Renault Fluence 2009, Fluence 2010 User Manual

0 General vehicle information

01A VEHICLE MECHANICAL SPECIFICATIONS

01C VEHICLE BODYWORK SPECIFICATIONS

01D MECHANICAL INTRODUCTION

02A LIFTING EQUIPMENT

03B COLLISION

04B CONSUMABLES - PRODUCTS

04E PAINT

X38, and B32 or L38

OCTOBER 2009

EDITION ANGLAISE

"The repair procedures given by the manufacturer in this document are based on the technical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer in

the production of the various component units and accessories from which the vehicles are constructed".

All rights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

© Renault s.a.s 2007

FLUENCE - MEGANE GENERATION -

Section 0

Contents

		Pages
01A	VEHICLE MECHANICAL SPECIFICATIONS		04E	PAINT
	Vehicle: Specifications	01A-1		Anti-corrosion protection
				product: Description	04E-1
				Colour code: Specifications	04E-5
01C	VEHICLE BODYWORK SPECIFICATIONS
	Vehicle panel gaps:
	Adjustment value	01C-1

01D MECHANICAL INTRODUCTION
Tightening torques: General
information	01D-1

02A LIFTING EQUIPMENT

Vehicle: Towing and lifting

02A-1

03B COLLISION
Vehicle involved in an
impact: Impact fault finding	03B-1

04B CONSUMABLES - PRODUCTS
Vehicle: Parts and
consumables for the repair	04B-1

VEHICLE MECHANICAL SPECIFICATIONS	01A
Vehicle: Specifications

L38

144110

Dimensions in metres:

	(A)			0.908
	(B)			2.702
	(C)			1.010
	(D)			4.620
	(E)			1.545
	(F) (unladen)			1.478
	(G)			1.563
	(H)			1.809

01A-1

VEHICLE MECHANICAL SPECIFICATIONS	01A
Vehicle: Specifications

B32

134816

Dimensions in metres:

	(A)	0.860
	(B)	2.642
	(C)	0.793
	(D)	4.294
	(E)	1.546
	(F) (unladen)	1.479
	(G)	1.547
	(H)	1.755

		Engine			Gearbox			Emissions stan-
	Engine type	Engine suffix	Cubic capacity	Gearbox type		Gearbox suffix
								dard
			(cm³)

01A-2

		VEHICLE MECHANICAL SPECIFICATIONS									01A
					Vehicle: Specifications
	K4M			838		1598	JH3	183			EURO 3
											EURO 4
				839			DP0	111			EURO 3
											EURO 4
	K9K			830		1461	JR5	175			EURO 4
				832			TL4	022
				838			JR5	175			EURO 3
				842			TL4	022

01A-3

VEHICLE BODYWORK SPECIFICATIONS	01C
Vehicle panel gaps: Adjustment value

B32

137528

	No.	Location				Clearances (mm)
	(1)	bonnet / front bumper				3.5	± 1.5
	(2)	bonnet / headlight				2 ± 1.7
	(3)	bonnet / front wing				3.5	± 1.1
	(4)	bonnet / front wing				3.5	± 1.1
	(5)	front wing / A-pillar				4
	(6)	front wing / front side door				4 ± 0.8
	(7)	front side door / rear side door				4.5	± 1.5
	(8)	front side door / rear side door				4.2	± 1.2
	(9)	front side door / sill panel				4.5	± 1.5
	(10)	front wing / sill panel				2.5	± 1

01C-1

VEHICLE BODYWORK SPECIFICATIONS	01C
Vehicle panel gaps: Adjustment value

L38

144526

	No.	Location				Clearances (mm)
	(1)	bonnet / front bumper				3.5	± 1.5
	(2)	bonnet / headlight				3 ± 1.9
	(3)	bonnet / front wing				3.5	± 1.5
	(4)	bonnet / front wing				3.5	± 1.5
	(5)	front wing / A-pillar				4
	(6)	front wing / front side door				4 ± 1
	(7)	front side door / rear side door				4.5	± 1.7
	(8)	front side door / rear side door				4.5	± 1.2
	(9)	front side door / sill panel				4.5	± 1.5
	(10)	front wing / sill panel				2.5	± 1

01C-2

VEHICLE BODYWORK SPECIFICATIONS	01C
Vehicle panel gaps: Adjustment value

B32

137529

	No.	Location				Clearances (mm)
	(11)	rear side door / rear wing				4	±	0.8
	(12)	roof / tailgate				5	±	1.5
	(13)	tailgate / rear wing				4.5		± 2
	(14)	tailgate / rear wing				4	±	1.7
	(15)	tailgate / rear screen				3	±	1
	(16)	rear wing / rear light				1	±	0.7
	(17)	rear bumper / rear light				1.5		± 1
	(18)	tailgate / rear bumper				4	±	2

01C-3

VEHICLE BODYWORK SPECIFICATIONS	01C
Vehicle panel gaps: Adjustment value

L38

144527

	No.	Location				Clearances (mm)
	(11)	rear side door / rear wing panel				4	±	0.8
	(12)	roof / rear screen				4	±	1.4
	(13)	rear screen / rear wing panel				3	±	2
	(14)	boot lid / rear wing panel				1.5		± 1.5
	(15)	boot lid / rear screen				4	±	1.9
	(16)	rear wing panel / rear light				1.5		± 1.5
	(17)	rear wing panel / fuel filler flap cover					2.5± 1
	(18)	boot lid / rear bumper				4.5		± 1.9
	(19)	boot lid / rear bumper				6	±	2.2

01C-4

MECHANICAL INTRODUCTION	01D
Tightening torques: General information

I - TABLE OF STANDARD TORQUES

	Fastenings			Standard
				tightening
	Diameter		Property
				torque
			class	(N.m)
	M6	8.8		10
	M8	8.8		25
	M10	8.8		50
	M10	10.9		62
	M12	10.9		105
	M14	10.9		180
	M16	10.9		280
	M18	10.9		400
Special notes on electrical earths
	Fastenings		Standard
			tightening
	Diameter
			torque
			(N.m)
	M6	8
	M8	21
	M10	44

The property class is indicated on the bolt (1) or (2) .

II - FUNCTION OF A BOLTED ASSEMBLY

The bolting system connects parts of an assembly to prevent their separation or sliding when submitted to exterior forces.

Exterior forces

120737

The assembly is submitted to forces that are:

-static and / or dynamic,

-simple (e.g. simple traction),

-multiple (traction + flexion + torsion).

120736

01D-1

MECHANICAL INTRODUCTION	01D
Tightening torques: General information

Creating tension (or preload) F0

120738

The assembly is held together by the tension created in the bolt when it is tightened.

A reliable assembly is only possible if the correct tension is used:

-insufficient tension: risk of loosening,

-too much tension: risk of deformation of the parts to be assembled, or shearing of the bolt.

	120739
(3)	Bolt
(4)	Assembled components
(5)	Extension of the bolt
(6)	Non-tightened assembly
(7)	Tightened assembly
(X1)	compression of the assembly
(Fo)	tension
(C)	tightening torque

Customer complaints resulting from incorrect tightening may be, following assembly, a safety issue (fire, loss of control of the vehicle etc.), an immobilising fault or a noise.

III - TIGHTENING PROCEDURES

The two controlled tightening procedures adapted to automotive repairs because of their low cost and simple operation are torque tightening and angle tightening (also called torque and angle).

1 - Torque tightening

This is the most commonly used procedure. Is consists of tightening until a given resisting torque is reached, known as tightening torque.

The tightening torque is distributed in a large part as friction torque (under the head and in the thread) and in a small part as useful torque (to create the tension).

This practise spreads the tension significantly due to the variation in the friction coefficients from one assembly to another and the uncertainty of the tightening procedures and methods.

2 - Angle tightening

The principle consists of putting the parts of the assembly in contact using a mating torque (approximately 25 to 30% of the final torque) then to tighten to a determined angle.

This method, which is not dependent on the friction of the tightened assembly, gives more precise results than torque tightening.

IV - OBSERVING THE TIGHTENING TORQUES AND ANGLES

Bolted assemblies whose tightening torques and angles are explicitly specified in the removal / refitting procedures must be observed using the appropriate tools (torque wrench, angle measuring disc). Failure to observe this can lead to safety risks, immobilising faults or unwanted noises.

For other bolted assemblies, non-measured tightening (using standard spanners) is acceptable. Nevertheless, the corresponding tightening torque is indicated in the table of standard tightening torques.

V - RECOMMENDED TIGHTENING TOOLS

For measured tightening, the repairer must have available torque wrenches to tighten from 4 to 400 N.m as well as an angle measuring disc.

The torque wrenches used may be click type or electronic.

01D-2

MECHANICAL INTRODUCTION	01D
Tightening torques: General information

For example:

-1 torque wrench 4 - 40 N.m,

-1 torque wrench 20 - 100 N.m,

-1 torque wrench 80 - 400 N.m,

-1 angle measurement disc.

The torque wrenches used must comply with the ISO 6789 standard. They must be calibrated regularly following the supplier's recommendations using the appropriate procedures.

VI - PRECAUTIONS WHEN USING A CLICK TYPE TORQUE WRENCH

A click type torque wrench is a manual tightening tool. The trigger mechanism causes a break or disengagement of the wrench past a force threshold.

This threshold depends on the setting of the wrench but also depends on the way the wrench is handled.

When used following best practises, the accuracy of the tightness when using a click type torque wrench is

± 15%.

The instructions to be observed are:

120740

(6)

lever arm

- Place the hand in the centre of the handle. An incorrectly positioned hand on the handle will alter the trigger threshold.

120741

-Pull the wrench gently and steadily, without applying any torsion. Excessive tightening speed as well as jerkiness are major causes of overtightening. Any torsion applied to the wrench will alter the trigger threshold.

-Hold the wrench on the bolt using a minimum of effort. Any effort applied to the wrench head will alter the trigger threshold.

120742

-Apply the tightening effort perpendicular to the mounting observing a tolerance of ± 15˚ relative to the perpendicularity. If the wrench is not perpendicular to the mounting axis, this will result in insufficient tightening.

-Stop tightening as soon as the wrench is triggered. Continued tightening after the wrench is triggered will lead to overtightening.

01D-3

MECHANICAL INTRODUCTION	01D
Tightening torques: General information

120743

If the length of the wrench is modified (extending the handle, adapting an end piece) it is essential to recalibrate the wrench to its new configuration.

Modifying the length of the wrench will modify its trigger threshold.

Use the formula: C1 = CO x L2 / (L1+L2)

-CO: torque to apply,

-C1: adjustment torque to be displayed on the wrench,

-L1: length of the extension,

-L2: length of the wrench.

Unless there are special instructions in the repair method, a universal joint (CARDAN joint type) should be used for measured tightening. Using a universal joint will result in a difference between the set torque of the wrench and the actual torque applied.

Before storing the wrench, loosen the adjustment spring completely. A wrench stored with a spring under tension will lose its tightening accuracy.

VII - PRECAUTIONS WHEN USING ELECTRONIC TORQUE WRENCHES

An electronic torque wrench is a manual tightening tool. The tightening torque and, depending on the model, the angle is read directly.

When used following best practises, the accuracy of the tightness when using an electronic torque wrench is ± 5%.

Electronic torque wrenches are not affected by the position of the operator's hand.

It is advisable to handle the wrench with care and to stop tightening when the required value is displayed on the wrench.

01D-4

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

Equipment required

safety strap(s)

I - TOWING

WARNING

See the current towing regulations in each country.

Never use the drive shafts as attachment points.

The towing points may only be used for towing on the road.

Never use the towing points for removing the vehicle from a ditch or to lift the vehicle, either directly or indirectly.

Screw in and lock the towing ring before towing.

Vehicles fitted with automatic transmission:

-It is preferable to transport the vehicle on a flatbed or tow it by lifting the front wheels. As an exception the vehicle may be towed with the wheels on the ground but at a speed below 12 mph (20 km/h) and over a maximum distance of 18 miles (30 km) (with the gear lever in neutral).

Vehicles fitted with Renault Card:

-If the vehicle battery is flat, the steering column remains locked. In this case, fit a new battery or connect to an electrical source to lock the airbag computer using the diagnostic tool, (see Fault finding - Replacement of components) (88C, Airbags and pretensioners), which unlocks the steering column.

-If it is not possible to lock the airbag computer, the front of the vehicle must be lifted.

1 - position of front attachment point

B32

137700

L38

144388

02A-1

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

2 - position of rear attachment point

B32

137702

L38

144389

Fully screw in the tow eye supplied in the onboard vehicle tool kit located in the luggage compartment inside the emergency spare wheel.

II - LIFTING BY TROLLEY JACK

IMPORTANT

To prevent any accidents, the trolley jack must only be used to lift and/or move the vehicle. The vehicle height must be maintained with axle stands which are strong enough to support the weight of the vehicle.

137695

137698

To mount the vehicle on axle stands, the entire vehicle must be lifted on one side at (3) , (1) ,and axle stands must be placed under the reinforcements provided as jacking points for the vehicle's own jack at4() , (2) .

02A-2

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

III - LIFTING ON A LIFT

1 - Safety advice reminder

131005

Safety advice reminder:

If it is necessary to remove heavy components from the vehicle, it is preferable to use a four-post lift.

There is a danger that the vehicle will tilt on a two-post lift after certain components have been removed (e.g. engine and transmission assembly, rear axle, gearbox). Fit the safety strap(s) available from the Parts Department.

2 - Fitting the straps

112347

Fitting the straps:

For safety reasons, these straps must always be in perfect condition. Replace them as soon as they show signs of wear.

When fitting the straps, check that the seats and fragile parts of the vehicle are correctly protected.

a - Tilting towards the front

Pass the strap under the rear right-hand arm of the lift.

Pass the strap through the inside of the vehicle.

Pass the strap under the rear left-hand arm of the lift.

Pass the belt through the inside of the vehicle again.

Tighten the strap.

b - tilting towards the rear

Pass the strap under the front right-hand arm of the lift.

Pass the strap through the inside of the vehicle.

Pass the strap under the front left-hand arm of the lift.

Pass the belt through the inside of the vehicle again.

Tighten the strap.

c - Permitted jacking points

To lift the vehicle, position the pads of the lifting arms as shown below, taking care not to damage the underside of the sill panel.

02A-3

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

IMPORTANT

Only the jacking points described in this section allow the vehicle to be raised in complete safety.

Do not raise the vehicle using points other than those described in this section.

Front lifting points

137692

Position the lift arms under the side cross members (1)

.

Rear lifting points

137696

Position the lift arms under the end of the sill panel body flanges (3) .

Note:

If this arrangement is not possible, notably when underbody supports are being used for bodywork rebuilding on a body jig bench, depending on the case, proceed as follows.

02A-4

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

IV - DISENGAGING THE JACKING POINTS

1 - Disengaging the front side cross members

B32

137705

02A-5

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

L38

144387

Detailed view of front support points (2)

Support the vehicle at the jacking points at the front (2) and under the sill panel body flanges at the rear (3) .

137694

02A-6

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

IMPORTANT

This situation increases the risk of the vehicle tilting forwards; removing components from the rear section of the vehicle is therefore prohibited.

2 - disengaging the rear sill panel body flanges

B32

137705

02A-7

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

L38

144387

Detailed view of rear support points (4)

Support the vehicle under the side cross members at the front (1) , and under the jacking points at the rear

(4) .

137697

02A-8

LIFTING EQUIPMENT	02A
Vehicle: Towing and lifting

IMPORTANT

In this instance, the risk of the vehicle tilting towards the rear is high. It is forbidden to remove components from the front section of the vehicle.

02A-9

COLLISION	03B
Vehicle involved in an impact: Impact fault finding

I - CHECKING THE SUBFRAME

B32

137224

a

03B-1

COLLISION	03B
Vehicle involved in an impact: Impact fault finding

L38

142677

a	-			(Dg) - (Jd) = 1667 mm
	-			(Dd) - (Jg) = 1695 mm
a				(Jg) - (Jd) = 1087 mm
			-
	Note:
	the front and rear end points are not symmetri-
	cal. To check them, measure the centre-to-centre
	distance of these points.

Chronological order of checks

Front impact:

-(Dg) - (Gd) = (Dd) - (Gg)

-(Gg) - (Hd) = 1400 mm

-(Gd) - (Hg) = 1390 mm

-(Hg) - (Hd) = 968 mm Rear impact:

-(Dg) - (Gd) = (Dd) - (Gd)

-(Gg) - (B1d) = (Gd) - (B1g)

03B-2

COLLISION	03B
Vehicle involved in an impact: Impact fault finding

II - DETAILED VIEW OF INSPECTION POINTS

Points Hg and Hd (side member front leader pin)

137227

Points Gg and Gd (front side member rear leader pin)

136911

Points Dg and Dd

136909

points B1g and B1d (rear axle mounting)

136909

a

03B-3

COLLISION	03B
Vehicle involved in an impact: Impact fault finding

B32

Points Jg and Jd (side member rear leader pin)

144420

a

L38

Points Jg and Jd (side member rear leader pin)

144422

a

03B-4

	CONSUMABLES - PRODUCTS				04B
	Vehicle: Parts and consumables for the repair
Consumables for mechanical repair:
	DEFINITION		PACKAGING	PART NUMBER
			MECHANICAL SEALANTS
	SILICOR		85 g tube	77 11 236 470
	sealing paste
	MASTIXO		100 g tube	77 11 236 172
	Joint face seal
	BEARING SEALING KIT		Kit	77 11 237 896
	For crankshaft bearing cap side
	sealing
	SILICONE ADHESIVE SEAL		100 g cartridge	77 11 227 484
	Engine and gearbox sealing paste
	TRANSPARENT SEALING MAS-		45 g tube	77 11 223 369
	TIC
	SILICOJOINT		90 g tube	77 11 236 469
	LOCTITE ADHESIVE 597		Cartridge	77 11 219 705
	Sealing paste for PXX gearboxes
	RESIN ADHESIVE or SEALING		25 ml tube	77 11 237 640
	RESIN
	Sealing resin for engine and gear-
	box covers
	EXHAUST MASTIC		1.5 kg tin	77 01 421 161
	For exhaust pipe union seals
	LEAK DETECTOR		400 ml aerosol	77 11 236 176
			ADHESIVES
	FRENETANCHE		50 ml bottle	77 11 236 471
	Sealing the threading at low and
	medium pressure
	HIGH-STRENGTH THREADLOCK		50 ml bottle	77 11 230 112
	For locking bolts
	SEALING RESIN		50 ml bottle	77 11 236 472
	For locking the bearings
			LUBRICANT CLEANERS
	NÉTELEC		150 ml aerosol	77 11 225 871
	Avoid bad contacts in electrical cir-
	cuits

04B-1

	CONSUMABLES - PRODUCTS				04B
	Vehicle: Parts and consumables for the repair
	INJECTOR CLEANER		355 ml container	77 11 224 188 or 77 11 225 539
	CLOTH FOR INJECTION SYSTEM			77 11 211 707
	SUPER RELEASING AGENT		500 ml aerosol	77 11 236 166
	SUPER RELEASING AGENT		250 ml aerosol	77 11 420 439
	SUPER CLEANER FOR JOINT		300 ml aerosol	77 11 238 181
	FACES
	For cleaning joint faces
	SURFACE CLEANER		5 L container	77 01 404 178
	SILICONE LUBRICANT		500 ml aerosol	77 11 236 168
	SILICONE-FREE LUBRICANT		500 ml aerosol	77 11 236 167
	BRAKE CLEANER		600 ml aerosol	77 11 422 413
			150 ml aerosol	77 11 422 414
	BIO BRAKE CLEANER		750 ml spray bottle	77 11 427 217
	AIR CONDITIONING CLEANER		250 ml aerosol	77 11 230 498
	CARBURETTOR CLEANER		Aerosol	77 11 236 177
	IXTAR ENGINE CLEANER		400 ml can	77 11 229 365
			GREASE
	BR2+ GREASE		1 kg pack	77 01 421 145
	For:
	- the lower arm bearings,
	- the anti-roll bar grooves,
	- the driveshaft splines.
	SILICONE GREASE		100 g tube	77 11 419 216
	For:
	- the tubular rear axle bushes,
	- the anti-roll bar bushes.
	COPPER ANTI-SEIZE GREASE		85 g tube	77 11 236 173
	Grease for turbochargers (high
	temperature)
	COPPER-ALUMINIUM LUBRI-		500 ml aerosol	77 11 236 169
	CANT
	Grease for turbochargers (high
	temperature)
	GREASE		180 g sachets	77 11 420 011
	For driveshaft seals

04B-2

	CONSUMABLES - PRODUCTS					04B
	Vehicle: Parts and consumables for the repair
	WHITE GREASE		400 ml aerosol		77 11 236 174
	For wheel sensors
	MULTIPURPOSE GREASE		500 ml aerosol		77 11 236 170
			250 ml aerosol		77 11 236 171
	FLUORSTAR 2L		100 g tube		82 00 168 855
	Silicone-free electric sealing grease
			LACQUER
	JELT ARGENT		5 g bottle		77 11 230 111
	Varnish for repairing heated rear
	screens
			BRAKE
	DOT 4, ISO CLASS 6, RENAULT		0.5 L container		77 11 218 589
	STANDARD: 03-50-006,
			5 L container		77 11 238 318
	For vehicles with and without elec-
	tronic stability program (ESP)		25 L container		77 11 238 319
	DOT 4, ISO CLASS 4, RENAULT		0.5 L container		77 11 172 381
	STANDARD: 03-50-005		5 L container		77 01 395 503
	Authorised for vehicles without ESP
			25 L container		77 11 171 926
	DOT 4		0.5 L container		86 71 000 000
	Authorised for vehicles without		5 L container		86 71 014 277
	ESP, without clutch with hydraulic
	tappet		25 L container		86 71 014 278
			COOLING SYSTEM
	ANTIFREEZE (TYPE D)		1 L container		77 11 170 548
			1 L container		77 11 171 589
	COOLANT (TYPE D)		2 L container		77 11 170 545
			5 L container		77 11 170 546
			OIL
	ENGINE OIL		(see Engine oil: Specifications) (Technical Note 6013A, 04A, Lubri-
				cants)
			(see Manual gearbox oil: Specifications) (Technical Note 6012A, 04A,
				Lubricants)
	GEARBOX OIL		(see Automatic gearbox oil: Specifications) (Technical Note 6012A,
				04A, Lubricants)
			(see Sequential gearbox oil: Specifications) (Technical Note 6012A,
				04A, Lubricants)

04B-3

	CONSUMABLES - PRODUCTS					04B
	Vehicle: Parts and consumables for the repair
	AXLE OIL		(see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubri-
				cants)
	ELF RENAULT MATIC D2		2 L container		77 01 402 037
	Oil for power-assisted steering:
	Pump connected, pump assembly
	(except Laguna III)
	TOTA L P O W E R - A S S I S T E D		1 L container
	STEERING FLUID
	Oil for power-assisted steering:
	Pump assembly (Laguna III)
	PLANETELF PAG 488				77 11 172 668
			250 ml container
	SANDEN SP 10				77 01 419 313
	Oil for air conditioning compressor
			TYRES
	TYRE PASTE		1 kg pack		77 11 223 052
			5 kg pack		77 11 223 053
	TYRE REPAIR AGENT		400 ml tube		77 11 221 296
			300 ml tube		77 11 222 802
			BLANKING PLUG
	Engine type		Injection type		Part no.
	F5R				77 01 206 382
	F8Q				77 01 206 340
	F9Q				77 01 208 229
	G9T AND G9U				77 01 208 229
	K9K		DELPHI		77 01 206 804
	K9K		SIEMENS		77 01 476 857
	M9R				77 01 209 062
	P9X				77 01 474 730
	ZD3				77 01 208 229
			MISCELLANEOUS
	GREY ABRASIVE PAD				77 01 405 943
Consumables for bodywork repair:
			HOLLOW SECTION WAX
	SPR CC		1 L container		77 11 172 672

04B-4