Renault Clio: D4F, and JA3

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / D4F, and JA3

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Remove:
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery tray (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the engine undertray,
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection).
• Drain:
  • the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • the gearbox (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox),
  • the engine if necessary (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12).

AIR CONDITIONING

• Drain the refrigerant circuit (see Refrigerant circuit: Draining - Filling) (MR 392, 62A, Air conditioning).

• Remove:
  • the front wheels (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres),
  • the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts),
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts)

• Remove:
  • the clips for the passenger compartment heating hoses using the (Mot. 1448),
  • the passenger compartment heater hoses (1),
  • the expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting, 19A-101).

AIR CONDITIONING

• Unclip the wiring harness of the pressure switch on the condenser.
• Disconnect the pressure switch connector on the condenser.
• Remove:
  • the bolts (2) from the air conditioning pipe unions on the compressor,
  • the bolts (3) from the air conditioning pipe unions on the condenser.

WARNING

Plugs must be fitted on the hoses to prevent moisture from entering the system.

• Remove:
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (MR 393, 41A, Front lower structure),
  • the cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the petrol injection computer (see 17B, Petrol injection, Petrol injection computer: Removal - Refitting, 17B-37),
  • the injection computer support mounting bolts,
  • the injection computer support.

• Remove:
  • the earth terminal nuts,
  • the earth terminals (4).

• Remove:
  • the cover from the fuse holder board,
  • the fuses (5).

• Remove:
  • the fuse holder (6) by pressing on the tab (7),
  • the feed wire (8) from the fuse holder board,
  • the supply cable from the battery protection fuse box.

• Remove the Protection and Switching Unit cover.
• Disconnect the connectors (9) from the Protection and Switching Unit.
• Remove the sequential gearbox computer (see Sequential gearbox converter: Removal - Refitting) (MR 392, 21B, Sequential gearbox).

• Remove the bolts (10) from the wiring channel on the body.
• Move the wiring harness to one side.

• Disconnect:
  • the quick-release union from the brake servo pipe (11),
  • the quick-release union from the petrol vapour rebreathing pipe (12).

• Disconnect the connector (13) from the fuel vapour absorber bleed solenoid valve.

• Disconnect the quick-release union from the fuel supply pipe (14) on the injector rail.

IMPORTANT

During this operation, be sure to:

• beware of fuel splashes when disconnecting the union,
• protect sensitive areas from fuel outflow.

• Remove the bolts (15) from the exhaust downpipe.
• Remove the exhaust pipe towards the rear of the vehicle.

• Disconnect the oxygen sensor connector (16).
• Feed the oxygen sensor wiring harness into the engine compartment.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the lower engine torque reaction tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).

• Support the " engine - gearbox " assembly on engine marks using the (Mot. 1390).
• Remove the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22).
• Remove the left-hand suspended engine mounting (see 19D, Engine mounting, Left-hand suspended engine mounting: Removal - Refitting, 19D-34).
• Raise the vehicle, moving the engine towards the front.
• Remove the " engine - gearbox " assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacements (see ) (Technical Note 6004A, 10A, Engine and peripherals).

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the " engine - gearbox " assembly in the vehicle,
  • the left-hand suspended engine mounting (see 19D, Engine mounting, Left-hand suspended engine mounting: Removal - Refitting, 19D-34),
  • the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22).
• Remove the (Mot. 1390).

III - FINAL OPERATION.

• Refit:
  • the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13),
  • the oxygen sensor wiring harness.
• Connect the oxygen sensor connector.
• Refit the exhaust downpipe.
• Torque tighten the exhaust downpipe bolts (9 Nm).
• Connect:
  • the quick-release union to the fuel supply pipe on the injector rail,
  • the quick-release union to the petrol vapour rebreathing pipe,
  • the quick-release union to the brake servo pipe.
• refit the wiring harness.
• Screw the bolts for the wiring harness channel on the body.
• Refit the sequential gearbox computer (see Sequential gearbox converter: Removal - Refitting) (MR 392, 21B, Sequential gearbox).
• Connect the Protection and Switching Unit connectors.
• Refit:
  • the Protection and Switching Unit cover,
  • the supply cable on the battery protection fuse box,
  • the feed wire on the fuse holder board,
  • the fuse holder,
  • the fuses,
  • the cover from the fuse holder board,
  • the earth terminals on the side member,
  • the earth terminal nuts,
  • the injection computer mounting,
  • the injection computer support bolts,
  • the petrol injection computer (see 17B, Petrol injection, Petrol injection computer: Removal - Refitting, 17B-37),
  • the cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (MR 393, 41A, Front lower structure).

AIR CONDITIONING

• Refit:
  • the bolts to the air conditioning pipe unions on the condenser,
  • the bolts to the air conditioning pipe unions on the compressor.
• Connect the pressure switch connector to the condenser.
• Clip the pressure switch wiring harness on the condenser.

• Refit:
  • the expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting, 19A-101),
  • the passenger compartment heater hoses,
  • the clips for the passenger compartment heating hoses using the (Mot. 1448).
• Refit:
  • the clip for the top hose on the cooling radiator using the (Mot. 1448),
  • the front right-hand hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts),
  • the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts),
  • the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the front wheels (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres).
• Refill:
  • the engine if necessary (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12),
  • the gearbox (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox),
  • the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16).
• Refit:
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the engine undertray,
  • the battery tray (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17).

AIR CONDITIONING

• Fill the refrigerant circuit (see Refrigerant circuit: Draining - Filling) (MR 392, 62A, Air conditioning).

READ NEXT: