Renault velSatis Configuration guide

General Information
SPECIFICATIONS
LIFTING
TOWING
LUBRICANTS
CONSUMABLES
OIL CHANGE AND ENGINE OIL REFILLING
ENGINE AND TRANSMISSION ASSEMBLY
VALUES AND ADJUSTMENT
AXLE ASSEMBLIES VALUES AND
ADJUSTMENT
BJ0F - BJ0G - BJ0J - BJ0K - BJ0V
77 11 311 002
"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 introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed."
DECEMBER 2001
All copyrights reserved by Renault.
EDITION ANGLAISE
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.
© RENAULT 2001

General Information
Contents
Page
01A
02A
03A
04A
04B
05A
SPECIFICATIONS
Engine - Gearbox 01A-1
Vehicle identification 01A-2
LIFTING
Trolley jack - Axle stands 02A-1
Underbody lift 02A-2
TOWING
All types 03A-1
LUBRICANTS
Packaging 04A-1
CONSUMABLES
Packaging 04B-1
OIL CHANGE AND ENGINE OIL
REFILLING
Engine 05A-1
Gearbox 05A-3
Power assisted steering 05A-4
Page
07A
07B
ENGINE AND TRANSMISSION
ASSEMBLY VALUES AND
ADJUSTMENT
Capacities - Grades 07A-1
Accessories belt tension 07A-2
Tightening the cylinder head 07A-6
AXLE ASSEMBLIES VALUES AND
ADJUSTMENT
Wheels and tyres 07B-1
Brakes 07B-2
Underbody heights 07B-3
Front axle geometry checking values 07B-4
Rear axle geometry checking values 07B-5

SPECIFICATIONS
Engine - Gearbox 01A
101A
SPECIFICATIONS
Engine - Gearbox
VEHICLE IDENTIFICATION
Example: BJ0K
B : Body type (five-door)
J : Project code
0K : Engine suffix
Vehicle type
Engine
Gearbox type
Type Cubic capacity
(cm3)
BJ0K F4R 1998 PK6
BJ0E - BJ0F - BJ0G - BJ0M G9T 2188 PK6 / SU1
BJ0J P9X 2958 SU1
BJ0V V4Y 3498 SU1
01A-1

SPECIFICATIONS
Vehicle identification 01A
01A-2
Vehicle identification
LOCATION OF VEHICLE IDENTIFICATION PLATE
1 Vehicle type and type series number
This information is repeated on marking (B).
2 MGVW (Maximum Gross Vehicle Weight)
3 GTW (Gross Train Weight - loaded vehicle with
trailer)
4 Front axle MGVW
5 Rear axle MGVW
6 Technical specifications of the vehicle
7 Vehicle paint reference
8 Equipment level
9 Vehicle type
10 Trim code
11 Additional equipment details
12 Fabrication number
13 Interior trim code

LIFTING APPARATUS
Trolley jack - Axle stands 02A
02A-1
102A
LIFTING APPARATUS
Trolley jack - Axle stands
Safety symbol (special precautions to be taken when carrying out operations).
If a trolley jack is used, appropriate axle
stands must always be used.
IMPORTANT:
The vehicle subframe is protected by products which
guarantee against corrosion for 12 years.
Materials fitted with rubber pads should always be
used to prevent any direct metal to metal contact
which could damage the original corrosion protection.
The vehicle must not be raised by placing the jack
beneath the front suspension arm or under the rear
axle.
To lift a front or rear wheel, place the jack at (B) on the
subframe underbody flange in alignment with
marks (A).
To lift both the front and rear wheels laterally, use the
cup Cha. 280-02.
Place the jack under the sill body flange at the centre
point of the front door.
CAUTION:
Position the body flange correctly into the shim groove.
To move the vehicle onto axle stands, lift the entire
vehicle laterally and position the axle stands under the
body flange stiffeners provided for the tool kit trolley
jack (B).
SPECIAL TOOLING REQUIRED
Cha. 280-02 Adaptor cup for trolley jack

LIFTING APPARATUS
Underbody lifts 02A
02A-2
Underbody lifts
SAFETY NOTES
If heavy components need to be removed from the
vehicle, it is preferable to use a four-post lift if possible.
In fact, after removing a large component (for
example: engine and transmission assembly, rear
axle, fuel tank, etc.), the vehicle has lost a large
proportion of its load and there is a risk that it can
become unstable on two-post lift supports (see the
position of the arms further on).
This is even more dangerous when the vehicle is lifted
to greater height
When the vehicle is lifted from underneath the body by
a two-post lift it is necessary to fit safety straps which
are available at Parts Stores part no.: 77 11 172 554.
FITTING THE STRAPS
For obvious safety reasons, these straps should be
kept in perfect condition (if they become frayed,
replace them immediately).
When fitting the straps, check that the protectors are
located on the seats and the fragile parts of the
vehicle, do not overtighten the straps.
Place the straps under the post-lift arms and pass
them around the vehicle.
The following example demonstrates the vehicle
lashing for an operation on the front of the vehicle.

LIFTING APPARATUS
Underbody lifts 02A
02A-3
POSITIONING OF THE LIFTING ARMS
Position the lifting arm on the subframe underbody
flange in alignment with the markings (A).
FRONT
REAR

TOWING
All types 03A
03A-1
103A
TOWING
All types
OBSERVE THETOWING REQUIREMENTS OFTHE COUNTRYYOU ARE IN.
NEVER USE THE DRIVESHAFTS AS AN ATTACHMENT POINT.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the
vehicle from a ditch or to lift the vehicle, either directly or indirectly.
FRONT REAR

LUBRICANTS
Packaging 04 A
04A-1
104 A
LUBRICANTS
Packaging
DESCRIPTION PACKAGING PART NUMBER
GREASES
●MOLYKOTE "BR2"
for main bearing journal faces, thrust pad guide tubes,
clutch fork pads, lower suspension arm bearings,
torsion bar splines, steering box and driveshaft splines.
1 kg tin 77 01 421 145
●MOLYKOTE "33 Medium"
bushes, tubular rear axle, anti-roll bar bushes. 100 g tube 77 01 028 179
●ANTI-SEIZE
(high temperature grease) Turbo, etc. 80 ml tube 77 01 422 307
●"MOBIL CVJ" 825 Black Star or MOBIL EXF57C
for driveshaft seals. 180 g sachet 77 01 366 100
●MULTIPURPOSE GREASE
wheel sensor. Aerosol 77 01 422 308
MECHANICAL SEALANTS
●Mastic
for sealing exhaust pipe unions. 1.5 kg tin 77 01 421 161
●RHODORSEAL 5661 – Cartridge
– 100 g tube 77 01 421 042 77 01 404 452
●HARDENER KIT (RHODORSEAL 5661)
for side sealing of bearing caps. Kit 77 01 421 080
●AUTO blue seal
sealing paste. 100 g tube 77 01 396 227
VARNISHES
●"CIRCUIT PLUS"
varnish for repairing heated rear screens. Bottle 77 01 421 135
BRAKES
●Brake fluid 0.5 litre bottle DOT 4 77 11 172 381
●"Low viscosity" brake fluid. 0.5 litre bottle DOT 4 77 11 218 589

CONSUMABLES
Packaging 04B
04B-1
204B
CONSUMABLES
Packaging
DESCRIPTION PACKAGING PART NUMBER
MECHANICAL SEALANTS
●AUTO grey seal
sealing paste. 100 g tubes 77 01 422 750
●Loctite 518
for sealing the gearbox housing. 24 ml syringe 77 01 421 162
●Leak detector. Aerosol 77 11 143 071
ADHESIVES
●"LOCTITE-FRENETANCH"
stops bolts loosening and allows them to be released. 24 cc bottle 77 01 394 070
●"LOCTITE-FRENBLOC"
locks bolts. 24 cc bottle 77 01 394 071
●"LOCTITE SCELBLOC"
for bonding bearings. 24 cc bottle 77 01 394 072
LUBRICANT CLEANING AGENTS
●"NETELEC"
unseizing agent, lubricant. Aerosol 77 11 171 287
●Carburettor cleaner. 300 ml aerosol 77 11 171 437
●Injector cleaner 355 ml can 77 01 423 189
●Super-concentrated unseizing agent. 500 ml aerosol 77 01 408 466
●"DECAPJOINT" (FRAMET)
for cleaning the gasket faces of aluminium cylinder
heads.
Aerosol 77 01 405 952
●Brake cleaner. 400 ml aerosol 77 11 171 911

FLUID CHANGE AND FLUID REFILLING
Engine 05A
05A-1
105A
FLUID CHANGE AND FLUID REFILLING
Engine
DRAINING: plug (1)
FILLING: plug (2)
F4R ENGINE
G9T ENGINE
TOOLING REQUIRED
Engine drain plug spanner

FLUID CHANGE AND FLUID REFILLING
Engine 05A
05A-2
DRAINING: plug (1)
FILLING: plug (2)
P9X ENGINE
V4Y ENGINE

FLUID CHANGE AND FLUID REFILLING
Gearbox 05A
05A-3
Gearbox
DRAINING: plug (1)
FILLING and LEVEL: cap (2)
F4R and G9T ENGINES
Manual gearbox
G9T, P9X and V4Y ENGINES
Automatic gearbox

FLUID CHANGE AND FLUID REFILLING
Power assisted steering 05A
05A-4
Power assisted steering
CHECKINGTHE LEVEL
POWER ASSISTED STEERING PUMP LEVEL
For topping up or filling, use ELF RENAULTMATIC D2
or MOBIL ATF 220 oil.
The level, when correct, should be visible between the
MIN and MAX marks on the reservoir (1).
ENGINES OF ALL TYPES

ENGINE AND GEARBOX VALUES AND SETTINGS
Capacities - Grades 07A
07A-1
107A
ENGINE AND GEARBOX VALUES AND SETTINGS
Capacities - Grades
* Check with dipstick.
NOTE: never exceed the maximum mark on the dipstick.
Brake fluids must be approved by the Technical Department.
Components
Average capacity* in litres
After an oil change,
check using the
dipstick
After replacing the oil
filter
Diesel engine (oil)
G9T 5.6 6.3
P9X 6.5 7.3
Petrol engine (oil)
F4R 5 5.2
V4Y 4.75 4.8
Manual gearbox
PK6 2.2
Automatic gearbox
SU1 7.6
Components Capacity in litres Grade
Brake circuit Standard: 0.7 ABS: 1 SAE J 1703 and DOT 4 (low viscosity when
cold)
Components Capacity in litres Grade
Fuel tank Approximately 80 Unleaded petrol Diesel
Power assisted
steering Separate reservoir 1.1 ELF RENAULT MATIC D2 or MOBIL ATF 220
Coolant circuit
F4R
G9T
P9X
V4Y
6.8
7
7
7.4
GLACEOL RX
(type D)
add only coolant
Edition 2

ENGINE AND GEARBOX VALUES AND SETTINGS
Accessories belt tensioning 07A
07A-2
F4R ENGINE Accessories belt tensioning
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery.
Remove:
– the engine covers,
– the front right wheel,
– the side protection.
To remove the belt, pivot the automatic belt tensioner
in the direction shown below using a 16 mm angled
ring spanner.
Remove the accessories belt.
REFITTING
NOTE: never refit a belt once it has been removed,
but replace it.
Refitting is the reverse of removal.
Connect the battery and carry out the necessary
programming.
Edition 2

ENGINE AND GEARBOX VALUES AND SETTINGS
Accessories belt tensioning 07A
07A-3
G9T ENGINE
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery.
Remove:
– the engine covers,
– the front right wheel,
– the side protection.
Special notes for removing the accessories belt
Pivot the auto tensioner to the left using a spanner to loosen the belt. Lock
the tension wheel by putting a 4 mm Allen key in the hole (1).
REFITTING
NOTE: never refit a belt once it has been removed, but replace it.
Refitting is the reverse of removal.
Connect the battery and carry out the necessary programming.
Edition 2

ENGINE AND GEARBOX VALUES AND SETTINGS
Accessories belt tensioning 07A
07A-4
P9X ENGINE
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery.
Remove:
– the engine covers,
– the front right wheel,
– the side protection.
Special notes for removing the accessories belt
Swivel the auto tensioner as indicated below using a
19 mm offset wrench to loosen the belt.
Remove the belt.
REFITTING
NOTE: never refit a belt once it has been removed,
but replace it.
Refitting is the reverse of removal.
Tighten the tension wheel bolts to a torque of
2.5 daNm.
Tighten the tension wheel bolts to a torque of
5.8 daNm.
Connect the battery and carry out the necessary
programming.
Edition 2

ENGINE AND GEARBOX VALUES AND SETTINGS
Accessories belt tensioning 07A
07A-5
V4Y ENGINE
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery.
Remove:
– the front right wheel,
– the side protection.
→tension checking point
Power assisted steering pump belt,
Air conditioning compressor and alternator belt,
REFITTING
NOTE: always replace a belt after it has been
removed.
Proceed in the reverse order to removal.
Connect the battery and carry out the necessary
programming.
SPECIAL TOOLING REQUIRED
Mot. 1505 Belt tension measuring tool
Components
Power
assisted
steering
pump belt,
Air conditioning
compressor and
alternator belt,
Fitting tension
(Hz) 234 ±±
±± 8 260 ±± ±± 8
Edition 2

ENGINE AND GEARBOX VALUES AND SETTINGS
Tightening the cylinder head 07A
07A-6
F4R ENGINE Tightening the cylinder head
CYLINDER HEAD
The bolts can be reused if the length under the head does not exceed 117.5 mm (otherwise replace all the bolts).
Cylinder head tightening procedure
REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to
achieve correct tightening of the bolts.
Do not oil the new bolts. However, the bolts must be oiled if they are being reused.
Tighten all the bolts to 2 daNm in the order recommended below.
Check that all the bolts are correctly tightened to 2 daNm then, bolt by bolt, tighten to an angle of 165˚ ±±
±± 6˚.
Do not retighten the cylinder head bolts after applying this procedure.
Edition 2