Renault Clio: D4F, and 784 or 786

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / D4F, and 784 or 786

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 engine cover,
  • the engine undertray,
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • 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 bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the intercooler (see 12B, Turbocharging, Intercooler: Removal - Refitting, 12B-21).
• 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 air conditioning circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (MR 392, 62A, Air conditioning).

• Remove:
  • the exhaust downpipe bolts (1),
  • the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts),
  • the front right-hand hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts),
  • the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).

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 compressor - condenser connecting pipe bolts (2),
  • the compressor - condenser connection pipe.
  • the compressor - expansion valve connecting pipe bolt (3),
  • the dehydrator reservoir - expansion valve connecting pipe bolt (4).
• Uncouple the connecting pipes.
• Plug the openings.

• Remove:
  • the air filter unit air inlet pipe (5),
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (MR 393, 41A, Front lower structure),
  • the expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting, 19A-101),
  • the cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the passenger compartment radiator cooling hoses on the bulkhead,
  • the Protection and Switching Unit cover.

• Disconnect:
  • the Protection and Switching Unit connectors (6),
  • the fuse,
  • the fuse holder to the fuse board,
  • the supply cable on the battery protection fuse box,
  • the petrol injection computer connectors.
• Remove the earth nuts.
• Move the wiring harness to one side.

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

• Disconnect:
  • the petrol vapour recirculation solenoid valve connector (8),
  • the fuel vapour recirculation pipe (7),
  • the brake servo non-return valve.

WARNING

To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

IMPORTANT

Wear latex gloves during the operation.

IMPORTANT

During this operation, be sure to:

• be careful of fuel splashes when disconnecting the union.

• Disconnect the fuel inlet union on the injection rail.
• Plug the openings.

• Place a hose clamp (Ms. 583) between the brake fluid reservoir and the clutch master cylinder.
• Disconnect the clutch slave cylinder by pulling the clips (9) and (10)
• Unclip the gearbox clutch pipe.
• Plug the openings.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Support the " engine - gearbox " assembly on the engine marks (11) 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

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

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 blanking plugs from the openings.
• Connect the clutch slave cylinder pipes.
• Remove the hose clamp (Ms. 583).
• Remove the blanking plugs from the openings.
• Connect:
  • the petrol inlet union on the injector rail,
  • the brake servo non-return valve,
  • fuel vapour recirculation pipe,
  • the petrol vapour recirculation solenoid valve connector.
• Refit:
  • the gearbox control cables,
  • the earth nuts.
• Connect:
  • the connectors to the petrol injection computer,
  • the Protection and Switching Unit connectors,
  • the fuse,
  • the fuse holder to the fuse board,
  • the feed wire from the battery protection fuse box.
• Refit:
  • the Protection and Switching Unit cover,
  • the passenger compartment radiator cooling hoses on the bulkhead,
  • the cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting, 19A-101),
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (MR 393, 41A, Front lower structure),
  • the air filter unit air inlet pipe.

AIR CONDITIONING

• Remove the blanking plugs.
• Couple the connecting pipes.
• Refit:
  • the dehydrator reservoir - expansion valve connecting pipe bolt,
  • the compressor - expansion valve connecting pipe bolt,
  • the compressor - condenser connection pipe.
  • the compressor - condenser connecting pipe bolts.
• Torque tighten the connecting pipe bolts (8 Nm).
• Connect:
  • the pressure switch from the condenser,
  • the air conditioning compressor clutch connector.
• Clip the pressure switch wiring harness on the condenser.
• Refit:
  • the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13),
  • 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 exhaust downpipe bolts.
• Torque tighten the exhaust downpipe bolts (9 Nm).
• Refit:
  • the intercooler (see 12B, Turbocharging, Intercooler: Removal - Refitting, 12B-21),
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • 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),
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Perform the following operations:
  • fill up the engine oil if necessary (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12),
  • fill the gearbox (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox),
  • fill and bleed the coolant circuit (see 19A, Cooling, Cooling system: Draining - Refilling, 19A- 16),
  • bleed the clutch circuit (see Clutch circuit: Bleed) (MR 392, 37A, Mechanical component controls).
• Refit:
  • the engine undertray,
  • the engine cover.

M4R, and DP0

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

IMPORTANT

To prevent the vehicle from falling, lash it to the vehicle lift using a strap.

• Remove the engine cover.
• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).

• Lift the air resonator (A) to remove it from the battery cover.
• Pull the air resonator (B) towards the front of the vehicle to remove it.

• Detach the air intake sleeve:
  • from the front end panel at (1),
  • from the air resonator on the front end panel at (2),
  • from the air filter unit at (3).
• Remove the air inlet sleeve.

• Unclip the electrical wiring from the air inlet duct at (4).
• Loosen the air duct clips:
  • on the air flow sensor (5),
  • on the motorised throttle valve (6).
• Extract the oil vapour rebreathing hose (7) on the rocker cover using the tool (Mot. 1448).
• Remove the air inlet duct.

• Disconnect the air flowmeter connector (8).
• Unclip the air flowmeter connector electrical wiring at (9).
• Remove the engine undertray.
• Drain:
  • the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • the automatic transmission (see Automatic gearbox oil: Draining - Filling) (23A, Automatic transmission),
  • the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).
• Remove:
  • the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres),
  • the front sections of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
  • the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection),
  • the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure),
  • the front end panel air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, 12A-10).

• Remove:
  • the bolts (10) from the air conditioning pipe unions,
  • the air conditioning pipe (11).

WARNING

To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air.

• Pull out the air conditioning pipe (12).
• Remove:
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (41A, Front lower structure),
  • the radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts).

• Disconnect the brake servo pipe (13) from the intake distributor.

• Disconnect:
  • the petrol vapour rebreather pipe (14),
  • the fuel supply pipe (15).

WARNING

To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

• Unclip the fuel supply pipe at (16).

• Remove:
  • the bolts (17) from the exhaust flange,
  • the exhaust flange seal.

• Remove:
  • the engine tie-bar bolts (18),
  • the engine tie-bar.
• Remove the battery cover.

• Remove the cover (19) from the power supply fuse unit.

• Unclip the optional relay unit (20).

• Unclip the electrical wiring connector (21).
• Disconnect the electrical wiring connector (21).

• Remove the nut (22) from the protective fuse mounting wiring.
• Move aside the protective fuse mounting wiring.
• Remove the battery (see Battery: Removal - Refitting) (80A, Battery).

• Remove the fuse (23).

• Remove the nut (24) from the supply wiring of the power supply fuse unit.
• Disconnect the supply wiring from the power supply fuse unit.
• Extract the fuse holder from the power supply fuse unit (25).
• Remove the battery tray (see Battery tray: Removal - Refitting) (80A, Battery).

• Remove the air filter unit in the direction of the arrows.

• Detach the automatic transmission control cable ball joint by pressing at (26).
• Pull out the automatic transmission control cable by pulling tab (27).

• Disconnect the hoses from:
  • the heater matrix (28),
  • the expansion bottle (29).

• Remove the Protection and Switching Unit cover.
• Disconnect the engine electrical wiring connectors (30) from the Protection and Switching Unit.

• Disconnect the engine electrical wiring connectors (31) from the injection computer.

• Disconnect the upstream oxygen sensor connector (32).

• Remove the plastic cover (33).
• Detach the downstream oxygen sensor connector at (34).
• Disconnect the downstream oxygen sensor connector.
• Unclip the downstream oxygen sensor electrical wiring from the power-assisted steering box.
• Feed the downstream oxygen sensor electrical wiring into the engine compartment.

• Disconnect the automatic transmission earth wire (35).

• Disconnect the earth cables (36) from the side member.

• Disconnect the automatic transmission connector (37).
• Unclip the automatic transmission electrical wiring at (38).
• Feed the automatic transmission electrical wiring into the engine compartment.

• Position the (Mot. 1390) under the " engine - gearbox " assembly.
• Lower the vehicle down onto the pads of the (Mot.1390).
• Adjust the pads of the tool (Mot. 1390) at (39) to ensure that the " engine - gearbox " assembly is stable.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Undo the upper engine tie-bar bolt (40).
• Remove the upper engine tie-bar bolt (41).

• Remove the upper engine tie-bar.

• Remove:
  • the bolt (42) of the rubber pad on the right-hand suspended engine mounting,
  • the bolts (43) of the rubber pad on the right-hand suspended engine mounting.

• Remove:
  • the bolts (44) from the right-hand suspended engine mounting cover,
  • the right-hand suspended engine mounting cover,
  • the rubber pad on the right-hand suspended engine mounting.

• Separate the neck of the electrical wiring from the gearbox support.
• Remove:
  • the left-hand suspended engine mounting shaft nut (45),
  • the nuts (46) from the left-hand suspended engine mounting rubber pad,
  • the left-hand suspended engine mounting rubber pad.

• Remove:
  • the bolts (47) from the left-hand suspended engine mounting support on the body,
  • the left-hand suspended engine mounting support on the body.
• Gently move the engine towards the front of the vehicle.

• Lift the vehicle to remove the " engine-gearbox " assembly.

Note: Check that no component obstructs the movement of the body around the " engine - gearbox " assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacements (see Engine: Standard replacement) (Technical Note 6020A, 10A, Engine and peripherals).
• parts always to be replaced: seal between catalytic converter and exhaust downpipe hose.

II - REFITTING OPERATION FOR PART CONCERNED

• Position the " engine - gearbox " assembly in the body.

• Fit:
  • the rubber pad on the right-hand suspended engine mounting.
  • the right-hand suspended engine mounting cover.
• Pretighten:
  • the bolts for the right-hand suspended engine mounting cover,
  • the bolts for the right-hand suspended engine mounting rubber pad.

Note: Allow the two parts to move freely.

• Fit the bolt of the right-hand suspended engine mounting rubber pad.
• Tighten to torque and in order:
  • the bolts of the right-hand suspended engine mounting cover (62 N.m),
  • the bolts for the right-hand suspended engine mounting rubber pad (62 N.m),
  • the bolt of the right-hand suspended engine mounting rubber pad (105 N.m),
  • the upper engine tie-bar bolts (105 N.m).
• Refit:
  • the left-hand suspended engine mounting support on the body,
  • the left-hand suspended engine mounting support bolts,
  • the left-hand suspended engine mounting rubber pad,
  • the nuts for the left-hand suspended engine mounting rubber pad,
  • the left-hand suspended engine mounting shaft nut.
• Tighten to torque:
  • the support bolts for the left-hand suspended engine mounting on the vehicle body (62 N.m),
  • the left-hand suspended engine mounting rubber pad nuts (62 N.m),
  • the left-hand suspended engine mounting central nut (62 N.m).

III - FINAL OPERATION

• Connect:
  • the engine electrical wiring,
  • the air conditioning pipe unions,
  • the cooling hoses,
  • the air flowmeter connector,
  • the fuel supply pipe,
  • the petrol vapour rebreathing pipe,
  • the brake servo pipe on the inlet manifold.
• Clip:
  • the fuel supply pipe,
  • the air flowmeter connector electrical wiring.

• Be sure to replace the clip on the gearbox control cable ball joint each time it is removed.
• Fit the gearbox control cable.
• Fit a new exhaust flange seal.
• Tighten to torque:
  • the exhaust flange bolts (21 N.m),
  • the engine tie-bar bolt on the engine (180 N.m),
  • the engine tie-bar bolt on the sub-frame (105 N.m).
• Refit:
  • the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),
  • the battery (see Battery: Removal - Refitting) (80A, Battery),
  • the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (41A, Front lower structure),
  • the front end panel air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, 12A-10),
  • the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure),
  • the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection),
  • the front sections of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
  • the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).

• Fit the air inlet duct on the air flowmeter, paying attention to the fitting mark.

• Fit the air inlet duct on the motorised throttle valve, paying attention to the fitting mark.
• Connect the oil vapour rebreathing hose on the rocker cover.
• Torque tighten the air inlet duct clips (6 N.m).
• Clip the electrical wiring onto the air inlet duct.

• Before refitting the air intake sleeve, check that the upper mounting is correctly clipped onto the front end panel air resonator.
• Refit the air intake sleeve.

• Push the air resonator towards the rear of the vehicle so that the corner of the air resonator is between the two lines marked on the air inlet hose.
• Press on the air resonator to fit it into the battery cover.
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Perform the following operations:
  • fill the automatic transmission (see Automatic gearbox oil: Draining - Filling) (23A, Automatic transmission),
  • fill the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).
  • fill and bleed the coolant circuit (see 19A, Cooling, Cooling system: Draining - Refilling, 19A- 16).
• Refit the engine cover.

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