Renault Clio: D4F, and 740 or 742 or 764

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / D4F, and 740 or 742 or 764

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting).

IMPORTANT

During this operation, secure the vehicle to the lift with a strap to prevent it from becoming unbalanced.

For strapping the vehicle (see 02A, Lifting equipment, Vehicle: Towing and lifting).

• Remove:
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the battery (see Battery: Removal - Refitting),
  • the battery tray,
  • the engine undertray.
• Drain:
  • the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • the gearbox (see Manual gearbox oils: Draining - Filling),
  • the engine if necessary (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12).

AIR CONDITIONING

• Drain the coolant circuit (see Air conditioning: Parts and consumables for the repair).

• Remove:
  • the front wheels (see Wheel: Removal - Refitting),
  • the front wheel arch liners (see MR 393 Bodywork, 55A, Exterior protection, Front wheel arch liners),
  • the front bumper (see MR 393, Bodywork, 55A, Exterior protection, Front bumper: Removal - Refitting),
  • the " left-hand driveshaft-stub axle carrier " assembly, (see Hub carrier - driveshaft assembly: Removal - Refitting)
  • the " right-hand driveshaft-stub axle carrier " assembly.

    (see Hub carrier - driveshaft assembly: Removal - Refitting)

• Disconnect:
  • the engine cooling fan assembly connectors,
  • the top hose (1) on the cylinder head coolant pipe housing outlet,
  • the passenger compartment heater hoses (2).
• Remove 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 from the condenser,
  • the air conditioning compressor clutch connector.
• Remove the air conditioning pipe union mounting bolts (3) on the compressor, evaporator and condenser.
• Fit plugs into the openings.

• Remove:
  • the radiator mounting cross member (see MR 393 Bodywork, 41A, Lower front structure, Radiator mounting cross member: Removal - Refitting).
  • the cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the earths,
  • the Protection and Switching Unit cover.

• Disconnect the connectors from the protection and switching unit.
• Unclip the oxygen sensor harnesses.
• Disconnect:
  • the brake servo pipe,
  • the oxygen sensor connectors,
  • the petrol vapour rebreather connector,
  • the connector from the lifting eye at the flywheel end,
• Disconnect:
  • the fuse,
  • the fuse holder to the fuse board,
  • the supply cable on the fuse board,
  • the supply cable from the battery protection fuse box.
• Remove:
  • the petrol injection computer (see 17B, Petrol injection, Petrol injection computer: Removal - Refitting, 17B-37),
  • the computer support mounting bolts,
  • the computer bracket.

• Remove the wiring channel mounting bolts (4) on the body.
• Remove the wiring duct.
• Disconnect:
  • the canister solenoid valve connector,
  • the canister solenoid valve pipe,
  • the petrol supply pipe from the injector rail.
• Fit plugs into the openings.

• Remove:
  • the gear control cables on the gearbox by pushing at (A),
  • the control cables by pushing at (B),
  • the wiring harness channel mountings on the gearbox.

• Remove:
  • the engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13),
  • the exhaust downpipe mountings.
• Fit a hose clamp between the brake fluid reservoir and the clutch master cylinder.

• Disconnect the clutch slave cylinder by pulling the clips (5) and (6)
• Collect the fluid in a container.

WARNING

Fit plugs into the openings.

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

• Unclip the gearbox clutch pipe.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Support the " engine - gearbox " assembly on the engine marks (7) with the (Mot. 1390).

• Mark the positions of the suspended engine mountings on the body.
• Remove:
  • the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22),
  • 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

• If carrying out a standard engine replacement (see Technical Note 6004A, 4 cylinder - D4 - petrol engine, 10A, Engine and peripherals, Standard replacement).

II - REFITTING OPERATION FOR PART CONCERNED

• Position the " engine - gearbox " assembly in the vehicle.
• Refit:
  • 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) from the " engine - gearbox " assembly.

III - FINAL OPERATION.

• Clip the clutch pipe to the gearbox.
• Remove the protective plugs from the pipe openings.
• Connect the clutch slave cylinder pipes.
• Remove the hose clamp between the brake fluid reservoir and the clutch master cylinder.
• Refit the exhaust downpipe mountings.
• Torque tighten the exhaust downpipe mountings (9 N.m).
• Refit the engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).
• Refit the wiring harness channel mountings on the gearbox.
• Refit the gearbox control cables.
• Remove the protective plug from the injector rail.
• Connect:
  • the fuel supply pipe to the injector rail,
  • the canister solenoid valve pipe,
  • the canister solenoid valve connector.
• Refit the wiring harness channel mountings to the body.
• Refit:
  • the wiring harness channel mountings to the body,
  • the computer mounting,
  • the computer bracket mounting bolts bolts,
  • the injection computer (see 17B, Petrol injection, Petrol injection computer: Removal - Refitting, 17B-37).
• Connect:
  • the supply cable on the battery protection fuse box,
  • the supply cable on the fuse board,
  • the fuse holder to the fuse board,
  • the fuse,
  • the connector on the lifting eye at the flywheel end,
  • the petrol vapour rebreather connector,
  • the oxygen sensor connectors,
  • the brake servo pipe,
  • the Protection and Switching Unit connectors.
• Refit:
  • the Protection and Switching Unit cover,
  • the earths,
  • the cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the radiator mounting cross member (see MR 393 Bodywork, 41A, Lower front structure, Radiator mounting cross member: Removal - Refitting).
• Clip the oxygen sensor wiring harnesses into place.

AIR CONDITIONING

• Refit the air conditioning pipe mounting bolts on the compressor, evaporator and condenser.
• Torque tighten the air conditioning mounting bolts on the compressor, evaporator and condenser (8 N.m).
• Connect:
  • the pressure switch from the condenser,
  • the air conditioning compressor clutch connector.
• Clip the pressure switch wiring harness on the condenser.

• Refit the expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting, 19A- 101).
• Connect:
  • the passenger compartment heating hoses,
  • the top hose from the cylinder head coolant outlet unit,
  • the fan assembly connectors.
• Refit:
  • the " right-hand driveshaft and stub-axle carrier assembly " (see Hub carrier - driveshaft assembly: Removal - Refitting),
  • the " left-hand driveshaft and stub axle carrier assembly " (see Hub carrier - driveshaft assembly: Removal - Refitting),
  • the front bumper (see MR 393, Bodywork, 55A, Exterior protection, Front bumper: Removal - Refitting),
  • the front wheel arch liners (see MR 393 Bodywork, 55A, Exterior protection, Front wheel arch liners),
  • the front wheels (see Wheel: Removal - Refitting).
• 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),
  • the engine cooling circuit (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16).
• Refit:
  • the engine undertray,
  • the battery tray,
  • the battery (see Battery: Removal - Refitting),
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17).

AIR CONDITIONING

• Refill the coolant circuit (see Air conditioning: Parts and consumables for the repair).

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