USER MANUAL C. Engine - V
Contents
1. The switch 3 on the control panel is used to activate the fuel pump The hose part no 77 11 160444 is connected to the quick fit coupling 1 to drain the fuel tank RENAULT SPORT C 13 2010 Release CLIO HI Note You are advised to stop the tank draining right from the first signs of any air bubbles in fuel at the draining pipe end Therefore the tank draining is not complete and a few fuel quantity stay in the tank variable from a car to an other because it cannot be drained by this method In order to prevent annoyances from a technical non conformity following a fuel check you are advised to apply the tank draining procedure and to use the official fuel right from the free sessions before the current event RENAULT SPORT C 14 2010 Release CLIO HI Injection ECU The injection ECU controls engine operation It also incorporates the data acquisition system A It is strictly forbidden to open the ECU It is delivered with security labels 1 If these labels are missing this can be considered a technical non compliance The decal 2 precise the last upgrade made by Renault Sport For the F4R 832 2010 the decal version is 2010 1 Water temperature sensor Water temp EVO 2010 The water temperature sensor 1 is fitted to the water outlet unit It has changed in the 2010 evolution with the connector of the engine loom 2 This information allows2. SETE RENAULT SPORT RENAULT 2010 Release 2 ENGINE CONTENTS 2 ENGINE 1 ENGINE 1 1 ENGINE IDENTIFICATION 1 2 CHARACTERISTICS ENGINE EVOLUTION F4R832 2010 1 3 LUBRICATION 1 4 SEALED PARTS 1 5 REMOVAL amp REFITTING OF THE POWERTRAIN 2 FUEL MIXTURE 2 1 PRESENTATION 2 2 OPERATING PRINCIPLE 3 STATIC IGNITION 3 4 4 5 5 5 5 5 6 1 DESCRIPTION POWER SUPPLY 1 DESCRIPTION 2009 RELI ABILITY 1 5V ACCESSORY BELT 77 11 162 521 2 ENGINE STARTER amp HEAT SHIELD 3 ENGINE STARTER LOOM 4 TIMING BELT PROTECTIVE SCREEN TIGHTENING TORQUES NNNNNNNNNNNNNNNNNNN RENAULT SPORT C 2 CLIO HI 2010 Release CLIO HI 2 1 ENGINE 2 1 1 ENGI NE I DENTI FI CATI ON The engine is identified by an engraving located on the engine block It includes In A the engine type and homologation letter In B the engine index In C the engine manufacturing number There is a reminder of the engine manufacturing number on the camshaft blanking cover plate If the number indicated on the camshaft blanking cover plate does not correspond with the one engraved on the engine the latter is correct A Any procedure carried out on the engine not included in this manual must be performed by a Renault Sport accredited engine partner RENAULT SPORT C 3 2010 Release CLIO HI 2 1 2 CHARACTERISTICS ENGINE EVOLUTION F4R832 2010 Type F4R 832 Number of cylinders 4 inline
3. Number of valves 16 Bore 82 mmM Travel 93mm Capacity 1998 cm3 Compression ratio 11 5 1 Max power 152 3kW 207bhp at 7 300rpm Max torque 223Nm 22 7m kg at 5 550 rpm Max engine speed 7 500rpm 5 000rpm in neutral F4R 832 engine performances Cup version 210 80 190 70 170 60 Power bhp 150 Torque 50 mkg 130 110 90 19 50 2000 3000 4000 5000 6000 7000 8000 Engine speed rpm Homologation The homologation number for the catalytic converter is ROSI 50181 2 1 3 LUBRI CATI ON A The minimum quantity of engine oil is 4 litres To prevent any oil surge it is essential to drive with a minimum of 4 litres First oil change antes After 500km Every 1 000km Elf Exelcium 5W40 RENAULT SPORT C 4 2010 Release CLIO 1 2 1 4SEALED PARTS A The engine has sealed parts The presence of these sealed parts is mandatory No procedure may be carried out on the engine unless by representatives of Renault Sport The following sections are sealed The camshaft The timing cover The sump RENAULT SPORT C 5 2010 Release CLIO HI 2 1 5REMOVAL amp REFITTING OF THE POWERTRAIN Removal Operations Photos Disconnect the battery Remove the drivetrain nuts Raise the vehicle Remove the front bumper Remove the front crossmember Attach the radiator to the engine using plastic clips or a strap Remove the air box and i
4. e allowed in 2010 The old one 77 11 162 255 is no longer available Assembly recommandation Fit some sealing paste on the timing pinion cover before mounting the protective screen as shown on the picture below RENAULT SPORT C 26 2010 Release CLIO HI 2 6 TIGHTENING TORQUES Components Tightening torques in Nm Gearbox buffer mounting on left side member Connecting torque rod yoke on gearbox spacer Gearbox mounting on gearbox Connecting torque rod on the yoke Engine suspension on the side member Gearbox mounting on the gearbox buffer mounting Connecting torque rod on the subframe Engine mounting cover on the engine suspension Engine mounting cover on the engine mounting a RENAULT SPORT C 27
5. ft and right subframe tubular trusses r f 77 11 160 147 et 77 11 160 146 Unscrew these 3 screws 13 Remove the inferior protection plate Remove the subframe see 4 2 Front axle Removing the subframe Remove the drivetrain Extract the drivetrain on the gearbox side Tilt the drivetrain Extract the drivetrain on the wheel side Place the powertrain on a hydraulic plate Remove the lower crossmember Remove the front end 2010 Release CLIO H1 Separate the engine mounting when removing the shaft 1 27 Separate the gearbox mounting 2 28 Release the shaft Remove the three mounting bolts Take out the powertrain and lower the hydraulic oo plate RENAULT SPORT C 10 2010 Release CLIO H1 Refitting Carry out the previous operations in reverse order A When refitting the powertrain it is important to comply with the following positioning procedure for the powertrain in order to guarantee the operational clearances required for the drivetrain Operations Components Photos Assembly torque Gearbox buffer mounting 1 tightening 75 Nm 1 on the left side member gt Assembly torque Connecting torque rod yoke tightening 62Nm 5 on the gearbox spacer Gearbox mounting 2 on 3 poet Lone gearbox buffer mounting tightening 75Nm 1 Connecting torque rod on d ie subframe rubber buffer on screwing subframe side 5 Assembly pre Engine suspensio
6. ge with the starter activated greater than 8 volts Below this threshold the battery must be charged or replaced A In order to avoid damage to the ECU it is not advisable to use a battery booster Operation in downgraded mode The ECU performs a self diagnostic from input parameters and warns the driver of an abnormal measurement by means of an alarm on the instrument panel The alarm is activated on the instrument panel as soon as the fault is present Each alarm is registered in the form of a diagnostic code in the data acquisitions In the event of an abnormal parameter the ECU works in downgraded mode with a default value for the faulty input These values are Air temperature 20 C Water temperature 98 C Throttle potentiometer 98 ntake pressure reconstituted from a map indexed on speed throttle RENAULT SPORT C 21 2010 Release CLIO H1 2 3 STATIC IGNITION 2 3 1 DESCRIPTION General The system includes The ECU which incorporates the ignition power stage A module comprised of two twin outlet coils Four spark plugs A high voltage wiring harness att Lb of Ove i Injection ECU The injection ECU controls engine operation It also incorporates the data acquisition system Coils 1 The coil box is fitted above the front right wheel arch It is made up of 2 ignition coils Each coil is controlled separately by the ECU and causes two sparks simultaneousl
7. n 3 on screwing the right side member Assembly pre Engine mounting cover 4 6 on the engine suspension screwing 3 RENAULT SPORT C 11 2010 Release CLIO HI 7 Fitting of engine in the engine compartment from below 8 Torque tightening 75Nm 9 Torque tightening 10 Torque tightening 11 Torque tightening 12 Torque tightening 13 Torque tightening 14 Torque tightening RENAULT SPORT 105Nm 62Nm 62Nm 105Nm 105Nm 105Nm Gearbox mounting 2 on the gearbox Connecting torque rod on yoke 5 Engine mounting cover 4 on the engine mounting 6 Engine suspension 3 on the right side member Gearbox mounting 2 on the gearbox buffer mounting Connecting torque rod on the subframe Engine mounting cover 4 on the engine suspension C 12 2010 Release CLIO HIJ 2 2 FUEL MIXTURE 2 2 1PRESENTATION Fuel circuit Fuel pump assembly Flow 80lph Pressure 3 5 bar The fuel pump assembly is immersed in the fuel tank 1 Fuel outlet 2 Connector 3 Electric pump 5 Pressure regulator 6 Dipstick 4 Fuel filter located in the body of the assembly This filter cannot be replaced The pump is controlled by the ECU as soon as the ignition is switched on and the engine is running If 3 seconds after the ignition has been switched on the engine does not start the pump stops Draining the fuel tank
8. nt system Injection ECU Water temperature sensor Air temperature sensor ntake pressure sensor Crankshaft phase sensor Camshaft phase sensor INTAKE camshaft dephaser solenoid valve Oxygen sensor Engine cut off switch Barrel position sensor Throttle position sensor Oil pressure sensor Power Coil Starter Cooling Motor fan Schematic diagram Battery V Water Air Oil Intake temp temp pressure pressure Crankshaft phase Oxygen sensor Barrel position AA Le Throttle position Camshaft J g ana cut off phase Injection ECU Dephaser Injectors solenoid valve N _ Coils Oxygen probe neaug Fuel pump Motor fan Starter RENAULT SPORT C 20 2010 Release CLIO HI Starting Starting from cold is made easier if the electrics are switched on by the circuit breaker button 1 on the control panel In this case the ECU performs a cold start It controls the fuel pump then after the engine start command performs wall wetting injections Also if cold starting fails it is advisable to turn off the general power supply and repeat the engine start procedure Deceleration cut off When the throttle is fully closed and the engine speed is greater than 3 000rpm the injectors are no longer controlled Injection is reestablished in one of the following two cases Throttle opening 10 Engine revs are less than 3 000rpm Battery voltage The ECU requires a volta
9. ntake pipe Disconnect the accelerator cable 1 at the throttle valve N B To avoid a wear out of the cable through scrubbing on the body the use of a collar is allowed Disconnect the brake booster vacuum pipe 2 at the intake manifold Disconnect the wiring harness 3 at the bulkhead and bring it back to the engine RENAULT SPORT C 6 2010 Release CLIO HI Disconnect the power wiring harness 4 at the 11 starter N B The use of a thermic protection on the cable is preconized 12 Disconnect the power wiring harness 5 at the alternator 13 Disconnect the engine cooling fan wiring harness 6 at the fan 14 Disconnect the earth cable 7 from the gearbox RENAULT SPORT C 7 2010 Release 15 16 17 18 19 20 21 Disconnect the high voltage wiring harness 8 at the coil box noting the position of each wire Disconnect the gearbox control tie rod 9 Unscrew the reverse gear unlocking cable 10 at the gearbox Disconnect the clutch control pipe 11 at the master cylinder Note Watch out for fluid discharge Disconnect the fuel pipes at the T on the bulkhead side Disconnect the oxygen sensor Disconnect the exhaust line at the manifold 12 RENAULT SPORT C 8 CLIO HI 2010 Release CLIO HIJ 22 23 24 25 26 27 28 29 RENAULT SPORT C 9 Cut the 2 plastic collars fixed to the le
10. port Spare Parts Department These parts can be fitted directly on the car without any modification Nevertheless the heat shield ref 77 11 162 618 Is especially designed for the starter motor ref 77 11 162 617 which is smaller gt As a consequence only this new heat shield can be fitted on the new starter motor The heat shield is now tightened directly on the engine with a M10 screw ref 77 03 002 912 Tightened on the engine block RENAULT SPORT C 24 2010 Release CLIO 1 2 5 3 ENGINE STARTER LOOM Otherwise Renault Sport recommends you to mount your starter motor loom as shown on the pictures below e Mount the plastic bracket on the lowest thread stud 1 e Put one cable through each plastic buckle 2 e Connect the loom to the starter motor from the engine block side 3 o It could be needed to bend the cable terminal in order to prevent from touching the solenoid excitation 4 e Pass the loom through a metal support fitted on the engine block 5 Exhaust f heat shiel Solenoid NOTE Old parts are no onger available RENAULT SPORT C 25 2010 Release CLIO HII 2 5 4 TIMING BELT PROTECTIVE SCREEN To strongly improve the timing belt protection The timing belt protective screen has been replaced by the new screen below under the new reference 77 11 162 626 These protective screens will be mounted on the 2010 F4R832 Clio Cup engines Only the new protective screen 77 11 162 626 will b
11. the ECU To control the injection system To control the engine cooling fan assembly as soon as the temperature reaches 95 C To display the water temperature on the display 2 RENAULT SPORT C 15 2010 Release Air temperature sensor Air temp The air temperature sensor 1 is located on the intake manifold This information allows the ECU To control the injection system To display the air temperature on the display Air intake pressure sensor Intake pressure The air intake pressure sensor 1 is located on the intake manifold This information allows the ECU To control the injection system To display the intake pressure on the display Crankshaft phase sensor TDC or S mot This sensor 1 is located on the gearbox spacer This information allows the ECU to specify The Top Dead Centre TDC position The engine speed RENAULT SPORT C 16 2010 Release Camshaft phase sensor EVO 2010 This sensor 1 is located on the air intake side of the cylinder head It has changed in the 2010 Evolution with the connector of the engine loom 2 This information allows the ECU to specify The position of the intake camshaft To control the camshaft dephaser solenoid valve Throttle position sensor The throttle position sensor 1 This information allows the ECU To control the injection system To control the camshaft dephaser solenoid valve To display the
12. throttle position on the display A This sensor must work properly to ensure that the engine operates properly In the event of a fault an alarm message appears on the display An analysis of data acquisition is used to anticipate any faults RENAULT SPORT C 17 2010 Release Oxygen sensor Lambda sensor The oxygen sensor 1 is located on the exhaust manifold This information allows the ECU to control the injection system Camshaft dephaser solenoid valve EVO 2010 This actuator 1 allows under the ECU Control the variable timing of the intake camshaft It has changed in the 2010 evolution with the connector of the engine loom 2 RENAULT SPORT C 18 2010 Release Engine cut off switch Upshift This switch 1 is located at the end of the gearbox control bar This information allows the ECU to control the engine cut off during the gear upshift Barrel position sensor Potentiometer This sensor 1 is located at the end of the gearbox barrel This information allows the ECU to display the gear selected on the display Oil pressure sensor Oil pressure This sensor 1 is located on the engine pressure rail This information allows the ECU to display the oil pressure on the display RENAULT SPORT C 19 2010 Release CLIO HII 2 2 2 OPERATING PRINCIPLE Components comprising the engine management system Fuel circuit Fuel pump Injectors Manageme
13. y The coil for cylinders 1 and 4 is controlled via tracks 56 62 and 63 of the ECU CH2 The coil for cylinders 2 and 3 is controlled via tracks 33 41 and 42 of the ECU CH2 Spark plugs A For correct engine operation it is essential to use spark plugs with part no 82 00 492 426 RENAULT SPORT C 22 2010 Release CLIO HI 2 4 POWER SUPPLY 2 4 1 DESCRI PTI ON The injection circuit is comprised of an aluminium rail 1 and four injectors 2 The fuel circuit is without backflow It is made up of reinforced flexible pipes and screwed unions 3 2 5 2009 RELI ABI LI TY 2 5 1 5V ACCESSORY BELT 77 11 162 521 This new belt has the same length as the old one but only 5V It solves the problem of premature wear encountered on a few cars Please respect the following mounting indications Position on motor pulley Let free the internal groove of the pulley engine side Free grooves Position on alternator pulley Fit the belt in the middle of the pulley letting free both external grooves RENAULT SPORT C 23 2010 Release Position on free pulley Fit the belt in the middle of the pulley letting free both external grooves Free grooves The 6V belt 77 11 162 383 is no longer available 2 5 2 ENGINE STARTER amp HEAT SHIELD A new starter motor ref 77 11 162 617 and a new starter motor heat shield ref 77 11 162 618 are now available at your Renault S
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