Renault Clio: F4R

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / F4R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).

IMPORTANT

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

• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove the engine undertray.
• Perform the following operations:
  • drain the air conditioning circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (MR 392, 62A, Air conditioning),
  • drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • drain the gearbox oil (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox),
  • drain the engine oil (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12).
• Remove:
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the front end panel (see Front end panel: Removal - Refitting) (MR 393, 42A, Upper front structure),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the soundproofing unit,
  • the battery tray mounting (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery tray).

• Disconnect the hoses (1) from the heater radiator using the (Mot. 1448).

• Remove the exhaust manifold nuts.

• Disconnect:
  • the brake servo pipe (2) on the inlet distributor side,
  • the petrol vapour rebreather pipe (3) on the inlet distributor side,
  • the fuel supply pipe (4) from the injector rail,
  • the connector (5) from the inlet air pressure sensor,
  • the camshaft dephaser solenoid valve connector (6),
  • the petrol vapour recirculation solenoid valve connector (7).
• Move the wiring harness to one side.

• Remove:
  • the bolt (8 ) from the " expansion valve - condenser " connecting pipe,
  • the " compressor - condenser " connecting pipe bolt (9).
• Disconnect:
  • the " expansion valve - condenser " connecting pipe on the condenser side,
  • the " compressor - condenser " connecting pipe on the condenser side,
  • the cooling radiator hose on the cooling radiator using the (Mot. 1448),
  • the fan assembly connectors.
• Remove:
  • the " engine cooling fan - radiator - condenser - expansion bottle " assembly,
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (MR 393, 41A, Front lower structure),
  • the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13),
  • the driveshafts (see Front left-hand driveshaft: Removal - Refitting) and (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts).

• Disconnect:
  • the upstream oxygen sensor connector (10),
  • the downstream oxygen sensor connector (11).
• Unclip the wiring harness at (12) from the downstream oxygen sensor.

Note: with the wiring harness sitting on the engine, it is necessary to move the heat shields aside when removing the engine.

• Disconnect:
  • the injection computer connectors,
  • the connectors in the connection unit.

• Disconnect:
  • the fuse (13),
  • the fuse holder (14) from the fuse board,
  • the supply cable (15) from the fuse board,
  • the supply cable (16) from the battery protection fuse box.
• Remove:
  • the petrol injection computer,
  • the earth nut on the side member,
  • the earth nut on the left-hand wheel arch.

• Cut the adhesive tape in order to move the wiring harness away from its channel.
• Move the engine wiring away from the channel

• Disconnect the clutch control duct (17) by pushing the clip (18) and moving it aside.
• Remove the gearbox controls.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Position the (Mot. 1390).
• Remove:
  • 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).
• Move the " engine-gearbox " assembly forward positioned on the (Mot. 1390).
• Raise the vehicle using a two-post lift to remove the " engine-gearbox " assembly from the engine compartment.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacements (see ) (Technical Note 6027A, 10A, Engine and peripherals).

II - REFITTING OPERATION FOR PART CONCERNED

• Position the " engine - gearbox " assembly in the engine compartment.
• Refit:
  • 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).
• Remove the tool (Mot. 1390).

III - FINAL OPERATION

• Connect the clutch control duct.
• Bleed the clutch control.
• Refit the gearbox controls.
• Fit the wiring harness.
• Refit:
  • the earth nut on the left-hand wheel arch,
  • the earth nut on the side member,
  • the petrol injection computer.
• Connect:
  • the injection computer connectors,
  • the connectors in the connection unit.
• Refit the engine compartment connection unit cover.
• Position the engine wiring harness in its channel.
• Attach the wiring harness using ADHESIVE TAPE on its channel.
• Connect:
  • the supply cable to the battery protection fuse box,
  • the supply cable to the fuse board,
  • the fuse holder to the fuse board,
  • the fuse.
• Pass the downstream oxygen sensor wiring harness behind the heat shield.
• Connect:
  • the upstream oxygen sensor connector,
  • the downstream oxygen sensor connector.
• Clip the downstream oxygen sensor wiring harness into place.
• Refit:
  • the driveshafts (see Front left-hand driveshaft: Removal - Refitting) and (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),
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (MR 393, 41A, Front lower structure),
  • the " engine cooling fan - radiator - condenser " assembly.
• Connect:
  • the cooling radiator upper and lower hoses using the (Mot. 1448),
  • the engine cooling fan assembly connectors,
  • the cooling radiator hose to the cooling radiator using the (Mot. 1448),
  • the " compressor - condenser " connecting pipe on the condenser side,
  • the " expansion valve - condenser " connecting pipe on the condenser side.
• Refit:
  • the bolt (9) on the " compressor - condenser " connecting pipe,
  • the bolt (8) of the " expansion valve - condenser " connecting pipe.
• Connect:
  • the petrol vapour recirculation solenoid valve connector.
  • the camshaft dephaser solenoid valve connector,
  • the inlet air pressure sensor connector,
  • the fuel supply pipe on the injector rail,
  • the petrol vapour rebreather pipe on the inlet distributor side,
  • the brake servo pipe on the inlet distributor side
• Fit:
  • a new exhaust manifold seal on the cylinder head,
  • the exhaust manifold on the cylinder head.
• Refit the exhaust manifold nuts.

• Torque tighten in order the exhaust manifold nuts (30 N.m).
• Connect the heating radiator hoses using the (Mot.1448).
• Refit:
  • the battery tray mounting (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery tray),
  • the soundproofing unit,
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the front end panel (see Front end panel: Removal - Refitting) (MR 393, 42A, Upper front structure),
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection).
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Perform the following operations:
  • top up the engine oil (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12),
  • fill up the gearbox oil (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox),
  • fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • bleed the cooling circuit,
  • fill the air conditioning circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (MR 392, 62A, Air conditioning).
• Using the Diagnostic tool, check that there are no faults stored by the computer, and clear them if necessary.
• Check:
  • that there are no leaks,
  • using the Diagnostic tool, that there are no faults stored by the computer, and clear them if necessary.
• Refit the engine undertray.
• Carry out a road test to check that the vehicle is in good working order.

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