2013 USER MANUAL

C. ENGINE
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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 A B

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.

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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

210 80

190 70

170 60
Power Torque
[bhp] 150 50 [mkg]

130 40

110 30

90 20

70 10

50 0
2000 3000 4000 5000 6000 7000 8000
Engine speed [rpm]

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

Elf Excellium NF 5W40

After 500km Every 1,000km
MANDATORY

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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 Position of ORECA

Electronic TAG

CAUTION :

When the engine is sealed by ORECA, do never try to remove the Electronic TAG, just
replace the 8 others screws

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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

x9

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)

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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.

Attach the radiator to the engine, using plastic clips

6-
or a strap.

7 - Remove the air box and intake pipe. 1

Disconnect the accelerator cable (1) at the throttle
valve.
8-
N.B.: To avoid a wear-out of the cable through
scrubbing on the body, the use of a collar is allowed. 2
Disconnect the brake booster vacuum pipe (2) at
9-
the intake manifold.

Disconnect the wiring harness (3) at the bulkhead

10 -
and bring it back to the engine.

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4
Disconnect the power wiring harness (4) at the
starter.
11 -
N.B.: The use of a thermic protection on the cable is
preconized.

5
Disconnect the power wiring harness (5) at the
12 -
alternator.

6
Disconnect the engine cooling fan wiring harness
13 -
(6) at the fan.

14 - Disconnect the earth cable (7) from the gearbox.

7

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Disconnect the high voltage wiring harness (8) at

15 -
the coil box, noting the position of each wire.

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

Unscrew the reverse gear unlocking cable (10) at 9

17 -
the gearbox.

Disconnect the clutch control pipe (11) at the 10

master cylinder. 11
18 -
Note: Watch out for fluid discharge.
Disconnect the fuel pipes, at the ”T” on the bulkhead
19 -
side.

20 - Disconnect the oxygen sensor.

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

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Cut the 2 plastic collars fixed to the left

and right subframe tubular trusses (réf.
22 -
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).

Remove the drivetrain:
Extract the drivetrain on the gearbox side.
26 -
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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GB mountings

Engine mountings

Separate the engine mounting when removing

27 - 1
the shaft (1).

Separate the gearbox mounting (2):

28 - Release the shaft 2
Remove the three mounting bolts

Take out the powertrain and lower the hydraulic

29 -
plate.

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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

Gearbox buffer mounting

Assembly + torque 1
1- (1) on the left side
tightening: 75 Nm.
member.

Assembly + torque Connecting torque rod yoke

2-
tightening: 62Nm. (5) on the gearbox spacer.
5
Gearbox mounting (2) on
Assembly + torque
3- gearbox buffer mounting
tightening: 75Nm.
(1).

Connecting torque rod on

Assembly + pre-
4- subframe (rubber buffer on
screwing.
subframe side)

6
Assembly + pre- Engine suspension (3) on
5-
screwing. the right side member.

Engine mounting cover (4) 3

Assembly + pre-
6- on the engine suspension
screwing. 4
(3).

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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.
3

The hose (part no. 77 11 160 444) is

connected to the quick-fit coupling (1) to drain
the fuel tank

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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)

RENAULT specific tool MOT 1397

(réf 77 11 162 966) for fuel tower
screwing / unscrewing

Figure 2

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)

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Injection ECU 2

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
1 1
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) 2009
1
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
2 1 2010

2010

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Air temperature sensor (Air temp.)

The air temperature sensor (1) is located on the 1

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:

1
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. 1
The engine speed.

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Camshaft phase sensor (EVO 2010)

2009
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: 1

The position of the intake camshaft.
To control the camshaft dephaser
solenoid valve.

2010
2010

Throttle position sensor

The throttle position sensor (1)

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.

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Oxygen sensor (Lambda sensor)

The oxygen sensor (1) is located on the exhaust 1

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)
2

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Engine cut-off switch (Upshift)

1
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 1

pressure rail.

This information allows the ECU to display the oil

pressure on the display.

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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

Battery V Water Oil Intake

Air
temp temp pressure pressure
Crankshaft phase
Oxygen sensor

Barrel position Throttle position

Camshaft Upshift cut-off

phase

Injection ECU

Dephaser Injectors
solenoid valve

Coils
Oxygen probe
heating
Fuel pump Motor fan Starter

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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
1
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 3
and screwed unions (3). 2

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).

Free grooves

− Position on alternator pulley :

Fit the belt in the middle of the pulley, letting free

both external grooves.

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− Position on free pulley :

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

Free 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)
On starter
fastening
screw 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
On cylinder
block

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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)

Exhaust
heat shield (2
)
(1) Thread stud

Bottom view, behind the exhaust heat shield

Solénoïd

(4)

(5
(3
)

NOTE : Old parts are no onger available.

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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

Tightening
Components
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

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