Renault Clio: K4M, and JH3 - K4J, and JH3 - K4M, and TL4

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / K4M, and JH3 - K4J, and JH3 - K4M, and TL4

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
• Remove:
  • the battery (see Battery: Removal - Refitting) (80A, Battery),
  • the battery tray (see Battery: Removal - Refitting) (80A, Battery),
  • the air filter unit air inlet pipe,
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres),
  • the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
  • the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection).
• Drain:
  • the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • the manual gearbox (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox).

AIR CONDITIONING

• Drain the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).

• Remove:
  • the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts).
• Loosen the clip of the air filter unit air outlet pipe on the throttle valve.
• Disconnect the air filter unit air outlet pipe from the throttle valve.

• Separate the clip on each heater matrix cooling hose (1) using the tool (Mot. 1448).
• Disconnect:
  • the heater matrix cooling hose from the water chamber,
  • the heater matrix cooling hose from the cylinder block cooling hose.

• Unclip the heater matrix cooling hoses at (2).
• Remove:
  • the expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting, 19A-101),
  • the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, 12A-10),
  • the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13),
  • the exhaust downpipe nuts,
  • the seal between the catalytic converter and the exhaust downpipe hose.

AIR CONDITIONING or CLIMATE CONTROL

• Remove the bolt (3) from the " expansion valve - compressor " connecting pipe on the compressor.

WARNING

To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air.

• Disconnect the " expansion valve - compressor " connecting pipe from the compressor.

• Remove:
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (41A, Front lower structure),
  • the " condenser - cooling radiator - engine cooling fan assembly " (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20).

• Remove:
  • the bolts (4) from the Protection and Switching Unit cover,
  • the Protection and Switching Unit cover.

• Disconnect the connectors (5) from the Protection and Switching Unit.

• Disconnect the brake servo pipe union (6) from the inlet distributor.

K4J - K4M, and JH3

• Disconnect the oxygen sensor connectors.

• Disconnect:
  • the union (7) of the fuel vapour rebreathing pipe from the petrol vapour rebreathing solenoid valve,
  • the connector (8) of the fuel vapour rebreathing solenoid valve.

• Disconnect:
  • the fuse (9),
  • the fuse holder (10) from the fuse board.
• Remove:
  • the nut from the supply cable of the fuse board (11),
  • the supply cable nut from the battery protection fuse box (12),
  • the nut of each side member earth cable.
• Remove:
  • the supply cable from the fuse board,
  • the supply cable from the battery protection fuse box,
  • the earth cables on the side member.

• Disconnect the connector (13) from the petrol injection computer.

• Remove the earth nut (14).
• Remove:
  • the earth cable from the shock absorber cup height adjuster,
  • the wiring channel.

IMPORTANT

During this operation, be sure to:

• be careful of fuel splashes when disconnecting the union.

WARNING

To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

To prevent impurities from entering the circuit, place protective plugs on all fuel circuit components exposed to the open air.

• Disconnect the fuel supply pipe union (15) from the injector rail.
• Unclip the fuel supply pipe from the retaining bracket.

JH3

• Move aside the gear control cables by:
  • pressing at (A),
  • pressing at (B).
• Remove the wiring channel mountings from the gearbox.

TL4

• Move aside the gear control cables (16) by:
  • unclipping each gear control cable (17) from the gearbox control levers using an open-jawed spanner,
  • pulling each control cable sleeve stop ring towards (A).

• Fit the tool (Ms. 583) between the brake fluid reservoir and the clutch master cylinder.

JH3

• Disconnect the clutch pipe union from the hydraulic clutch slave cylinder by pulling on the clips (18) and (19).

TL4

• Disconnect the clutch pipe union from the hydraulic clutch slave cylinder by pressing the clip (20).

• Fit a blanking plug:
  • on the opening of the hydraulic clutch slave cylinder,
  • on the clutch pipe union.
• Unclip the clutch pipe from the left-hand suspended engine mounting support on the gearbox.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the " engine - gearbox " assembly using the tool (Mot. 1390) positioning it on the marks (21) of the " engine - gearbox " assembly,
  • the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22),
  • the left-hand suspended engine mounting shaft nut.
• Hit the shaft of the left-hand suspended engine mounting using a copper hammer.
• Raise the vehicle, moving the engine towards the front.
• Remove the " engine and gearbox " assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacements (see ) (Technical Note 6023A, 10A, Engine and peripherals).
• parts always to be replaced: seal between catalytic converter and exhaust downpipe hose.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the " engine - gearbox " assembly in the vehicle,
  • the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22).
• Torque tighten the left-hand suspended engine mounting shaft nut (62 N.m).
• Remove the (Mot. 1390) from the " engine - gearbox " assembly.

III - FINAL OPERATION

• Remove the blanking plug:
  • on the opening of the hydraulic clutch slave cylinder,
  • on the clutch pipe union.
• Connect the clutch pipe to the hydraulic clutch slave cylinder.
• Clip the clutch pipe onto the left-hand suspended engine mounting support on the gearbox.
• Remove the tool (Ms. 583) between the brake fluid reservoir and the clutch master cylinder.
• Clip each gear control cable onto:
  • the gear control cable sleeve stops,
  • the gearbox control levers.
• Connect the fuel supply pipe union to the injector rail.
• Clip the fuel supply pipe onto the retaining bracket.
• Fit:
  • the wiring channel,
  • the earth cable on the shock absorber cup height adjuster.
• Tighten the earth nut on the shock absorber cup height adjuster (8 N.m).
• Connect the petrol injection computer connectors.
• Fit:
  • the earth cables on the side member,
  • the supply cable of the battery protection fuse box on the battery protection fuse box,
  • the fuse board supply cable on the fuse board.
• Torque tighten:
  • the nut of each earth cable on the side member (8 N.m),
  • the nut of the supply cable on the battery protection fuse box (6 N.m),
  • the nut of the fuse board supply cable (8 N.m).
• Connect:
  • the fuse holder to the fuse board,
  • the fuse,
  • the connector of the fuel vapour rebreathing solenoid valve,
  • the union of the fuel vapour rebreathing pipe to the petrol vapour rebreathing solenoid valve.

K4M, and JH3 - K4J, and JH3

• Connect the oxygen sensor connectors.

• Connect:
  • the brake servo pipe union on the inlet distributor,
  • the Protection and Switching Unit connectors.
• Refit:
  • the Protection and Switching Unit cover,
  • the bolts on the Protection and Switching Unit cover,
  • the " condenser - cooling radiator - engine cooling fan assembly " (see 19A, Cooling, Cooling radiator: Removal - Refitting, 19A-20),
  • the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (41A, Front lower structure).

AIR CONDITIONING or CLIMATE CONTROL

• Connect the " expansion valve - compressor " connecting pipe to the compressor.
• Torque tighten the bolt of the connecting pipe between the " expansion valve - compressor " (8 N.m).

• Refit:
  • a new seal between the catalytic converter and the exhaust downpipe hose,
  • the exhaust downpipe nuts,
  • the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13),
  • the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, 12A-10),
  • the expansion bottle (see 19A, Cooling, Expansion bottle: Removal - Refitting, 19A-101).
• Connect the heater matrix cooling hose to:
  • the water chamber,
  • the cylinder block cooling hose.
• Fit the clip on each heater matrix cooling hose using the tool (Mot. 1448).
• Clip on the heater matrix cooling hoses.
• Connect the air filter box air outlet pipe to the throttle valve.
• Torque tighten the air filter unit air outlet pipe clip (5.5 N.m).
• Refit:
  • the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection),
  • the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
  • the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres),
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the air filter unit air inlet pipe,
  • the battery tray (see Battery: Removal - Refitting) (80A, Battery),
  • the battery (see Battery: Removal - Refitting) (80A, Battery).
• Perform the following operations:
  • fill the manual gearbox (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox),
  • fill and bleed the cooling circuit (see 19A, Cooling, Cooling system: Draining - Refilling, 19A- 16),
  • bleed the clutch circuit (see Clutch circuit: Removal - Refitting) (37A, Mechanical component controls).

AIR CONDITIONING

• Fill the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).

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