renault 4 mentnance guide

SPECIFICATIONS Specifications

01

SPECIFICATIONS Plain-sided van and estate car

01

SPECIFICATIONS Long chassis plain-sided van and estate car (R.2370-R.2430)

01

SPECIFICATIONS Vehicle identification

01

DIAGNOSTIC STATION Diagnostic centre checking values

01

DIAGNOSTIC CENTRE Diagnostic centre checking values

01


01


01


01


01


01


01

DIAGNOSTIC CENTRE Main adjustments (Renault 4)

01

Engine 680


01

Engine 680

SPECIFICATIONS Cross section

01

Engine 680

SPECIFICATIONS Engine identification

01

Engine 680

SPECIFICATIONS Engine

01

Engine 680

SPECIFICATIONS Valve guides

01

Engine 680

SPECIFICATIONS Valve prings

01

Engine 680

SPECIFICATIONS "Inlet-exhaust" manifold

01

Engine 680

SPECIFICATIONS Pistons

01

Engine 680

SPECIFICATIONS Crankshaft

01

Engine 680

SPECIFICATIONS Bearing shells

01

Engine 680

SPECIFICATIONS Regrinding a roll-hardened crankshaft

01

Engine 680

SPECIAL POINTS - INTERCHANGEABILITY Cylinder head gasket

01

Engine 680

SPECIAL POINTS - INTERCHANGEABILITY Liners - Pistons - Cylinder block - Liner base seals

01

Engine 680

SPECIAL POINTS - INTERCHANGEABILITY Chain tensioner

01

Engine 680

SPECIAL POINTS - INTERCHANGEABILITY Dismantling

01

Engine 680

SPECIAL POINTS - INTERCHANGEABILITY Manifolds - Oil pump

01

Engine 680

SPECIAL POINTS - INTERCHANGEABILITY Coolant mixture - Fuel tank - Water pump

01

Engine 688

SPECIFICATIONS Tightening torques in m. da N

01

Engine 688

SPECIFICATIONS Cross section

01

Engine 688

SPECIFICATIONS Lubrication diagram

01

Engine 688

SPECIFICATIONS Engine identification

01

Engine 688

SPECIFICATIONS Engine

01

Engine 688

SPECIFICATIONS Valve guide - Valve seats

01

Engine 688

SPECIFICATIONS Valve timing

01

Engine 688

SPECIFICATIONS Piston rings - Connecting rods - Crankshaft

01

Engine 688

SPECIFICATIONS Piston rings - Connecting rods - Crankshaft

01

Engine 688

SPECIFICATIONS Oil pump - Fuel pimp - Fuel tank

01

Engine 688

SPECIFICATIONS Chain tensioner - Oilbath type cylinder block

01

Engine 688

SPECIFICATIONS Chain tensioner - Oilbath type cylinder block

01

LIFTING METHODS Lifting methods

02

LIFTING METHODS Lifting methods

02

LUBRICANTS - CONSUMABLES Lubricants - Fluids

04

LUBRICANTS - CONSUMABLES Diagnostic maintenance

04

LUBRICANTS - CONSUMABLES Engine operations check

04

OIL DRAIN - REFILL Lubrication engine

05

OIL DRAIN - REFILL Lubrication engine

05

OIL DRAIN - REFILL Lubrication Gearbox

05

TOOLING Classification of tooling

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Engine

06

TOOLING Clutch

06

TOOLING Electrical equipment

06

TOOLING Electrical equipment

06

TOOLING Gearbox

06

TOOLING Gearbox

06

TOOLING Gearbox

06

TOOLING Gearbox

06

TOOLING Gearbox

06

TOOLING Gearbox

06

TOOLING Gearbox

06

TOOLING Front axle

06

TOOLING Front axle

06

TOOLING Front axle

06

TOOLING Front axle

06

TOOLING Front axle

06

TOOLING Wheels - Hubs

06


06


06


06

WHEELS - HUBS Wheels - Hubs

06

BRAKING SYSTEM Braking system

06


06


06

CHASSIS SUPPORTS Chassis support

06

M.S. TOOLS M.S. tools

06


06


06


06

EQUIPMENT Equipment

06

EQUIPMENT Equipment

06

MATERIAL Grease

06

MATERIAL Grease

06

MECHANICAL SEALERS Mechanical sealers

06

MECHANICAL SEALERS Mechanical sealers

06

MECHANICAL SEALERS Adhesives

06

CLEANING FLUIDS - RELEASE AGENTS Cleaning fluids - Release agents

06

COOLANT Coolant

06

ASSORTED ITEMS Assorted items

06

Engine 680

REMOVING - REFITTING Removing - Refitting

10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680

REMOVING - REFITTING Details concerning vehicles fitted with type 354 gearbox

10

Engine 680


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 680

LINERS - PISTONS Changing

10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 680

LINERS - PISTONS Cylinder block - Liners - Pistons

10

Engine 680

CYLINDER BLOCK Changing

10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 680


10

Engine 688

CYLINDER BLOCK - PISTONS - LINERS Exploded view

10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 688


10

Engine 680

OIL PUMP Removing - Overhauling - Refitting

10

Engine 680


10

Engine 680


10

Engine 688


10

Engine 688


10

Engine 688


10

OIL PRESSURE Checking

10

OIL FILTER Changing

10

Engine 680

CYLINDER HEAD Changing

11

Engine 680


11

Engine 680


11

Engine 680


11

Engine 680


11

Engine 680


11

Engine 680


11

CYLINDER HEAD Checking the gasket joint face

11

Engine 688


11

Engine 688


11

Engine 688


11

Engine 688


11

Engine 688


11

Engine 688


11

VALVE SPRINGS Changing

11

Engine 680

VALVE GUIDE Changing

11

Engine 680


11

Engine 688


11

Engine 688


11

Engine 680

CAMSHAFT Changing

11

Engine 680

CAMSHAFT Changing

11

Engine 688

CAMSHAFT Changing

11

Engine 680

SPROCKET-DRIVEN TIMING GEAR Changing the intermediate sprocket

11

Engine 680

TIMING CHAIN Changing

11

Engine 688

TIMING CHAIN Changing

11

Engine 688

CAMSHAFT BEARING Changing the oil seal

11

Engine 688


11

Engine 688


11

Engine 688

CAMSHAFT BEARING Changing the bush

11

Engine 680

WATER PUMP Removing - Refitting

11

Engine 688

WATER PUMP Removing - Refitting

11

Engine 680

"INLET - EXHAUST" MANIFOLD Changing the gasket

11

Engine 688

"INLET - EXHAUST" MANIFOLD Changing the gasket

11

DRIVE BELTS Tensioning

11


11


11

FUEL PUMP Checking the pressure

12

FUEL PUMP Checking the pressure

12

FUEL TANK Removing - Refitting

12

CARBURETTORS Specifications

12

CARBURETTORS Removing - Refitting

12

CARBURETTORS Adjusting idling speed

12

CARBURETTORS Adjusting idling speed - Idling speed table

12

CARBURETTORS Checking needle valve and seat for leaks

12

CARBURETTORS Replacing and electric choke carburettor by a manual choke type

12

CARBURETTORS Solex - Setting values

12

CARBURETTORS How to set

12


12


12


12

CARBURETTORS 32 EISA

12

CARBURETTORS Float level

12


12


12

CARBURETTORS Znith - Setting values

12


12

CARBURETTORS 28IF

12

Engine

680,800,839

ANTI POLLUTION Oil fume rebreathing system

14

Engine 688

ANTI POLLUTION Oil fume rebreathing system

14

Vehicles,R1120,R1121,R 1123,R1126,R2102,R21 04,R2106,R2109,R2391, R2392

STARTING - CHARGING CIRCUIT Removing - Refitting

16

Vehicles,R2108,R2370,R 2430

STARTER Removing - Refitting

16

STARTING - CHARGING CIRCUIT Overhauling Ducellier

16

STARTING - CHARGING CIRCUIT Overhauling - Ducellier

16

STARTING - CHARGING CIRGUIT Overhauling - Ducellier

16

STARTING - CHARGING CIRCUIT Overhauling

16


16


16

Femsa


16

Femsa


16

Bosch

STARTING -CHARGING CIRCUIT Overhauling

16

Bosch


16

Ducellier-Bosch-Femsa starters

STARTING - CHARGING CIRCUIT Changing the drive pinion assembly

16

STARTING - CHARGING CIRCUIT Changing bushes

16

STARTING- CHARGING CIRCUIT Remove neat shield

16

Starter

6185-6187

STARTING - CHARGING CIRCUIT Changing solenoid

16

STARTING - CHARGING CIRCUIT Dynamo or alternator

16

STARTING - CHARGING CIRCUIT Dynamo

16


16


16


16


16

Paris-Rhne A12R11 Ducellier 7549,7597


16

Paris-Rhne

A12R11


16


16

Paris-Rhne

A12R11


16

SEV 71228102


16

Paris-Rhne

A12R11


16

SEV 71228102

STARTING CHARGING CIRCUIT Dynamo

16

STARTING CHARGING CIRCUIT Checking dynamo or alternator Checking on the vehicle

16

STARTING - CHARGING CIRCUIT Checking

16


16


16


16

STARTING - CHARGING CIRCUIT Windscreen wiper

16

IGNITION - INJECTION Spcifications

17


17


17


17


17


17


17


17


17

IGNITION - INJECTION Gnral lectrical

17

IGNITION - INJECTION Gnral lectrical

17

IGNITION - INJECTION Gnral electrical

17

IGNITION - INJECTION Distributor

17


17

IGNITION - INJECTION Distribution

17

Engines 680,690,800,839


17

IGNITION - INJECTION Setting on the test stand

17

IGNITION - INJECTION Overhauling

17

COOLING SYSTEM Draining - Refilling

19

Engine 680


19

Engine 688


19

COOLING SYSTEM Checking for leaks

19

COOLING SYSTEM Checking for leaks

19

EXPANSION CHAMBER Removing - Refitting

19

EXPANSION CHAMBER Removing - Refitting

19

Engine 680

RADIATOR Removing - Refitting

19

Engine 688

RADIATOR Removing - Refitting

19

OIL PRESSURE Checking

19

CLUTCH Spcifications Two types of clutch have been fitted

20

CLUTCH Spcifications Identification of diaphragm spring type clutches

20

SPECIFICATIONS Identification of diaphragm spring type clutches

20

MECHANISM Changing

20

MECHANISM Clutch with diaphragm spring pressure plate

20

FLYWHEEL Removing - Refitting

20

CLUTCH WITH DIAPHRAGM SPRING PRESSURE PLATE Removing - Refitting

20

CLUTCH WITH DIAPHRAGM SPRING PRESSURE PLATE Removing - Refitting

20

CLUTCH WITH DIAPHRAGM SPRING PRESSURE PLATE Resurfacing

20

WITHDRAWAL PAD Changing

20

WITHDRAWAL PAD Type 354 gearbox

20

FORK Changing

20

FORK Type 354 gearbox with clutch housing

20

Engines 680,690,800,839

CLUTCH CABLE Changing

20

OIL SEAL Changing

20

OIL SEAL Refitting

20

OPERATING CLEARANCE Adjusting

20

SPECIFICATIONS Gearbox type 313

21


21


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21


21

SECONDARY SHAFT Changing 4th speed gear on type 334 gearbox

21

SECONDARY SHAFT Changing 4th speed gear on type 334 gearbox

21

DIFFERENTIAL OUTLET Changing an oil seal

21

DIFFERENTIAL OUTLET Gearbox type 328

21

DIFFERENTIAL RING NUT Changing oil seal

21

FRONT MOUNTING PAD Changing

21

FRONT MOUNTING PAD Gearbox type 328

21


21


21

SPECIFICATIONS Sections (type 334)

21

SPECIFICATIONS Shift interlocking system (type 334)

21

SPECIFICATIONS tightening torques (type 334)

21

SPECIFICATIONS Lubrication (type 334)

21

SPECIFICATIONS Adjustments (type 334)

21


21


21


21


21

SPECIFICATIONS sections (type 354)

21

SPECIFICATIONS Tightening torques (type 354)

21

SPECIFICATIONS Adjustments (type 354)

21

SPECIFICATIONS Special points (type 354)

21

SPECIFICATIONS Interchangeability (type 354)

21


21


21

REMOVING - REFITTING Gearboxes type 313-328-334

21


21


21


21

vehicles R1123,R1126,R2106,R2 108,R2109,R2391,R239 2

REMOVING - REFITTING Gearbox type 354

21


21


21

REMOVING - REFITTING Gearbox type 354 on R2370 - R2430 vehicles

21


21

COMPLETELY OVERHAULING GEARBOX Gearbox type 313

21


21


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21


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21


21


21


21


21


21


21


21


21


21


21


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21


21


21


21


21


21


21


21


21


21


21


21


21


21


21


21


21

COMPLETE OVERHAUL Gearbox type 354

21


21


21


21


21


21


21


21

DRIVE SHAFTS Removing - Refitting

29

DRIVE SHAFTS Removing - Refitting

29

DRIVE SHAFTS Changing a bellows on a "GE76" coupling

29


29


29


29

DRIVE SHAFTS Changing a bellows on a "G1 62 Spider" coupling

29


29


29


29


29


29


29


29

DRIVE SHAFTS Changing a bellows on a 4 - ball coupling

29


29


29


30


30

SPECIFICATIONS Greases

30

SPECIFICATIONS Front axle geometry

30

SPECIFICATIONS Front axle geometry

30

SPECIFICATIONS Front axle identification

30

SPECIFICATIONS Front axle identification

30

SPECIFICATIONS Drive shaft identification

30

SPECIFICATIONS Drive shaft identification

30

SPECIFICATIONS Fitting an anti-squeak washer

30


30


30

FRONT AXLE GEOMETRY Checking - Adjusting

30

CASTOR ANGLE Fitting a tie-rod

30

CASTOR ANGLE Fitting a tie-rod

30

STEERING BOX HEIGHT SETTING (FRONT AXLE WITH 13 CASTOR ANGLE) Fitting a tie-rod

30

STEERING BOX HEIGHT SETTING (FRONT AXLE WITH 13 CASTOR ANGLE) Compress front axle

30


30


30

STEERING BOX HEIGHT SETTING (FRONT AXLE WITH 13 CASTOR ANGLE) Shim selection table

30

STEERING BOX HEIGHT SETTING (FRONT AXLE WITH 13 CASTOR ANGLE) Shim selection table

30

CHECKING AND ADJUSTING PARALELISM Finding the steering centre point

30

CHECKING AND ADJUSTING PARALELISM Compress front axle, using either

30

SPECIFICATIONS Position for tightening rubber bushes

30

SPECIFICATIONS Position for tightening rubber bushes / Torsion bars

30

SPECIFICATIONS Pre-1969 vehicles

30

SPECIFICATIONS Shock absorber mountings

30

UPPER ARM Removing - Refitting

31

UPPER ARM Removing - Refitting

31

UPPER ARM Dismantling - Checking - Reassembling

31

UPPER ARM Changing the rubber bushes

31

UPPER ARM Changing the ball joint

31

LOWER ARM Removing - Refitting

31

LOWER ARM Removing - Refitting

31

LOWER ARM Dismantling - Checking - Reassembling

31

LOWER ARM Changing the rubber bush

31

LOWER ARM Changing the ball joint

31

LOWER ARM Changing the ball joint

31

STUB AXLE CARRIER Removing - Refitting

31

STUB AXLE CARRIER Removing - Refitting

31

STUB AXLE CARRIER Changing the bearings

31

STUB AXLE CARRIER Changing the bearings

31

STUB AXLE CARRIER Dismantling - Checking - Reassembling

31

FRONT HALF-AXLE Removing - Refitting

31

FRONT HALF-AXLE Checking

31

FRONT HALF-AXLE How to check

31

FRONT SHOCK ABSORBERS Removing - Refitting

32

FRONT ANTI-ROLL BAR Removing - Refitting

32

FRONT TORSION BARS Removing - Refitting

32

FRONT TORSION BARS Refitting

32


32


32


32


32


33


33


33

SPECIFICATIONS Rear hub layout

33

SPECIFICATIONS Rear axle geometry

33

SPECIFICATIONS Special points - Interchangeability

33

SPECIFICATIONS Suspension arms for R.2370 - R2430 vehicles

33

REAR AXLE GEOMETRY Rear axle geometry

33

REAR ARM Checking

33

REAR ARM Parallelism

33

REMOVING - REFITTING Removing

33

REMOVING - REFITTING Removing

33

ARM BEARINGS Outer bearings

33

CHANGING AN OUTER BEARING ASSEMBLY Removing - Refitting

33

INNER BEARINGS Removing

33

BEARINGS Removing - Refitting - Adjusting

33


33


33

REAR SHOCK ABSORBERS Removing

34


34


34

REAR ANTI-ROLL BAR Removing - Refitting

34

REAR TORSION BAR Removing - Refitting

34


34


34


34

REAR TORSION BAR Lever adjustment

34


34


34

REAR TORSION BAR Adjustment by bar rotation

34

REAR TORSION BAR Rear suspension

34

REAR TORSION BAR Checking load on the wheels

34

WHEEL BALANCING Balance weights

35

STEERING BOX Changing

36

STEERING BOX Changing

36

STEERING BOX Adjusting the plunger

36


36


36

STEERING BOX Calculating the thickness of setting shims to be added

36

STEERING BOX Checking

36

CHANGING ANTI-KNOCK BEARINGS ON STEERING BOX WITHOUT RETURN SPRINGS Steering box need not be removed for this operation

36

CHANGING ANTI-KNOCK BEARINGS ON STEERING BOX WITHOUT RETURN SPRINGS Steering box need not be removed for this operation

36

STEERING WHEELS Removing - Refitting

36

STEERING WHEELS Refitting

36

STEERING COLUMN Tightening universal joint

36

STEERING COLUMN Changing the flexible coupling

36

ONE PIECE STEERING WHEEL SHAFT Removing - Refitting

36


36


36

ONE PIECE STEERING WHEEL SHAFT Changing bushes

36


36


36


36

ACCELERATOR CABLE Changing

37

ACCELERATOR CABLE Adjustment

37

SPECIFICATIONS Brake layout

37

SPECIFICATIONS Brake layout

37

SPECIFICATIONS Checking values for brake distributors or limiters

37

SPECIFICATIONS 1976 model modifications

37

SPECIFICATIONS Brake pipes and unions

37

MASTER CYLINDER Removing - Refitting

37

MASTER CYLINDER Overhauling single master cylinder

37

MASTER CYLINDER Overhauling tandem master cylinder

37

MASTER CYLINDER Adjusting operating clearance

37

PRESSURE DROP INDICATOR Description

37

PRESSURE DROP INDICATOR Removing - Refitting

37

BRAKE PEDAL Removing - refitting

37

FRONT BRAKE LININGS Changing

37


37


37

FRONT BRAKE LININGS Adjusting

37

FRONT BRAKE BACKPLATE Removing - Refitting

37

FRONT WHEEL CYLINDER Removing - Refitting

37

FRONT WHEEL CYLINDER Overhauling

37

REAR BRAKE DRUM Removing - Refitting - Adjusting

37

REAR BRAKE DRUM Adjusting bearing end play

37

REAR BRAKE LINING Removing - Refitting

37

REAR BRAKE LINING Refitting

37

REAR BRAKE LINING Adjusting

37

REAR BRAKE BACKPLATE Removing - Refitting

37

REAR WHEEL CYLINDER Removing - Refitting

37

BLEEDING Bleeding with pressure bleeding apparatus

37

BRAKE DISTRIBUTOR Checking

37

BRAKE DISTRIBUTOR Changing

37

BRAKE LIMITER Checking - Adjusting

37

BRAKE LIMITER L.H. side limiter

37

THE LIMITER CANNOT BE REPAIRED Changing

37

HANDBRAKE Adjustment

38

HANDBRAKE Adjustment

38

HANDBRAKE Changing handbrake lever

38

REMOVING - REFITTING SECONDARY CABLES Removing

38

REMOVING - REFITTING SECONDARY CABLES Removing

38

SPECIFICATIONS

60

SPECIFICATIONS

60

MOTOR Removing - Refitting

60


60


60

MOTOR Changing brushes

60

MATRIX Removing - Refitting

60

HEADLIGHTS Removing - Refitting light unit

80

HEADLIGHTS Beam setting

80

Fuel gauge tank unit Removing - Refitting

80

INSTRUMENT PANEL

83

INSTRUMENT PANEL Veglia instrument panel

83


83


83

INSTRUMENT PANEL Changing instruments

83

IGNITION - STARTER SWITCH Removing - Refitting

84


85


85


85


85


85

OVERHAULING THE MOTOR The motor must be removed for this operation

85

BOSCH MOTOR Removing - Refitting

85

BOSCH MOTOR Removing - Refitting

85

FEMSA MOTOR Removing - Refitting

85

CHANGING BRUSCHES S.E.V. motor

85

FEMSA MOTOR Remove motor

85

HEADLIGHTS WASHER-WIPERS (SWEDEN) Headlights washer-wipers (sweden)

85

HEADLIGHTS WASHER-WIPERS (SWEDEN) Removing - Refitting motor

85

ELECTRIC CHOKE Operation

85

FITTING A CAR RADIO "Ultra-compact" radio

86

FITTING A CAR RADIO "Ultra-compact" radio

86

STANDARD FLUSH-FITTING RADIO Standard flush-fitting radio

86

STANDARD FLUSH-FITTING RADIO Aerials

86

STANDARD FLUSH-FITTING RADIO Wing-mounted aerial

86

STANDARD FLUSH-FITTING RADIO Supressing interference

86

FITTING ADDITIONAL LIGHTS Fitting additional lights

86

FITTING A TOWING ADDITIONAL Saloon

86

FITTING A TOWING ADDITIONAL Saloon

86

FITTING A TOWING ADDITIONAL Van and long chassis estate car

86

FITTING A TOWING ADDITIONAL Towing bracket wiring harness

86

FITTING OF A DUAL CONTROL PEDAL ASSEMBLY

86

FITTING CROSS SHAFT

86

FITTING THE R.H. PEADL ASSEMBLY

86

FITTING ACCELERATOR Fitting accelerator

86

FITTING A DUAL CONTROL PEADL ASSEMBLY Fitting a dual control pedal assembly

86

FITTING CLAMPS ON THE L.H. PEDAL ASSEMBLY Fitting clamps on the L.H. pedal assembly

86

OIL PRESSURE SWITCH Checking

87

COOLANT TEMPERATURE SWITCH Checking

87

COOLING FAN MOTOR Changing the motor

87

CHECKING THE TEMPERATURE SWITCH ON THE RADIATOR Checking the temperature switch on the radiator

87

WIRING HARNESS LAYOUT Wiring harness layout

88

WIRING DIAGRAM 1971 model

88

WIRING DIAGRAM 1972 - 1973 and 1974 models

88

WIRING DIAGRAM 1972 - 1973 and 1974 models

88

WIRING DIAGRAM 1976 model

88

WIRING List of units

88

WIRING List of wiring harnesses

88

renault 4 mentnance guide

Documents

tooling engine

specifications specifications

tooling gearbox

specifications crankshaft

specifications pistons

tooling clutch

specifications valve

specifications valve