3.10.

Engine sump assembly

• Clean the gasket plane.

• Put the oil pump and the oil splash plate (24 N.m)

• Put black gasket Dow Corning 732 at gasket plane connections

24
• Check the planes are aligned on flying wheel side

• Do not put the screw under the crankshaft pinion

25
• Applied a tightening torque of 15 N.m

3.11. Accessories assembly

• Make a chamfer on the
crankshaft pulley cover and a
gasket (cf picture).

Gasket on the
entire outline

26
• Twist slightly the cover at the level of the belt to be sure it will not rub.

• Assemble the plastic cover on timing side and make a gasket (black Dow
Corning 732).

27
• Screw admission camshaft pulley plug without Loctite (25 N.m)

• Assemble the big crankshaft pulley at 40 N.m + 110° with green Loctite
648

• Block the hole of TDC gage rod with a screw

28
• Put the camshaft plugs on flying wheel side

• Assemble the camshaft shifting solenoid valve and the oil canister

• Put the water box with his gasket

29
• Assemble the oil and camshaft sensors. Assemble the water/oil exchanger
at 45° ( cf picture, 60 N.m) and the oil filter (10 N.m) by putting oil on the
gaskets.

• Put the oil pressure connection

• Assemble NGK spark plugs and ignition coils

30
• Put the superior cover on timing side (tightening torque: 5 N.m)

• Assemble intake pipe with his gasket

31
 • Injection rail fitting

Check there is no impurity in the rail.

Use Loctite 542 for thread sealing (be careful, do not put Loctite in the rail).
The injection rail banjo has to be upward (cf picture) once the assembly is done.

• Assemble hoses

Assemble hoses of P_injection_rail and P_oil sensors with teflon on the threads.

32
 • Assemble the throttle valve

Change the potentiometer position (turn 180°).

BEFORE AFTER

For more simplicity, we advise you to change the throttle stop by a BTR screw
assemble with single-coil spring lock washers.

BEFORE AFTER

Block the hole on the manifold with the screw given in the kit R3.

33
• Put the beam before assemble the manifold on the engine

Manifold brackets
• Assemble Tair and Pair sensors

• Set up the oil level gage

34
• Drill the thermostat with 4 holes Ø4 mm before assemble it with the water
box cover

• Assemble the oil calister hose and the pressure regulator

• Make a gasket (Dow Corning 732) on the superior timing cover

35
• Install the crankshaft lip seal on flying wheel side

• Assemble the ball bearing on flying wheel side (glued with green Loctite
648)

• Check the flying wheel weight and assemble it (70 N.m)

4100 g mini,
with screws

36
Your engine is ready.

37
4. Appendix
4.1. Tightening torques table

RENAULT CLIO R3
Tightenng torque Nb of tightening
Parts Products used
(N.m) max

Top engine
area

Head cylinder 20 + 100° + 100° 3

Head cylinder
12 Loctite 518
cover
Spark plugs 30
ADM camshaft
75
pulley
ECH camshaft
30 + 86°
pulley
Tension roller 28 Loctite 243
Driving roller 50 Loctite 243
Water probe 33
Water box 13
Intake pipe 21
Injection rail 8,5
Dowel pin exhaust
10
camshaft
Dowel pin (roller) 10
Manifold bracket 15
Manifold 15
Dowel pin intake
10 Loctite 243
camshaft
Alternator 25
Compressor 25
Lifting eye 44

38
Low engine area

Oil on thread and under

Main bearings 20 + 62° 3
the head
Connecting rod Oil on thread and under
25 + 110° 1
screws the head
Damper pulley 40 + 110° Grease
Oil pump 24
Water pump 9
Oil sump 15
Oil splash plate 24
Water/Oil exchanger 60 Oil on the gasket
Oil filter 10 Oil on the gasket
P_Oil sensor 30
Oil level gage 20
Flying wheel 30 + 35°

39
4.2. Frequency of replacement and

Frequency of replacement Concerned element

After each rally or each training session Oil filter
After each dismantle All dismantle gaskets
Head cylinder screws
After 1 tightening
Con-rod screws
Main bearing screws
After 3 tightening
Flying wheel screws
500 km SS Main and con-rod bearings
Engine Revise
(Look kit de révision
[Link])
Patm sensor
2000 km SS
Throttle sensor
Oil pump
Water pump

40
41
42

Volume to remove (cm3)

0,2
0,4
0,6
0,8

1,2
1,4
1,6
1,8

2,2
2,4
2,6
2,8

3,2
3,4
3,6
3,8

4,2
4,4
4,6
4,8

5,2
5,4
5,6
5,8

6,2
6,4
6,6
0

6
0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

Piston machining / volume to remove

1,00

1,10

1,20

1,30

1,40

1,50
Piston machining (mm)

1,60

1,70

1,80

1,90

2,00

2,10

2,20

2,30

2,40

2,50

2,60

2,70

2,80

2,90

3,00

3,10

3,20

3,30

3,40

3,50

3,60

3,70

3,80

3,90

4,00
Table of piston machining 4.3.
 Head cylinder machining / volume to remove
5,00
4,80
4,60
4,40
4,20
4,00
3,80
3,60
3,40
3,20
3,00
2,80
2,60
2,40
2,20
2,00
1,80
1,60

Volume to remove (cm3)

1,40
1,20
4.4. Table of head cylinder machining

1,00
0,80
0,60
0,40
0,20
0,00

0,00
0,05
0,10
0,15
0,20
0,25
0,30
0,35
0,40
0,45
0,50
0,55
0,60
0,65
0,70
0,75
0,80
0,85
0,90
0,95
1,00

Head cylinder machining (mm)

43