Renault F4R User manual

© Renault s.a.s 2008
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
JUNE 2008 Edition Anglaise
X95, and F4R or F9Q or K4M or K9K
1Engine and peripherals
10A ENGINE AND CYLINDER BLOCK ASSEMBLY
11A TOP AND FRONT OF ENGINE
12A FUEL MIXTURE
12B TURBOCHARGING
13A FUEL SUPPLY
13B DIESEL INJECTION
13C PREHEATING
14A ANTIPOLLUTION
16A STARTING - CHARGING
17A IGNITION
17B PETROL INJECTION

© Renault s.a.s 2008
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
JUNE 2008 Edition Anglaise
X95, and F4R or F9Q or K4M or K9K
19A COOLING
19B EXHAUST
19C TANK
19D ENGINE MOUNTING

MEGANE III - Section 1
Contents
Page
MEGANE III - Section 1ContentsPage
10A ENGINE AND CYLINDER BLOCK
ASSEMBLY
Crankshaft seal at timing end
Removal - Refitting 10A-1
Crankshaft seal at gearbox
end : Removal - Refitting 10A-12
Sump: Removal - Refitting 10A-25
Engine oil: Draining -
Refilling 10A-40
Oil filter: Removal - Refitting 10A-48
Exchanger: Removal -
Refitting 10A-55
Oil pressure sensor:
Removal - Refitting 10A-64
Oil level sensor: Removal -
Refitting 10A-69
Oil pump: Removal -
Refitting 10A-76
Oil pressure: Check 10A-82
Multifunction support:
Removal - Refitting 10A-84
Engine/gearbox assembly:
Removal - Refitting 10A-98
Flywheel: Removal - Refitting 10A-157
11A TOP AND FRONT OF ENGINE
Final compression pressure:
Check 11A-1
Accessories belt: Removal -
Refitting 11A-7
Crankshaft accessories
pulley: Removal - Refitting 11A-15
Timing belt: Removal -
Refitting 11A-29
Rocker cover: Removal -
Refitting 11A-88
Camshaft: Removal -
Refitting 11A-114
Cylinder head: Removal -
Refitting 11A-135
Camshaft dephaser:
Removal - Refitting 11A-177
Camshaft dephaser solenoid
valve: Removal - Refitting 11A-184
Camshaft seal at timing end:
Removal - Refitting 11A-186
Oil decanter: Removal -
Refitting 11A-205
12A FUEL MIXTURE
Air resonator: Removal -
Refitting 12A-1
Air filter: Removal - Refitting 12A-2
Air filter unit: Removal -
Refitting 12A-4
Air flowmeter: Removal -
Refitting 12A-7
Air inlet flap: Removal -
Refitting 12A-11
Throttle valve: Removal -
Refitting 12A-17
Throttle valve: Cleaning 12A-21
11A TOP AND FRONT OF ENGINE

Contents
Inlet manifold: Removal -
Refitting 12A-23
Injector holder shim:
Removal - Refitting 12A-31
Exhaust manifold - Intake
distributor: Removal -
Refitting 12A-34
Exhaust manifold: Removal -
Refitting 12A-37
12B TURBOCHARGING
Turbocharging:Precautions
for repair 12B-1
Turbocharger: Removal -
Refitting 12B-8
Turbocharger oil pipe:
Removal - Refitting 12B-22
Intercooler: Removal -
Refitting 12B-37
Intercooler air inlet pipe:
Removal - Refitting 12B-41
Turbocharger outlet exhaust
gas duct: Removal - Refitting 12B-49
Intercooler air outlet pipe:
Removal - Refitting 12B-56
13A FUEL SUPPLY
Manual priming pump:
Removal - Refitting 13A-1
Fuel filter: Removal -
Refitting 13A-3
Fuel pressure: check 13A-7
Fuel flow: check 13A-10
12A FUEL MIXTURE 13B DIESEL INJECTION
Diesel injection: Precautions
for repair 13B-1
Diesel injection: List and
location of components 13B-12
Diesel injection computer:
Removal - Refitting 13B-17
Camshaft position sensor:
Removal - Refitting 13B-19
Crankshaft position sensor:
Removal - Refitting 13B-25
Leak flow from high-pressure
pump: Check 13B-27
High pressure pump:
Removal - Refitting 13B-30
Fuel flow actuator: Removal -
Refitting 13B-54
Venturi: Removal - Refitting 13B-58
Diesel return pipe: Removal -
Refitting 13B-62
Diesel injector fuel return rail:
Removal - Refitting 13B-63
Injector rail protector:
Removal - Refitting 13B-70
High-pressure pipe between
the pump and rail: Removal -
Refitting 13B-71
High-pressure pipe between
the rail and injector: Removal
- Refitting 13B-87
Injector rail: Removal -
Refitting 13B-108
Rail pressure sensor:
Removal - Refitting 13B-117
Fuel temperature sensor:
Removal - Refitting 13B-118
Leak flow from injectors:
Check 13B-126

Contents
Diesel injector: Removal -
Refitting 13B-136
Accelerometer: Removal -
Refitting 13B-150
13C PREHEATING
Pre/postheating unit:
Removal - Refitting 13C-1
Heater plugs Removal -
Refitting 13C-3
14A ANTIPOLLUTION
Fuel vapour canister:
Removal - Refitting 14A-1
Exhaust gas recirculation
solenoid valve: Removal -
Refitting 14A-3
Intercooler: Removal -
Refitting 14A-7
Exhaust gas recirculation
assembly: Removal -
Refitting 14A-18
Exhaust gas recirculation
rigid pipe: Removal -
Refitting 14A-30
16A STARTING - CHARGING
Alternator: Removal -
Refitting 16A-1
Starter: Removal - Refitting 16A-16
13B DIESEL INJECTION 17A IGNITION
Coils Removal - Refitting 17A-1
Spark plugs: Removal -
Refitting 17A-5
17B PETROL INJECTION
Oxygen sensors: Removal -
Refitting 17B-1
Petrol injection computer:
Removal - Refitting 17B-7
Pinking sensor: Removal -
Refitting 17B-9
Camshaft position sensor:
Removal - Refitting 17B-13
Crankshaft position sensor:
Removal - Refitting 17B-15
Injector rail - Injectors:
Removal - Refitting 17B-19
19A COOLING
Engine cooling circuit:
Specifications 19A-1
Engine cooling circuit: check 19A-2
Engine cooling circuit: List
and location of components 19A-4
Cooling circuit: Draining -
Refilling 19A-17
Cooling radiator: Removal -
Refitting 19A-31
Water pump: Removal -
Refitting 19A-45
Thermostat: Removal -
Refitting 19A-57
Plenum chamber: Removal -
Refitting 19A-61
Engine cooling fan assembly:
Removal - Refitting 19A-73

Contents
Water pump inlet pipe:
Removal - Refitting 19A-83
Expansion bottle: Removal -
Refitting 19A-96
Electric water pump:
Removal - Refitting 19A-99
Coolant temperature sensor:
Removal - Refitting 19A-101
19B EXHAUST
Exhaust: Parts and
consumables for the repair
work 19B-1
Exhaust: Precautions for
repair 19B-12
Catalytic converter: Removal
- Refitting 19B-17
Expansion chamber:
Removal - Refitting 19B-31
Connector pipe: Removal -
Refitting 19B-35
Silencer: Removal - Refitting 19B-40
Particle filter: Removal -
Refitting 19B-47
Exhaust gas temperature
sensor: Removal - Refitting 19B-50
Particle filter pressure
sensor: Removal - Refitting 19B-52
Particle filter temperature
sensors: Removal - Refitting 19B-53
Exhaust fuel injector:
Removal - Refitting 19B-54
Exhaust fuel injector
solenoid valve: Removal -
Refitting 19B-56
Exhaust fuel injector cooler:
Removal - Refitting 19B-58
Connecting hose: Removal -
Refitting 19B-60
19A COOLING 19C TANK
Fuel tank: Draining 19C-1
Fuel tank: Removal -
Refitting 19C-4
Filler neck: Removal -
Refitting 19C-14
Fuel level sensor module:
Removal - Refitting 19C-16
19D ENGINE MOUNTING
Left-hand suspended engine
mounting: Removal -
Refitting 19D-1
Right-hand suspended
engine mounting: Removal -
Refitting 19D-18
Lower engine tie-bar:
Removal - Refitting 19D-33

10A-1
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
K4M
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
aRemove:
-the engine cover,
-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-17) ,
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
-the engine undertray bolts,
-the engine undertray,
-the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-29) ,
-the crankshaft timing sprocket.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the crankshaft seal (1) at the timing end.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Crankshaft seal on
timing end (10,03,03,04).
aUse SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean and degrease:
- the seal mating face on the crankshaft,
- the seal housing on the cylinder block.
Essential special tooling
Mot. 1385 Crankshaft oil seal fitting tool
(timing end) (35 x 47 x 7)
134680
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

10A-2
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
K4M
10A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit a new crankshaft seal at the timing end, using
the tool (Mot. 1385)(2) .
III - FINAL OPERATION
aRefit:
-the crankshaft timing sprocket,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-29) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
-the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the engine undertray,
-the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-17) ,
- the engine cover.
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
134681

10A-3
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
K9K
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal -
Refitting) (80A, Battery).
aRemove:
-the engine cover,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
-the engine undertray bolts,
-the engine undertray,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) .
aRemove the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-33) .
aRemove:
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) .
aRemove the camshaft position sensor (see 13B,
Diesel injection, Camshaft position sensor: Re-
moval - Refitting, page 13B-19) .
aRemove the timing belt (see 11A, Top and front of
engine, Timing belt: Removal - Refitting, page
11A-29) .
aRemove the crankshaft timing sprocket (1) .
Essential special tooling
Mot. 1577 Lip seal extractor (shaft dia-
meter 28 mm to 42 mm).
Mot. 1586 Tool for fitting PTFE cranks-
haft seal, timing end.
Mot. 1714 Adapter for fitting PTFE
crankshaft seal, timing end.
K9K, and 830
K9K, and 830
109043

10A-4
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
K9K
10A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aFit the end piece (2) onto the tool (Mot. 1577) (3) .
aPosition the jaws of the tool (Mot. 1577) onto the
crankshaft nose (4) .
aPush on the tool (Mot. 1577) until contact is made
between the ends (5) of the jaws and the crankshaft
seal.
aSeparate the jaws by screwing the nut (Mot. 1577)
of the tool (6) .
105257
105260
105261
105262

10A-5
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
K9K
10A
aScrew down the threaded rod (7) of the (Mot. 1577).
aRemove the crankshaft seal using the tool (Mot.
1577).
REFITTING
I - REFITTING PREPARATION OPERATION
a
aUse SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean and degrease:
-the crankshaft seal mating face on the crankshaft,
-the crankshaft seal housing in the crankshaft closu-
re panel.
aparts always to be replaced: Crankshaft seal on
timing end (10,03,03,04).
II - REFITTING OPERATION FOR PART
CONCERNED
aTighten the threaded rod (8) :
-of the tool (Mot. 1586) in the crankshaft with an
M12 thread,
-of the tool (Mot. 1714) in the crankshaft with an
M14 thread.
aInsert the spacer (9) of the (Mot. 1586) in the
crankshaft.
105263
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).
20772
20771

10A-6
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
K9K
10A
aFit the protector equipped with the crankshaft seal
onto the spacer, taking care not to touch the cranks-
haft seal.
aFit the cover (10) and the nut (11) (positioning the
thread (12) of the nut towards the outside of the en-
gine).
aScrew on the nut until the cover touches the spacer.
20770
20769
20768
20767

10A-7
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
K9K
10A
aRemove:
-the nut,
-the cover,
-the protector,
-the spacer,
-the threaded rod.
III - FINAL OPERATION
aRefit:
-the crankshaft timing sprocket,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-29) .
aRefit the camshaft position sensor (see 13B, Diesel
injection, Camshaft position sensor: Removal -
Refitting, page 13B-19) .
aRefit:
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) ,
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
aRefit the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-33) .
aRefit:
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
- the engine undertray,
-the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the engine cover.
aConnect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
20766
K9K, and 830
K9K, and 830

10A-8
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
F4R
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine cover,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the engine undertray bolts,
-the engine undertray,
-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 radiator mounting cross member (see Radiator
support cross member: Removal - Refitting)
(31A, Front axle components),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
-the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-29) .
aRemove the crankshaft timing sprocket (1) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the timing end crankshaft seal using a
screwdriver.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Crankshaft seal on
timing end (10,03,03,04).
Essential special tooling
Mot. 990-03 Crankshaft oil seal fitting tool
(timing end).
120219
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

10A-9
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
F4R
10A
aUse SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean and degrease:
-the crankshaft seal mating face,
-the cylinder block seal housing.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit a new crankshaft seal at the timing end, using
the tool (Mot. 990-03) (2) .
III - FINAL OPERATION
aRefit:
-the crankshaft timing sprocket,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-29) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) ,
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-thelower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
-the radiator mounting cross member (see Radiator
support cross member: Removal - Refitting)
(31A, Front axle components),
-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),
- the engine undertray,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
- the engine cover.
120220

10A-10
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
F9Q
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal -
Refitting) (80A, Battery).
aRemove:
-the engine cover,
-the engine undertray bolts,
-the engine undertray,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
-the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-29) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
- the crankshaft sprocket (1) ,
-the crankshaft seal at the timing end using a flat-
blade screwdriver, taking care not to damage the
mating face of the crankshaft.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Crankshaft seal on
timing end (10,03,03,04).
aUse SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean and degrease:
- the crankshaft seal mating face on the crankshaft,
- the crankshaft seal housing on the cylinder block.
Essential special tooling
Mot. 990-03 Crankshaft oil seal fitting tool
(timing end).
120219
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

10A-11
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at timing end Removal - Refitting
F9Q
10A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-anew crankshaft seal at the timing end, using the
tool (Mot. 990-03) (2) ,
-the crankshaft sprocket.
III - FINAL OPERATION
aRefit:
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-29) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-18) ,
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-7) ,
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the engine undertray,
- the engine cover.
aConnect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
136199

10A-12
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at gearbox end : Removal - Refitting
K4M
10A
REMOVAL
I - REFITTING PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine cover,
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-4) .
aUndo the clip on the throttle valve air inlet pipe.
aDisconnect the air filter unit air outlet pipe from the
throttle valve.
aRemove:
-the air outlet pipe from the air filter unit,
-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 engine undertray bolts,
-the engine undertray,
-thefront bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain the manual gearbox (see Manual gearbox
oil: Draining - Refilling) (21A, Manual gearbox).
aRemove:
-the starter (see 16A, Starting - Charging, Starter:
Removal - Refitting, page 16A-16) ,
-the crankshaft position sensor (see 17B, Petrol in-
jection, Crankshaft position sensor: Removal -
Refitting, page 17B-15) ,
-the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the front right-hand wheel driveshaft (see Front ri-
ght-hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the front left-hand wheel driveshaft (see Front left-
hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the radiator mounting cross member (see Radiator
support cross member: Removal - Refitting)
(31A, Front axle components),
-the front axle subframe (see Front axle sub-fra-
me: Removal - Refitting) (31A, Front axle compo-
nents),
-the left-hand suspended engine mounting (see
19D, Engine mounting, Left-hand suspended
engine mounting: Removal - Refitting, page
19D-1) ,
-the manual gearbox (see Manual gearbox: Remo-
val - Refitting) (21A, Manual gearbox).
-the « pressure plate - disc» assembly (see Me-
chanism / Disk: Removal - Refitting) (20A,
Clutch),
-the flywheel (see 10A, Engine and cylinder block
assembly, Flywheel: Removal - Refitting, page
10A-157) .
Essential special tooling
Mot. 1129-01 Crankshaft oil seal fitting tool
(flywheel end) (80 x 100 x8
seal).
Tightening torquesm
clip on the throttle valve
air inlet pipe 6 N.m

10A-13
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at gearbox end : Removal - Refitting
K4M
10A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the crankshaft seal (1) using a screwdriver.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Crankshaft seal on
gearbox end (10,03,03,05).
aUse SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean and degrease:
-the seal mating face on the crankshaft,
-the seal housing on the cylinder block.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the crankshaft seal using the (Mot. 1129-01)
(2) .
III - FINAL OPERATION
aRefit:
-the flywheel (see 10A, Engine and cylinder block
assembly, Flywheel: Removal - Refitting, page
10A-157) ,
-the « pressure plate - disc» assembly (see Me-
chanism / Disk: Removal - Refitting) (20A,
Clutch),
-the manual gearbox (see Manual gearbox: Remo-
val - Refitting) (21A, Manual gearbox),
-the left-hand suspended engine mounting (see
19D, Engine mounting, Left-hand suspended
engine mounting: Removal - Refitting, page
19D-1) ,
-the front axle subframe (see Front axle sub-fra-
me: Removal - Refitting) (31A, Front axle compo-
nents),
-the radiator mounting cross member (see Radiator
support cross member: Removal - Refitting)
(31A, Front axle components),
-the new differential output seals (see Differential
output seal: Removal - Refitting) (21A, Manual
gearbox),
134550
Note:
Take care not to damage the seal mating face on
the crankshaft.
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).
134544

10A-14
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal at gearbox end : Removal - Refitting
K4M
10A
-the front right-hand wheel driveshaft (see Front ri-
ght-hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the front left-hand wheel driveshaft (see Front left-
hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-33) ,
-the crankshaft position sensor (see 17B, Petrol in-
jection, Crankshaft position sensor: Removal -
Refitting, page 17B-15) ,
-the starter (see 16A, Starting - Charging, Starter:
Removal - Refitting, page 16A-16) ,
-thefront bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
-the engine undertray,
-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),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-4) ,
-the air outlet pipe for the air filter unit.
aConnect the air filter box air outlet pipe to the throttle
valve.
aTorque tighten the clip on the throttle valve air in-
let pipe (6 N.m).
aRefit:
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing).
aPerform the following operations:
-fill the manual gearbox with oil (see Manual gear-
box oil: Draining - Refilling) (21A, Manual gear-
box),
-bleed the clutch control circuit (see Clutch circuit:
Bleeding) (37A, Mechanical component controls).
aRefit the engine cover.