Tài liệu sửa chữa xe ô tô Renault 19 (Repair Manual) - P2

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
EXPLODED VIEW
PRD2013
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 TRANSMISSION
23
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
Parts which must be changed
automatically
Gearbox (Removal - Refitting)
5th gear linkage in situ
Differential output seal
Speedometer drive
MANUAL GEARBOXES
21
29-1
29-2
29-9
29-19
29-26
Consumables
Driveshafts
Gaiter at wheel end

Gaiter at gearbox end
Gaiter - bearing assembly
DRIVESHAFTS
29
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
Parts which must be changed
automatically
Oil
Draining - Filling - Levels
Checking and adjusting the
potentiometer

Oil pressure
Strainer
Automatic transmission (Removal -
Refitting)
AUTOMATIC TRANSMISSION
23
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
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
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
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
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
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

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.
ESSENTIAL SPECIAL TOOLS
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
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
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
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
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
000JB0
BA
E
DC
000000
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
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
1
st
2
nd
3
rd
4

th
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
1
st
2
nd
3
rd
4
th

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
1
st

2
nd
3
rd
4
th
5
th
Reverse
21-2
39
11
26
39
11
26
39
11
26
39
11
26
39
11
26
Final drive
set
Speedo
drive set
1

st
2
nd
3
rd
4
th
5
th
Reverse
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
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
1
st
2
nd
3
rd

4
th
5
th
Reverse
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
1
st
2
nd
3
rd
4
th
5
th
Reverse
Final drive
set
Speedo
drive set
1
st
2
nd
3
rd
4
th

5
th
Reverse
21-4
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
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
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
R1 3 5
24
DI2118
4 forward gears
1 reverse
21-7
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
MATERIALS
MANUAL GEARBOXES
Gearbox (Removal - Refitting)

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.
ESSENTIAL SPECIAL TOOLS
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
TIGHTENING TORQUES (in daN.m)
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
MANUAL GEARBOXES
Gearbox (Removal - Refitting)
- the driveshaft - stub axle carrier assembly from
the lower ball joint,
21
C
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
MANUAL GEARBOXES
Gearbox (Removal - Refitting)
Slacken:
- the two mounting bolts on the engine,
- the clutch protection plate,
- the gear lever.
21
C
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

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