1 Engine and peripherals

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1 1 Engine and peripherals Contents ANTIPOLLUTION 4A ANTIPOLLUTION Fuel vapour recirculation circuit: check -1 Fuel vapour canister: Removal - Refitting -3 Fuel vapour canister:checking -5-7 system: Operating diagram -17 : Operating diagram -19 solenoid valve: Removal - Refitting -23 unit: Removal - Refitting -35 Intercooler: Removal - Refitting -43 mounting: Removal - Refitting -60 assembly: Removal - Refitting -61 assembly: Removal - Refitting -78 rigid pipe: Removal - Refitting -95 solenoid valve: Cleaning -105 X84, and B84 or C84 or E84 or G84 or K84 or L84 or S APRIL 2009 Edition Anglaise "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. Renault s.a.s 2008

2 Fuel vapour recirculation circuit: check B84 or C84 or G84 or S84, and F4R B84 or C84 or G84 or S84, and K4J B84 or C84 or G84 or S84, and K4M I - CHECKING THE OPERATION OF THE FUEL VAPOUR ABSORBER BLEED II - FUEL VAPOUR ABSORBER BLEEDING CONDITIONS a Note: A fault with this system may result in rough idling or the engine stalling. a The fuel vapour absorber bleed solenoid valve is controlled by track C-E1 of the computer if: - the coolant temperature is above 55 C, - the air temperature is above 10 C, - the engine is not at idle speed, -a given load threshold is reached, -the throttle potentiometer is not in the «no load» position. During «on board diagnostic» fault finding, fuel vapour absorber bleeding is not authorised. It is possible to display the fuel vapour absorber bleed solenoid valve opening cyclic ratio with the diagnostic tools by consulting parameter PR102: Fuel vapour absorber bleed solenoid valve OCR. The solenoid valve is closed for a value below 1.2% (1) Inlet manifold (2) Fuel vapour absorber bleed solenoid valve (3) Fuel vapour absorber (4) Tank (5) Breather (6) Anti-return valve (F4R 776 only) a Check the conformity of the circuit (see Petrol vapour rebreathing: Operation). a Check the condition of the pipes to the tank. -1

3 Fuel vapour recirculation circuit: check B84 or C84, and F4R, and 774 I - CHECKING THE OPERATION OF THE FUEL VAPOUR ABSORBER BLEED II - FUEL VAPOUR ABSORBER BLEEDING CONDITIONS a Note: A fault with this system may result in rough idling or the engine stalling. a The fuel vapour absorber bleed solenoid valve is controlled by track C-E1 of the computer if: - the coolant temperature is above 55 C, - the air temperature is above 10 C, - the engine is not at idle speed, -a given load threshold is reached, -the throttle potentiometer is not in the «no load» position. During «on board diagnostic» fault finding, fuel vapour absorber bleeding is not authorised. It is possible to display the fuel vapour absorber bleed solenoid valve opening cyclic ratio with the diagnostic tools by consulting parameter PR102 «Fuel vapour absorber bleed solenoid valve OCR». The solenoid valve is closed for a value below 1.2% (1) Inlet manifold (2) Fuel vapour absorber bleed solenoid valve (3) Fuel vapour absorber (4) Tank (5) Breather (6) Anti-return valve a Check the conformity of the circuit (see Fuel vapour recirculation circuit: Function). a Check the condition of the pipes to the tank. -2

Fuel vapour canister: Removal - Refitting B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 B84 or C84 or G84 or S84, and K4J B84 or C84 or G84 or S84, and K4M The absorber is located on the

4 Fuel vapour canister: Removal - Refitting B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 B84 or C84 or G84 or S84, and K4J B84 or C84 or G84 or S84, and K4M The absorber is located on the fuel tank under the vehicle. REMOVAL a Disconnect: the tank vapour inlet pipe (2), a Remove the absorber (1) from the fuel tank retaining notch by pushing it in the direction of the arrow. -the pipe (3) circulating vapours to the solenoid valve, - the breather pipe (4). a Remove the absorber. REFITTING a Proceed in the reverse order to removal. -3

5 Fuel vapour canister: Removal - Refitting B84 or C84, and F4R, and 774 The absorber is located on the fuel tank under the vehicle. REMOVAL a Disconnect: the pipe (2) bringing the fuel vapour from the tank, a Release absorber (1) from the fuel tank retaining notch by pushing it in the direction of the arrow. - pipe (3) taking the fuel vapours to the solenoid valve, - the breather pipe (4). a Remove the absorber. REFITTING a Proceed in the reverse order to removal. -4

6 Fuel vapour canister:checking B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 B84 or C84 or G84 or S84, and K4J B84 or C84 or G84 or S84, and K4M Essential special tooling Mot Fuel pressure test kit. CHECKING THE FUEL VAPOUR ABSORBER a On the fuel vapour absorber, cap the circuit coming from the tank. a Connect the pressure gauge of the (Mot ) to the absorber breather outlet. a With the engine idling, check that there is no vacuum at the absorber breather outlet (in the same way, the command value displayed by the diagnostic tool in parameter: Fuel vapour absorber bleed solenoid valve OCR remains minimal X equal to or less than 1.5%). Is there a vacuum? - Yes: with the ignition off, use a vacuum pump to apply a vacuum of 500 mbar to the solenoid valve outlet. The vacuum pressure should not vary by more than 10 mbar over 30 seconds. Does the pressure vary? Yes: the solenoid valve is faulty, replace it. No: there is an electrical fault, check the circuit. - No: under bleeding conditions (see «bleeding conditions» ), the vacuum should increase (at the same time, the parameter value on the diagnostic tool should also increase). CHECKING THE FUEL VAPOUR ABSORBER TANK CONNECTION a Check this connection by connecting a vacuum pump to the pipe going to the absorber. -5

7 Fuel vapour canister:checking B84 or C84, and F4R, and 774 Essential special tooling Mot Fuel pressure test kit. Essential equipment diagnostic tool CHECKING THE FUEL VAPOUR ABSORBER a On the fuel vapour absorber, cap the circuit coming from the tank. a Connect the pressure gauge of the (Mot ) to the absorber breather outlet. a With the engine idling, check that there is no vacuum at the absorber breather outlet (in the same way, the command value read by the diagnostic tool in parameter: Fuel vapour absorber bleed solenoid valve OCR remains minimal X equal to or less than 1.5 %). a Is there a vacuum? - Yes: with the ignition off, use a vacuum pump to apply a vacuum of 500 mbar to the outlet solenoid valve. The vacuum pressure should not vary by more than 10 mbar over 30 seconds. Does the pressure vary? Yes: the solenoid valve is faulty, replace it. No: there is an electrical fault, check the circuit. - No: under bleeding conditions, the vacuum should increase (at the same time the parameter value on the diagnostic tool should also increase). CHECKING THE FUEL VAPOUR ABSORBER-TANK CONNECTION a Check this connection by connecting a vacuum pump to the pipe going to the absorber. -6

B84 or C84 or G84 or S84, and K4M, and 760 or 761 or 766 or

breather pipe (2) Sized opening 101820 (3) Oil vapour

breather pipe 102073 To remove the oil vapour recovery

8 B84 or C84 or G84 or S84, and K4M, and 760 or 761 or 766 or 812 or 813 I - LOCATION OF COMPONENTS (1) Oil vapour breather pipe (2) Sized opening (3) Oil vapour recovery plate on the cylinder head cover (4) Oil vapour breather pipe To remove the oil vapour recovery plate (3), (see 11A, Top and front of engine, Cylinder head gasket). -9

9 B84 or C84 or G84 or S84, and K4M, and 760 or 761 or 766 or 812 or 813 II - OPERATING DIAGRAM A: At low loads, the oil vapours are rebreathed in small quantities through the calibrated jet (6) (5) Air inlet (6) Sized opening III - CHECK To ensure the antipollution system works properly, the oil vapour rebreathing circuit must be kept clean and in good condition B: Under average and heavy loads, the oil vapours are rebreathed in large quantities through the gas throttle valve (1) Engine (2) Oil vapour recovery plate (3) Motorised throttle (4) Inlet manifold -10

10 B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 I - PRESENTATION OF COMPONENTS (1) duct (2) Oil vapour recirculation valve (3) Oil vapour recovery plate located on the rocker cover

B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 F4R, and 776 106629 (A) (B) Circuit upstream of turbocharger, used for medium and high loads.

11 B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 F4R, and (A) (B) Circuit upstream of turbocharger, used for medium and high loads. The vapour is sucked back in by the prevailing vacuum pressure in the inlet manifold Circuit downstream of throttle valve, used for low loads. The vapour is sucked back in by the prevailing vacuum pressure between the throttle and engine Oil vapour recovery plate located on the rocker cover -14

12 B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 For removal, (see 11A, Top and front of engine, Cylinder head gasket). II - OIL VAPOUR RECIRCULATION CIRCUIT (4) Throttle upstream oil vapour recirculation aperture

13 B84 or C84 or G84 or S84, and F4R, and 770 or 771 or 776 (5) Air duct (6) Throttle valve (7) Intake distributor (8) Throttle upstream oil vapour recirculation aperture (9) Oil vapour recovery plate (10) Oil vapour recirculation valve III - CHECK To ensure the antipollution system works properly, the oil vapour rebreathing circuit must be kept clean and in good condition. -16

Technical Note 3676A CB1N

Technical Note 3676A CB1N Basic manual: Workshop Repair Manual 345 and Technical Note 3286A Features of Renault Clio Sport SPL lighter version (see manufacturer's plate) For parts not dealt with in this