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Copying or translating, in part or in full, of this document or use of the service part The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault. in the production of the various component units and accessories from which his vehicles are constructed."...
General Contents Page SPECIFICATIONS Engine - Clutch - Gearbox 01-1 Vehicle identification 01-2 LIFTING Trolley jack - Axle stands 02-1 Underbody lifts 02-2 TOWING All types 03-1 LUBRICANTS AND CONSUMABLES Packaging 04-1 OIL CHANGE AND ENGINE OIL REFILLING Engine 05-1 Gearbox 05-3 Power-assisted steering...
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In degrees: ± 3˚. In daNm: ± 10%. MATERIALS AND TOOLS The repair methods described for the vehicles in the RENAULT range require special materials and tools in certain cases. There is a wide choice in the catalogue of special materials and tools.
SPECIFICATIONS Vehicle identification Vehicle identification LOCATION OF VEHICLE IDENTIFICATION PLATE Vehicle type and chassis number Technical specifications of the vehicle This information is repeated in the marking (B). Vehicle paint reference MGVW (Maximum Gross Vehicle Weight) Equipment level GTW (Gross Train Weight - loaded vehicle with Vehicle type trailer) 10 Trim code...
LIFTING LIFTING Trolley jack - Axle stands Trolley jack - Axle stands Safety symbol (special precautions to be taken when carrying out operations).. ESSENTIAL SPECIAL TOOLS Cha. 280 -02 Adaptor cup for trolley jack Cha. 408-01 Adaptor socket for trolley jack Cha.
LIFTING Underbody lifts Underbody lifts SAFETY ADVICE FRONT Various cases have to be considered: 1 - REMOVING COMPONENTS As a general rule, never use a two-post lift whenever a four-post lift can be used. If this is not possible, place the lifting pads beneath the underbody flange by the tool kit jack supports.
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LIFTING Underbody lifts 2 - REMOVING AND REFITTING HEAVY TOOLING REQUIRED COMPONENTS Straps: WARNING: always use a safety harness if using a – 10 metres long, two-post lift to remove heavy components. – 25 mm wide. For your safety, take care to ensure that the vehicle is Straps are available from SODICAM under Part No.: balanced when placed on a two-post lift.
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LIFTING Underbody lifts FITTING THE SAFETY STRAPS Fastening the vehicle with straps allows work to be carried out beneath the vehicle free from obstruction. The strap must be placed at the front and/or rear of the vehicle during any operation involving the transfer of weight.
TOWING TOWING All types All types OBSERVE THE TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN. NEVER USE THE DRIVESHAFTS AS AN A TTACHMENT POINT. The towing points may only be used for towing the vehicle on the road. They should never be used for removing the vehicle from a ditch or to lift the vehicle, either directly or indirectly.
LUBRICANT CONSUMABLES LUBRICANT CONSUMABLES Packaging Packaging DESCRIPTION PACKAGING PART NUMBER LUBRICANTS MOLYKOTE "BR2" 1 kg tin 77 01 421 145 for main bearing journal faces, thrust pad guide tubes, clutch fork pads, lower suspension arm bearings, torsion bar splines, steering box, driveshaft splines.
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LUBRICANT CONSUMABLES Packaging DESCRIPTION PACKAGING PART NUMBER MECHANICAL SEALANTS AUTO grey seal 100 g tube 77 01 422 750 sealing paste. LOCTITE 518 24 ml syringe 77 01 421 162 for sealing the gearbox housing Leak detector. Aerosol 77 11 143 071 ADHESIVES "LOCTITE-FRENETANCH"...
FLUID CHANGE AND FLUID REFILLING Power assisted steering Power assisted steering CHECKING THE LEVEL POWER ASSISTED STEERING PUMP LEVEL For topping up or filling, use ELF RENAULTMATIC D2 or MOBIL ATF 220 fluid. The level, when correct, should be visible between the MIN and MAX marks on the reservoir (1).
Brake fluids must be approved by the Technical Department Components Capacity in litres Grade Fuel tank Approximately 70 Unleaded petrol Diesel Power assisted steering Separate reservoir ELF RENAULT MATIC D2 or MOBIL ATF 220 Coolant circuit GLACEOL RX K4M-F4P (type D) Add only coolant 07-1...
VALUES AND SETTINGS Accessories belt tensioning Accessories belt tensioning REMOVAL F4P engine Put the vehicle on a 2 post lift. Disconnect the battery. Remove: – the right front mudguard and side protector – the power steering reservoir mounting. Turn the belt's automatic pulley tensioner in the direction indicated below using a 16 mm wrench.
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VALUES AND SETTINGS Accessories belt tensioning K4M engine L7X Engine Swivel the automatic belt tensioner in the direction Tighten the tension wheel using a 9.53 mm square. indicated below using a 13 mm offset ring spanner. Tighten the tension wheel using a 6 mm Allen key (1). Remove the accessories belt.
VALUES AND SETTINGS F9Q engine Procedure for tensioning the timing belt SPECIAL TOOLING REQUIRED Mot. 1505 Tool for checking belt tension Mot. 1543 Tool for pretensioning a belt TENSIONING PROCEDURE The crankshaft groove (4) should be located at the centre of the two ribs (2) on the crankshaft closure Engine cold (ambient temperature) cover, mark (3) on the crankshaft timing sprocket should be offset one tooth to the left of the vertical axis...
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VALUES AND SETTINGS F9Q engine Procedure for tensioning the timing belt Fit the new timing belt by aligning the belt markings with those of the camshaft and crankshaft sprockets. Place the tensioner against the belt by tightening bolt (2) on the tensioner support.
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VALUES AND SETTINGS F9Q engine Procedure for tensioning the timing belt Remove pin Mot. 1054. Fit the crankshaft accessories pulley bolt fitted with the washer numbered 4 included in the tool kit Mot. 1543. NOTE: Do not forget to remove it again when fitting the crankshaft pulley. 16351R 16563R 07-8...
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VALUES AND SETTINGS F9Q engine Procedure for tensioning the timing belt Fit Mot. 1543 and the cover numbered 1 on the crankshaft accessories pulley bolt. 16351-2R1 Apply pretension between the crankshaft timing sprocket and the tensioner using the tool Mot. 1543 and the cover 1, adjusting the torque wrench to a torque of 1.1 daNm.
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VALUES AND SETTINGS F9Q engine Procedure for tensioning the timing belt Connect the sensor of Mot. 1505. Tighten the belt until you reach the recommended fitting value of 88 ± 3Hz by tightening the bolt (2). Tighten the tensioner to a torque of 1 daNm. 16151-5R1 Turn the crankshaft two revolutions.
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VALUES AND SETTINGS F9Q engine Procedure for tensioning the timing belt Refit the pin Mot. 1054 and set the timing at its setting point, (begin to press on the pin a half-tooth before alignment of the mark on the camshaft pulley and that made by the operator on the inner timing housing, to prevent it falling into a crankshaft balance hole).
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VALUES AND SETTINGS K4M engine Procedure for tensioning the timing belt SPECIAL TOOLING REQUIRED Mot. 799 - Tool for immobilising pinions on the toothed timing belt Mot. 1368 Timing pulley tightening tool Mot. 1453 Engine support tool Mot. 1489 Top Dead Centre pin Mot.
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VALUES AND SETTINGS K4M engine Procedure for tensioning the timing belt Mount tool Mot. 1496, on the end of the camshafts. Fitting the belt Check that the crankshaft is resting on the Top Dead The tension wheel and the timing pulley must be Centre pin Mot.
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VALUES AND SETTINGS K4M engine Procedure for tensioning the timing belt Refit: Pre-tighten the tension wheel nut to a torque of – the timing belt, 0.7 daNm. – the pulley by tightening the mounting bolt using Mot. 1368 (to a torque of 4.5 daNm for information Fit the crankshaft accessories pulley by moving the only).
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VALUES AND SETTINGS K4M engine Procedure for tensioning the timing belt Checking the tension and the timing. Checking the tension Turn the crankshaft clockwise twice (timing end), and before the end of the second turn, tighten the pin Mot. 1489 in the cylinder block and move the crankshaft slowly and smoothly to rest on the pin.
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VALUES AND SETTINGS K4M engine Procedure for tensioning the timing belt Fit tool Mot. 1496, on the end of the camshafts. PROCEDURE The second procedure is used for the replacement of all components requiring the slackening of one or more of the camshaft pulleys. All the camshaft nuts must be replaced during this operation.
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Fit the pulley, tightening the mounting bolt using Mot. 1368 (to a torque of 4.5 daNm for information only). Position the RENAULT badge engraved on the camshaft pulley spokes (A) vertically upwards, fit the timing belt on the camshaft pulleys then fit the camshaft pulley locking tool Mot.
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VALUES AND SETTINGS K4M engine Procedure for tensioning the timing belt Fit the crankshaft accessories pulley by pretightening Remove camshaft pulley locking tool Mot. 1490. the bolt (without locking the bolt, clearance of 2 to 3 mm between the bolt and the pulley). Rotate the timing system through six revolutions in a clockwise direction (timing side) using the exhaust Belt tension...
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VALUES AND SETTINGS K4M engine Procedure for tensioning the timing belt Check that the crankshaft is resting on pin Mot. 1489. Checking the timing and the tension Checking the tension Turn the crankshaft clockwise twice (timing end) and before the end of the second turn, tighten the pin Mot.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt SPECIAL TOOLING REQUIRED Mot. 799-01 Tool for immobilising pinions for the toothed timing belt Mot. 1054 Top Dead Centre pin Mot. 1453 Engine support tool Mot. 1496 Tool for setting the camshafts Mot.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Method for undoing the exhaust camshaft pulley Remove the upper toothed pinion from the bracket. and the inlet camshaft dephaser. The operation is performed using tools Mot. 1509 and Mot. 1509-01. 07-21...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Fit: – the upper bolt (3) whilst positioning the spacer (4) of – the spacer (1) of tool Mot. 1509-01 on the stud (2), tool Mot. 1509-01 between the tool and the camshaft bearing cap housing (do not lock the bolt).
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Tighten the shouldered nut (6) and the bolt (7), then Replacing the inlet camshaft dephaser seal bring the pinions of tool Mot. 1509 into contact with the camshaft pulleys by tightening the nuts (8) to a torque Fit the seal of the inlet camshaft dephaser using tool of 8 daNm.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Adjusting the timing WARNING: it is essential to degrease the end of the crankshaft (timing end), the bore and the bearing faces of the timing pinion, the bearing faces of the accessories pulley and the ends of the camshafts (timing side), the bores and the bearing faces of the exhaust camshaft pulley and the inlet camshaft dephaser;...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Check that the ring of the camshaft dephaser is correctly locked (no rotation of the ring to the left or to the right). 07-25...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Fit tool Mot. 1496, on the ends of the camshafts. Incorrect position Remove the old nut from the pulley, the old bolt from the dephaser and replace them with a new Pinned crankshaft nut and bolt (leave a clearance of 0.5 - 1 mm between the nut or the bolt and the camshaft...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt The tension wheel and the pulley must be replaced when the timing belt is replaced. Ensure that the lug (1) of the tension wheel is correctly positioned in the groove (2). Refit: –...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Belt tension Check that there is still a clearance of 0.5 - 1 mm between the nut, the bolt and the camshaft pulleys. NOTE: do not turn the tension wheel in an anti- clockwise direction.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Mark a reference (C) using a pencil between the camshaft pulleys and the camshaft bearing cap housing. REMOVE THE TOP DEAD CENTRE PIN. 07-29...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Lock the flywheel using a large screwdriver, then turn Incorrect position the bolt of the crankshaft accessories pulley though an angle of 115˚ ± 15˚. Fit the camshaft pulley locking tool Mot. 1509 fitted with the additional tool Mot.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Tighten the new bolt of the inlet camshaft dephaser to Pinned crankshaft a torque of 10 daNm. Tighten the exhaust camshaft pulley nut to a torque of 3 daNm. then turn through an angle of 86° ± 16°. Remove tool Mot.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Checking the timing Ensure that the tension wheel marks are in the correct position before checking the timing. Fit the Top Dead Centre pin (check that the marks made previously on the camshaft pulleys are aligned).
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt PROCEDURE The second procedure is used for replacing all components located on the front of the timing which do not require the exhaust camshaft pulley and the inlet camshaft dephaser to be undone.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Check that the crankshaft is pinned on the Top Dead Pinned crankshaft Centre pin and not in the balancing hole (crankshaft groove (5) upwards). Incorrect position 07-34...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Check that the ring of the camshaft dephaser is correctly locked (no rotation of the ring to the left or to the right). 07-35...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt The tension wheel rollers and timing pulley must be replaced when the timing belt is replaced. Ensure that the lug (1) of the tension wheel is correctly positioned in the groove (2). Refit: –...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt NOTE: do not rotate the tension wheel in an anti- clockwise direction. Align the marks (6) and (7) of the tension wheel, using a 6 mm Allen key in (B). Pre-tighten the tension wheel nut to a torque of 0.7 daNm.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Mark a reference (C) on the ring of the inlet camshaft dephaser and the exhaust pulley in relation to the camshaft bearing cap housing. Remove the camshaft setting tool Mot. 1496 for as well as the Top Dead Centre pin, tool Mot.
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Checking the timing and the tension Incorrect position Checking the tension: Rotate the crankshaft through two revolutions in a clockwise direction (timing side). Before the end of the two revolutions (in other words, half a tooth before the marks previously made are aligned), insert the crankshaft Top Dead Centre pin (so as to be between the balancing hole and the pinning hole) then move...
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VALUES AND SETTINGS F4P engine Procedure for tensioning the timing belt Checking the timing: Ensure that the tension wheel marks are in the correct position before checking the setting of the timing. Fit the Top Dead Centre pin (check that the marks made previously on the camshaft pulleys are aligned).
VALUES AND SETTINGS F4P-K4M Tightening the cylinder head Tightening the cylinder head ENGINES CYLINDER HEAD TIGHTENING PROCEDURE The bolts can be reused if the length under the head does not exceed 118.5 mm (F4P engine) or 117.7 mm (K4M engine) otherwise replace all the bolts. REMINDER: Use a syringe to remove any oil which may have entered the cylinder head fastening bolt holes to ensure correct tightening of the bolts.
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VALUES AND SETTINGS F9Q engine Tightening the cylinder head METHOD FOR TIGHTENING THE CYLINDER HEAD REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to ensure correct tightening of the bolts. All cylinder head bolts must always be changed after removal.
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VALUES AND SETTINGS L7X Engine Tightening the cylinder head METHOD FOR TIGHTENING THE CYLINDER HEAD REMINDER: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to ensure correct tightening of the bolts. Pretighten bolt by bolt to 2 daNm in the recommended order.
VALUES AND SETTINGS Brakes Brakes Disc thickness (in mm) Disc thickness (in mm) Max. disc run- Type Front Rear out (in mm) Normal Min. Normal Max. BG0A BG0B 21.5 BG0R BG0R KG0R 23.5 KG0A KG0B BG0A(1) BG0B(1) BG0R(1) 23.5 BG0A* BG0B* BG0R* BG0D...
VALUES AND SETTINGS Underbody height Underbody height at the front At the rear Dimension (X) (in mm) VEHICLE H1-H2 =...mm H4-H5 =...mm LH and RH BG0A KG0A BG0B KG0B BG0D 122.5 KG0D BG0G KG0G BG0R KG0R Tolerence: ± 3.5 mm The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not exceed 5 mm, the driver's side always being higher.
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VALUES AND SETTINGS Underbody height Underbody height MEASUREMENT POINTS 18209 Dimension H2 is measured under the bolt at mounting Dimension H5 is taken under the rear axle bracket. point A of the austral arm. 07-47...
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VALUES AND SETTINGS BG0A Front axle angle checking values Front axle angle checking values with 15’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚46’ H5 - H2 = 28 mm ±30’ 4˚16’ H5 - H2 = 8 mm 4˚46’...
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VALUES AND SETTINGS BG0B with 15’’ tyres Front axle angle checking values POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚49’ H5 - H2 = 26 mm ±30’ 4˚19’ H5 - H2 = 6 mm 4˚49’ H5 - H2 = -14 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0R Front axle angle checking values with 15’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚51’ H5 - H2 = 25 mm ±30’ 4˚21’ H5 - H2 = 5 mm 4˚51’ H5 - H2 = -15 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0A Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚49’ H5 - H2 = 28 mm ±30’ 4˚19’ H5 - H2 = 8 mm 4˚49’ H5 - H2 = -12 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0B Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚52’ H5 - H2 = 27 mm ±30’ 4˚22’ H5 - H2 = 7 mm 4˚52’ H5 - H2 = -13 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0R, BG0G Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚48’ H5 - H2 = 25 mm ±30’ 4˚18’ H5 - H2 = 5 mm 4˚48’ H5 - H2 = -15 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0D Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚48’ H5 - H2 = 25 mm ±30’ 4˚18’ H5 - H2 = 5 mm 4˚48’ H5 - H2 = -15 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0A, BG0B Front axle angle checking values with 17’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚35’ H5 - H2 = 42 mm ±30’ 4˚05’ H5 - H2 = 22 mm 4˚35’ H5 - H2 = 2 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0G Front axle angle checking values with 17’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚37’ H5 - H2 = 41 mm ±30’ 4˚07’ H5 - H2 = 21 mm 4˚37’ H5 - H2 = 1 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0R with 17’’ tyres Front axle angle checking values POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚25’ H5 - H2 = 40 mm ±30’ 3˚55’ H5 - H2 = 20 mm 4˚25’ H5 - H2 = 0 mm ADJUSTABLE Max.
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VALUES AND SETTINGS BG0D Front axle angle checking values with 17’’ tyres POSITION OF ADJUSTMENT ANGLES VALUES FRONT AXLE CASTOR 3˚26’ H5 - H2 = 39 mm ±30’ 3˚56’ H5 - H2 = 19 mm 4˚26’ H5 - H2 = -1 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0A Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚49’ H5 - H2 = 28 mm ±30’ 4˚19’ H5 - H2 = 8 mm 4˚49’ H5 - H2 = -12 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0B Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚52’ H5 - H2 = 27 mm ±30’ 4˚22’ H5 - H2 = 7 mm 4˚52’ H5 - H2 = -13 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0R, KG0G Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚48’ H5 - H2 = 25 mm ±30’ 4˚18’ H5 - H2 = 5 mm 4˚48’ H5 - H2 = -15 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0D Front axle angle checking values with 16’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚48’ H5 - H2 = 25 mm ±30’ 4˚18’ H5 - H2 = 5 mm 4˚48’ H5 - H2 = -15 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0A, KG0B Front axle angle checking values with 17’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚35’ H5 - H2 = 44 mm ±30’ 4˚05’ H5 - H2 = 24 mm 4˚35’ H5 - H2 = 4 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0G Front axle angle checking values with 17’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚37’ H5 - H2 = 43 mm ±30’ 4˚07’ xH5 - H2 = 23 4˚37’ H5 - H2 = 3 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0R Front axle angle checking values with 17’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚25’ H5 - H2 = 42 mm ±30’ 3˚55’ H5 - H2 = 22 mm 4˚25’ H5 - H2 = 2 mm ADJUSTABLE Max.
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VALUES AND SETTINGS KG0D Front axle angle checking values with 17’’ tyres POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚26’ H5 - H2 = 42 mm ±30’ 3˚56’ H5 - H2 = 22 mm 4˚26’ H5 - H2 = 2 mm ADJUSTABLE Max.
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VALUES AND SETTINGS Rear axle angles checking values Rear axle angles checking values POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CAMBER -0˚40' ± 10' UNLADEN ADJUSTABLE PARALLELISM (for 2 wheels) Toe-in UNLADEN ADJUSTABLE -32’ ± 10’ -3,2 mm ± 1 mm POSITION FOR TIGHTENING RUBBER BUSHES –...
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