1962-1994 Renault R4 Service and Repair Manual

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🏷️ Basic Information Identification Make: Renault Model: R4 Production Years Covered: 1962-1994 Generation Codes: R1120, R2390, R2370, R1123, R1128, R1129, R2105, R210B, R210C, R2370, R2374, R2375, R2376, R2377, R2390, R2391, R2392, R2393, R4F 👋 Introduction Market Position Vehicle Segment: Subcompact / Economy car, pioneering the hatchback design. Target Audience: Affordable, practical transportation for individuals and small families. Competitive Analysis Key Competitors: Citroën 2CV, Volkswagen Beetle (in some markets), Fiat 500/600, Ford Anglia. Unique Selling Proposition: Front-wheel drive, spacious interior for its size, efficient and simple mechanicals, unique dashboard gearbox design. Key Features Design Philosophy: Simplicity, functionality, and cost-effectiveness, with a focus on maximizing interior space. Practicality: Large, upward-opening tailgate and versatile interior seating arrangements. Durability: Designed for long-term use and ease of maintenance, a hallmark of post-war French engineering. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Likely Printed (typical for this era, but digital PDF versions are common now) Page Count: Estimated 300-500 pages (typical for comprehensive service manuals of this scope) Coverage Scope: All models and all repairs A-Z 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, and tuning for all inline-four petrol engines (e.g., 603, 688 series). Transmission: Service and repair of the Renault dashboard gearbox (transaxle), including clutch, gearbox internals, and linkages. Drivetrain: Front-wheel drive system, driveshafts, CV joints, and differential service. Suspension: Front torsion bar independent suspension, rear longitudinal leaf springs, shock absorbers, and steering linkage. Brakes: Front disc brakes (on later models), rear drum brakes, hydraulic system, master cylinder, wheel cylinders, and brake lines. Electrical System: Wiring diagrams, starter motor, alternator, ignition system, lighting, instrumentation, fuses, and accessories. Fuel System: Carburetor service (e.g., Solex, Zenith), fuel pump, fuel lines, and fuel tank. Cooling System: Radiator, fan, thermostat, water pump, and coolant hoses. Exhaust System: Muffler, pipes, and catalytic converter (if applicable to later models). Bodywork Chassis: Panel repair, rust prevention, door mechanisms, glass replacement, and structural integrity. Procedures Included Maintenance Schedules: Regular service intervals for oil changes, filter replacements, ignition timing, valve adjustments, and lubrication. Troubleshooting Diagnostics: Systematic fault finding for common mechanical and electrical issues, including symptom-based diagnosis. Engine Overhaul: Complete engine rebuild procedures, including cylinder head removal, piston and con-rod installation, crankshaft bearing replacement, and timing chain/belt replacement. Transmission Repair: Gearbox disassembly, repair of synchromesh mechanisms, bearing replacement, and clutch adjustment/replacement. Brake System Repair: Bleeding the brake system, replacing brake pads/shoes, servicing wheel cylinders and calipers, and replacing brake lines. Electrical Component Testing: Testing and replacement of ignition coil, distributor, spark plugs, alternator, starter, and other electrical components. Suspension Alignment: Front-end alignment procedures, wheel bearing adjustment, and shock absorber replacement. Body Repair Techniques: Sheet metal repair, welding, door and latch adjustment, and window seal replacement. Carburetor Adjustment: Detailed instructions for tuning and rebuilding various Solex and Zenith carburetors fitted to the R4. Wiring Diagram Interpretation: Clear, annotated wiring diagrams for easy identification and troubleshooting of electrical circuits. Technical Depth Detail Level: Comprehensive, from routine maintenance to complete engine and transmission rebuilds. Diagnostic Procedures: In-depth diagnostic charts and troubleshooting guides for identifying root causes of issues. Torque Specifications: Precise torque values for all critical fasteners, engine components, and suspension parts. Clearances Tolerances: Specific internal engine clearances (e.g., piston-to-cylinder, bearing clearances) and other critical component tolerances. Special Tools: Identification and usage instructions for specialized tools required for specific repairs. Illustrations Diagrams: High-quality line drawings, exploded views, and diagnostic schematics to aid understanding. 📊 Manual Specifications File Format Digital Format: Typically PDF for modern digital sales, allowing for searchability and easy access. Print Quality: High resolution for clear text and diagrams, ensuring readability of technical details. Printability: Designed for printing of individual sections or the entire manual. Searchability: If digital, it will have OCR (Optical Character Recognition) for keyword searching. Binding Type Physical Binding: Historically, typically perfect bound or spiral bound for lay-flat usability in a workshop environment. Paper Type Physical Paper: Durable, often coated paper to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, air-cooled (early models) or water-cooled (later models). Engine Codes: 603 series (e.g., 603.60, 603.61), 688 series (e.g., 688.07, 688.08, 688.61). Displacement Cc: 845 cc to 1108 cc (depending on model year and variant). Bore Stroke: Varies by engine variant; e.g., 603.60: 50 mm x 72 mm; 688.08: 60 mm x 84 mm. Compression Ratio: Typically 7.25:1 to 8.0:1, depending on fuel grade and engine variant. Performance Horsepower Bhp: Approx. 26-34 bhp at 4000-4700 rpm (depending on engine variant and tuning). Torque Lb-Ft: Approx. 41-50 lb-ft at 2000-2500 rpm (depending on engine variant). Fuel System Carburetor Type: Single-barrel downdraft carburetors (e.g., Solex 32 BIA, Solex 32 PICS, Zenith 32 NDIX). Fuel Type: Unleaded gasoline (later models), historically leaded gasoline. Fuel Pump: Mechanical fuel pump, typically diaphragm type. 🔧 Transmission Standard Type: Renault 'CVT' - a simplified manual gearbox with...

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Description

🏷️ Basic Information

Identification

Make:

Renault

Model:

Production Years Covered:

1962-1994

Generation Codes:

R1120, R2390, R2370, R1123, R1128, R1129, R2105, R210B, R210C, R2370, R2374, R2375, R2376, R2377, R2390, R2391, R2392, R2393, R4F

👋 Introduction

Market Position

Vehicle Segment:

Subcompact / Economy car, pioneering the hatchback design.

Target Audience:

Affordable, practical transportation for individuals and small families.

Competitive Analysis

Key Competitors:

Citroën 2CV, Volkswagen Beetle (in some markets), Fiat 500/600, Ford Anglia.

Unique Selling Proposition:

Front-wheel drive, spacious interior for its size, efficient and simple mechanicals, unique dashboard gearbox design.

Key Features

Design Philosophy:

Simplicity, functionality, and cost-effectiveness, with a focus on maximizing interior space.

Practicality:

Large, upward-opening tailgate and versatile interior seating arrangements.

Durability:

Designed for long-term use and ease of maintenance, a hallmark of post-war French engineering.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Likely Printed (typical for this era, but digital PDF versions are common now)

Page Count:

Estimated 300-500 pages (typical for comprehensive service manuals of this scope)

Coverage Scope:

All models and all repairs A-Z

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul, and tuning for all inline-four petrol engines (e.g., 603, 688 series).

Transmission:

Service and repair of the Renault dashboard gearbox (transaxle), including clutch, gearbox internals, and linkages.

Drivetrain:

Front-wheel drive system, driveshafts, CV joints, and differential service.

Suspension:

Front torsion bar independent suspension, rear longitudinal leaf springs, shock absorbers, and steering linkage.

Brakes:

Front disc brakes (on later models), rear drum brakes, hydraulic system, master cylinder, wheel cylinders, and brake lines.

Electrical System:

Wiring diagrams, starter motor, alternator, ignition system, lighting, instrumentation, fuses, and accessories.

Fuel System:

Carburetor service (e.g., Solex, Zenith), fuel pump, fuel lines, and fuel tank.

Cooling System:

Radiator, fan, thermostat, water pump, and coolant hoses.

Exhaust System:

Muffler, pipes, and catalytic converter (if applicable to later models).

Bodywork Chassis:

Panel repair, rust prevention, door mechanisms, glass replacement, and structural integrity.

Procedures Included

Maintenance Schedules:

Regular service intervals for oil changes, filter replacements, ignition timing, valve adjustments, and lubrication.

Troubleshooting Diagnostics:

Systematic fault finding for common mechanical and electrical issues, including symptom-based diagnosis.

Engine Overhaul:

Complete engine rebuild procedures, including cylinder head removal, piston and con-rod installation, crankshaft bearing replacement, and timing chain/belt replacement.

Transmission Repair:

Gearbox disassembly, repair of synchromesh mechanisms, bearing replacement, and clutch adjustment/replacement.

Brake System Repair:

Bleeding the brake system, replacing brake pads/shoes, servicing wheel cylinders and calipers, and replacing brake lines.

Electrical Component Testing:

Testing and replacement of ignition coil, distributor, spark plugs, alternator, starter, and other electrical components.

Suspension Alignment:

Front-end alignment procedures, wheel bearing adjustment, and shock absorber replacement.

Body Repair Techniques:

Sheet metal repair, welding, door and latch adjustment, and window seal replacement.

Carburetor Adjustment:

Detailed instructions for tuning and rebuilding various Solex and Zenith carburetors fitted to the R4.

Wiring Diagram Interpretation:

Clear, annotated wiring diagrams for easy identification and troubleshooting of electrical circuits.

Technical Depth

Detail Level:

Comprehensive, from routine maintenance to complete engine and transmission rebuilds.

Diagnostic Procedures:

In-depth diagnostic charts and troubleshooting guides for identifying root causes of issues.

Torque Specifications:

Precise torque values for all critical fasteners, engine components, and suspension parts.

Clearances Tolerances:

Specific internal engine clearances (e.g., piston-to-cylinder, bearing clearances) and other critical component tolerances.

Special Tools:

Identification and usage instructions for specialized tools required for specific repairs.

Illustrations Diagrams:

High-quality line drawings, exploded views, and diagnostic schematics to aid understanding.

📊 Manual Specifications

File Format

Digital Format:

Typically PDF for modern digital sales, allowing for searchability and easy access.

Print Quality:

High resolution for clear text and diagrams, ensuring readability of technical details.

Printability:

Designed for printing of individual sections or the entire manual.

Searchability:

If digital, it will have OCR (Optical Character Recognition) for keyword searching.

Binding Type

Physical Binding:

Historically, typically perfect bound or spiral bound for lay-flat usability in a workshop environment.

Paper Type

Physical Paper:

Durable, often coated paper to withstand workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, air-cooled (early models) or water-cooled (later models).

Engine Codes:

603 series (e.g., 603.60, 603.61), 688 series (e.g., 688.07, 688.08, 688.61).

Displacement Cc:

845 cc to 1108 cc (depending on model year and variant).

Bore Stroke:

Varies by engine variant; e.g., 603.60: 50 mm x 72 mm; 688.08: 60 mm x 84 mm.

Compression Ratio:

Typically 7.25:1 to 8.0:1, depending on fuel grade and engine variant.

Performance

Horsepower Bhp:

Approx. 26-34 bhp at 4000-4700 rpm (depending on engine variant and tuning).

Torque Lb-Ft:

Approx. 41-50 lb-ft at 2000-2500 rpm (depending on engine variant).

Fuel System

Carburetor Type:

Single-barrel downdraft carburetors (e.g., Solex 32 BIA, Solex 32 PICS, Zenith 32 NDIX).

Fuel Type:

Unleaded gasoline (later models), historically leaded gasoline.

Fuel Pump:

Mechanical fuel pump, typically diaphragm type.

🔧 Transmission

Standard

Type:

Renault 'CVT' - a simplified manual gearbox with an automatic clutch (acting like a torque converter in a traditional automatic) and a single dry plate clutch.

Gear Selection:

Three forward gears plus reverse, operated by a single lever on the dashboard.

Gear Ratios:

Specific ratios provided within the manual for each gear.

Optional

Variants:

While the core 'automatic clutch' manual transmission was standard, some export markets or specific versions might have had minor variations in gearing or clutch operation.

Features

Clutch Operation:

Centrifugal automatic clutch system, eliminating the need for a clutch pedal.

Fluid Type:

Gearbox oil, typically API GL-4 specification. Consult manual for exact viscosity (e.g., 80W-90).

📐 Dimensions

Exterior

Length:

Approx. 3,700 mm (145.7 in) to 3,870 mm (152.4 in) depending on model.

Width:

Approx. 1,520 mm (59.8 in) to 1,540 mm (60.6 in).

Height:

Approx. 1,470 mm (57.9 in) to 1,500 mm (59.1 in).

Wheelbase:

Approx. 2,270 mm (89.4 in) to 2,290 mm (90.2 in).

Ground Clearance:

Approx. 170 mm (6.7 in), designed for rough terrain.

Cargo

Cargo Volume Seats Up:

Approximately 330 liters (11.6 cu ft) with rear seats in place.

Cargo Volume Seats Down:

Can be expanded significantly with rear seats folded, often exceeding 1 cubic meter.

Weights

Curb Weight:

Approx. 600 kg (1,323 lbs) to 720 kg (1,587 lbs) depending on model and equipment.

Gross Vehicle Weight:

Typically around 1100-1200 kg.

🛡️ Safety Features

Ratings

Crash Test Results:

No formal standardized crash test results from bodies like NHTSA or Euro NCAP in the manner they exist today for vehicles of this era.

Active Features

Braking System:

Front disc (later models) and rear drum brakes offer adequate stopping power for the vehicle's performance.

Steering:

Direct rack-and-pinion steering, providing good feedback.

Passive Features

Body Construction:

Unitary construction with crumple zones designed to absorb impact energy, though basic by modern standards.

Seat Belts:

Optional or standard depending on year and market; the manual will detail installation and adjustment.

Windscreen:

Laminated safety glass for the windscreen.

💡 Technology Features

Infotainment

Audio System:

Typically a basic AM radio, often optional. The manual covers its installation and basic troubleshooting.

Driver Assistance

No Electronic Assistance:

The R4 predates most modern electronic driver assistance systems; its technology is purely mechanical.

Connectivity

No Connectivity:

No provisions for mobile phone integration or modern connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first.

Air Filter Replacement:

Recommended every 10,000-15,000 km (6,000-9,000 miles) or annually.

Spark Plug Replacement:

Typically every 15,000-20,000 km (9,000-12,000 miles), with gap adjustment at each oil change.

Valve Adjustment:

Recommended at 10,000-20,000 km (6,000-12,000 miles) intervals due to the mechanical valve lifters.

Ignition Timing Adjustment:

Check and adjust annually or as needed, especially if engine performance degrades.

Fluid Specifications

Engine Oil:

SAE 20W-50 or 10W-40 for most ambient temperatures. Consult manual for specific seasonal recommendations. API SF or SG classification.

Engine Oil Capacity:

Approx. 3.5 liters (3.7 US quarts) with filter change.

Coolant:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Consult manual for specific coolant type.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (glycol-based). Regular replacement recommended.

Gearbox Oil:

SAE 80W-90 API GL-4 gear oil.

Gearbox Oil Capacity:

Approx. 1.5 liters (1.6 US quarts).

Known Issues

Rust Susceptibility:

Common issue due to age and typical body construction; requires diligent rust prevention and repair.

Carburetor Tuning:

Carburetors can become finicky with age; requires periodic cleaning and adjustment for optimal performance and fuel economy.

Automatic Clutch Wear:

The automatic clutch mechanism can wear over time, leading to slipping or rough engagement. Service and adjustment are detailed in the manual.

Suspension Wear:

Torsion bars and associated bushings can wear, affecting ride height and handling. Regular inspection and replacement are necessary.

Electrical Gremlins:

As with many older vehicles, wiring can degrade. The manual's wiring diagrams are crucial for troubleshooting.

📚 Vehicle History

Brand Heritage

Manufacturer:

Renault, a historic French automotive manufacturer renowned for innovation and practical design.

Post War Context:

Developed as a successor to the popular Renault Juvaquatre, aiming for a modern, efficient, and affordable family car.

Model Evolution

Introduction Year:

Design Inspiration:

Inspired by the Citroën 2CV's concept of rugged, utilitarian transport, but with a more modern hatchback design and front-wheel drive.

Key Variants:

R4 Parisienne, R4L, R4TL, R4 GTL, R4 Clan, R4 Jogging, R4 Savane, and commercial variants like the R4 Fourgonnette.

Production

Production End Year:

1994 (production ceased in France, but continued in some other countries for a period).

Global Production Figures:

Over 8 million units produced worldwide, making it one of the best-selling European cars ever.

Manufacturing Locations:

Primarily France (Billancourt, Flins), but also assembled in numerous countries including Spain, Portugal, Belgium, Algeria, Colombia, and Yugoslavia.

🏆 Awards & Recognition

Recognitions

Design Award Context:

While not awarded specific 'car of the year' accolades in the modern sense, its revolutionary design for space utilization and practicality was widely recognized and emulated.

Longevity Award:

Its remarkable 33-year production run and global sales success serve as a testament to its engineering and market appeal.

Ratings

Reliability Reputation:

Generally considered robust and reliable when properly maintained, though susceptible to rust. Its mechanical simplicity makes repairs straightforward.