Renault Clio: M4R, and DP0

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / M4R, and DP0

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.

• Remove the engine cover.
• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 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 intake sleeve.

• Detach the wiring harness from the air inlet duct at (4).
• Undo the air duct securing clips:
  • on the air flow sensor (5),
  • on the motorised throttle valve (6).
• Remove the oil vapour rebreather duct (7) from the rocker cover using the (Mot. 1448).
• Remove the air inlet duct.

• Disconnect the air flowmeter connector (8).
• Unclip the air flowmeter connector wiring harness 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) (MR 392, 23A, Automatic transmission),
  • the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Filling) (MR 392, 62A, Air conditioning).
• Remove:
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the frontal impact cross member (see Front impact cross member: Removal - Refitting) (MR 393, 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

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

• Pull out the air conditioning pipe (12).
• Remove:
  • the front wheels (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres),
  • the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (MR 393, 41A, Front lower structure),
  • the radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the driveshafts (see Front left-hand driveshaft: Removal - Refitting) (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts).

• Disconnect the brake servo hose (13).

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

WARNING

Protect sensitive areas from fuel spillage.

• Unclip the fuel supply pipe at (16).

• Remove:
  • the exhaust clamp mounting bolts (17),
  • the exhaust clamp seal.

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

• Remove the fuse box cover (19).

• Unclip the relay box (20).

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

• Disconnect the lead (22).

• Disconnect the positive battery terminal (23).
• Remove:
  • the battery mounting clamp,
  • the battery.

• Remove the fuse (24).

• Disconnect the electrical connector (25).
• Pull the fuse holder out from the fuse box (26).

• Unhook the fuse box from the battery tray at (27).
• Move the fuse box away from the battery tray.

• Unclip the battery tray from the battery tray base at (28).
• Remove the battery tray.

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

• Remove:
  • the battery tray base mounting bolts (29),
  • the battery tray base.

• Detach the automatic transmission control cable ball joint by pressing at (30).
• Pull out the automatic transmission control cable by pulling tab (31).

• Disconnect:
  • the passenger compartment heating hoses (32),
  • the expansion bottle hoses (33).

• Remove the Protection and Switching Unit cover.
• Remove the engine wiring harness connectors (34) from the Protection and Switching unit.

• Disconnect the engine wiring harness connectors (35) from the injection computer.

• Disconnect the upstream oxygen sensor connector (36).

• Remove the plastic cover (37).
• Detach the downstream oxygen sensor connector at (38).
• Disconnect the downstream oxygen sensor connector.
• Unclip the downstream oxygen sensor wiring harness from the power-assisted steering box.
• Feed the downstream oxygen sensor wiring harness into the engine compartment.

• Disconnect the automatic transmission earth wire (39).

• Disconnect the side member earth wires.

• Disconnect the automatic transmission connector (41).
• Unclip the automatic transmission wiring harness at (42).
• Feed the automatic transmission wiring harness 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 (Mot. 1390) at (43) to ensure that the " engine-gearbox " assembly is stable.

II - REMOVAL OF PART CONCERNED

• Undo the upper engine tie-bar mounting bolt (44).
• Remove the upper engine tie-bar mounting bolt (45)

• Remove the upper engine tie-bar.

• Remove:
  • the bolt (46) mounting the rubber mounting bush to the engine cover,
  • the bolts (47) mounting the rubber mounting bush to the body.

• Remove:
  • the engine cover mounting bolts (48),
  • the engine cover,
  • the rubber mounting bush.

• Separate the neck of the wiring harness from the gearbox support.
• Remove:
  • the nut (49) mounting the rubber mounting bush to the gearbox cover,
  • the rubber mounting bush mounting bolts (50),
  • the rubber mounting bush.

• Remove:
  • the bolts (51) mounting the gearbox support on the body,
  • the gearbox support.
• 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 and gearbox " assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacements (see ) (Technical Note 6020A, 10A, Engine and peripherals).

II - REFITTING PART CONCERNED

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

• Fit:
  • the rubber mounting bush,
  • the engine cover.
• Pretighten:
  • the engine cover mounting bolts,
  • the bolts securing the rubber mounting bush to the body.

Note: Allow the two parts to move freely.

• Fit the bolts securing the rubber mounting bush to the engine cover.
• Torque tighten and in order:
  • the engine cover mounting bolts (62 Nm),
  • the rubber mounting bush mounting bolts on the body (62 Nm),
  • the rubber mounting bush mounting bolt on the engine cover (105 Nm),
  • the upper engine tie-bar mounting bolts (105 Nm).
• Refit:
  • the gearbox support,
  • the mounting bolts securing the gearbox support to the body,
  • the rubber mounting bush,
  • the mounting studs securing the rubber mounting bush to the gearbox support,
  • the mounting nut securing the rubber mounting bush to the gearbox cover.
• Torque tighten:
  • the gearbox support mounting bolts on the body (62 Nm),
  • the rubber mounting bush mounting bolts on the gearbox mounting (62 Nm),
  • the rubber mounting bush mounting nut on the gearbox (62 Nm).

III - FINAL OPERATION.

• Connect:
  • the engine wiring harness,
  • the air conditioning pipe unions,
  • the cooling hoses,
  • the air flowmeter connector,
  • the fuel supply pipe,
  • the petrol vapour rebreather pipe,
  • the brake servo pipe.
• Clip:
  • the fuel supply pipe,
  • the air flowmeter connector wiring harness.

• Be sure to replace the clip on the gearbox control cable ball joint each time it is removed.
• Fit the gearbox control cable.
• The exhaust clamp seal must be replaced.
• Torque tighten:
  • the exhaust clamp mounting bolts (21 Nm),
  • the engine tie-bar mounting bolt on the engine (180 Nm),
  • the engine tie-bar mounting bolt on the sub-frame (105 Nm).
• Refit:
  • the front end panel air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, 12A-10),
  • the frontal impact cross member (see Front impact cross member: Removal - Refitting) (MR 393, 41A, Front lower structure),
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the driveshafts (see Front left-hand driveshaft: Removal - Refitting) and (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 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) (MR 393, 41A, Front lower structure),
  • the front section of 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).

• Fit the air inlet duct on the air flowmeter following the assembly marking.

• Fit the air inlet duct on the motorised throttle valve following the assembly marking.
• Connect the oil vapour rebreather pipe to the rocker cover.
• Torque tighten the air inlet duct clips (6 Nm).
• Clip the wiring harness onto the air inlet duct.

• Before refitting the air inlet hose, check that the air resonator upper mounting at the front end is correctly clipped at.
• 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) (MR 392, 80A, Battery).
• Perform the following operations:
  • fill the automatic transmission (see Automatic gearbox oil: Draining - Filling) (MR 392, 23A, Automatic transmission),
  • fill the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Filling) (MR 392, 62A, Air conditioning).
  • fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • bleed the cooling system.
• Refit the engine cover.

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