2016 Renault Megane Service & Repair Manual

201 6 RENAULT MEGANE III SERVICE & REPAIR MANUAL

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

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

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

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

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

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

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

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

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

2016 Renault Megane Service & Repair Manual

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