oscar
Well-known member
- Joined
- Aug 31, 2013
- Messages
- 2,601
- Reaction score
- 2
everything you need to know about the timing belt on the K4M-854 engine from how to do it, tools required, labour time & precautions from official renault technical data source. this covers all variants of the renault sport twingo range regardless of trim level (cup, non cup, gordini, wind vvt)
CAUTION! this engine has been identified as an INTERFERENCE engine in which the possibility of valve to piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.
REPAIR TIMES - 5.40 Hours (Phase 1 & 2)
SPECIAL TOOLS
*Camshaft setting bar - Renault Nos. MOT.1496/1750.
*Camshaft sprockets locking tool - Renault No. MOT.1490-01.
*Crankshaft timing pin - Renault No. MOT.1489.
*Exhaust camshaft blanking plug tool - Renault No. MOT.1488
*Guide pulley wrench - Renault No. MOT.1368
*Inlet camshaft blanking plug tool - Renault No. MOT.1487
SPECIAL PRECAUTIONS
*Disconnect battery earth lead
*DO NOT turn crankshaft or camshaft when timing belt is removed
*Remove spark plugs to ease turning engine
*Turn engine in normal direction of rotation (clockwise) unless otherwise stated
*Observe all tightening torques
* DO NOT turn engine via camshaft or any other sprockets.
REMOVAL
1. Raise and support front of vehicle.
2. Remove :
* Windscreen wiper arms.
* Scuttle panel.
* Front bumper.
* Headlamps.
* Bonnet shut panel.
* Air intake duct.
* Air filter assembly.
* Throttle body assembly.
* RH front wheel
* RH front wheel arch liner
* Engine undershield.
* Auxiliary drive belt.
NOTE: Auxiliary drive belts, tensioner pulley and guide pulleys MUST be replaced.
3. Support engine.
4. Remove :
* RH engine mounting and bracket.
* Rear engine torque reaction link
5. Disconnect wiring harness from timing belt lower cover
6. Disconnect wiring harness from rear of cylinder head cover.
7. Remove :
* Engine lifting eye.
* Blanking plugs from rear of camshafts
* Blanking plug from cylinder block (Fig 1.1)
8. Turn crankshaft clockwise until grooves in camshafts are almost aligned (Fig 1.2)
NOTE: grooves located below cylinder head upper face.
9. Insert crankshaft timing pin in cylinder block (Fig 1.3) Tool No. MOT.1489.
10. Turn crankshaft slightly until crankshaft web stops against timing pin (Fig 1.4)
11. Ensure grooves in camshafts are aligned (Fig 1.2)
12. Fit setting bar to rear of camshafts (Fig 1.5) Tool Nos. MOT.1496/1750.
13. Lock flywheel with large screwdriver. Slacken crankshaft pulley bolt (Fig 1.6)
14. Remove:
*Crankshaft pulley bolt (Fig 1.6)
*Crankshaft pulley (Fig 1.7)
*Timing belt covers (Fig 1.8 & Fig 1.9)
15. Slacken tensioner pulley nut (Fig 1.10)
16. Remove:
*Tensioner pulley nut (Fig 1.10)
*Tensioner pulley (Fig 1.11)
*Guide pulley bolt (Fig 1.12)
*Guide pulley.
*Timing belt.
NOTE: DO NOT allow crankshaft sprocket to fall off the crankshaft!
INSTALLATION
NOTE: Timing belt, tensioner pulley and guide pulley MUST be replaced.
1. Ensure crankshaft timing pin is inserted (Fig 1.3)
2. Ensure crankshaft web is against the timing pin (Fig 1.4)
3. Ensure grooves in camshafts are aligned (Fig 1.2)
4. Ensure setting bar is fitted to the rear of the camshafts (Fig 1.5)
5. Remove and degrease the crankshaft sprocket. Degrease end of crankshaft. Refit crankshaft sprocket.
NOTE: Crankshaft keyway at 12 o'clock position (Fig 1.13)
6. Fit camshaft sprockets locking tool (Fig 1.14) Tool No. MOT.1490-01.
7. Remove
*Exhaust camshaft sprocket blanking plug (Fig 1.16)
NOTE: Replace camshaft stud if loosened when removing nut.
*Inlet camshaft sprocket blanking bolt (Fig 1.17)
*Inlet camshaft sprocket bolt (Fig 1.17)
*Camshaft sprockets locking tool (Fig 1.14)
*Exhaust camshaft sprocket (Fig 1.18) Degrease sprocket. Degrease end of camshaft.
*Inlet camshaft sprocket (Fig 1.19) Degrease sprocket. Degrease end of camshaft.
WARNING! : Failure to degrease components may lead to sprockets slipping on crankshaft and camshafts, resulting in severe engine damage.
8. Fit exhaust camshaft sprocket (Fig 1.18). Use new nut. Lightly tighten nut (Fig 1.15)
9. Fit new camshaft sprocket (Fig 1.19). Use new bolt. Lightly tighten bolt (Fig 1.17)
10. Ensure camshaft sprockets can turn freely without tilting.
11. Ensure Renault logo on exhaust camshaft sprocket is positioned as shown (Fig 1.20)
12. Ensure inlet camshaft sprocket mark at 12 o'clock position (Fig 1.21)
13. Mark cylinder head with paint or chalk where indicated (Fig 1.22)
14. Ensure inlet camshaft VVT unit (Dephaser) is locked within inlet camshaft sprocket (it should not be possible to rotate the VVT unit to the left or to the right) (Fig 1.23)
15. Fit new tensioner pulley (Fig 1.11)
NOTE: Ensure lug on rear of tensioner pulley located in the groove in the water pumps housing (Fig 1.24)
16. Fit timing belt loosely to sprockets and pulleys.
NOTE: Ensure timing belt is taut between camshaft sprockets
17. Fit new guide pulley. Tighten guide pulley bolt (Fig 1.12). Tightening torque : 50 Nm. Use tool No. MOT.1368.
18. Turn tensioner pulley clockwise until movable pointer (Fig 1.25) is aligned with the notch (Fig 1.26) use 6 mm Allen key (Fig 1.27)
19. Temporarily tighten tensioner pulley nut (Fig 1.10). Tightening torque : 7 Nm.
20. Fit timing belt lower cover (Fig 1.9).
21. Lock flywheel with large screwdriver.
22. Fit new crankshaft pulley and bolt (Fig 1.7 & 1.6). Tightening torque : 120 Nm + 95 degrees + 10 degrees.
23. Fit camshaft sprocket locking tool (Fig 1.14)
24. Tighten inlet camshaft sprocket bolt (Fig 1.17). Tightening torque : 100 Nm.
25. Fit new inlet camshaft sprocket blanking plug (Fig 1.16). Tightening torque : 15 Nm.
26. Tighten exhaust camshaft sprocket nut (Fig 1.15). Tightening torque : 30 Nm + 85 degrees + 4 degrees.
27. Remove:
*Timing belt lower cover access panel (Fig 1.28)
*Camshaft setting bar (Fig 1.5)
*Camshaft sprocket locking tool (Fig 1.14)
*Crankshaft timing pin (Fig 1.3)
28. Turn crankshaft two turns clockwise until just before setting position (Fig 1.21 & Fig 1.22)
29. Insert crankshaft timing pin in cylinder block (Fig 1.3)
30. Turn crankshaft slightly clockwise.
31. Ensure crankshaft web is against the timing pin (Fig 1.4)
32. Remove crankshaft timing pin (Fig 1.3)
33. Ensure tensioner pulley pointer is aligned with the notch (Fig 1.25 & 1.26)
34. If not :
* Slacken tensioner pulley nut (Fig 1.10) by a maximum of one turn whilst holding 6 mm Allen key (Fig 1.27)
* Turn tensioner pulley until the pointer is aligned with the notch (Fig 1.25 & Fig 1.26). Use 6 mm Allen key (Fig 1.27)
35. Tighten tensioner pulley nut (Fig 1.10). Tightening torque : 27 Nm.
36. Insert crankshaft timing pin in cylinder block (Fig 1.3)
37. Ensure crankshaft web is against the timing pin (Fig 1.4)
38. Ensure grooves in camshafts are aligned correctly (Fig 1.2)
39. Ensure setting bar can be easily fitted (Fig 1.5). If not : repeat installation procedure.
40. Remove:
*Setting bar (Fig 1.5)
*Timing pin (Fig 1.3)
41. Refit blanking plug to cylinder block (Fig 1.1). Tightening torque : 20 Nm.
42. Refit timing belt lower cover access panel (Fig 1.28)
43. Fit new blanking plugs to rear of camshafts. Use tool Nos. MOT.1487 & 1488.
NOTE: DO NOT start engine without auxiliary drive belt fitted as damage may occur to crankshaft pulley.
44. Install components in reverse order of removal.
CAUTION! this engine has been identified as an INTERFERENCE engine in which the possibility of valve to piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.
REPAIR TIMES - 5.40 Hours (Phase 1 & 2)
SPECIAL TOOLS
*Camshaft setting bar - Renault Nos. MOT.1496/1750.
*Camshaft sprockets locking tool - Renault No. MOT.1490-01.
*Crankshaft timing pin - Renault No. MOT.1489.
*Exhaust camshaft blanking plug tool - Renault No. MOT.1488
*Guide pulley wrench - Renault No. MOT.1368
*Inlet camshaft blanking plug tool - Renault No. MOT.1487
SPECIAL PRECAUTIONS
*Disconnect battery earth lead
*DO NOT turn crankshaft or camshaft when timing belt is removed
*Remove spark plugs to ease turning engine
*Turn engine in normal direction of rotation (clockwise) unless otherwise stated
*Observe all tightening torques
* DO NOT turn engine via camshaft or any other sprockets.
REMOVAL
1. Raise and support front of vehicle.
2. Remove :
* Windscreen wiper arms.
* Scuttle panel.
* Front bumper.
* Headlamps.
* Bonnet shut panel.
* Air intake duct.
* Air filter assembly.
* Throttle body assembly.
* RH front wheel
* RH front wheel arch liner
* Engine undershield.
* Auxiliary drive belt.
NOTE: Auxiliary drive belts, tensioner pulley and guide pulleys MUST be replaced.
3. Support engine.
4. Remove :
* RH engine mounting and bracket.
* Rear engine torque reaction link
5. Disconnect wiring harness from timing belt lower cover
6. Disconnect wiring harness from rear of cylinder head cover.
7. Remove :
* Engine lifting eye.
* Blanking plugs from rear of camshafts
* Blanking plug from cylinder block (Fig 1.1)
8. Turn crankshaft clockwise until grooves in camshafts are almost aligned (Fig 1.2)
NOTE: grooves located below cylinder head upper face.
9. Insert crankshaft timing pin in cylinder block (Fig 1.3) Tool No. MOT.1489.
10. Turn crankshaft slightly until crankshaft web stops against timing pin (Fig 1.4)
11. Ensure grooves in camshafts are aligned (Fig 1.2)
12. Fit setting bar to rear of camshafts (Fig 1.5) Tool Nos. MOT.1496/1750.
13. Lock flywheel with large screwdriver. Slacken crankshaft pulley bolt (Fig 1.6)
14. Remove:
*Crankshaft pulley bolt (Fig 1.6)
*Crankshaft pulley (Fig 1.7)
*Timing belt covers (Fig 1.8 & Fig 1.9)
15. Slacken tensioner pulley nut (Fig 1.10)
16. Remove:
*Tensioner pulley nut (Fig 1.10)
*Tensioner pulley (Fig 1.11)
*Guide pulley bolt (Fig 1.12)
*Guide pulley.
*Timing belt.
NOTE: DO NOT allow crankshaft sprocket to fall off the crankshaft!
INSTALLATION
NOTE: Timing belt, tensioner pulley and guide pulley MUST be replaced.
1. Ensure crankshaft timing pin is inserted (Fig 1.3)
2. Ensure crankshaft web is against the timing pin (Fig 1.4)
3. Ensure grooves in camshafts are aligned (Fig 1.2)
4. Ensure setting bar is fitted to the rear of the camshafts (Fig 1.5)
5. Remove and degrease the crankshaft sprocket. Degrease end of crankshaft. Refit crankshaft sprocket.
NOTE: Crankshaft keyway at 12 o'clock position (Fig 1.13)
6. Fit camshaft sprockets locking tool (Fig 1.14) Tool No. MOT.1490-01.
7. Remove
*Exhaust camshaft sprocket blanking plug (Fig 1.16)
NOTE: Replace camshaft stud if loosened when removing nut.
*Inlet camshaft sprocket blanking bolt (Fig 1.17)
*Inlet camshaft sprocket bolt (Fig 1.17)
*Camshaft sprockets locking tool (Fig 1.14)
*Exhaust camshaft sprocket (Fig 1.18) Degrease sprocket. Degrease end of camshaft.
*Inlet camshaft sprocket (Fig 1.19) Degrease sprocket. Degrease end of camshaft.
WARNING! : Failure to degrease components may lead to sprockets slipping on crankshaft and camshafts, resulting in severe engine damage.
8. Fit exhaust camshaft sprocket (Fig 1.18). Use new nut. Lightly tighten nut (Fig 1.15)
9. Fit new camshaft sprocket (Fig 1.19). Use new bolt. Lightly tighten bolt (Fig 1.17)
10. Ensure camshaft sprockets can turn freely without tilting.
11. Ensure Renault logo on exhaust camshaft sprocket is positioned as shown (Fig 1.20)
12. Ensure inlet camshaft sprocket mark at 12 o'clock position (Fig 1.21)
13. Mark cylinder head with paint or chalk where indicated (Fig 1.22)
14. Ensure inlet camshaft VVT unit (Dephaser) is locked within inlet camshaft sprocket (it should not be possible to rotate the VVT unit to the left or to the right) (Fig 1.23)
15. Fit new tensioner pulley (Fig 1.11)
NOTE: Ensure lug on rear of tensioner pulley located in the groove in the water pumps housing (Fig 1.24)
16. Fit timing belt loosely to sprockets and pulleys.
NOTE: Ensure timing belt is taut between camshaft sprockets
17. Fit new guide pulley. Tighten guide pulley bolt (Fig 1.12). Tightening torque : 50 Nm. Use tool No. MOT.1368.
18. Turn tensioner pulley clockwise until movable pointer (Fig 1.25) is aligned with the notch (Fig 1.26) use 6 mm Allen key (Fig 1.27)
19. Temporarily tighten tensioner pulley nut (Fig 1.10). Tightening torque : 7 Nm.
20. Fit timing belt lower cover (Fig 1.9).
21. Lock flywheel with large screwdriver.
22. Fit new crankshaft pulley and bolt (Fig 1.7 & 1.6). Tightening torque : 120 Nm + 95 degrees + 10 degrees.
23. Fit camshaft sprocket locking tool (Fig 1.14)
24. Tighten inlet camshaft sprocket bolt (Fig 1.17). Tightening torque : 100 Nm.
25. Fit new inlet camshaft sprocket blanking plug (Fig 1.16). Tightening torque : 15 Nm.
26. Tighten exhaust camshaft sprocket nut (Fig 1.15). Tightening torque : 30 Nm + 85 degrees + 4 degrees.
27. Remove:
*Timing belt lower cover access panel (Fig 1.28)
*Camshaft setting bar (Fig 1.5)
*Camshaft sprocket locking tool (Fig 1.14)
*Crankshaft timing pin (Fig 1.3)
28. Turn crankshaft two turns clockwise until just before setting position (Fig 1.21 & Fig 1.22)
29. Insert crankshaft timing pin in cylinder block (Fig 1.3)
30. Turn crankshaft slightly clockwise.
31. Ensure crankshaft web is against the timing pin (Fig 1.4)
32. Remove crankshaft timing pin (Fig 1.3)
33. Ensure tensioner pulley pointer is aligned with the notch (Fig 1.25 & 1.26)
34. If not :
* Slacken tensioner pulley nut (Fig 1.10) by a maximum of one turn whilst holding 6 mm Allen key (Fig 1.27)
* Turn tensioner pulley until the pointer is aligned with the notch (Fig 1.25 & Fig 1.26). Use 6 mm Allen key (Fig 1.27)
35. Tighten tensioner pulley nut (Fig 1.10). Tightening torque : 27 Nm.
36. Insert crankshaft timing pin in cylinder block (Fig 1.3)
37. Ensure crankshaft web is against the timing pin (Fig 1.4)
38. Ensure grooves in camshafts are aligned correctly (Fig 1.2)
39. Ensure setting bar can be easily fitted (Fig 1.5). If not : repeat installation procedure.
40. Remove:
*Setting bar (Fig 1.5)
*Timing pin (Fig 1.3)
41. Refit blanking plug to cylinder block (Fig 1.1). Tightening torque : 20 Nm.
42. Refit timing belt lower cover access panel (Fig 1.28)
43. Fit new blanking plugs to rear of camshafts. Use tool Nos. MOT.1487 & 1488.
NOTE: DO NOT start engine without auxiliary drive belt fitted as damage may occur to crankshaft pulley.
44. Install components in reverse order of removal.
