megane 2 manual 2006

Renault s.a.s 2008

"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

77 11 318 022 APRIL 2009 Edition Anglaise

X84, and B84 or C84 or E84 or G84 or K84 or L84 or S84

1 Engine and peripherals10A 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 technicalspecifications current when it was prepared.The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

77 11 318 022 APRIL 2009 Edition Anglaise

X84, and B84 or C84 or E84 or G84 or K84 or L84 or S84

17C LPG INJECTION

19A COOLING

19B EXHAUST

19C TANK

19D ENGINE MOUNTING

Mgane II - Section 1

Contents

Page

Mgane II - 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-4

Sump: Removal - Refitting 10A-6

Conrod bearing shell: Removal - Refitting 10A-30

Engine oil: Draining - Refilling 10A-43

Oil filter: Removal - Refitting 10A-53

Oil filter unit: Removal - Refitting 10A-59

Exchanger: Removal - Refitting 10A-65

Oil pressure sensor: Removal - Refitting 10A-71

Oil level sensor: Removal - Refitting 10A-77

Oil pump: Removal - Refitting 10A-80

Oil pressure: Check 10A-84

Multifunction support: Removal - Refitting 10A-86

Engine/gearbox assembly: Removal - Refitting 10A-97

Crankshaft position sensor: Removal - Refitting 10A-197

Flywheel: Removal - Refitting 10A-198

Drive plate: Removal - Refitting 10A-206

11A TOP AND FRONT OF ENGINE

Final compression pressure: Check 11A-1

Accessories belt: Removal - Refitting 11A-4

Crankshaft accessories pulley: Removal - Refitting 11A-11

Timing belt: Removal - Refitting 11A-18

Timing chain: Removal - Refitting 11A-147

Rocker cover: Removal - Refitting 11A-158

Camshaft: Removal - Refitting 11A-172

Cylinder head: Removal - Refitting 11A-187

Camshaft dephaser: Removal - Refitting 11A-298

Oil decanter: Removal - Refitting 11A-301

10A ENGINE AND CYLINDER BLOCK ASSEMBLY

Contents

12A FUEL MIXTURE

Specifications 12A-1

Air intake: Description 12A-2

Air resonator: Removal - Refitting 12A-8

Air filter: Replacement 12A-9

Air filter: Removal - Refitting 12A-10

Air filter unit: Removal - Refitting 12A-11

Air flowmeter: Removal - Refitting 12A-26

Engine damper flap: Removal - Refitting 12A-31

Air inlet flap: Removal - Refitting 12A-33

Throttle valve: Removal - Refitting 12A-40

Throttle valve: Cleaning 12A-44

Air inlet duct: Removal - Refitting 12A-46

Inlet manifold: Removal - Refitting 12A-49

Injector holder shim: Removal - Refitting 12A-62

Exhaust manifold - Intake distributor: Removal - Refitting 12A-68

Exhaust manifold: Removal - Refitting 12A-73

12B TURBOCHARGING

Turbocharging: Precautions for repair 12B-1

Turbocharger: Removal - Refitting 12B-4

Turbocharger oil pipe: Removal - Refitting 12B-52

Intercooler: Removal - Refitting 12B-69

13A FUEL SUPPLY

Petrol supply circuit 13A-1

Diesel fuel supply circuit 13A-2

Diesel supply system: Operating diagram 13A-3

Fuel circuit: Operating diagram 13A-4

Manual priming pump: Removal - Refitting 13A-5

Petrol filter : General information 13A-17

Fuel filter: Removal - Refitting 13A-18

Diesel filter: Removal - Refitting 13A-25

Particle filter injector fuel filter: Removal - Refitting 13A-30

Injector rail - Injectors: Removal - Refitting 13A-31

Electric fuel: Checking 13A-36

Fuel flow: check 13A-39


Specifications 13B-1

Diesel injection: Specifications 13B-7

Diesel injection: Precautions for repair 13B-12

Location of components 13B-26

Diesel injection: List and location of components 13B-42

Diesel injection computer: Removal - Refitting 13B-64

Camshaft position sensor: Removal - Refitting 13B-68

Crankshaft position sensor: Removal - Refitting 13B-73

Contents

Leak flow from high-pressure pump: Check 13B-79

High pressure pump: Removal - Refitting 13B-80

Fuel flow actuator: Removal - Refitting 13B-114

Fuel pressure regulator: Removal - Refitting 13B-127

Venturi: Removal - Refitting 13B-133

Diesel return pipe: Removal - Refitting 13B-140

Diesel injector fuel return rail: Removal - Refitting 13B-148

Injector rail protector: Removal - Refitting 13B-154

High pressure pipe: Checking 13B-157

High pressure pipes: Removal - Refitting

High-pressure pipe between the pump and rail: Removal - Refitting 13B-160

High-pressure pipe between the rail and injector: Removal - Refitting 13B-181

Injector rail: Removal - Refitting 13B-204

Rail pressure sensor 13B-225

Rail pressure sensor: Removal - Refitting 13B-226

Oxygen sensor: Removal - Refitting 13B-235

Fuel temperature sensor: Removal - Refitting 13B-237

Leak flow from injectors: Check 13B-251

Diesel injector: Removal - Refitting 13B-258

Diesel injector: check 13B-281


Diesel injector adjustment value 13B-282

Accelerometer: Removal - Refitting 13B-283

13C PREHEATING

Pre/postheating unit: Removal - Refitting 13C-1

Heater plugs Removal - Refitting 13C-2

14A ANTIPOLLUTION

Fuel vapour recirculation circuit: check 14A-1

Fuel vapour canister: Removal - Refitting 14A-3

Fuel vapour canister:Checking 14A-5

Oil vapour rebreathing 14A-7

Oil vapour rebreathing system: Operating diagram 14A-17

Exhaust gas recirculation: Operating diagram 14A-19

Exhaust gas recirculation solenoid valve: Removal - Refitting 14A-23

Exhaust gas recirculation unit: Removal - Refitting 14A-35

Intercooler: Removal - Refitting 14A-43

Exhaust gas recirculation mounting: Removal - Refitting 14A-60

Exhaust gas recirculation assembly: Removal - Refitting 14A-61


Contents

Exhaust gas recirculation assembly: Removal - Refitting 14A-78

Exhaust gas recirculation rigid pipe: Removal - Refitting 14A-95

Exhaust gas recirculation solenoid valve: Cleaning 14A-105

16A STARTING - CHARGING

Charging circuit: Identification 16A-1

Starting system: Identification 16A-2

Alternator: Removal - Refitting 16A-3

Starter: Removal - Refitting 16A-21

Alternator pulley: Removal - Refitting 16A-40

17A IGNITION

Coils Removal - Refitting 17A-1

Spark plugs: Removal - Refitting 17A-3


Fuel injection: List and location of components 17B-1

Oxygen sensors: Removal - Refitting 17B-20

Accelerator pedal potentiometer: Removal - Refitting 17B-26

14A ANTIPOLLUTION

Position and speed sensor 17B-27

Petrol injection computer: Removal - Refitting 17B-30

17C LPG INJECTION

LPG injection: Precautions for repair 17C-1

LPG tank - pipe neck: Removal - Refitting 17C-2

LPG tank: Draining 17C-5

LPG tank: Removal - Refitting 17C-8

LPG expansion valve: Removal - Refitting 17C-12

LPG pressure sensor: Removal - Refitting 17C-15

LPG expansion valve solenoid valve: Removal - Refitting 17C-17

LPG expansion valve outlet union: Removal - Refitting 17C-18

Coolant circuit union: Removal - Refitting 17C-19

LPG injection rail: Removal - Refitting 17C-20

LPG injector: Removal - Refitting 17C-23

LPG computer: Removal - Refitting 17C-24

19A COOLING

Engine cooling: Parts and consumables for the repair work 19A-1

Engine cooling: Precautions for repair 19A-2


Contents

Engine cooling circuit: Specifications 19A-3

Engine cooling circuit: check 19A-5

Engine cooling circuit: Operating diagram 19A-7

Cooling circuit: Draining - Refilling 19A-15

Cooling radiator: Removal - Refitting 19A-22

Water pump: Removal - Refitting 19A-29

Thermostat: Removal - Refitting 19A-44

Plenum chamber: Removal - Refitting 19A-45

Engine cooling fan assembly: Removal - Refitting 19A-55

Thermoplunger unit: Removal - Refitting 19A-63

Water pump inlet pipe: Removal - Refitting 19A-65

Expansion bottle: Removal - Refitting 19A-69

Electric water pump: Removal - Refitting 19A-76

Coolant temperature sensor: Removal - Refitting 19A-81

19B EXHAUST

Exhaust: Precautions for repair 19B-1

Exhaust: Parts and consumables for the repair work 19B-6

Catalytic pre-converter: Removal - Refitting 19B-29

Catalytic converter: Removal - Refitting 19B-46

19A COOLING

Expansion chamber: Removal - Refitting 19B-62

Connector pipe: Removal - Refitting 19B-65

Silencer: Removal - Refitting 19B-74

Particle filter: List and location of components 19B-80

Particle filter: Function 19B-84

Particle filter: Removal - Refitting 19B-85

Particle filter: Cleaning 19B-101

Exhaust gas temperature sensor: Removal - Refitting 19B-106

Exhaust gas pressure sensor: Removal - Refitting 19B-112

Particle filter pressure sensor: Removal - Refitting 19B-114

Particle filter temperature sensors: Removal - Refitting 19B-125

Exhaust fuel injector: Removal - Refitting 19B-137

Exhaust fuel injector cooler: Removal - Refitting 19B-140

Connecting hose: Removal - Refitting 19B-142

19C TANK

Fuel tank: Description 19C-1

Fuel tank: Draining 19C-7

Fuel tank: Removal - Refitting 19C-11

Filler neck: Removal - Refitting 19C-14

Sender unit: Removal - Refitting 19C-15

Pump-sender unit-filter: Removal - Refitting 19C-18

19B EXHAUST

Contents

Petrol filter: General information 19C-20

Fuel level sensor: Checking 19C-21

Additional fuel circuit reservoir: Removal - Refitting 19C-22

Additional fuel circuit petrol pump: Removal - Refitting 19C-24

19D ENGINE MOUNTING

Suspended engine mounting 19D-1

Suspended engine mounting: Tightening torque 19D-3

Left-hand suspended engine mounting: Removal - Refitting 19D-12

Right-hand suspended engine mounting: Removal - Refitting 19D-20

Lower engine tie-bar: Removal - Refitting 19D-36

19C TANK

10A-1

ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal at timing end Removal - Refitting

B84 or C84 or E84 or K84 or L84, and M9R

10A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 364, 02A, Lifting equip-ment).

a Disconnect the battery (see Battery: Removal - Re-fitting) (MR 364, 80A, Battery).

a Remove:

- the front right-hand wheel (see Wheel: Removal -Refitting) (MR 364, 35A, Wheels and tyres),

- the front right-hand wheel arch liner (see Frontwheel arch liner: Removal - Refitting) (MR 365,55A, Exterior protection).

a Remove:

- the right-hand side stiffener bolts on the half sub-frame cross member,

- the right-hand side reinforcement from the half sub-frame cross member (1) ,

- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-4) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the crankshaft sealing ring using the (2)supplied in the spare parts kit for the new gasket.

Tightening torquesm

crankshaft seal on thetiming end

47 Nm

101212

114853

10A-2



10AREFITTING

I - REFITTING PREPARATION OPERATION

a

II - REFITTING OPERATION FOR PART CONCERNED

a Position the sealing ring notches opposite the not-ches in the timing cover.

a Engage the sealing ring notches in the timing covernotches.

a Tighten the sealing ring by hand using the tool sup-plied in the new gasket spare parts kit.

113656

WARNINGThe joint faces must be clean, dry and free fromgrease (avoid finger marks).

114850

114851

10A-3



10A

a Torque tighten the crankshaft seal on the timingend (47 Nm).

III - FINAL OPERATION.a Refit:

- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-4) ,

- the right-hand side reinforcement to the half sub-frame cross member,

- the right-hand side stiffener bolts on the half sub-frame cross member,

- the front right-hand wheel arch liner (see Frontwheel arch liner: Removal - Refitting) (MR 365,55A, Exterior protection),

- the front right-hand wheel (see Wheel: Removal -Refitting) (MR 364, 35A, Wheels and tyres).

a Connect the battery (see Battery: Removal - Refit-ting) (MR 364, 80A, Battery).

114852

10A-4

ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal at gearbox end : Removal - Refitting


10A

REMOVAL



a Remove the engine covers.

a Disconnect the battery (see Battery : Removal -Refitting) (MR 364, 80A, Battery).

a Remove:

- the engine and gearbox assembly (see 10A, Engi-ne and cylinder block assembly, Engine/gear-box assembly: Removal - Refitting, page 10A-97) ,

- the gearbox (see Manual gearbox: Removal - Re-fitting) (MR 364, 21A, Manual gearbox),

- the clutch disc and pressure plate (see Mecha-nism / Disk: Removal - Refitting) (MR 364, 20A,Clutch),

- the flywheel (see 10A, Engine and cylinder blockassembly, Flywheel: Removal - Refitting, page10A-198) (MR 364, 20A, Clutch).


a Remove:

- the crankshaft sealing cover bolts (1 ) at theflywheel end,

- the crankshaft sealing cover at the flywheel end.

REFITTING

I - REFITTING PREPARATION OPERATIONa Clean and degrease:

- the flywheel end crankshaft sealing cover joint faceon the sump,

- the flywheel end seal mating face on the cranks-haft.

Tightening torquesm

bolts (4) and (7) of thecrankshaft sealing coveron the cylinder block(initial torque)

5 Nm

crankshaft sealing coverbolts on the cylinderblock

10 Nm

WARNING

It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump will irrepara-bly damage the engine by:- blocking the strainer,- raising the oil level above maximum, with a risk of

engine racing.114068


10A-5

ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal at gearbox end : Removal - Refitting


10AII - REFITTING OPERATION FOR PART CONCERNED

a Fit:

- the seal protector-new sealing cover assemblyon the crankshaft nose,

- the guide bolts (M6 - length 90 mm) (2) .

a Remove:

- the seal protector ,

- the guide bolts .

a Screw in the crankshaft sealing cover bolts on thecylinder block without tightening them.

a Pre-tighten to torque and in order bolts (4) and (7)of the crankshaft sealing cover on the cylinderblock (initial torque) (5 Nm).

a Torque tighten in order the crankshaft sealing co-ver bolts on the cylinder block (10 Nm).

III - FINAL OPERATION.

a Refit:

- the flywheel (see 10A, Engine and cylinder blockassembly, Flywheel: Removal - Refitting, page10A-198) (MR 364, 20A, Clutch),

- the clutch disc and pressure plate (see Mecha-nism / Disk: Removal - Refitting) (MR 364, 20A,Clutch),

- the gearbox (see Manual gearbox: Removal - Re-fitting) (MR 364, 21A, Manual gearbox),

- the engine and gearbox assembly (see 10A, Engi-ne and cylinder block assembly, Engine/gear-box assembly: Removal - Refitting, page 10A-97) .

a Connect the battery (see Battery : Removal - Refit-ting) (MR 364, 80A, Battery).

a Refit the engine covers.

114414

114413

114068

10A-6

ENGINE AND CYLINDER BLOCK ASSEMBLYSump: Removal - Refitting

B84 or C84 or G84 or S84, and K4J B84 or C84 or G84 or S84, and K4M

10A

REMOVAL


a Disconnect the battery (see Battery: Removal - Re-fitting) (MR 364, 80A, Battery).

a Remove the engine undertray.

a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-43) (MR 364, 05A, Oil change).

a Remove:

- the engine covers,

- the dipstick,

- the front wheels,

- the wheel arch liners,

a Remove the half-subframe side stiffeners (1) .a Fit the cooling assembly to the upper cross member

using a safety strap(s).

Essential equipment

safety strap(s)

Tightening torquesm

sump bolts 14 Nm

sump mounting boltsare tightened to torque

14 Nm

gearbox - sump assem-bly bolts

44 Nm

sump bolts 14 Nm

sump mounting boltsare tightened to torque

14 Nm

gearbox - sump assem-bly bolts

44 Nm

sump bolts on the multi-function support

21 Nm

half-subframe bolts 105 Nm

half-subframe nuts 21 Nm

wheel bolts 110 Nm

101212

Note:

When fitting the safety strap(s), be careful:- not to crush the cooling hoses,- not to strap up the half-subframe.

10A-7



10A

a Remove:

- the half-subframe nuts,

- the half-subframe bolts,

- the half sub-frame (2) .a Remove:

- the right-hand driveshaft flange bolts from the relaybearing,

- the relay bearing bolts from the sump.

a Remove the bolt from the sump on the multifunctionsupport.

a Remove:

- the sump mounting bolt,

- the sump.

REFITTINGa Clean the joint faces with SUPER CLEANING

AGENT FOR JOINT FACES (see Vehicle: Partsand ingredients for the repairwork) (MR 364, 04B,parts or consumables for repair) to dissolve any re-maining seal.

a Apply the product to the section to be cleaned: waitapproximately ten minutes, then remove the residueusing a wooden spatula.

102008

AIR CONDITIONING or CLIMATE CONTROL


WARNINGExcess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould cause damage to certain components(engine, radiator, etc.).

10A-8



10A

a Apply:- four beads at (3) and (4) of ADHESIVE SILICONESEAL, with a diameter of 5 mm.

- two spots of ADHESIVE SILICONE SEAL at (5) ,with a diameter of 7 mm where the crankshaft andcylinder block closure panels intersect.

I - FIRST FITTING

a Refit the oil splash plate onto the cylinder block.

20167

20166

20170

Note:

When refitting the sump, check that:- the oil splash plate tabs (6) are positioned cor-

rectly in the slots (7) ,- the cylinder block and the flywheel end of the

sump are aligned to prevent clutch housingdeformation.

10A-9



10A

a Refit the sump with a new seal.a Fit:

- the sump bolts without tightening them,- the gearbox - sump assembly bolts without tighte-ning them.

a Tighten to torque and in order the sump bolts (14Nm).

a Check that all the sump mounting bolts are tighte-ned to torque (14 Nm).

a Torque tighten the gearbox - sump assemblybolts (44 Nm).

20171

10A-10



10AII - SECOND FITTING

a Refit the sump with a new seal.a Fit:

- the sump bolts without tightening them,- the gearbox - sump assembly bolts without tighte-ning them.

a Tighten to torque and in order the sump bolts (14Nm).

a Check that all the sump mounting bolts are tighte-ned to torque (14 Nm).

a Torque tighten the gearbox - sump assembly

bolts (44 Nm).

III - REFITTING (FOR FIRST AND SECOND FITTINGS)

a Refit the sump mounting bolt on the multifunctionsupport.

a Tighten to torque the sump bolts on the multifunc-tion support (21 Nm).

a Torque tighten:- the half-subframe bolts (105 Nm),- the half-subframe nuts (21 Nm),- the wheel bolts (110 Nm).

a Proceed in the reverse order to removal.a Top up the engine oil (see 10A, Engine and cylin-

der block assembly, Engine oil: Draining - Refil-ling, page 10A-43) (MR 364, 05A, Oil change).

a Connect the battery (see Battery: Removal - Refit-ting) (MR 364, 80A, Battery).

108881

20171


10A-11


B84 or C84 or G84 or S84, and F9Q, and 800 or 803 or 804 or 808 or 816 or 818

10A

REMOVALa Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).a Disconnect the battery (see Battery: Removal - Re-

fitting) (80A, Battery).a Remove the engine undertray.a Drain the engine oil (see 10A, Engine and cylinder

block assembly, Engine oil: Draining - Refilling,page 10A-43) .

a Remove:

- the engine covers,- the dipstick,- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),

- the front wheel arch liners (see Front wheel archliner: Removal - Refitting) (55A, Exterior protec-tion),

- the engine undertray bolts,- the engine undertray.

a Remove the half-subframe side reinforcements (1) .a Fit the cooling assembly to the upper cross member


Essential equipment

safety strap(s)

Tightening torquesm

sump bolts (8), (15), (4),(19), (11), (12)

18 N.m

sump bolts (10), (13),(9), (14), (8), (15), (7),(16), (6), (17), (5), (13),(18), (3), (20), (2), (21),(1), (22)

15 N.m

half-subframe bolts 105 N.m

half-subframe nuts 21 N.m

101212

Note:

When fitting the safety strap(s), be careful:- not to crush the cooling pipes,- not to strap up the half-subframe.

10A-12



10A

a Remove:

- the half-subframe nuts,- the half-subframe bolts,- the half sub-frame (2) ,- the lower engine tie-bar bolts,- the lower engine tie-bar,- the sump mountings,- the sump.

REFITTINGa Clean the joint faces with SUPER CLEANING

AGENT FOR JOINT FACES (see Vehicle: Partsand ingredients for the repairwork) (04B, Consu-mables - Products).

a Apply the product to the part to be cleaned, wait ap-proximately ten minutes then remove the residuewith a wooden spatula.

102008

WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-ger marks).

WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.).

Note:

There are two fitting procedures for preparing the cylinder block gasket face when refitting:- the first fitting procedure is used if SILICONE

ADHESIVE SEALANT has been used to sealthe crankshaft closure panel (see Vehicle:Parts and ingredients for the repairwork)(04B, Consumables - Products),

- the second fitting is used if a seal is used for thecrankshaft closure panel sealing.

10A-13



10AI - FIRST FITTING

a Apply a bead of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products):- at (A) , both sides of bearing No. 1,- at (B) , the joint between the cylinder block and thecrankshaft closure panel.

a Refit the oil sump fitted with a new seal.

II - SECOND FITTING

a Apply a bead of SILICONE ADHESIVE SEALANT(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) at (A) , onthe joint between the crankshaft closure panel andthe cylinder block.

a Refit the oil sump fitted with a new seal.

15159 15159

Note:

Do not cut the two crankshaft closure panel sealtabs which sit higher than the cylinder block gas-ket face (B) .

10A-14



10AIII - REFITTING (FOR THE FIRST AND SECOND FITTINGS)

a Stage 1: Torque tighten in order the sump bolts (8), (15),

(4), (19), (11), (12) (18 N.m).- Stage 2: Torque tighten in order the sump bolts (10), (13),

(9), (14), (8), (15), (7), (16), (6), (17), (5), (13),(18), (3), (20), (2), (21), (1), (22) (15 N.m).

a Refit the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting, page 19D-36) .

a Torque tighten:- the half-subframe bolts (105 N.m),- the half-subframe nuts (21 N.m).


der block assembly, Engine oil: Draining - Refil-ling, page 10A-43) .

a Connect the battery (see Battery: Removal - Refit-ting) (80A, Battery).

15195

10A-15


B84 or C84 or G84 or S84, and K9K

10A

REMOVAL


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

a Disconnect the battery (see Battery : Removal -Refitting) (80A, Battery).

a Remove:

- the engine covers,

- the dipstick,

- the engine undertray bolts,

- the engine undertray,

- the front bumper (see Front bumper: Removal -Refitting) (55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),

- the front section of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection).

a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-43) .

a Remove the half-subframe side stiffeners (1) .a Fit the cooling assembly to the upper cross member


a Move the diesel drain pipe away from the injector railprotector.

Essential equipment

safety strap(s)

Tightening torquesm

sump bolts on the gear-box

44 N.m

sump bolts on the cylin-der block

14 N.m

sump bolts on the multi-function support

21 N.m

catalytic converter ups-tream strut bolts

21 N.m



half-subframe side stif-fener bolts

21 N.m

101212

Note:


K9K, and 732 or 734

10A-16



10A

a Remove:

- the half-subframe nuts,


- the half-subframe (2) .

a Remove:

- the lower engine tie-bar (see 19D, Engine moun-ting, Lower engine tie-bar: Removal - Refitting,page 19D-36) ,

- the lower engine tie-bar support lower mountingbolts.

a Loosen the lower engine tie-bar upper bolt.

a Remove:

- the right-hand driveshaft flange bolts from the relaybearing,

- the relay bearing bolts from the sump,

- the relay bearing,

- the catalytic converter upstream stay bolts,

- the catalytic converter upstream strut.

a Disconnect the oil level sensor (if equipped).

a Remove the bolt from the sump on the multifunctionsupport.

II - OPERATION FOR REMOVAL OF PART CONCERNEDa Remove:

- the sump bolts,- the sump.

REFITTING


a Clean the strainer with a soft, lint-free cloth.

a Clean the joint faces with SUPER CLEANER FORJOINT FACES (see Vehicle: Parts and consuma-bles for repair) (04B, Consumables - Products) todissolve any part of the seal still adhering.

102008

K9K, and 732 or 734


Note:

If the sump cannot be extracted because it is incontact with the oil pump strainer, do not forcethe removal of the sump as this may damage theoil splash plate.Loosen the oil pump bolts by a few turns (the tipof your finger should pass between the bolt headand the oil pump casing) using 10 mm and 13mm open-jawed spanners and while tilting thesump towards the front of the vehicle.

K9K, and 732 or 734



10A-17



10Aa Apply the product to the section to be cleaned: wait

approximately ten minutes, then remove the residueusing a wooden spatula.

a Apply:- four beads at (3) and (4) of ADHESIVE SILICONESEAL, with a diameter of 5 mm.

- two spots of ADHESIVE SILICONE SEAL at (5) ,with a diameter of 7 mm where the crankshaft andcylinder block closure panels intersect.


1 - FIRST FITTING

a Refit the oil splash plate onto the cylinder block.

20167

20166

20170

Note:

When refitting the sump, check that:- the oil splash plate tabs (6) are positioned cor-

rectly in the slots (7) ,- the cylinder block and the sump engine flywheel

end are aligned to prevent damage to the clutchhousing.

10A-18



10A

a Refit:- the oil sump mounting seal,- the engine oil sump,- the sump bolts to the gearbox, without tighteningthem,

- the sump bolts to the cylinder block, without tighte-ning them.

a Tighten to torque the sump bolts on the gearbox(44 N.m).

a Torque tighten in order the sump bolts on the cy-linder block (14 N.m).

113492

20171

10A-19



10A2 - SECOND FITTING

a Refit:- the oil sump mounting seal,- the engine oil sump,- the sump bolts to the gearbox, without tighteningthem,

- the sump bolts to the cylinder block, without tighte-ning them.

a Torque tighten the sump bolts on the gearbox (44N.m).

a Torque tighten in order the sump bolts on the cy-linder block (14 N.m).

III - FINAL OPERATION

a Connect the oil level sensor.

a Refit the sump bolt on the multifunction support.

a Tighten to torque the sump bolts on the multifunc-tion support (21 N.m).

a Refit the catalytic converter upstream stay.

a Tighten the bolts of the catalytic converter upstreamstrut until contact is made.

a Torque tighten the catalytic converter upstreamstrut bolts (21 N.m).

a Refit:

- the relay bearing,

- the relay bearing bolts from the sump,

- the bolts of the right-hand driveshaft bracket on therelay bearing.

108881

20171

Note:

If the oil pump was loosened beforehand in orderto extract the sump, position the sump in order topass the oil pump strainer into the oil splashplate of the sump.Position a component jack to support the sump.Tilt the sump towards the front of the vehicle, inorder to facilitate access to the oil pump bolts.Torque tighten the oil pump bolts (25 N.m) usingthe small torque wrench 77 11 226 888.

Fit the sump and then follow the following instruc-tions.

Note:

Before pressing the sump on the cylinder block,check that the sump seal is still in place and thatit has not come out of the grooves on the sides.


10A-20



10A

a Refit the lower engine tie-bar support lower bolts.a Torque tighten the lower engine tie-bar support

lower bolts (see 19D, Engine mounting, Suspen-ded engine mounting, page 19D-1) .


a

a Refit:- the half-subframe bolts,- the half-subframe nuts,- the half-subframe.

a Torque tighten:- the half-subframe bolts (105 N.m),- the half-subframe nuts (21 N.m).

a Fit the diesel drain pipe on the injector rail protector.

a Remove the safety strap(s).a Refit:

- the half-subframe side stiffeners,- the half-subframe side stiffener bolts.

a Torque tighten the half-subframe side stiffenerbolts (21 N.m).

a Refit:- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),- the engine undertray,

- the front section of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres).

a Connect the battery (see Battery : Removal - Refit-ting) (80A, Battery).

a Fill up the engine oil (see 10A, Engine and cylinderblock assembly , Engine oil: Draining - Refilling,page 10A-43) .

a Refit:- the dipstick,- the engine covers.

K9K, and 732 or 734

Note:Apply a drop of HIGH STRENGTH THREADLOCK (see Vehicle: Parts and consumablesfor repair) (04B, Consumables - Products) onthe bolts of the half-subframe.

K9K, and 732 or 734

10A-21


B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776

10A


Towing and lifting) (MR 364, 02A, Lifting equip-ment).


a Remove the engine undertray.a Drain the engine oil (see 10A, Engine and cylinder

block assembly, Engine oil: Draining - Refilling,page 10A-43) .

a Remove:

- the engine covers,- the dipstick,- the front wheels,- the wheel arch liners.

a Remove:

- the half sub-frame side reinforcement mountingbolts,

- the side reinforcements (1) .a Attach the cooling assembly to the upper cross

member using the safety strap(s).

Essential equipment

safety strap(s)

Tightening torquesm

half-subframe mountingbolts

105 Nm

half-subframe mountingnuts

21 Nm

wheel bolts (F4R 776) 130 Nmwheel bolts 110 Nm

battery cover bolts 4 Nm

101212

Note:


10A-22



10A

a Remove:

- the mounting nuts from the half-subframe,

- the half-subframe mounting bolts,

- the half sub-frame (2) .a Remove:

- the engine tie-bar,

- the sump mountings,

- the sump.

REFITTINGa Clean the gasket faces with DECAPJOINT to dissol-

ve off any part of the gasket still attached.

a Apply the product to the section to be cleaned: waitapproximately ten minutes, then remove the residueusing a wooden spatula.

a Apply a bead of SILICONE ADHESIVE SEALANTat (A) , on the joint between the crankshaft closurepanel and the cylinder block.

a Refit the sump with a new seal.

102008



15159

Note:

Do not cut the two tabs on the crankshaft closurepanel seal, which sit higher than the joint face ofthe cylinder block (B) .

10A-23



10A

a Stage 1:

Tighten to torque and in order, bolts (8) , (15) , (4), (19) , (11) , (12) (18 Nm).

- Stage 2:

Tighten to torque and in order bolts (10) , (13) , (9), (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18) ,(3) , (20) , (2) , (21) , (1) and (22) (15 Nm).


a Torque tighten:

- the half-subframe mounting bolts (105 Nm),

- the half-subframe mounting nuts (21 Nm),

- the wheel bolts (F4R 776) (130 Nm),

- the wheel bolts (110 Nm),

- the battery cover bolts (4 Nm).

a Proceed in the reverse order to removal.

a Top up the engine oil (see 10A, Engine and cylin-der block assembly, Engine oil: Draining - Refil-ling, page 10A-43) .


15195

10A-24


B84 or C84, and F4R, and 774

10A




a Drain the engine (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-43) .

a Remove:

- the engine undertray,- the front wheels,- the wheel arch liners.

a Attach the cooling assembly to the upper crossmember.

a Remove:

- the left and right-hand side reinforcement moun-tings (1) ,

- the radiator cross member mountings (2) ,- the engine tie-bar,- the sump mountings,- the sump.

REFITTINGa

Tightening torquesm

sump mounting bolts 8,15, 4, 19, 11, 12

18 Nm

sump mounting bolts10, 13, 9, 14, 8, 15, 7,16, 17, 5, 18, 3, 20, 2,21,1 22

15 Nm

radiator cross memberfront mounting bolts

105 Nm

radiator cross memberrear mounting bolts

210 Nm

engine tie-bar on thesubframe

105 Nm

engine tie-bar on theengine

180 Nm

IMPORTANTDuring this operation, secure the vehicle on thelift with a strap to prevent it from unbalancing.

106077

Note:

Applying excess sealant could cause it to besqueezed out when parts are tightened. The pro-duct-fluid mix may cause damage to some com-ponents (engine, radiator, etc.).

10A-25


B84 or C84, and F4R, and 774

10A

a Apply a bead of RHODORSEAL 5661 at (3) (oneach side of bearing no.1) and at (4) (on the connec-tion between the crankshaft closure panel and thecylinder block).

a Refit the sump with a new seal.

a Torque tighten and in order:

- the sump mounting bolts 8, 15, 4, 19, 11, 12 (18Nm),

- the sump mounting bolts 10, 13, 9, 14, 8, 15, 7,16, 17, 5, 18, 3, 20, 2, 21,1 22 (15 Nm).

a Torque tighten:- the radiator cross member front mounting bolts

(105 Nm),- the radiator cross member rear mounting bolts

(210 Nm),- the engine tie-bar on the subframe (105 Nm),- the engine tie-bar on the engine (180 Nm).




15159

15195

10A-26


B84 or C84 or G84 or S84, and M9R

10A

REMOVAL

I -

II - REMOVAL PREPARATION OPERATIONa Position the vehicle on a lift (see Underbody lift)

(MR 364, 02A, Lifting equipment).a Disconnect the battery (see Battery : Removal -

Refitting) (MR 364, 80A, Battery).a Remove the engine protectors.

a Remove:

- the oil filler cap - dipstick assembly (1) ,- the dipstick guide tube bolt (2) ,- the dipstick guide tube.- the front wheels (see Wheel: Removal - Refitting)

(MR 364, 35A, Wheels and tyres),- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (MR 365, 55A, Exteriorprotection),

- the engine undertray,- the front bumper (see Front bumper: Removal -

Refitting) (MR 365, 55A, Exterior protection).

Essential special tooling

Mot. 1716 Removes housing with sili-cone seals.

Essential equipment

safety strap(s)

Tightening torquesm

sump bolts 16 N.m



the side stiffener lowerbolts

21 N.m

dipstick guide tube bolt 10 N.m 114035

10A-27



10A

a Fit the cooling assembly to the upper cross memberusing a safety strap(s).

a Remove:

- the side stiffener lower bolts (3) ,- the half subframe nuts (4) ,- the bolts (5) from the half subframe.


III - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the sump bolts.

a Cut the sump's silicone seal (except on side of thecoupling face and the rear suspended mountingsupport) using the (Mot. 1716).

102008

Note:

When fitting the safety strap(s), be careful:- not to crush the cooling hoses,- deform the air conditioning pipes,- not to strap up the half-subframe.

114997

114263

10A-28



10A

a Gradually detach the sump.

a Remove the sump.

REFITTING

I - REFITTING PREPARATIONS OPERATIONa Check that the sump is not:

- scratched,- deformed.If this is the case, replace the sump.

a Check that the base plate is not scratched.


a Apply a bead of SILICONE ADHESIVE SEAL of adiameter of 5 mm 2 to the sump to ensure a seal.

a Fit the sump.

a Tighten the sump bolts until contact is made.

a Tighten to torque and in order the sump bolts (16N.m).

114264

Note:

To prevent deformation, use a series of smallmovements.

IMPORTANT- Do not scratch the aluminium sealing surfaces.- Wear goggles.- Wear gloves during the operation.

WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. The pro-duct mix may damage some components(engine, radiator, etc.).

WARNINGThe sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).

114410

10A-29



10AIII - FINAL OPERATION

a Apply some FREIN DE VIS HAUTE RESISTANCEto the half-subframe bolts.

a Refit:

- the half-subframe,


- the half-subframe nuts.

a Torque tighten:

- the half-subframe bolts (105 N.m),- the half-subframe nuts (21 N.m).

a Refit the side reinforcement lower bolts.

a Torque tighten the side stiffener lower bolts (21N.m).

a Remove the safety strap(s).a Refit:

- the front bumper (see Front bumper: Removal -Refitting) (MR 365, 55A, Exterior protection),


- the front wheel arch liners (see Front wheel archliner: Removal - Refitting) (MR 364, 55A, exteriorprotection),

- the front wheels (see Wheel: Removal - Refitting)(MR 364, 35A, Wheels and tyres).


a Top up the engine oil (see 10A, Engine and cylin-der block assembly, Engine oil: Draining - Refil-ling, page 10A-43) .

a Fit a new seal in the dipstick guide tube housing.

a Lubricate the seal with engine oil.

a Fit the dipstick guide tube into the cylinder block.

a Torque tighten the dipstick guide tube bolt (10N.m).

a Refit:

- the "filler cap - dipstick" assembly,

- the engine protectors.

Note:

Check that the seal has not come out of its hou-sing.

10A-30

ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting

F9Q

10AREMOVING - REFITTING




a Drain the oil from the engine (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-43) .

a Remove the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-53) .

a Remove the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting, page 19D-36) .

a Remove the sump (see 10A, Engine and cylinderblock assembly, Sump: Removal - Refitting,page 10A-6) .

a Remove the oil pump (see 10A, Engine and cylin-der block assembly, Oil pump: Removal - Refit-ting, page 10A-80) .

II - REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO.2

a Use SURFACE CLEANER (see Vehicle: Partsand ingredients for the repairwork) (04B, Consu-mables - Products) to clean the big ends.

a Mark the position of the con rod cap in relation to thecon rod body using a indelible pencil.


Mot. 1914 Tool for fitting G9 con rodbearing shells

Mot. 1920 Tool for fitting F9 / K9 con rodbearing shells

Essential equipment

indelible pencil

diagnostic tool

Tightening torquesm

con rod cap bolts 25 N.m + 110 10

IMPORTANTTo avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Vehicle: Precautions for repair) .

IMPORTANTWear leaktight gloves (Nitrile type) for this opera-tion.

139306

10A-31


F9Q

10A

a Remove:

- the con rod bolts,- the con rod cap,- the lower con rod bearing shell.

a Use SURFACE CLEANER (see Vehicle: Partsand ingredients for the repairwork) (04B, Consu-mables - products) to clean the bearing mating faceon the con rod cap.

a Fit the tie rod of the tool (Mot. 1914) (1) on the conrod body.

a Push the con rod upwards to release the con rodfrom the crankpin.

a Turn the crankshaft 90 clockwise (timing end).

139300

Note:

If reusing the con rod bearing shells, mark theposition of the lower con rod bearing shell in rela-tion to the con rod cap.

139310

10A-32


F9Q

10A

a

Pull the con rod - piston assembly using the tie rod ofthe tool (Mot. 1914), taking care not to allow the pis-ton to touch the piston base cooling jets.

a Remove the upper con rod bearing shell.

a Use SURFACE CLEANER (see Vehicle: Partsand ingredients for the repairwork) (04B, Consu-mables - products) to clean the bearing mating faceon the con rod body.

REFITTING

I - REFITTING OPERATION FOR THE CON ROD BEARING SHELLS ON CYLINDER NO.2a parts always to be replaced: con rod cap bolts

(10,03,02,10)

139315

WARNINGFailure to observe the following procedure maydamage the piston base cooling jets.

Note:

If reusing the con rod bearing shells, mark theposition of the upper con rod bearing shell inrelation to the con rod body.

10A-33


F9Q

10A

a Screw the head of the tool (Mot. 1920) for F9Q engi-nes onto the sleeve of the tool (Mot. 1914).

a Position the lower con rod bearing shell on the tool(Mot. 1920).

a

Fit the lower con rod bearing shell on the con rodcap using the tool (Mot. 1920).

a Position the lower con rod bearing shell so that theends do not protrude beyond the con rod cap.

a Lubricate the surface of the con rod bearing shell(crankshaft end) using new engine oil.

133814

133815

Note:

The contact surface between the bearing shelland the con rod must be dry and free of grease.

10A-34


F9Q

10A

a Position the upper con rod bearing shell on the tool(Mot. 1920).

a Fit the upper con rod bearing shell on the con rodbody using the tool (Mot. 1920).

a Position the lower con rod bearing shell so that theend do not protrude beyond the con rod body.


a Push the con rod - piston assembly back up into pla-ce.

a Turn the crankshaft 90 anticlockwise.

a Lubricate the crankpin with new engine oil.

a Pull the con rod - piston assembly to position the conrod on the crankshaft.

a

Refit:

- the con rod cap according to the mark made duringremoval,

- the new con rod bolts.

a Torque and angle tighten the con rod cap bolts (25N.m + 110 10 ).

II - REMOVAL - REFITTING OPERATIONS FOR THE CON ROD BEARING SHELLS ON CYLINDERS NO.3, 1 AND 4

a Perform the same removal - refitting operations asfor the con rod bearing shells on cylinder no. 2.


a parts always to be replaced: engine oil sumpseal (10,03,01,09)parts always to be replaced: Oil filter (10,05,05,03)parts always to be replaced: Engine oil sumpdrain plug seal (10,03,01,04)

a Refit the oil pump (see 10A, Engine and cylinderblock assembly, Oil pump: Removal - Refitting,page 10A-80) .

a Refit the engine oil sump (see 10A, Engine and cy-linder block assembly, Sump: Removal - Refit-ting, page 10A-6) .


a Refit the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-53) .

a Disconnect the crankshaft position sensor to preventthe engine from starting.


a Start the engine using the starter until the engine oilwarning light goes out.

a Connect the crankshaft position sensor.

a Refit the engine undertray.

a Clear the present faults using the diagnostic tool.

139318

Note:

Before refitting the con rod cap, ensure that thereare no impurities (filings, cloth lint, etc.) on thecon rod body or cap surfaces.

Note:

For removing and refitting the con rod bearingshells on cylinders no. 1 and no. 4, position thepistons at Bottom Dead Centre before performingthe same removal and refitting operations as forthe con rod bearing shells on cylinder no. 2.

10A-35


K9K

10AREMOVAL




a Drain the oil from the engine (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-43) .

a Remove the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-53) .

a Remove the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting, page 19D-36) .

a Strap the radiator to the vehicle using safetystrap(s).

a Remove the clips from the front wheel arch liners onthe radiator mounting cross member.

a Remove the side reinforcement mountings on theradiator mounting cross member (1) .

a Remove the radiator mounting cross member wi-thout removing the front bumper (see Radiator sup-port cross member: Removal - Refitting) (31A,Front axle components).


Mot. 1914 Tool for fitting G9 con rodbearing shells

Mot. 1920 Tool for fitting F9 / K9 con rodbearing shells

Essential equipment

safety strap(s)component jackindelible pencil

torque wrench

diagnostic tool

Tightening torquesm

con rod cap bolts 20 N.m + 45 6

oil pump bolts 25 N.m

IMPORTANTTo avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Vehicle: Precautions for repair) .

IMPORTANTWear leaktight gloves (Nitrile type) for this opera-tion.

101212

10A-36


K9K

10A

a Remove the relay bearing of the front right-handwheel driveshaft.

a Disconnect the oil level sensor connector (if equip-ped) (2) .

a Remove the catalytic converter upstream stay (3) .

a

Undo the bolts of the engine oil sump.a Fit a component jack to support the engine oil

sump.a Remove the bolts from the engine oil sump.a Detach the engine oil sump, while supporting it with

the component jack.

123838

123834

112328

140940

WARNINGFailure to observe the following procedure maydamage the oil pump strainer.

10A-37


K9K

10A

a Tilt the engine oil sump forwards in order to accessthe oil pump bolts.

a Partially loosen the oil pump bolts 3 mm to 5 mm.a Detach the oil pump from its position in order to re-

move the engine oil sump.a Remove:

- the engine oil sump,- the engine oil sump seal,- the oil pump.

II - REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO.2

a Use SURFACE CLEANER (see Vehicle: Partsand ingredients for the repairwork) (04B, Consu-mables - Products) to clean the big ends.

a Mark the position of the con rod cap in relation to thecon rod body using a indelible pencil.

a Position the crankshaft at Top Dead Centre.

140917

139306

10A-38


K9K

10A

a Remove:

- the con rod bolts,- the con rod cap,- the lower con rod bearing shell.

a Use SURFACE CLEANER (see Vehicle: Partsand ingredients for the repairwork) (04B, Consu-mables - products) to clean the bearing mating faceon the con rod cap.

a Fit the tie rod of the tool (Mot. 1914) on the con rodbody.

a Push the con rod upwards to release the con rodfrom the crankpin.

a Turn the crankshaft 90 clockwise (timing end).

139300

Note:

If reusing the con rod bearing shells, mark theposition of the lower con rod bearing shell in rela-tion to the con rod cap.

139310

10A-39


K9K

10A

a

Pull the con rod - piston assembly using the tie rod ofthe tool (Mot. 1914), taking care not to allow the pis-ton to touch the piston base cooling jets.

a Remove the upper con rod bearing shell.

a Use SURFACE CLEANER (see Vehicle: Partsand ingredients for the repairwork) (04B, Consu-mables - products) to clean the bearing mating faceon the con rod body.

REFITTING

I - REFITTING OPERATION FOR THE CON ROD BEARING SHELLS ON CYLINDER NO.2a parts always to be replaced: con rod cap bolts

(10,03,02,10)

a

Fit the head of the tool (Mot. 1920) with the marking" K9K INF " on the threaded sleeve of the tool (Mot.1914).

a Position the lower con rod bearing shell on the tool(Mot. 1920).

139315

WARNINGFailure to observe the following procedure maydamage the piston base cooling jets.

Note:

If reusing the con rod bearing shells, mark theposition of the upper con rod bearing shell inrelation to the con rod body.

Note:

Always replace con rod bearing shells with awidth of 20 mm by con rod bearing shells with awidth of 18 mm.If the set of con rod bearing shells only includescon rod bearing shells which are 18mm wide,only use the head of the tool (Mot. 1920) with themarking " K9K SUP ".

10A-40


K9K

10A

a

Fit the lower con rod bearing shell on the con rodcap using the tool (Mot. 1920).

a Position the lower con rod bearing shell so that theends do not protrude beyond the con rod cap.


a Remove the tool head with the marking " K9K INF "and fit the head with the marking " K9K SUP ".

a Position the upper con rod bearing shell on the tool(Mot. 1920).

a Fit the upper con rod bearing shell on the con rodbody using the tool (Mot. 1920).

a Position the upper con rod bearing shell so that theends do not protrude beyond the con rod body.


a Push the con rod - piston assembly back up into pla-ce.

a Turn the crankshaft 90 anticlockwise.

a Lubricate the crankpin with new engine oil.

a Pull the con rod - piston assembly to position the conrod on the crankshaft.

a

Refit:- the con rod cap according to the mark made during

removal,

- the new con rod bolts.a Torque and angle tighten the con rod cap bolts (20

N.m + 45 6).

133814

133815

Note:

The contact surface between the bearing shelland the con rod must be dry and free of grease.

139318

Note:

Before refitting the con rod cap, ensure that thereare no impurities (filings, cloth lint, etc.) on thecon rod body or cap surfaces.

10A-41


K9K

10AII - REMOVAL - REFITTING OPERATIONS FOR THE CON ROD BEARING SHELLS ON CYLINDERS NO.3, 1 AND 4

a Perform the same removal - refitting operations asfor the con rod bearing shells on cylinder no. 2.


a parts always to be replaced: engine oil sumpseal (10,03,01,09)parts always to be replaced: Oil filter (10,05,05,03)parts always to be replaced: Engine oil sumpdrain plug seal (10,03,01,04)

a Use a wooden spatula or an ABRASIVE PAD toclean the joint face of the cylinder block and engineoil sump.

a Refit the oil pump.

a Fit without tightening the oil pump bolts, while kee-ping a clearance of 3 mm to 5 mm.

a Fit the engine oil sump seal.

a Apply SILICONE ADHESIVE SEALANT (see Vehi-cle: Parts and ingredients for the repairwork) :- four beads with a diameter of 5 mm at (A) ,- two drops with a diameter of 5 mm at (B) .

a Fit the engine oil sump while supporting it using acomponent jack.

Note:

For removing and refitting the con rod bearingshells on cylinders no. 1 and no. 4, position thepistons at Bottom Dead Centre before performingthe same removal and refitting operations as forthe con rod bearing shells on cylinder no. 2.

WARNINGDo not scrape the joint faces of the aluminium,any damage caused to the joint face will result ina risk of leaks.

WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-ger marks).

WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.).

20166

20167

10A-42


K9K

10A

a Tilt the engine oil sump forwards in order to accessthe oil pump bolts.

a Torque tighten the oil pump bolts (25 N.m) usingthe torque wrench PROSTEEL, part number 77 11226 888 starting with the 13 mm bolt.

a

a Refit the engine oil sump bolts.a Torque tighten in order the engine oil sump bolts

(see 10A, Engine and cylinder block assembly,Sump: Removal - Refitting, page 10A-6) .

a Refit the catalytic converter upstream stay (see 19B,Exhaust, Catalytic converter: Removal - Refit-ting, page 19B-46) .

a Connect the connector to the oil level sensor.a Refit the relay bearing of the front right-hand wheel

driveshaft (see Front right-hand wheel driveshaft:Removal - Refitting) .

a Refit the radiator mounting cross member (see Ra-diator support cross member: Removal - Refit-ting) (31A, Front axle components).

a Refit the side reinforcement mountings on the radia-tor mounting cross member.

a Refit the mountings of the front right-hand wheelarch liner on the radiator mounting cross member.

a Remove the safety strap(s) from the radiator.


a Disconnect the crankshaft position sensor (4) to pre-vent the engine from starting.

a Refit the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-53)


a Start the engine using the starter until the engine oilwarning light goes out.

a Connect the crankshaft position sensor.


a Clear the present faults using the diagnostic tool.

140918

Note:

Check that the engine oil sump seal is definitelyin place before tightening the engine oil sumpbolts.

123824

10A-43

ENGINE AND CYLINDER BLOCK ASSEMBLYEngine oil: Draining - Refilling

F4R

10A

I - OIL SERVICEa Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).

naturally aspirated engine

turbocharged engine

a Remove:

- the oil filler cap (3) ,- the dipstick (2) .



Mot. 1018 Sump plug tool.

Essential equipment

oil recovery container

8 mm square drain plug socket

Tightening torquesm

drain plug 20 N.m

Engine

Average oil capacity (check and adjust with

dipstick) (l)Oil changewithout oilfilter repla-cement

Oil changeplus oil fil-ter replace-ment

F4R 5.2 5.3

102739

106506

10A-44


F4R

10Anaturally aspirated and turbocharged engines

a Fit a oil recovery container under the engine oildrain plug.

a Remove the drain plug (3) using the (Mot. 1018).a Allow the engine oil to flow into the oil recovery con-

tainer.

a Refit the new seal to the drain plug (no direction offitting).

a Torque tighten the drain plug (20 N.m) using a 8mm square drain plug socket.


II - FILLINGa

a Use a funnel to fill the engine with engine oil recom-mended by the manufacturer (see Engine oil: Spe-cifications) (Technical Note 6013A, 04, Lubricants).

a Check the level on the dipstick.a Refit the engine oil filler cap.

106084

113765

WARNINGAlways check the oil level using the dipstick.Do not exceed the maximum level on the dipstick(as this could damage the engine).Correct the engine oil level if necessary beforedelivering the vehicle to the customer.

Note:

Prevent oil outflow on the engine to avoid dama-ging the surrounding components.

Note:

When filling up the engine oil, always leave atleast 10 minutes for the oil to drain down beforechecking the level on the dipstick.

10A-45



10A



a Remove the oil filler cap fitted with the dipstick (1) .a Remove the engine undertray.



tainer.



Essential equipment



Tightening torquesm

drain plug (with a rolledcopper seal)

44 N.m

drain plug (with a flatcopper seal)

50 N.m

Engine

Average oil capacity (check and adjust with

dipstick) (l)Oil changewithout oilfilter repla-cement

Oil changeplus oil fil-ter replace-ment

M9R 7006.2 6.6

M9R 722

M9R 724 7 7.4

114770

114651

10A-46



10ACopper seal

a

a Fit:

- the new seal on the drain plug (3) (if the seal is rol-led, orient the groove (4) towards the plug),

- the drain plug on the sump.a Using a 8 mm square drain plug socket, torque ti-

ghten the:- drain plug (with a rolled copper seal) (44 N.m),- drain plug (with a flat copper seal) (50 N.m).


II - FILLINGa


a Check the level on the dipstick.

a Refit the engine oil filler cap.

113764

Note:

There are two types of drain seals for this engine:- rolled copper seals,- flat copper seals.


Note:


Note:

When filling up the engine oil, always leave atleast 10 minutes for the oil to drain down beforechecking with a dipstick.

10A-47


K9K

10A



a Remove:

- the oil filler cap (1) ,- the dipstick (2) .




tainer.



Essential equipment



Tightening torquesm

drain plug 20 N.m

Engine

Average oil capacity (check and adjust with dipstick) (l)

Oi l changewithout oil fil-ter replace-ment

Oi l changeplus oil filterreplacement

K9K 4.4 4.5

101531

101533

10A-48


K9K

10A




II - FILLINGa



113765


Note:


Note:


10A-49


K4J or K4M

10A

I - OIL SERVICE


a Remove:

- the oil filler cap (1) ,- the dipstick.


a Fit a oil recovery container under of the engine oildrain plug.


tainer.






Essential equipment



Tightening torquesm

drain plug 20 N.m

Engine

Average oil capacity (adjust using dipstick) (litres)

o i l c h a n gewithout oil filterreplacement

Oil change plusoil filter replace-ment

K4J, K4M 4.7 4.8

101530

18749

113765

10A-50


K4J or K4M

10AII - FILLINGa


a Check the level on the dipstick.

a Refit the engine oil filler cap.


Note:


Note:


Note:

When filling up the engine oil, always leave atleast 10 minutes for the oil to drain down beforechecking with a dipstick.

10A-51


F9Q

10A



a Remove:

- the oil filler cap (1) ,- the dipstick.




tainer.



Essential equipment



Tightening torquesm

drain plug 20 N.m

Engine

Average oil capacity (adjust using dipstick) (litres)

o i l c h a n gewithout oil filterreplacement

Oil change plusoil filter replace-ment

F9Qwithoutparticle fil-ter

4.5 4.6

F9Q withparticle fil-ter

4.7 4.9

101529

19120

10A-52


F9Q

10A

a Fit the new seal to the drain plug (no direction of fit-ting).



II - FILLINGa



113765


Note:


Note:


10A-53

ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - Refitting


10A

REMOVAL

I - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).a Remove:

- the engine undertray bolts,- the engine undertray.


a Position the (Mot. 1329) (1) on the oil filter.a Remove the oil filter.

REFITTING

I - REFITTING PREPARATION OPERATIONa Lubricate the oil filter seal with new engine oil.

II - REFITTING OPERATION FOR PART CONCERNEDa Tighten the oil filter until it comes into contact with

the oil filter seal on the oil-water heat exchanger.

a Tighten the oil filter three-quarters of a turn by hand.

III - FINAL OPERATIONa Wipe any oil run-off with a cloth.a Top up the engine oil.a Refit the engine undertray.


Mot. 1329 Oil filter removing tool (76mm diameter).

111850

10A-54



10A




a Remove:

- the mounting bolts (1) from the air conditioningcompressor stay.

- the air conditioning compressor stay.


REFITTINGa Lubricate the oil filter seal with new engine oil.a Tighten the oil filter until it comes into contact with

the oil filter seal on the engine.a Tighten the oil filter 3/4 of a turn by hand.a Refit the air conditioning compressor strut.a Torque tighten the air conditioning compressor

stay mounting bolts (44 Nm).a Top up the engine oil.a Wipe any oil run-off with a cloth.a Refit the engine undertray.



Tightening torquesm

air conditioning com-pressor stay mountingbolts

44 Nm

111851

111852

10A-55


B84 or C84 or G84 or S84, and K4M B84 or C84 or G84 or S84, and K4J

10A





REFITTINGa Lubricate the oil filter seal with new engine oil.a Tighten the oil filter until it comes into contact with

the oil filter seal on the engine.a Tighten the oil filter by hand 3/4 of a turn.a Top up the engine oil.a Refit the engine undertray.



110385

10A-56



10A

REMOVAL




a Undo the cover (1) of the oil filter unit until the hole(2) appears.

a Allow the engine oil to flow out.

II - REMOVAL OPERATION FOR PART CONCERNED

a Remove:

- the cover (3) - filter element (4) assembly,- the cover seal (5).

REFITTING

I - REFITTING PREPARATIONS OPERATIONa Clean the oil filter unit cover.

Tightening torquesm

cover 25 N.m

125075

113320

10A-57



10A

a Fit:

- a new seal on the cover,

- a new filter cartridge in the cover.

II - REFITTING OPERATION FOR PART CONCERNEDa Manually fit the cover - filter element assembly.a Torque tighten the cover (25 N.m).

III - FINAL OPERATION.a Refit the engine undertray.a Fill the engine with engine oil recommended by the

manufacturer (see Engine oil: Specifications)(Technical Note 6013, 04A, Lubricants).

a Start the engine and let it run until the oil pressurewarning light goes off.

113869

WARNINGAlways check the oil level using the dipstick.Do not exceed the maximum level on the dipstick(could destroy the engine).Correct the engine oil level if necessary beforedelivering the vehicle to the customer.

Note:


10A-58


B84 or C84 or G84 or S84, and F9Q

10A

If the AC pipe is significantly deformed when the oil fil-ter is removed, there may be a refrigerant leak.To manage the risk of a leak in the MEGANE II andSCENIC II equipped with F9Q engine, the ADVICE inthis Technical Note relating to the removal of the oil fil-ter from the TOP OF THE ENGINE must be strictly fol-lowed.

REMOVAL



a Remove:

- the engine covers,- the engine undertray.


II - REMOVING THE OIL FILTER

a From the top of the engine, position the (Mot. 1329)with a 27 mm open-jawed spanner on the oil filter.

a Remove the oil filter.

REFITTING

I - REFITTING PREPARATIONS OPERATIONa Lubricate the new oil filter seal.

II - REFITTING THE OIL FILTERa Tighten the oil filter until it makes contact.a Tighten the oil filter 3/4 of a turn by hand.

III - FINAL OPERATION.a Top up the engine oil (see 10A, Engine and cylin-


a Refit:- the engine undertray,- the engine covers.



115078

10A-59

ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter unit: Removal - Refitting


10A

REMOVAL



a Remove the front engine cover.

a Disconnect the battery (see Battery: Removal - Re-fitting) (80A, Battery).

a Remove:

- the engine undertray bolts,


- the oil filter (see 10A, Engine and cylinder blockassembly, Oil filter: Removal - Refitting, page10A-53) ,

- the front bumper (see Front bumper: Removal -Refitting) (55A, Exterior protection).

a Drain the refrigerant circuit using a refrigerant char-ging station (see Coolant circuit Draining - Refil-ling) (62A, Air conditioning).

a Unclip the air inlet scoop (1) .

a Remove:

- the engine accessories unit cover bolts (2) ,- the engine accessories unit cover.


Car. 1363 Set of tr im removal levers.

Mot. 1448 Long nose pliers for hoseclips.

Essential equipment

refrigerant charging station

Tightening torquesm

oil filter unit bolts (2)and (4) (initial torque)

5 N.m

oil filter unit bolts 25 N.m

intercooler air inlet pipe 5.5 N.m

intercooler air outletpipe

5.5 N.m

front end panel lowerbolts

44 N.m

front end panel upperbolts

21 N.m

114933

112658

10A-60



10A

a Disconnect the connectors (3) from the engine ac-cessories unit.

a Unfasten the bonnet opening cable (4) .a Remove:

- the front end panel clips (5) ,- the front end panel upper bolts (6) .

a Disconnect the screen washer pipes.

a Remove:- the front end panel lower bolts (7) ,- the front panel,- the air inlet scoop.

a Drain the engine cooling system (see 19A, Cooling,Cooling circuit: Draining - Refilling, page 19A-15).

a Remove the bolts (8) from the intercooler air outletpipe.

a Undo the clip on the intercooler air outlet pipe (9) atthe intercooler end.

a Disconnect:

- the intercooler air outlet pipe at the intercooler end,

- the pipes between the expansion bottle and thecooling radiator (10) on the cooling radiator side,

- the evaporator-condenser connecting hose pres-sure sensor connector (11) .

a Unclip the wiring of the pressure sensor connectoron the engine cooling fan assembly.

a Remove:

- the bolt (12) of the condenser - evaporator con-necting pipe on the condenser side,

- the bolt (13) of the compressor - condenser connecting pipe on the condenser side.

a Disconnect:

- the condenser - evaporator connecting pipe onthe condenser side,

- the compressor - condenser connecting pipeon the condenser side.

115585

102365

115023

WARNINGTo prevent moisture from entering the system,place plugs on the cold loop components whichare open to the air.

10A-61



10A

a Disconnect:

- the engine cooling fan assembly resistor connector(14) ,

- the engine cooling fan assembly connector.a Unclip the engine cooling fan assembly wiring.

a Undo the clip (15) for the air-air intercooler air inletpipe at the air-air intercooler end.

a Detach the pipe using the tool (Car. 1363).a Separate the clip on the top pipe of the cooling radia-

tor using the tool (Mot. 1448).a Disconnect:

- the top cooling radiator pipe,- the intercooler air inlet pipe at the intercooler end.

a Remove the motor-driven fan assembly - coolingradiator - condenser - intercooler assembly.

112661 115703

10A-62



10A

a Remove:

- the clip (16) on the pipe of the oil filter unit coolantinlet union using the tool (Mot. 1448),

- the clip (17) on the pipe of the oil filter unit coolantoutlet union using the tool (Mot. 1448).

a Disconnect the pipe from the oil filter unit coolant in-let union.


a Remove the bolts (18) from the oil filter unit.a Disconnect the pipe from the oil filter unit coolant

outlet union.

a Remove the oil filter unit.

REFITTING


If replacing the oil filter unit:a Remove the oil pressure sensor (see 10A, Engine

and cylinder block assembly, Oil pressure sen-sor: Removal - Refitting, page 10A-71) from the oilfilter unit.

a Refit the oil pressure sensor (see 10A, Engine andcylinder block assembly, Oil pressure sensor:Removal - Refitting, page 10A-71) on the new oilfilter unit.

a Always replace the seal between the oil filter unitand the cylinder block.

116380

116381

10A-63



10Aa Clean:

- the cylinder block gasket face,- the oil filter unit seal housing if being reused.


a Connect the pipe on the oil filter unit coolant outletunion.

a Refit the oil filter unit.

a Fit the oil filter unit bolts, without tightening them.a Torque tighten the oil filter unit bolts (2) and (4)

(initial torque) (5 N.m).a Tighten to torque and in order the oil filter unit

bolts (25 N.m).

III - FINAL OPERATIONa Connect the pipe on the oil filter unit coolant inlet

union.

a Fit:

- the clip on the pipe of the oil filter unit coolant outletunion using the tool (Mot. 1448),

- the clip on the pipe of the oil filter unit coolant inletunion using the tool (Mot. 1448).

a Refit the motor-driven fan assembly - cooling ra-diator - condenser - intercooler assembly.

a Connect:

- the bottom cooling radiator pipe,

- the top cooling radiator pipe.

a Fit:

- the clip on the bottom cooling radiator pipe usingthe tool (Mot. 1448),

- the clip on the top cooling radiator pipe using thetool (Mot. 1448).

a Connect the intercooler air inlet pipe to the intercoo-ler.

a Torque tighten the intercooler air inlet pipe (5.5N.m).

a Connect the engine cooling fan assembly connector.

a Clip the engine cooling fan assembly wiring.

a Connect the engine cooling fan assembly resistorconnector.

a Remove the blanking plugs from the connecti

megane 2 manual 2006

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