Renault Clio: D4F, and 784 or 786

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Top And Front Of Engine / Cylinder head: 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).
• Disconnect the battery (see ) (MR 392, 80A, Battery).
• Remove:
  • the engine undertray,
  • the engine cover,
  • 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).

• Remove the air deflector (1).

• Undo the intercooler air inlet pipe clip (2).
• Disconnect the intercooler air inlet pipe from the intercooler.

• Remove:
  • the air pipe (3) from the air filter box inlet,
  • the bolt (4) from the intercooler air inlet pipe on the inlet distributor.
• Remove the intercooler air inlet pipe clip (5) on the turbocharger.

Note: If the clip (6) is removed from the heat resistant protector, the latter must be replaced.

• Remove the intercooler air inlet pipe.
• Remove:
  • the front right-hand wheel (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres),
  • the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the engine undertray,
  • the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, 11A-5),
  • the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, 11A-31),
  • the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, 19B- 29),
  • the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, 11A-48),
  • the turbocharger oil pipes (see 12B, Turbocharging, Turbocharger oil pipe: Removal - Refitting, 12B-15),
  • the ignition coil (see 17A, Ignition, Coils: Removal - Refitting, 17A-2).

• Disconnect:
  • the fuel vapour recirculation pipe (7) from the air filter box air outlet pipe,
  • the oil vapour rebreathing pipe (9) from the air filter unit air outlet pipe,
  • the turbocharging pressure relief valve (8) from the air filter unit air outlet pipe.
• Undo the air filter unit air outlet pipe clips (10).
• Disconnect:
  • the turbocharging pressure relief valve control pipes,
  • the air filter unit air outlet pipe.
• Remove the air filter box air outlet pipe.

• Move the clips (11) on the turbocharger cooling hoses to one side, using the (Mot. 1448).
• Disconnect the turbocharger cooling hoses.

• Disconnect the inlet distributor vacuum hose (12).
• Undo the clips (13) on the compressor discharge valve air pipe.
• Remove the compressor discharge valve air pipe.

• Disconnect:
  • the connector (14) from the air temperature sensor,
  • the air pressure sensor connector (15).

• Remove the intercooler air outlet pipe bolts (16).
• Move the intercooler air outlet pipe towards the front of the vehicle.

• Disconnect:
  • the brake servo non-return valve pipe (17),
  • the petrol vapour rebreathing pipe (18) from the inlet distributor,
  • the oil vapour rebreathing pipe (19) on the inlet distributor,
  • the oil vapour rebreathing pipe (20) on the rocker cover,
  • the petrol vapour rebreathing pipe (21) from the petrol vapour rebreathing solenoid valve.
• Remove:
  • the oil vapour rebreathing pipe,
  • the petrol vapour rebreather pipe.

• Disconnect:
  • the injector rail - injector wiring harness connector (22),
  • the air inlet pressure connector (23),
  • the upstream oxygen sensor connector (24),
  • the petrol vapour rebreathing solenoid valve connector,
  • the coolant temperature sensor connector.

IMPORTANT

During this operation, be sure to:

• be careful of fuel splashes when disconnecting the union.

IMPORTANT

Wear latex gloves during the operation.

WARNING

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

• Disconnect the petrol supply union on the injector rail - injector.
• Plug the openings.
• Move the wiring harness away from the engine.

• Remove the clips (25) from the cooling hoses using the (Mot. 1448).
• Disconnect the cooling hoses.
• Remove the rocker cover (see 11A, Top and front of engine, Rocker cover: Removal - Refitting, 11A-183).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the cylinder head bolts,
  • the cylinder head,
  • the cylinder head gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

• Clean the cylinder head with SUPER CLEANER FOR JOINT FACES (see Vehicle: Parts and consumables for the repair) (MR 392, 04B, Consumables - Products).

WARNING

Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.

IMPORTANT

Wear goggles with side protectors for this operation.

IMPORTANT

Wear latex gloves during the operation.

WARNING

Do not allow this product to drip onto the paintwork.

Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage.

Note: The cylinder head bolts must be replaced each time they are removed and should not be oiled before being fitted.

• Always replace:
  • the cylinder head bolts,
  • the cylinder head gasket.

1 - Checking the gasket face

• With a ruler and shim set, check for cylinder head gasket face bow.

  The maximum deformation is 0.05 mm.

WARNING No regrinding of the cylinder head is permitted.

• Test the cylinder head for any cracks using the cylinder head testing tools (see Garage Equipment Catalogue).
• Strip the cylinder head (see ) (Technical Note 6004A, 10A, Engine and peripherals).

2 - If replacing the cylinder head

• Rebuild the cylinder head (see ) (Technical Note 6004A, 10A, Engine and peripherals).

II - REFITTING OPERATION FOR PART CONCERNED

• Fit the new cylinder head gasket onto the cylinder block, positioning the marking (1) on the oil filter side.

• Refit:
  • the cylinder head,
  • the new cylinder head bolts.
• Pretighten to torque and in order the cylinder head bolts (initial torque) (20 N.m).
• Check that all the cylinder head bolts are tightened to 20 N.m.
• Angle tighten, in order the cylinder head bolts (230

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