Renault Coupes/Sedans/Wagons 1975-1985 Repair Guide

Pistons, Liners and Connecting Rods

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REMOVAL





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Fig. Fig. 1 Mark the connecting rod and its cap for proper reassembly



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Fig. Fig. 2 Place rubber hose over the connecting rod studs to protect the crank and bores from damage



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Fig. Fig. 3 Carefully tap the piston out of the bore using a wooden dowel

Special tools are required for this procedure.

  1. Remove the cylinder head.
  2.  
  3. Remove the oil pan.
  4.  
  5. Remove the oil pump.
  6.  
  7. Place the liner clamp, tool number Mot.521 in place on the block.
  8.  
  9. Mark the connecting rods and caps for reassembly. Note that number one cylinder is at the flywheel end.
  10.  
  11. Remove the connecting rod caps.
  12.  
  13. Remove the liner clamp and pull out the liner and piston assemblies.
  14.  

OVERHAUL





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Fig. Fig. 4 New pistons and liners are sold in matched sets, A-D. Keep them together



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Fig. Fig. 5 Piston pin removal and installation tool



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Fig. Fig. 6 Removing the piston pin



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Fig. Fig. 7 The pin end of the connecting rods (A) must be heated for installation-note the special heater unit



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Fig. Fig. 8 Inserting the piston pin-D is the marked side of the rod and C is the thrust collar



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Fig. Fig. 9 Most rings are marked to show which side should face upward



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Fig. Fig. 10 After the piston assemblies have cooled, install the piston rings as shown



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Fig. Fig. 11 Use a ring expander tool to remove the piston rings



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Fig. Fig. 12 Most pistons are marked to indicate positioning in the engine (usually a mark means the side facing front)



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Fig. Fig. 13 Use a ring compressor to install the piston assemblies into the cylinder liners



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Fig. Fig. 14 The notch on the the side of the bearing cap matches the groove on the bearing insert

Special tools are required for this procedure.

  1. Clean the head and block mating surfaces using a commercially available gasket dissolver. Never scrape the mating surfaces.
  2.  
  3. Thoroughly clean the block bores, the liner seal locations and the crankshaft.
  4.  

Liners, Pistons, Rings and Piston Pins are sold in matched sets. No honing of the liners is necessary. No adjustments to the rings are possible.

  1. Obtain a new, matched set of liner-piston assemblies. Mark each in order, one through four to assure easy installation.
  2.  
  3. All of the new parts are coated with an antirust film. Remove this film with a safe solvent.
  4.  
  5. Drive the piston pins from the old piston and rod assemblies and assemble the new pistons to the rods using the new pins. If there is any difficulty inserting the new pins into the rods, the rods must be heated to 482°F (250°C). A special hot plate tool is available for this purpose. Since only the affected end of the rod should be heated to this degree, this tool, rather than an oven, is recommended. The tool number is Mot.574.
  6.  

When assembling the piston and rod, make sure that the arrow on the piston top faces the flywheel end of the engine and the mark made on the connecting rod faces the side away from the camshaft. The piston and rod must be assembled quickly to avoid heat loss. A press and mandrel are essential for rapid assembly. If one cannot be obtained, this job is best left to a machine shop. The pin must not protrude beyond the piston skirt on either side.

  1. The piston rings are pregapped. There is no adjustment possible. Use a ring compressor/expander to install the rings. The rings gaps should be staggered 90° apart, so that no two gaps line up. When installing the compression rings, make sure that the side stamped with an O faces up.
  2.  
  3. With the rings installed, lubricate the piston assembly with clean engine oil. Using a ring compressor, slide the piston/rod assembly into the liner. The machined sides of the connecting rod big end must be parallel with the flat edge on top of the liner.
  4.  
  5. Place the upper bearing half into the rod.
  6.  

INSTALLATION





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Fig. Fig. 15 Install the piston and liner assemblies into the engine block-the pin recess (inset) should face the front of the engine; D is the marked side of the rod (cam side)



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Fig. Fig. 16 Liner installation-(X) liner protrusion, (K) liner height from shoulder to top, (D) liner width and (J) shoulder seal O-ring used on 1,565cc and 1,647cc engines



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Fig. Fig. 17 Apply a strip of gauging material to the bearing journal, then install and torque the cap



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Fig. Fig. 18 After the cap is removed again, use the scale supplied with the gauge material to check clearances



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Fig. Fig. 19 Measure the liner protrusion with a dial indicator



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Fig. Fig. 20 Piston and liner assemblies installed



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Fig. Fig. 21 Torquing the connecting rod caps

When installing the liners, it is necessary to determine what thickness seals to use. To do this you must measure the liner protrusion above the block surface. Check the protrusion at two opposite points as shown and subtract the greater figure from 0.005". Choose a seal equal to or just above the result obtained by subtraction. Seals are identified by a color spot to indicate thickness: Blue is 0.033", Red is 0.004", and Green is 0.005" thick. Place the new seals on the liners, insert the liners, press them down by hand, and recheck their protrusion according to the Piston and liner Chart. The difference between liners should not exceed 0.0016".

  1. Slide the liner assemblies, in order, into the block. Don't forget that number one is at the flywheel end of the block. The arrows on the pistons must face the flywheel.
  2.  
  3. Position the liner clamp on the block.
  4.  
  5. Lubricate the crankshaft journals and pull each rod down into contact with the journals.
  6.  
  7. Lay a piece of Plastigage across each bearing cap on the bearing surface. Install each cap and torque it to the value shown on the Torque Specifications Chart. Remove the cap and check the width of the plastigage on the bearing, compare it to the bearing clearance shown in the Crankshaft Specifications Chart, and determine if you need new bearings.
  8.  
  9. Install the bearing caps and torque them.
  10.  
  11. Make sure that everything moves freely.
  12.  
  13. Assembly is the reverse of disassembly from here on.
  14.  

 
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