C. ENGINE

2013 USER MANUAL

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2 ENGINE

CONTENTS

2 ENGINE 2

2.1 ENGINE 3 2.1.1 ENGINE IDENTIFICATION 3 2.1.2 CHARACTERISTICS (ENGINE EVOLUTION F4R832 2010) 4 2.1.3 LUBRICATION 4 2.1.4 SEALED PARTS 5 2.1.5 ELBOW HOSE FITTING ON CYLINDER HEAD OIL STRAINER COVER 6 2.1.6 CYLINDER HEAD OIL STRAINER COVER FITTING 6 2.1.7 PLENUM AND CYLINDER HEAD OIL STRAINER COVER FITTING 7 2.1.8 REMOVAL & REFITTING OF THE POWERTRAIN 8 2.2 FUEL MIXTURE 15 2.2.1 PRESENTATION 15 2.2.2 OPERATING PRINCIPLE 22 2.3 STATIC IGNITION 24 2.3.1 DESCRIPTION 24 2.4 POWER SUPPLY 25 2.4.1 DESCRIPTION 25 2.5 RELIABILITY 25 2.5.1 5V ACCESSORY BELT : 77 11 162 521 25 2.5.2 ENGINE STARTER & HEAT SHIELD 26 2.5.3 ENGINE STARTER LOOM 27 2.5.4 TIMING BELT PROTECTIVE SCREEN 28 2.5.5 ALTERNATOR 29 2.5.6 WATER COOLER PROTECTION FENCE 31 2.6 TIGHTENING TORQUES 32

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2.1 ENGINE

2.1.1 ENGINE IDENTIFICATION

The engine is identified by an engraving located on the engine block. It includes: � In A: the engine type and

homologation letter : F4R. � In B: the engine index : 832 � 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.

Any procedure carried out on the engine not included in this manual must be performed by a Renault Sport accredited engine partner.

A B

C

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2.1.2 CHARACTERISTICS (ENGINE EVOLUTION F4R832 2010) � Type: F4R 832 � Number of cylinders: 4 inline � Number of valves: 16 � Bore: 82.7mm � 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

Homologation The homologation number for the catalytic converter is ROSI 50181.

2.1.3 LUBRICATION

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 Oil change rate Lubricant

After 500km Every 1,000km Elf Excellium NF 5W40

MANDATORY

50

70

90

110

130

150

170

190

210

2000 3000 4000 5000 6000 7000 8000 Engine speed [rpm]

Power [bhp]

0

10

20

30

40

50

60

70

80

Torque [mkg]

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2.1.4 SEALED PARTS

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

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2.1.5 ELBOW HOSE FITTING ON CYLINDER HEAD OIL STRAINER

COVER With time and heat, the steel elbow fitted on the upper oil strainer cover exit (situated on the top of cylinder head) can sometimes get loose. As shown on the following picture, regarding the position of this elbow, it can be extremely dangerous because of oil projections on the exhaust manifold.

For this reason, we ask you to inspect the fitting of this elbow: if it moves in its bore or if you manage to dismount it easily by hand, please respect the following instructions:

- Degrease properly both elbow male side and corresponding bore in cylinder head female side, using brake cleaner. - Put LOCTITE 648 (Green one) on both side and insert the elbow in the bore Remark : let the glue dry before starting the engine

2.1.6 CYLINDER HEAD OIL STRAINER COVER FITTING For the same reasons mentioned on §2.1.5 the upper oil strainer fitting screws on cylinder head tend to break We ask you to replace these 9 original black screws by the following references: - 9 CH screws M6x25mm class 12.9 (ref 77 11 158 346) - 9 washers M6x14x1,2mm (ref 77 11 158 358) (All elements are directly available to ALPINE spare parts department)

Torque to respect = 12 N.m CAUTION : When the engine is sealed by ORECA, do never try to remove the Electronic TAG, just replace the 8 others screws

Position of ORECA Electronic TAG

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2.1.7 PLENUM AND CYLINDER HEAD OIL STRAINER COVER

FITTING We remind you that for a correct stresses repartition between air intake plenum and cylinder head oil strainer cover, you have to fit them separately (without joining brackets first): - 9 screws for the cylinder head oil strainer cover (see §2-) - 5 screws for the plenum

Only when these 2 elements are correctly fastened on the engine, then fit them together using the 2 brackets:

Bracket n°1 Bracket n°2 (under throttle box)

x9

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2.1.8 REMOVAL & REFITTING OF THE POWERTRAIN

− Removal

Operations Photos

1 - Disconnect the battery

2 - Remove the drivetrain nuts.

3 - Raise the vehicle.

4 - Remove the front bumper.

5 - Remove the front crossmember.

6 - Attach the radiator to the engine, using plastic clips or a strap.

7 - Remove the air box and intake pipe.

8 -

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.

9 - Disconnect the brake booster vacuum pipe (2) at the intake manifold.

10 - Disconnect the wiring harness (3) at the bulkhead and bring it back to the engine.

1

2

3

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11 -

Disconnect the power wiring harness (4) at the 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.

4

5

6

7

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15 - Disconnect the high voltage wiring harness (8) at the coil box, noting the position of each wire.

16 - Disconnect the gearbox control tie-rod (9).

17 - Unscrew the reverse gear unlocking cable (10) at the gearbox.

18 -

Disconnect the clutch control pipe (11) at the master cylinder. Note: Watch out for fluid discharge.

19 - Disconnect the fuel pipes, at the ”T” on the bulkhead side.

20 - Disconnect the oxygen sensor.

21 - Disconnect the exhaust line at the manifold (12).

12

8

9

11

10

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22 -

Cut the 2 plastic collars fixed to the left and right subframe tubular trusses (réf. 77 11 160 147 et 77 11 160 146).

23 -

Unscrew these 3 screws (13). (13)

24 - Remove the inferior protection plate

25 - Remove the subframe (see 4-2 Front axle/Removing the subframe).

26 -

Remove the drivetrain: � Extract the drivetrain on the gearbox side. � Tilt the drivetrain. � � Extract the drivetrain on the wheel side.

27 - Place the powertrain on a hydraulic plate.

28 - Remove the lower crossmember.

29 –

Remove the front end.

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27 - Separate the engine mounting when removing the shaft (1).

28 - Separate the gearbox mounting (2):

� Release the shaft � Remove the three mounting bolts

29 - Take out the powertrain and lower the hydraulic plate.

GB mountings

Engine mountings

2

1

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− Refitting Carry out the previous operations in reverse order.

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

1 - Assembly + torque tightening: 75 Nm.

Gearbox buffer mounting (1) on the left side member.

2 - Assembly + torque tightening: 62Nm.

Connecting torque rod yoke (5) on the gearbox spacer.

3 - Assembly + torque tightening: 75Nm.

Gearbox mounting (2) on gearbox buffer mounting (1).

4 - Assembly + pre-

screwing.

Connecting torque rod on subframe (rubber buffer on subframe side)

5 - Assembly + pre-

screwing. Engine suspension (3) on the right side member.

6 - Assembly + pre-

screwing.

Engine mounting cover (4) on the engine suspension (3).

1

5

3

6

4

2

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7 - Fitting of engine in the engine compartment, from below.

8 - Torque tightening: 75Nm. Gearbox mounting (2) on the gearbox.

9 - Torque tightening: 105Nm. Connecting torque rod on yoke (5).

10 - Torque tightening: 62Nm. Engine mounting cover (4) on the engine mounting (6).

11 - Torque tightening: 62Nm. Engine suspension (3) on the right side member.

12 - Torque tightening: 105Nm. Gearbox mounting (2) on the gearbox buffer mounting.

13 - Torque tightening: 105Nm. Connecting torque rod on the subframe.

14 - Torque tightening: 105Nm. Engine mounting cover (4) on the engine suspension.

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2.2 FUEL MIXTURE

2.2.1 PRESENTATION 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 The switch (3) on the control panel is used to activate the fuel pump. The hose (part no. 77 11 160 444) is connected to the quick-fit coupling (1) to drain the fuel tank

3

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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.

Fuel pump access

To allow access and easy disassembly of the fuel tower from the inside of the car (without removing the fuel tank), a new fuel tower cover is available under the reference 77 11 162 965 and is fitted with 8 M4 “rivklé” type bolt (reference: 77 11 160 353), as for the previous cover.

To install it correctly, you need successively to: 1) Remove the old cover and disconnect the fuel tower alimentation connector 2) Remove the fuel tank (reason : many drillings and cuttings to do) 3) Position the cover as indicated on figure 1 4) Mark the outer contour and the position of the 8 holes. 5) Remove the cover and delimit the contour to cut (it must stay inside the 8 holes)

6) Realize the cutting then drill the 8 holes and insert the rivklés (screwing the 8 M4 screws ref 77 11 065 977) 7) Re assembly the fuel tank, re connect the fuel gauge alimentation and fit definitely the new cover

Note : The fuel tower screwing / unscrewing must be done with the RENAULT specific tool available under the reference : MOT 1397 (77 11 162 966) Besides, you must respect the following instructions for the fuel tower reassembly 1) Install a new seal after every disassembly 2) Push with your hand on the fuel tower and turn with hand the plastic nut 3) Screw the nut using the tool 77 11 162 966. The localisation of the arrow (8) must correspond with the localisation of the fuel tank mark (7) and the localisation of the fuel tower mark (6)

RENAULT specific tool MOT 1397 (réf 77 11 162 966) for fuel tower screwing / unscrewing

Figure 2

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Injection ECU The injection ECU controls engine operation. It also incorporates the data acquisition system.

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 + Yellow tag} or {2010.1 BIS}

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 allows 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

1

1 1

2

2009

1 2010 2

2010

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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.

1

1

1

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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 throttle position on the

display. For correct idle and start phases, set the small screw at 3% throttle (observable on the dashboard) at rest

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.

1

1

2009

1

2

2010 2010

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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)

1

1

2

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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.

1

1

1

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2.2.2 OPERATING PRINCIPLE Components comprising the engine management system

− Fuel circuit � Fuel pump � Injectors

− Management system

� Injection ECU � Water temperature sensor � Air temperature sensor � Intake 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

Injection ECU

Motor fan

Intake pressure

Oxygen sensor

Throttle position

Oil pressure

Air temp

Water temp

Battery V

Crankshaft phase

Starter Fuel pump

Barrel position

Upshift cut-off

Dephaser solenoid valve

Oxygen probe heating

Injectors

Coils

Camshaft phase

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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 voltage with the starter activated greater than 8 volts. Below this threshold, the battery must be charged or replaced.

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%. � Intake pressure: reconstituted from a map indexed on speed/throttle.

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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.

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 simultaneously:

� 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

For correct engine operation, it is essential to use spark plugs with part no. 82 00 492 426

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2.4 POWER SUPPLY 2.4.1 DESCRIPTION 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 RELIABILITY

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).

− Position on alternator pulley :

Fit the belt in the middle of the pulley, letting free both external grooves.

1

2

3

Free grooves

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− Position on free pulley :

Fit the belt in the middle of the pulley, letting free both external grooves. The 6V belt 77 11 162 383 is no longer available.

2.5.2 ENGINE STARTER & HEAT SHIELD The new starter motor (ref. 77 11 162 617) + new associated heat shield (ref. 77 11 162 618) are now available at your Renault Sport 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. ���� As a consequence, only this new heat shield can be fitted on the new starter motor. This new heat shield has been reinforced in 2011 for reliability reasons. An extra bracket has been added. Please find the necessary update kit : - 1 Bracket ref 00 11 167 498 - 4 washers Ø4,3x10x0,8 ref 77 11 158 357 - 2 steel rivet Ø4x18 ref 77 11 167 499 It is now fitted both on engine block and starter fastening screw

It’s mandatory to respect carefully the mounting instructions from TB_2011_X85CUP (September 2011) available on the Renault Sport extranet)

When your starter configuration requires, it’s mandatory to use this reinforced heat shield with the new bracket. The new heat shield already equipped with the extra bracket is available under the reference 77 11 167 498

Free grooves

On cylinder block

On starter fastening screw

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2.5.3 ENGINE STARTER LOOM Otherwise, Renault Sport recommends you to mount your starter motor loom as shown on the pictures below:

• Mount the plastic bracket on the lowest thread stud (1) • Put one cable through each plastic buckle (2) • 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)

• Pass the loom through a metal support fitted on the engine block (5)

Bottom view, behind the exhaust heat shield

NOTE : Old parts are no onger available.

(2

) (1) Thread stud

Exhaust heat shield

(3(5

)

(4)

Solénoïd

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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 are originally mounted on the 2010 F4R832 Clio Cup engines. Only the new protective screen 77 11 162 626 are allowed. 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:

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2.5.5 ALTERNATOR For reliability reasons, we strongly recommend you to improve your alternator as described below: 1) Open the black cover (2 screws + 1 nut) 2) Enclose the ends of each poles using silicone (windscreen glue type) as indicated below:

NOTE: the purpose is to create a link between poles and plastic areas to reduce the vibrations of the poles and so avoid their breakage. 3) Spread an anti-adhesive wax on the black cover 4) Fit the plastic cover and wait minimum 12hours for drying

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5) Remove the cover again to control the state of the silicone inside then fit it definitely with the screws.

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2.5.6 WATER COOLER PROTECTION FENCE To improve water cooler protection, a new protection fence can be fitted on the bumper as indicated below :

Outside view

Inside view

Remove the front bumper and use tyrap® (ref 77 03 085 044) to fit the fence :

- Lower and upper fasteners (4 + 4 tyraps®) : on the bumper skin - Lateral fasteners (1+1 tyraps ®) : on the Black bumper trim cover

This protection fence (570 x 55mm) is available to Renault Sport spare parts department under the following reference : 77 11 163 989

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2.6 TIGHTENING TORQUES

Components Tightening

torques in Nm

Gearbox buffer mounting on left side member 75

Connecting torque rod yoke on gearbox spacer 75

Gearbox mounting on gearbox 75

Connecting torque rod on the yoke 105

Engine mounting cover on the engine mounting 62

Engine suspension on the side member 62

Gearbox mounting on the gearbox buffer mounting 105

Connecting torque rod on the subframe 105

Engine mounting cover on the engine suspension 105