Renault Clio: K9K, and Right-hand Drive

Renault Clio III (2005-2013) Service Manual / Chassis / Mechanical Component Controls / Brake servo: Removal - Refitting / K9K, and Right-hand Drive

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 engine undertray,
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the non-return valve on the servo,
  • the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, 37A-2),
  • the lower cover strip,
  • the dashboard side panel.

• Remove:
  • the bolts (1),
  • the lower cover (2), disconnecting the various connectors.
  • the master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, 37A-107),
  • the engine tie-bar (see Lower engine tie-bar: Removal - Refitting) (MR 392, 19D, Engine mounting).
• Remove the sub-frame bolts to fit the tool as shown below.

• Position the (Mot. 1672).

• Remove:
  • the lifting eye bolt,
  • the lifting eye (5),
  • the EGR tube bolt,
  • the EGR tube (6),
  • the right-hand suspended mounting support (7) using only the (Mot. 1672) (see Right-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting).
• Lower the engine as much as possible using the (Mot. 1672).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the double safety connecting shaft (8) from between the brake servo pushrod and the brake pedal, and, after tilting the connecting shaft upwards, move ring (9) using a flat-blade screwdriver.
  • the brake servo nuts (10),
  • the brake servo.

Note: To pass the servo between the bulkhead and the engine, the pushrod must be oriented towards the bottom, with the engine slightly pulled forward.

REFITTING

I - REFITTING PREPARATIONS OPERATION

• Check that the brake servo seal (11) is present; replace the seal if it is faulty.
• The shaft connecting the brake servo pushrod and the brake pedal must be replaced every time it is removed.

• Before refitting, check that the dimension: (X1) = 128 mm.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the brake servo,
  • the brake servo nuts.
• The shaft connecting the brake servo pushrod and the brake pedal must be refitted from right to left, and from top to bottom.
• Torque tighten the brake servo nuts (21 Nm).

III - FINAL OPERATION.

• Refit:
  • the right-hand suspended mounting support (see Right-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting),
  • the EGR tube,
  • the EGR tube bolt,
  • the lifting eye,
  • the lifting eye bolt.
• Remove the (Mot. 1672).
• Refit:
  • the sub-frame bolts,
  • the engine tie-bar (see Lower engine tie-bar: Removal - Refitting) (MR 392, 19D, Engine mounting),
  • the master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, 37A-107),
  • the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, 37A-2),
  • the non-return valve on the servo,
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the engine undertray,
  • the engine cover.
• Torque tighten the sub-frame bolts (105 Nm).
• Bleed:
  • the clutch circuit (see 37A, Mechanical component controls, Clutch circuit: Bleed, 37A- 100),
  • the brake circuit (see 30A, General information, Braking circuit: Bleed, 30A-4).
• Adjust:
  • the brake switch (see 37A, Mechanical component controls, Brake pedal switch: Removal - Refitting, 37A-79),
  • the clutch switch (see Clutch pedal position sensor: Removal - Refitting).
• Check that the connecting shaft between the brake servo pushrod and the brake pedal is locked in place.
• Refit:
  • the lower cover and connect the various connectors,
  • the lower cover bolts,
  • the dashboard side panel,
  • the lower cover strip,
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).

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