinnnnddddeeeerrrr
http://vnx.su

52
NNNNOOOONNNN----SSSSIIIIDDDDEEEE DDDDOOOOOOOORRRR AAAANNNNDDDD LLLLIIIIDDDD MMMMEEEECCCCHHHHAAAANNNNIIIISSSSMMMMSSSS
HHHHoooooooodddd
http://vnx.su

52
HHHHoooooooodddd ffffrrrroooonnnntttt llllaaaattttcccchhhheeeessss
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HHHHoooooooodddd rrrreeeeaaaarrrr llllaaaattttcccchhhheeeessss
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HHHHoooooooodddd ccccoooovvvveeeerrrr llllaaaattttcccchhhheeeessss
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AAAAddddjjjjuuuussssttttiiiinnnngggg tttthhhheeee hhhhoooooooodddd
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HHHHoooooooodddd ccccoooovvvveeeerrrr llllaaaattttcccchhhh rrrreeeelllleeeeaaaasssseeee
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HHHHoooooooodddd ccccoooovvvveeeerrrr ggggaaaassss ssssttttrrrruuuuttttssss
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WWWWIIIINNNNDDDDOOOOWWWWSSSS
DDDDoooooooorrrr wwwwiiiinnnnddddoooowwwwssss
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WWWWiiiinnnnddddoooowwwwssss qqqquuuuaaaarrrrtttteeeerrrr
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56
EEEEXXXXTTTTEEEERRRRNNNNAAAALLLL AAAACCCCCCCCEEEESSSSSSSSOOOORRRRIIIIEEEESSSS
EEEElllleeeeccccttttrrrriiiicccc rrrreeeeaaaarrrr vvvviiiieeeewwww mmmmiiiirrrrrrrroooorrrr
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56
EEEEXXXXTTTTEEEERRRRNNNNAAAALLLL AAAACCCCCCCCEEEESSSSSSSSOOOORRRRIIIIEEEESSSS
BBBBooooooootttt lllliiiidddd ---- BBBBooooddddyyyy ssssttttyyyylllliiiinnnngggg ttttrrrraaaannnnssssffffeeeerrrr
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59
IIIINNNNTTTTEEEERRRRNNNNAAAALLLL SSSSAAAAFFFFEEEETTTTYYYY CCCCOOOOMMMMPPPPOOOONNNNEEEENNNNTTTTSSSS
FFFFrrrroooonnnntttt sssseeeeaaaatttt bbbbeeeellllttttssss
http://vnx.su

59
IIIINNNNTTTTEEEERRRRNNNNAAAALLLL SSSSAAAAFFFFEEEETTTTYYYY CCCCOOOOMMMMPPPPOOOONNNNEEEENNNNTTTTSSSS
RRRReeeeaaaarrrr sssseeeeaaaatttt bbbbeeeellllttttssss
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64
BBBBOOOODDDDYYYY SSSSEEEEAAAALLLLIIIINNNNGGGG
WWWWiiiinnnnddddssssccccrrrreeeeeeeennnn ppppiiiillllllllaaaarrrr sssseeeeaaaallll
http://vnx.su

66
WWWWIIIINNNNDDDDOOOOWWWW SSSSEEEEAAAALLLLSSSS
QQQQuuuuaaaarrrrtttteeeerrrr wwwwiiiinnnnddddoooowwww oooouuuutttteeeerrrr wwwwiiiippppeeeerrrr ssssttttrrrriiiipppp
http://vnx.su

70
TTTToooooooolllliiiinnnngggg aaaannnndddd ccccoooonnnnssssuuuummmmaaaabbbblllleeeessss
http://vnx.su

71
BBBBOOOODDDDYYYY IIIINNNNTTTTEEEERRRRIIIIOOOORRRR TTTTRRRRIIIIMMMM
QQQQuuuuaaaarrrrtttteeeerrrr ppppaaaannnneeeellll ttttrrrriiiimmmm
http://vnx.su

72
SSSSIIIIDDDDEEEE DDDDOOOOOOOORRRR AAAANNNNDDDD LLLLIIIIDDDD TTTTRRRRIIIIMMMM
DDDDoooooooorrrr ttttrrrriiiimmmm
http://vnx.su

73
NNNNOOOONNNN----SSSSIIIIDDDDEEEE DDDDOOOOOOOORRRR AAAANNNNDDDD LLLLIIIIDDDD TTTTRRRRIIIIMMMM
HHHHoooooooodddd oooouuuutttteeeerrrr ccccoooovvvveeeerrrr
http://vnx.su

73
PPPPaaaaddddddddiiiinnnngggg
http://vnx.su

73
HHHHoooooooodddd iiiinnnnnnnneeeerrrr lllliiiinnnniiiinnnngggg
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78
RRRREEEEAAAARRRR SSSSEEEEAAAATTTT TTTTRRRRIIIIMMMM
SSSSeeeeaaaatttt ccccuuuusssshhhhiiiioooonnnn ttttrrrriiiimmmm
http://vnx.su

78
RRRREEEEAAAARRRR SSSSEEEEAAAATTTT TTTTRRRRIIIIMMMM
SSSSeeeeaaaatttt bbbbaaaacccckkkk ttttrrrriiiimmmm
http://vnx.su

79
SSSSEEEEAAAATTTT AAAACCCCCCCCEEEESSSSSSSSOOOORRRRIIIIEEEESSSS
HHHHeeeeaaaaddddrrrreeeesssstttt ttttrrrriiiimmmm
http://vnx.su

79
SSSSEEEEAAAATTTT AAAACCCCCCCCEEEESSSSSSSSOOOORRRRIIIIEEEESSSS
SSSSkkkkiiii ccccoooommmmppppaaaarrrrttttmmmmeeeennnntttt ccccoooovvvveeeerrrr
http://vnx.su

40
VVVVeeeehhhhiiiicccclllleeee ddddiiiimmmmeeeennnnssssiiiioooonnnnssss
http://vnx.su

55
EEEEXXXXTTTTEEEERRRRNNNNAAAALLLL PPPPRRRROOOOTTTTEEEECCCCTTTTIIIIOOOONNNN
FFFFrrrroooonnnntttt bbbbuuuummmmppppeeeerrrrssss
http://vnx.su

55
FFFFrrrroooonnnntttt ssssppppooooiiiilllleeeerrrr
http://vnx.su

56
EEEEXXXXTTTTEEEERRRRNNNNAAAALLLL FFFFIIIITTTTTTTTIIIINNNNGGGGSSSS
RRRReeeeaaaarrrr ssssppppooooiiiilllleeeerrrr ((((BBBB oooonnnn CCCC oooonnnnllllyyyy))))
http://vnx.su

56
RRRReeeeaaaarrrr ssssppppooooiiiilllleeeerrrr ((((LLLL oooonnnnllllyyyy))))
http://vnx.su

56
SSSSiiiillllllll sssskkkkiiiirrrrtttt
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75
FFFFRRRROOOONNNNTTTT SSSSEEEEAAAATTTT FFFFRRRRAAAAMMMMEEEESSSS AAAANNNNDDDD SSSSLLLLIIIIDDDDEEEESSSS
CCCCoooommmmpppplllleeeetttteeee sssseeeeaaaatttt
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75
SSSSeeeeaaaatttt ffffrrrraaaammmmeeee
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75
SSSSeeeeaaaatttt sssslllliiiiddddeeeessss
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75
SSSSeeeeaaaatttt bbbbaaaacccckkkk ffffrrrraaaammmmeeee
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77
FFFFRRRROOOONNNNTTTT SSSSEEEEAAAATTTT TTTTRRRRIIIIMMMM
SSSSeeeeaaaatttt ttttrrrriiiimmmm
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77
FFFFRRRROOOONNNNTTTT SSSSEEEEAAAATTTT TTTTRRRRIIIIMMMM
SSSSeeeeaaaatttt bbbbaaaacccckkkk ttttrrrriiiimmmm
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40
DDDDeeeessssccccrrrriiiippppttttiiiioooonnnn ooooffff ppppaaaarrrrttttssss ((((eeeexxxxppppllllooooddddeeeedddd vvvviiiieeeewwww))))
http://vnx.su

41
RRRReeeeaaaarrrr eeeennnndddd ppppaaaannnneeeellll aaaasssssssseeeemmmmbbbbllllyyyy ((((AAAA))))
http://vnx.su

41
PPPPaaaarrrrtttt ooooffff aaaannnn eeeexxxxttttrrrreeeemmmmeeee rrrreeeeaaaarrrr ccccrrrroooossssssss mmmmeeeemmmmbbbbeeeerrrr ((((BBBB))))
http://vnx.su

44
CCCCoooommmmpppplllleeeetttteeee wwwwiiiinnnngggg ppppaaaannnneeeellll ((((AAAA))))
http://vnx.su

44
PPPPaaaarrrrtttt ooooffff aaaa wwwwiiiinnnngggg ppppaaaannnneeeellll ((((BBBB))))
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44
SSSSiiiiddddeeee cccchhhhaaaannnnnnnneeeellll ((((CCCC))))
http://vnx.su

44
RRRReeeeaaaarrrr lllliiiigggghhhhtttt ssssuuuuppppppppoooorrrrtttt ppppaaaannnneeeellll ((((DDDD))))
http://vnx.su

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PPPPaaaarrrrtttt ooooffff aaaa rrrreeeeaaaarrrr eeeennnndddd ppppaaaannnneeeellll ccccrrrroooossssssss mmmmeeeemmmmbbbbeeeerrrr ((((EEEE))))
http://vnx.su

44
RRRReeeeaaaarrrr eeeennnndddd ppppaaaannnneeeellll eeeexxxxtttteeeennnnssssiiiioooonnnn ((((FFFF))))
http://vnx.su

44
QQQQuuuuaaaarrrrtttteeeerrrr ppppaaaannnneeeellll lllliiiinnnniiiinnnngggg ((((GGGG))))
http://vnx.su

44
CCCCoooommmmpppplllleeeetttteeee qqqquuuuaaaarrrrtttteeeerrrr vvvveeeerrrrttttiiiiccccaaaallll ssssttttrrrreeeettttcccchhhheeeerrrr ((((HHHH))))
http://vnx.su

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PPPPaaaarrrrtttt ooooffff aaaa qqqquuuuaaaarrrrtttteeeerrrr vvvveeeerrrrttttiiiiccccaaaallll ssssttttrrrreeeettttcccchhhheeeerrrr ((((JJJJ))))
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SSSSeeeeaaaatttt bbbbaaaacccckkkk ffffaaaasssstttteeeennnniiiinnnngggg ssssttttiiiiffffffffeeeennnneeeerrrr ((((KKKK))))
http://vnx.su

44
JJJJaaaacccckkkk ssssuuuuppppppppoooorrrrtttt ((((oooonnnn RRRRHHHH ssssiiiiddddeeee)))) ((((LLLL))))
http://vnx.su

44
CCCCeeeennnnttttrrrreeee ccccrrrroooossssssss ppppaaaannnneeeellll ((((MMMM))))
http://vnx.su

44
HHHHaaaallllffff uuuunnnniiiitttt ((((NNNN))))
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45
RRRRooooooooffff ppppaaaannnneeeellll ((((AAAA))))
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45
RRRRooooooooffff rrrreeeeaaaarrrr ccccrrrroooossssssss mmmmeeeemmmmbbbbeeeerrrr ((((BBBB))))
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48
BBBBrrrrooookkkkeeeennnn ggggaaaassss ssssttttrrrruuuutttt bbbbaaaallllllll jjjjooooiiiinnnntttt
http://vnx.su

50
SSSSppppeeeecccciiiiaaaallll ttttoooooooollllssss
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50
CCCCoooonnnnssssuuuummmmaaaabbbblllleeeessss
http://vnx.su

52
BBBBooooooootttt lllliiiidddd lllloooocccckkkk aaaannnndddd bbbbaaaarrrrrrrreeeellll
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52
BBBBooooooootttt lllliiiidddd ggggaaaassss ssssttttrrrruuuutttt
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54
RRRReeeeaaaarrrr ssssccccrrrreeeeeeeennnn
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55
RRRReeeeaaaarrrr bbbbuuuummmmppppeeeerrrr
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71
BBBBOOOODDDDYYYY IIIINNNNTTTTEEEERRRRIIIIOOOORRRR TTTTRRRRIIIIMMMM
IIIInnnntttteeeerrrriiiioooorrrr ttttrrrriiiimmmm,,,, rrrreeeeaaaarrrr sssseeeeccccttttiiiioooonnnn
http://vnx.su

74
PPPPAAAARRRRCCCCEEEELLLL SSSSHHHHEEEELLLLVVVVEEEESSSS AAAANNNNDDDD RRRREEEEAAAARRRR CCCCRRRROOOOSSSSSSSS PPPPAAAANNNNEEEELLLL
CCCCrrrroooossssssss ppppaaaannnneeeellll ttttrrrriiiimmmm
http://vnx.su

77 11 190 841 NOVEMBER 1996 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".
All copyrights reserved by Renault.
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.
C Renault S.A. 1988
Transmission
CLUTCH
MANUAL GEARBOXES
AUTOMATIC TRANSMISSION
DRIVESHAFTS
http://vnx.su

EXPLODED VIEW
PRD2013
http://vnx.su

21-1
21-2
21-5
21-7
21-8
21-8
21-9
21-23
21-29
21-32
Contents
Pages
23-23
23-24
23-25
23-26
23-27
23-29
23-29
23-29
23-30
23-31
23-32
23-33
23-34
23-36
23-41
23-57
23-58
23-60
23-61
23-62
23-63
23-64
23-65
23-66
AD4 automatic transmission
Exploded view
Use
Identification
Gear ratios
Gear change thresholds
Consumables
Parts which must be changed
automatically
Oil
Oil drain intervals
Oil draining
Filling - Levels
Oil pressure
Changing the strainer
Hydraulic distributor
Automatic transmission (Removal -
Refitting)
Full-load validation
Load potentiometer
Computer (119)
Line pressure sensor (8)
Multifunction switch (485)
Vehicle speed sensor (250)
Solenoid valve
Engine torque reduction
Special features
AUTOMATIC TRANSMISSION23
Transmission
CLUTCH
Identification
Side views
Exploded view
Consumables
Mechanism - Clutch plate
Thrust pad - Fork
20
20-1
20-4
20-4
20-5
20-6
20-10
Identification
Gear ratios
Capacities - Lubricants
Special features
Consumables
automatically
Gearbox (Removal - Refitting)
5th gear linkage in situ
Differential output seal
Speedometer drive
MANUAL GEARBOXES21
29-1
29-2
29-9
29-19
29-26
Consumables
Driveshafts
Gaiter at wheel end
Gaiter at gearbox end
Gaiter - bearing assembly
DRIVESHAFTS29
Pages
23-1
23-2
23-3
23-4
23-5
23-6
23-6
23-7
23-8
23-11
23-13
23-15
MB automatic transmission
Exploded view
Use
Identification
Gear ratios
Gear change thresholds
Consumables
automatically
Oil
Draining - Filling - Levels
Checking and adjusting the
potentiometer
Oil pressure
Strainer
Automatic transmission (Removal -
Refitting)
AUTOMATIC TRANSMISSION23
http://vnx.su

76907S 90693R1
CLUTCH
Identification 20
ENGINE
TYPE
Mechanism Plate
180 CP 3300
F2N
F3N
B = White
GB= Blue grey
V = Green
76906R90693R85873S
2000 CP 4000
C1G
C1J
C2J
C3J
E6J
26 splines
E = 7.7 mm
D = 181.5 mm
76906R
26 splines
M = 6 pale pink springs
E = 7.7 mm
D = 200 mm
20-1
http://vnx.su

F8Q
CLUTCH
Identification 20
ENGINE
TYPE
MECHANISM CLUTCH PLATE
200 CP 4400 R = 4 red springs
J = 4 yellow springs
76906R93813R76907S
F7P
26 splines
D = 200 mm
E = 7.7 mm
76906R90693G1
200 CPV 3500 R = Red
J = Yellow
V = Green
76907S
26 splines
D = 200 mm
E = 7.7 mm
Special feature: 2 additional springs on the hub.
20-2
http://vnx.su

F8Q
Turbo
CLUTCH
Identification 20
ENGINE
TYPE
MECHANISM CLUTCH PLATE
76906R90693-2G2
200 CPV 4400 J = 4 yellow springs
G = 4 grey springs
76907S
26 splines
D = 200 mm
E = 7.7 mm
Special feature: 2 additional springs on the hub.
20-3
http://vnx.su

PRD2012
DI2001
CLUTCH
Side view 20
Single plate, dry, clutch, cable operated.
Diaphragm spring clutch plate.
Clutch plate with rubber hub.
Self-centring, guided, ball type thrust pad in
constant contact.
Automatic wear take-up mechanism.
Exploded view
20-4
http://vnx.su

CLUTCH
Consumables 20
Type Pack size Unit
MOLYKOTE BR2 1 kg tin
Right hand sunwheel splines
Shaft splines
Fork pivot
Release bearing guide
Fork pads
RHODORSEAL 5661 100 g tube Ends of driveshaft roll pins.
LOCTITE 518 24 ml syringe Housing assembly faces.
Clutch
20-5
http://vnx.su

CLUTCH
Mechanism - Clutch plate 20
ALL TYPES
IMPORTANT PRECAUTIONS WHICH MUST BE
FOLLOWED WHEN REPAIRING THE CLUTCH
In order to improve the sliding of the clutch
plates, their hubs are nickel-plated.
Clean the clutch shaft splines and refit the assem-
bly without any lubricant.
Special features of "diesel" clutch plates
These are fitted with a damping pre-hub which is
most efficient when its internal units are dry.
20-6
http://vnx.su

CLUTCH
Mechanism - clutch plate
REFITTING
Degrease the flywheel mounting face.
Use the plastic locating device supplied in the kit
to fit the plate.
20
REMOVAL
Fit locking sector Mot. 582.
Remove the mounting bolts from the mechanism
and remove the unit and the clutch plate.
Check and change the faulty parts.
92170R
CHANGING
This operation is carried out after the gearbox has been removed.
Mot. 582 Locking sector
Plus the tools required to remove the gearbox
TIGHTENING TORQUES (in daN.m)
7 mm diameter unit securing bolts
for 180 mm diameter clutch 1.8
8 mm diameter unit securing bolts
for 200 mm diameter clutch 2.5
94135S
20-7
http://vnx.su

CLUTCH
Mechanism - clutch plate 20
Gradually screw up then torque tighten the bolts
securing the mechanism.
Remove locking sector Mot. 582.
Coat the bore of the thrust pad, guide tube and
clutch shaft splines with grease MOLYKOTE BR2 .
74413R
20-8
http://vnx.su

CLUTCH
Mechanism - clutch plate 20
REMOVAL
F engines
Degrease the crankshaft bore which receives the centring bush.
Coat the external diameter of the bushing with Loctite FRENBLOC.
Using a tube with an external diameter of 38 mm, fit the bush fully into the crankshaft bore.
Observe the direction of fitting of the bush and check that it is fitted correctly.
C and E engines
The centring bush will not be used for these engines.
94235S
20-9
http://vnx.su

CLUTCH
Thrust pad - fork
Ensure that the assembly slides properly.
NOTE: when carrying out operations which do not
require removal of the gearbox or after fitting the
gearbox, DO NOT RAISE the fork as there is a risk
of it lifting out of catch (A) on the thrust pad.
20
CHANGING
This operation is carried out when the gearbox
has been removed.
REMOVAL
Remove:
- the thrust pad by tilting the fork,
- the rubber protector, and pull the fork to-
wards the inside of the clutch casing.
REFITTING
Coat the walls of the guide tube and the fork pads
with grease MOLYKOTE BR2.
Fit the fork and refit the rubber protector.
Fit the thrust pad on the guide tube, placing catch
(A) in the fork.
90300G1
Check the extent of fork travel.
It should be:
X = 17 to 18 mm
91830R1
After refitting the gearbox, re-set the toothed
quadrant and check that the wear take-up mecha-
nism operates correctly.
20-10
http://vnx.su

MANUAL GEARBOXES
Identification
An identification plate on the clutch housing shows:
At A : the gearbox type
At B : the gearbox suffix
At C : the fabrication number
At D : the production factory
At E : a notch is used when the gearbox has been
assembled with a C or E type engine.
21
87227G
Gearbox type
Repair manual which deals
with the gearbox concerned
JB B.V. JB
JC B.V. JC
X
0 0 0J B0 BA
E
D C0 0 0 0 0 0
TWO-COLOUR MARKING
JB0 - JB1 - JB3 - JC5
Two-thirds of the surface are painted with a colour which is peculiar to each gearbox type, enabling the gear-
box to be matched with the driveshaft.
The remaining one-third of the surface is painted with a specific colour according to the gearbox suffix.
JB4 - JB5
Two-colour marking (green and pink) in the form of two bands of equal width.
90775
21-1
http://vnx.su

MANUAL GEARBOXES
Gear ratios 21
JB0
Index Vehicle
017
B531 - B532 - B537
C531 - C532
L531 - L532 - L537
019
B534
L53H
023
B530 - C530 - L530
S530
035
B53W - C53W
L53W
Final drive
set
Speedo
drive set
1st 2nd 3rd 4th Reverse
57
16
56
15
58
15
61
15
19
21
28
31
43
21
37
28
39
11
26
41
11
JB1
Index Vehicle
023
B532 - C532 - L532
B535 - C535 - L535
025
B530 - C530 - L530
S530 - B537 - C537
L537 - S537 - B53A
C53A - B53G
027
B53H
L53H
029 L53G
034 B531 - C531 - L531
047
B53W - C53W
L53W
070
B530 - C530 - L530
S530 - B535 - C535
L535 - S535 - B537
C537 - L537 - B53A
C53A - L53A
58
15
61
15
58
15
61
15
19
21
29
30
31
39
43
21
37
28
39
11
26
43
11
JB4
Index Vehicle
000
B530 - C530 - L530
S530 - C531
006
B531 - L531
B53P - C53P - L53P
Final drive
set
Speedo
drive set
1st 2nd 3rd 4th Reverse
58
15
57
16 19
21
28
31
39
19
33
25
39
11
26
41
11
57
16
63
14
61
15
19
21
29
30
31
39
43
21
37
28
39
11
26
41
11
19
21
29
30
31
39
43
21
37
28
39
11
26
45
11
Final drive
set
Speedo
drive set
1st 2nd 3rd 4th 5th Reverse
21-2
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39
11
26
39
11
26
39
11
26
39
11
26
39
11
26
Final drive
set
Speedo
drive set
MANUAL GEARBOXES
Gear ratios 21
JB3
Index Vehicle
059
B533 - C533 - L533
D53C
027
B533 - C533 - L533
B53C - C53C - L53C
D53C
B53M - C53M
062
353A - 453A - 553A
853A
B53C - D53C - L53C
B53Y - D53Y - L53Y
094
B538 - C538 - L538
B53F - C53F - L53F
S53C - S53D
095
353C - 453C - 553C
853C - 353D - 453D
553D - 453H - 553H
B538 - C538 - L538
S53C - S53D
037
B538 - C538 - L538
B53C - C53C - D53C
L53C - B53F - C53F
L53F - B53Y - L53Y
071 B53D - C53D - L53D
083 B53D - C53D - L53D
060
B533 - L533 - B53B
C53B - L53B - B53I -
C53I - L53I - B53J -
C53J - L53J - S53J
061 B533
067
353A - 453A - 553A
853A - B53Y - C53Y
D53Y - L53Y
047
B53B
B53Y - C53Y - L53Y
61
15
19
21
29
30
31
41
41
22
37
28
34
11
61
15
19
21
29
30
31
41
41
22
37
28
34
11
19
21
35
34
28
34
41
22
37
28
34
11
59
14
57
16
19
21
29
30
31
39
43
22
37
28
41
11
58
15
55
16
19
21
29
30
31
39
43
21
37
28
41
11
21-3
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39
11
26
39
11
26
MANUAL GEARBOXES
Gear ratios 21
JB3
Index Vehicle
017 L532
051
B539 - C539 - B53D
C53D - D53D - L53D
044
B539 - C539 - L539
B53D - C53D -
D53D - L53D
031 B533 - B536 - L536
053 B53D - C53D - L53D
028
B532 - B533 - L533
C534 - L534 - S534
B53B - C53B - L53B
B53C - L53C - B53E
C53E - B53I - C53I -
L53I - B53J - C53J -
L53J - S53J
61
15
19
21
29
30
25
33
35
19
33
25
34
11
19
21
29
30
31
39
43
21
37
28
41
11
57
16
39
11
26
58
15
19
21
29
30
31
39
43
21
37
28
34
11
39
11
26
61
15
19
21
35
34
28
34
41
22
37
28
34
11
JB5
Index Vehicle
006
B531 - C531 - L531
B53P - C53P - L53P
000
B530 - C530 - L530
S530
57
16
61
15
19
21
29
30
39
19
33
25
39
11
26
41
11
19
21
29
30
39
19
33
25
39
11
26
41
11
Final drive
set
Speedo
drive set
27
34
27
34
JC5
Index Vehicle
002
B532 - C532 - L532
B53K - L53K - S53K
B53T - C53T - L53T
B53Z
56
17
19
21
34
35
43
21
37
28
39
11
26
41
11
31
41
Final drive
set
Speedo
drive set
Final drive
set
Speedo
drive set
21-4
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MANUAL GEARBOXES
Capacities - Lubricants
CAPACITY (in litres)
21
CHECKING THE LEVEL
Fill to the level of the opening.
92081R
4-speed gearbox
JB0
JB2
3.25
5-speed gearbox
JB1
JB3
3.40
JB4 2.75 JB5 2.90
JC5 3.10
There are two ways of checking the level.
Plug (A) without dipstick
Wipe the dipstick section.
Refit the plug, without screwing it up, with the
dipstick pointing downwards.
Remove the plug, the level should be on the boss
(2).
DI2123
Plug (B) with dipstick
OIL VISCOSITY GRADE
Tranself TRX 75/80 W
21-5
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MANUAL GEARBOXES
Lubricants 21
Precautions (TRX and TRZ oils)
"TRANSELF TRX and TRZ" oils are high technology products and certain precautions must be taken in order
to prevent the entry of water which, even in very small quantities, will reduce the quality of the oil and result
in seizure of the gearbox or of the final drive.
STORAGE AND USE
Special care must be taken to ensure that open cans are sealed correctly in order to prevent the entry of mate-
rials or water.
In particular:
Storing oil cans
The cans must be stored:
- sheltered from bad weather (rain, snow, outside splashes),
- in a dry area (avoid storing in the vicinity of a washing area),
- tightly sealed.
Storing units (gearbox or final drive)
When storing a gearbox or final drive which has not been drained, close the air inlets.
Store the unit in a dry area.
Using the oil
The oil cans must be resealed each time they have been used.
In order to prevent a large surface area of the oil coming into contact with the air, do not transfer the oil into
a larger container.
When carrying out work which requires draining of the gearbox, the oil must be replaced with new oil.
The oil can must be shaken before refilling the gearbox, especially if the oil has been stored for a long time.
Washing under pressure (of the vehicle or of a unit)
Close the gearbox and final drive breather.
If the gearbox is removed, correctly close all of the openings to prevent the entry of water.
21-6
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MANUAL GEARBOXES
Special features
GEAR CHANGE PATTERN
The gearboxes of the following types:
JB0
JB4
JB2
JB1
JB3 5 forward gears
JB5 1 reverse
JC5
are fitted with BORG-WARNER synchronisers.
To select reverse, raise ring (A) and move the le-
ver.
21
R 1 3 5
2 4
DI2118
4 forward gears
1 reverse
21-7
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MANUAL GEARBOXES
Consumables 21
Parts which must be changed automatically
When they have been removed:
- the lip seals,
- the O-rings,
- the thrust pad guide tubes,
- the secondary shaft and differential nuts,
- the speedometer gear and its shaft,
- the speedometer crown wheel,
- the roll pins,
- the bushes under the gears.
TYPE PACK SIZE UNIT
MOLYKOTE BR2 1 kg sachet
Clutch fork pivot
Thrust pad guide tube bore
Clutch shaft splines
Right hand sun wheel splines
Loctite 518 24 ml syringe Housing joint faces
LOCTITE FRENBLOC 24 cc bottle
5th speed fixed gear
5th speed synchroniser hub
Primary shaft nut
Secondary shaft bolt
RHODORSEAL 5661 100 g tube
Ends of roll pins on driveshafts
Screw threads on switches
21-8
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MATERIALS
MANUAL GEARBOXES
REMOVAL
The gearbox can be removed alone.
Place the vehicle on a two post lift.
Disconnect the battery.
Remove the front wheels.
On the left hand side of the vehicle
Remove:
- the steering tie rod ball joint using tool
T.Av. 476.
B.Vi. 31-01 Set of pin punches
T.Av. 476 Ball joint extractor
21
Brake caliper securing bolts 10
Shock absorber lower securing bolts 11
Steering ball joint nut 3.5
Nut holding key on stub axle carrier 5.5
Mounting securing bolts 4 to 5
Wheel bolts 8
Left hand driveshaft gaiter securing bolt 2.5
C
engines
85965R
- the three bolts holding the driveshaft gaiter,
- the two bolts securing the brake caliper and se-
cure the caliper to the suspension spring so as
to avoid stretching the hose,
- the protective casing (side).
92122R2
Loctite FRENBLOC
Brake caliper securing bolts
RHODORSEAL 5661
Ends of pins on driveshafts
MOLYKOTE "BR2"
Clutch shaft and sun wheel splines
21-9
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MANUAL GEARBOXES
- the driveshaft - stub axle carrier assembly from
the lower ball joint,
21C
engines
On the right hand side of the vehicle
Remove the driveshaft roll pins using tool
B.Vi. 31-01
90130R2
Remove:
- the two bolts (2) securing the base of the shock
absorber,
- the nut and key (1),
Check that the driveshaft rollers do not come out
manually. If they do, on reassembly, check that
the needle bearings have not fallen into the gear-
box.
Slacken lower bolt (3) on the base of the shock ab-
sorber and remove upper bolt (4).
91758R4
Tilt the stub axle carrier and uncouple the drives-
haft.
90311S
91755R
21-10
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MANUAL GEARBOXES
Slacken:
- the two mounting bolts on the engine,
- the clutch protection plate,
- the gear lever.
21C
engines
92028R2
Under the vehicle, remove bolt (H) from the en-
gine - gearbox tierod.
Disconnect:
- the starter leads,
- the connector on the reversing light switch.
On vehicles fitted with power assisted steering,
remove the two clamps securing the power
assisted steering pipes to the gearbox.
Remove:
- the air filter unit and its mounting,
- the integral electronic ignition (A.E.I.) sensor,
- the bolts from around the gearbox and from
the starter.
92031S
85966R
21-11
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MANUAL GEARBOXES
Gearbox (Removal - Refitting) 21
Lift the engine using a tool specific to this purpose
(example: desvil 300B).
89204S
Disconnect:
- the clutch cable,
92110S
Petrol engines - all types
Remove:
- the front mounting,
- the earthing braid.
C
engines
- the speedometer pin and cable.
92108-1R1
92112R
21-12
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MANUAL GEARBOXES
Remove the three bolts securing the rear centre
mounting and move it back as far as possible.
92108R1
NOTE: to make it easier to remove the bolts, raise
the gearbox slightly with a component jack.
Uncouple the gearbox from the engine, sliding
the 5th speed housing between the vehicle side-
member and the engine cradle.
Raise the engine.
Turn the gearbox to the front slightly so as to free
the final drive section then remove the gearbox
from the vehicle.
After uncoupling the gearbox from the engine,
attach it to a workshop crane securing the eyes in
place of two bolts around the gearbox.
92903S
C
engines
21-13
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MANUAL GEARBOXES
Remove the idle speed regulation valve moun-
ting.
Disconnect the starter and oil pressure sensor
wires.
REMOVAL
The gearbox is removed alone.
Remove the radiator after first draining the co-
oling system.
To detach the wiring, disconnect the connectors
on:
- the ignition power module,
- the throttle housing,
Disconnect the two side bolts which secure the en-
gine - gearbox tierod, starter end torx bolt (T).
using a suitable spanner.
E
engines
92817S
- the idle speed regulation valve.
92904R1
92826S
92904R
21-14
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MANUAL GEARBOXES
Disconnect the fan motor and thermal switch
connectors.
Unfasten the radiator mountings and move it to
the right hand side (without removing any of the
hoses or pipes), protecting the sides with card-
board.
Remove studs (A) and (B) using a nut and lock-nut,
using an angled spanner and a ball joint ratchet.
E
engines
92903S
86308R1
21-15
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MANUAL GEARBOXES
Uncouple the gear lever at the gearbox outlet le-
ver after detaching the protective gaiter.
F
engines
The gearbox cannot be removed alone. The en-
gine - gearbox assembly must be removed first (re-
fer to section 10) and then uncoupled.
85966R
98865R2
Remove the starter plate.
Bolt which secures the pendulum
mounting system to the gearbox 3.5
Nuts and bolts which secure the clutch
housing to the engine 5
Bolt which secures the clutch
protector 2.5
Drain plug 1.8
Filler plug 0.15
Bolt which secures the left hand
driveshaft 2.5
Removal (Special points)
Speedometer cable mounting. Pinch the tabs (ar-
rows) and remove the cable.
93902S
21-16
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MANUAL GEARBOXES
Disconnect the starter leads.
From the lower section, remove:
- nut (E) which secures the engine - gearbox,
F
engines
85812-1R
- the tierod - clutch protector assembly.
Place the engine on a stand.
Remove the bolts from around the gearbox and
from the starter.
Vehicles fitted with power assisted steering, re-
move the two clamps (C) which secure the power
assisted steering pipe.
92903S1
92028R3
21-17
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MANUAL GEARBOXES
Gearbox (Removal - Refitting) 21F
engines
90300G1
REFITTING
Ensure that the engine - gearbox locating rings
are present and correctly positioned:
- at A : gearbox assembled with a C or E type
engine,
- at B : gearbox assembled with an F type en-
gine.
Fit the thrust pad to the guide tube placing catch
(A) in the fork, ensure that it slides correctly.
86415R
Do not raise the fork since there is a risk of it lif-
ting out of catch (A) on the thrust pad. To prevent
this, immobilise the thrust pad - fork assembly by
inserting a tube (example: tool Elé. 1382) bet-
ween the fork and the sheath end on the housing
to prevent any movement of the thrust pad while
the gearbox is fitted.
Coat the walls of the guide tube and the fork pads
with MOLYKOTE BR2 grease .
21-18
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MANUAL GEARBOXES
Fit the gearbox in place.
F
engines
92903R1
Assemble the engine - gearbox.
Ensure that the locating rings are fitted correctly
in their locations.
Refit studs (A) and (B) in the same way as on remo-
val. These studs and the bolts around the gearbox
are used for alignment and centring.
Fit the fork and refit the rubber protector.
21-19
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MANUAL GEARBOXES
Speedometer cable mounting. Pinch the tabs (ar-
rows) and remove the cable (F type engine).
21
WARNING: fit bolt (V) and starter locating pin (D)
correctly.
92108-1S
All types
C and E type engines
86070R3
F type engine
86070-1R1
Reconnect the speedometer cable ensuring that
the pin is in the correct position (C and E type en-
gines).
93909S
21-20
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MANUAL GEARBOXES
Pull the cable at the clutch fork on the gearbox.
The cable should have at least 2 cm of slack.
21
Position the driveshaft in relation to the sun
wheel, pivot the stub axle carrier engaging the
driveshaft in the sun wheel using the angled drift
B. Vi. 31-01 to align the holes.
91830R1
All types
74937-4S
There is an inlet chamfer on the sun wheel to
make it easier to fit new roll pins.
Seal the ends of the pins (RHODORSEAL 5661).
After refitting the engine - gearbox assembly to
the vehicle, check the extent of the fork travel.
It should be: X = 17 to 18 mm
89204S
These checks enable the correct operation of the
clutch automatic wear take-up system to be veri-
fied.
21-21
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MANUAL GEARBOXES
Check the setting of the upper mountings (refer
to section 10).
Ensure that the engine movement limiter is fitted
the correct way: the nuts should be fitted at the
exhaust pipe end.
F
engines
92661S
Fill the cooling system.
All types
Fit the brake caliper mounting bolts with Loctite
FRENBLOC and torque tighten them.
Press on the brake pedal several times to bring the
pistons into contact with the brake pads.
Tighten the bolts and nuts to the specified torque.
Fill the gearbox.
21-22
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MANUAL GEARBOXES
5th speed linkage in situ
MATERIALS
B.Vi. 28-01 Extractor body
B.Vi. 31-01 Drifts for fitting roll pins
B.Vi. 1003 5th speed hub extractor
B.Vi. 1007 Jaws for B.Vi. 28-01, 02, 03
B.Vi. 1175 5th speed fixed gear mounting bolt
21
87180R
Loctite FRENBLOC :
Primary shaft nut
Secondary shaft bolt
5th speed fixed gear
5th speed hub
Primary shaft nut 13.5
Secondary shaft nut 7
REMOVAL
Remove the front left hand wheel.
Remove the side housing.
Drain the gearbox.
The rear housing must be removed horizontally as
it has a lubricating duct (A) which goes into the
primary shaft.
21-23
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Renault 19 Repair Manual 1996 Edition

Renault 19 Repair Manual 1996 Edition

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Renault 19 Repair Manual 1996 Edition