Renault Clio: Exhaust gas recirculation unit: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Antipollution / Exhaust gas recirculation unit: Removal - Refitting

K9K, and 750 or 752

REMOVAL

• Position the vehicle on a two-post lift.
• Remove the scuttle panel grille (see Scuttle panel grille: Removal - Refitting).

• Disconnect the exhaust gas recirculation solenoid valve electrical wiring harness (4).
• Detach the electric wiring harness.

• Disconnect:
  • the rubber pipe (5) from the air duct turbocharging pressure control valve,
  • the turbocharging air duct (6) from the exhaust gas recirculation unit.

• Remove:
  • the bracket (7),
  • the engine lifting eye (8),
  • the air inlet metal tube (9),
  • the exhaust gas recirculation solenoid valve heat shield (10),
  • the exhaust gas recirculation pipe (11),
  • the EGR unit mounting bolts (12),
  • the exhaust gas recirculation unit (13).

REFITTING

• Replace the exhaust gas recirculation tube complete with new clips.
• Fit the new clips
• Tighten the new clips using tool (Mot 1567).
• Replace the O-rings on the metal air inlet tube.
• Torque tighten:
  • the exhaust gas recirculation unit mounting bolts (21 N.m),
  • the inlet air metal tube mounting bolts (21 N.m),
  • the lifting eye (timing end) (21 N.m),
  • the exhaust gas recirculation solenoid valve heat shield mounting bolts (12 N.m).
• Proceed in the reverse order to removal.
• Connect the battery, starting with the positive terminal.

WARNING

Carry out the necessary programming (see Battery: Removal - Refitting).

• Refit the scuttle panel grille (see Scuttle panel grille: Removal - Refitting).

K9K

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Remove the engine undertray.
• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove:
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the water chamber (see 19A, Cooling, Water chamber: Removal - Refitting, 19A-63) (MR 392, 19A, Cooling).

• Remove:
  • the oil vapour rebreathing pipe (1),
  • the air inlet duct (2) between the turbocharger and the intercooler,
  • the air inlet duct clip (3) from the damper valve.

• Disconnect the connector (4) from the exhaust gas recirculation solenoid valve.
• Remove the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting, 12A-31) (MR 392, 12A, Fuel mixture).

• Position the tools (Ms. 583) or the hose clamps on the coolant inlet and outlet hoses (5) of the exhaust gas cooler.
• Remove:
  • the coolant circulation cover mounting bolts (6),
  • the coolant circulation cover,
  • the seals of the coolant circulation cover.

Note: Prepare for the outflow of coolant.

• Remove the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, 19B-29) (MR 392, 19B, Exhaust).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the lifting bracket mounting bolts (7) from the timing end,
  • the lifting bracket (8) on the timing end,
  • the air inlet metal tube (9),
  • the mounting bolts (10) from the exhaust gas inlet pipe,
  • the mounting bolts (11) from the exhaust gas recirculation unit assembly,
  • the exhaust gas recirculation unit assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• All the supporting surfaces on each removed part must be carefully cleaned.

WARNING

Take care not to damage the bearing faces to prevent any risk of coolant leaks.

Always replace:

• the air inlet metal tube and its O-rings,
• the seals of the coolant circulation cover,
• the seal between the cut-off valve downstream duct and the exhaust gas cooler mounting,
• the seal between the catalytic converter and the turbocharger.

K9K

II - OPERATION FOR REFITTING PART CONCERNED

• Refit the exhaust gas recirculation unit assembly.
• Torque tighten the EGR unit assembly mounting bolts (25 N.m).

III - FINAL OPERATION

• Refit the mounting bolts of the exhaust gas inlet pipe.
• Torque tighten the exhaust gas inlet pipe bolts (35 N.m).
• Refit:
  • the air inlet metal tube,
  • the lifting bracket on the timing end.
• Torque tighten the mounting bolts of the lifting bracket on the timing end (10 N.m).
• Refit:
  • the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, 19B- 29) (MR 392, 19B, Exhaust),
  • the coolant circulation cover.
• Torque tighten the coolant circulation cover mounting bolts (10 N.m).

WARNING

Ensure that the water inlet and outlet hoses of the exhaust gas cooler are correctly aligned so that they are not kinked.

• Refit the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting, 12A-31) (MR 392, 12A, Fuel mixture).
• Connect the exhaust gas recirculation solenoid valve connector.
• Refit:
  • the air inlet duct clip on the damper valve,
  • the oil vapour rebreathing pipe,
  • the water chamber (see 19A, Cooling, Water chamber: Removal - Refitting, 19A-63) (MR 392, 19A, Cooling),
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment).
• Loosen the mounting nut of the air pipe at the intercooler inlet.
• Fit the air duct between the turbocharger and the intercooler air inlet pipe.
• Lock the air duct onto the turbocharger and the intercooler inlet air pipe.
• Tighten the bolt of the air duct on the rocker cover.
• Torque tighten the nut mounting the intercooler air inlet pipe on the alternator (8 N.m).
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery) (MR 392, 80A, Battery).
• Remove the engine undertray.
• Fill and bleed the cooling circuit (see 19A, Cooling, Cooling system: Draining - Refilling, 19A- 16) (MR 392, 19A, Cooling).
• Use the diagnostic tool to clear any faults which may be stored by the computer before restarting the engine.

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