Renault Clio: M4R, and TL4

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / M4R, and TL4

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
• Remove the front engine cover.
• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).

• Remove:
  • the nut (1) from the protective fuse mounting wiring,
  • the protective fuse mounting wiring,
  • the battery (see Battery: Removal - Refitting) (80A, Battery).

• Disconnect the air filter unit air inlet pipe:
  • from the front end panel at (2),
  • from the air resonator on the front end panel at (3),
  • from the air filter unit at (4).
• Remove the air pipe at the air filter unit inlet.

• Unclip the wiring from the air filter unit air outlet pipe at (5).
• Undo the clips on the air filter unit air outlet pipe:
  • on the air flow sensor (6),
  • on the motorised throttle valve (7).
• Separate the clip (8) of the oil vapour rebreathing hose on the rocker cover using the tool (Mot. 1448).
• Disconnect the oil vapour rebreathing hose on the rocker cover.
• Remove the air outlet pipe from the air filter box.

• Disconnect the air flowmeter connector (9).
• Unclip the air flowmeter connector wiring (10).
• Remove the engine undertray.
• Drain:
  • the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • the manual gearbox (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox).
  • 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 section 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 headlights (see Headlight: Removal - Refitting) (80B, Headlights),
  • 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 bolt (11) from the compressor-condenser connecting pipe, on the condenser,
  • the bolt (12) from the compressor-condenser connecting pipe, on the compressor,
  • the compressor-condenser connecting pipe (13),
  • the bolt (14) from the dehydrator reservoir-expansion valve connecting pipe on the dehydrator reservoir.
• Disconnect the dehydrator reservoir-expansion valve connecting pipe on the dehydrator reservoir.
• Remove the bolt (15) from the compressor-intermediate pipe connecting pipe on the compressor.
• Disconnect the compressor-intermediate pipe connecting pipe on the compressor.

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) (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 union (16) from the inlet distributor.

• Disconnect: - the petrol vapour rebreather pipe (17), - the fuel supply pipe (18).

WARNING

Protect sensitive areas from fuel spillage.

• Unclip the fuel supply pipe at (19).

• Disconnect the upstream oxygen sensor connector (20).
• Move the connector away from the upstream oxygen sensor.

• Remove the plastic cover (21).
• Detach the downstream oxygen sensor connector at (22).
• Disconnect the downstream oxygen sensor connector.
• Unclip the downstream oxygen sensor wiring from the power-assisted steering box.
• Feed the downstream oxygen sensor wiring into the engine compartment.

• Remove:
  • the bolts (23) from the exhaust flange,
  • the exhaust flange seal.
• Remove the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).

• Remove the cover (24) from power supply fuse unit.

• Unclip the optional relay unit (25).

• Remove the fuse (26).

• Unclip the fuse holder (27).
• Remove the nut (28) from the supply wiring of the power supply fuse unit.
• Disconnect the supply wiring from the power supply fuse unit.
• Remove the battery tray (see Battery tray: Removal - Refitting) (80A, Battery).

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

• Unclip:
  • the control cables (29) on the gearbox using an open-ended spanner,
  • the control cable sleeve stops (30) on the gearbox.

• Remove the clip (31) from the expansion bottle.

• Move the expansion bottle away from its housing in the direction of the arrow.

• Separate the clips (32) on the passenger compartment heater hoses using the tool (Mot. 1448).
• Disconnect the passenger compartment heater hoses.

• Remove:
  • the bolts (33) from the Protection and Switching Unit cover,
  • the Protection and Switching Unit cover.

• Disconnect the engine wiring connectors (34) from the Protection and Switching Unit.

• Disconnect the injection computer connectors (35).

• Remove:
  • the bolt (36) from the manual gearbox earth wiring.
  • the manual gearbox earth wiring.

• Remove the nut (37) from the side member earth wiring.
• Move the earth wiring away from the side member.

• Push on the clip of the hydraulic clutch control pipe.
• Disconnect the hydraulic clutch control pipe (38).
• Unclip the hydraulic clutch control pipe.

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

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22).

• Separate the neck of the electrical wiring from the gearbox support.
• Remove:
  • the left-hand suspended engine mounting shaft nut (40),
  • the nuts (41) from the left-hand suspended engine mounting rubber pad,
  • the left-hand suspended engine mounting rubber pad.

Note: Tap the bolt with a copper hammer, if necessary.

• Remove the " engine and gearbox " assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacements (see Engine: New 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.
• Refit:
  • 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.
• Torque tighten (see 19D, Engine mounting, Suspended engine mounting: Tightening torque, 19D-1).
• Refit the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22).
• Lift the (Mot. 1390) from the " engine - gearbox " assembly.

III - FINAL OPERATION

• Connect the hydraulic clutch control pipe.
• Clip on the hydraulic clutch control pipe.
• Fit the side member earth wiring.
• Refit the side member earth wiring nuts.
• Torque tighten the side member earth wiring nuts (8 N.m).
• Refit:
  • the manual gearbox earth wiring,
  • the bolt to the manual gearbox earth wiring.
• Torque tighten the manual gearbox earth wiring bolt (21 N.m).
• Connect:
  • the injection computer connectors,
  • the engine wiring connectors to the Protection and Switching Unit.
• Refit:
  • the Protection and Switching Unit cover,
  • the bolts on the Protection and Switching Unit cover.
• Torque tighten the Protection and Switching Unit cover bolts (4 N.m).
• Connect the passenger compartment heater hoses.
• Fit:
  • the passenger compartment heater hose clips,
  • the expansion bottle into its housing.
• Refit the clip to the expansion bottle.
• Clip:
  • the control cables onto the gearbox using an open-ended spanner,
  • the gearbox control cable sleeve stops onto the gearbox.
• Refit:
  • the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),
  • the air filter unit.
• Connect the air flowmeter connector.
• Clip on the air flowmeter connector wiring.
• Connect the supply wiring of the power supply fuse unit.
• Refit the nut of the supply wiring for the power supply fuse unit.
• Torque tighten the nut of the supply wiring for the power supply fuse unit (8 N.m).
• Clip in the fuse holder.
• Refit:
  • the fuse,
  • the cover of the power supply fuse unit.
• Clip on the optional relay unit.
• Refit the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).
• Tighten to torque the (see 19D, Engine mounting, Suspended engine mounting: Tightening torque, 19D-1)
• Refit:
  • a new exhaust flange seal,
  • the exhaust flange bolts.
• Torque tighten the exhaust flange bolts (21 N.m).
• Clip the downstream oxygen sensor wiring onto the power-assisted steering box.
• Connect the downstream oxygen sensor connector.
• Clip the downstream oxygen sensor connector.

• Refit the plastic cover (42).
• Connect:
  • the upstream oxygen sensor connector,
  • the brake servo pipe to the brake servo,
  • the petrol vapour rebreathing pipe,
  • the fuel supply pipe.
• Clip on the fuel supply pipe.
• Refit:
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front left-hand wheel driveshaft (see Front left-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 air conditioning pipes,
  • the air conditioning pipe bolts.
• Connect the compressor-intermediate pipe connecting pipe on the compressor.
• Refit the bolt to the compressor-intermediate pipe connecting pipe on the compressor.
• Torque tighten the compressor-intermediate pipe connecting pipe bolt on the compressor (8 N.m).
• Connect the dehydrator reservoir-expansion valve connecting pipe on the dehydrator reservoir.
• Refit the dehydrator reservoir-expansion valve connecting pipe bolt on the dehydrator reservoir.
• Torque tighten the dehydrator reservoir - expansion valve connecting pipe bolt on the dehydrator reservoir (8 N.m).
• Refit:
  • the compressor-condenser connecting pipe,
  • the condenser-compressor connecting pipe bolt on the compressor,
  • the compressor-condenser connecting pipe bolt on the condenser.
• Tighten to torque:
  • the compressor-condenser connecting pipe bolt on the compressor (8 N.m),
  • the compressor-condenser connecting pipe bolt on the compressor (8 N.m).
• Refit:
  • 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 headlights (see Headlight: Removal - Refitting) (80B, Headlights),
  • the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection),
  • the front section 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).

• Refit the air filter unit air outlet pipe on the air flowmeter, taking care to follow the markings for fitting.

• Refit the air filter unit air outlet pipe on the motorised throttle valve, taking care to follow the markings for fitting.
• Connect the oil vapour rebreathing hose on the rocker cover.
• Fit the oil vapour rebreathing hose clip onto the rocker cover using the tool (Mot. 1448).
• Torque tighten the air filter box air outlet pipe clips (6 N.m).
• Refit:
  • the battery (see Battery: Removal - Refitting) (80A, Battery),
  • the protective fuse mounting wiring,
  • the protective fuse mounting cable nut.
• Torque tighten the protective fuse mounting wiring nut (6 N.m).

• Before refitting the air filter unit air inlet pipe, check that the upper mounting of the air resonator is correctly clipped on the front end panel.
• Refit the air filter unit air inlet pipe.
• Connect the air filter unit air inlet pipe:
  • to the front end panel,
  • on the air resonator on the front end panel,
  • on the air filter box.
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Perform the following operations:
  • fill the manual gearbox (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox),
  • fill the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning),
  • fill and bleed the cooling circuit (see 19A, Cooling, Cooling system: Draining - Refilling, 19A- 16),
  • bleed the clutch circuit (see Clutch circuit: Bleed) (37A, Mechanical component controls).
• Refit:
  • the engine cover,
  • the engine undertray.
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).

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