Renault Clio: K9K, and 766 or 768

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Top And Front Of Engine / Rocker cover: Removal - Refitting / K9K, and 766 or 768

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove:
  • the engine cover,
  • the air inlet duct,
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection).

• Disconnect:
  • the pressure sensor (1) on the inlet duct,
  • the turbocharger pressure regulation pipe (5).
• Cut the Rislan clip.
• Pull the clips (2) from the air duct.
• Remove:
  • the air pipe mounting nut on the alternator,
  • the air duct bolt on the rocker cover,
  • the air duct (3).
• Undo the clip (4) from the intercooler tube on the inlet side.
• Remove the intercooler tube on the inlet side.

• Unclip the clips (6) from the rail protector.
• Remove:
  • the rail protector mountings,
  • the retaining bracket of the engine cover on the gearbox side,
  • the rail protector.

• Disconnect:
  • the heater plugs (7)
  • the injector connectors.

• Undo the clip (8) from the oil vapour rebreathing pipe using the (Mot. 1448).
• Disconnect the oil vapour rebreathing pipe (9).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the mounting bolts (10) from the rocker cover,
  • the rocker cover (11).

REFITTING

I - REFITTING PREPARATION OPERATION

• Be sure to replace the rocker cover seal.

Note: The cylinder head gasket and rocker cover faces must be clean, dry and free of grease (avoid finger marks).

Note: Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.)

• Apply LOCTITE 518 (12), 2 mm in diameter

II - REFITTING OPERATION FOR PART CONCERNED

• Refit the rocker cover, fitted with a new gasket.
• Torque tighten in order the rocker cover bolts (10 N.m).

III - FINAL OPERATION

• Connect the oil vapour rebreathing pipe.
• Unclip the clip from the oil vapour rebreathing pipe using the tool (Mot. 1448).
• Refit the inner timing cover.
• Connect:
  • the injector connectors,
  • the heater plugs.
• Refit:
  • the rail protector,
  • the retaining bracket of the engine cover on the gearbox side,
  • the rail protector mountings,
  • the intercooler tube on the inlet side.
• Fasten the clip on the intercooler tube on the inlet side.
• Fit the air duct between the turbocharger and the air pipe at the intercooler inlet.
• Clip the air duct on the turbocharger and the inlet pipe of the intercooler.
• Refit:
  • the air duct bolt on the rocker cover,
  • the air pipe mounting nut on the alternator,
  • a Rislan clip.
• Torque tighten the nut mounting the intercooler air inlet pipe on the alternator (8 N.m).
• Connect:
  • the turbocharger pressure regulation pipe,
  • the pressure sensor on the inlet tube.
• Refit:
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the air inlet duct,
  • the engine cover.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).

K9K, and 764 or 772

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove the front engine cover.

• Remove the air filter box air inlet pipe (1).

• Remove the intercooler inlet and outlet pipe nuts (2) on the alternator.

• Disconnect the connector (3) from the inlet air pressure sensor.

K9K, and 764

• Disconnect the turbocharger pressure regulation pipe.

• Undo the clip (4) from the intercooler outlet pipe.
• Move the intercooler outlet air pipe to one side (5).
• Remove:
  • the clips (6) from the intercooler inlet air pipe,
  • the bolt (7) on the rocker cover,
  • the intercooler air inlet pipe (8).

• Unclip the clips (9) from the injector rail protector cover.
• Remove:
  • the injector rail protector cover bolt (10),
  • the injector rail protector cover nut (11),
  • the injector rail protector cover.

• Disconnect the injector connectors (12).
• Move the injector harness to one side.
• Unclip the diesel return pipe.

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