Renault Clio: Water chamber: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Cooling / Water chamber: Removal - Refitting

D4F, and 740 or 742 or 784

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 ) (MR 392, 80A, Battery).

D4F, and 740 or 742

• Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17) (MR 392, 12A, Fuel mixture).

D4F, and 784

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

D4F, and 784

• Undo the compressor discharge valve pipe clips (2).
• Disconnect the compressor discharge valve pipe.
• Remove the compressor discharge valve pipe.

• Remove the engine undertray.
• Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the water chamber hose clips using the (Mot. 1448).

Note: Protect the TDC sensor with a cloth to prevent coolant entering the gearbox aperture.

• Disconnect the water chamber hoses.

• Remove:
  • the water chamber bolts (3),
  • the water chamber (4),
  • the water chamber seal.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING

Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.

IMPORTANT

Wear protective gloves during the operation.

IMPORTANT

Wear goggles with side protectors for this operation.

WARNING

The joint faces must be clean, dry and free from grease (avoid finger marks).

• The water chamber seal must be replaced.

II - REFITTING OPERATION FOR PART CONCERNED

• Position the water chamber with a new seal.
• Screw on the water chamber bolts without tightening them.
• Torque tighten the water chamber bolts (9 N.m).
• Connect the water chamber hoses.
• Refit the water chamber hose clips using the (Mot.1448).

III - FINAL OPERATION

D4F, and 784

• Refit the compressor discharge valve pipe.
• Connect the compressor discharge valve pipe.
• Tighten the compressor discharge valve pipe clips.
• Refit the air filter unit air inlet pipe.

D4F, and 740 or 742

• Refit the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17) (MR 392, 12A, Fuel mixture).

• Connect the battery (see ) (MR 392, 80A, Battery).
• Fill and bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).
• Refit the engine undertray.

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 battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the engine cover,
  • the engine undertray.
• Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).
• Clean the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

• Remove:
  • the air filter unit air inlet pipe (1)
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17) (MR 392, 12A, Fuel mixture).

• Disconnect the vacuum pipe (2) from the vacuum pump.
• Unclip the coolant hose (3).
• Remove the clip (4) from the coolant hose using the (Mot. 1448) or (Mot. 1202-01) or (Mot. 1202-02).
• Disconnect the coolant hose.
• Move the water chamber hose clips (5) to one side using the (Mot. 1448) or (Mot. 1202-01) or (Mot.1202-02).
• Disconnect:
  • the water chamber hoses,
  • the coolant temperature sensor connector.

II - REMOVAL OF THE PART CONCERNED

• Remove:
  • the water chamber bolts (6),
  • the water chamber.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING

The joint faces must be clean, dry and free from grease (avoid finger marks).

• Replace the seal of the water chamber.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit the water chamber.
• Screw on the water chamber bolts without tightening them.
• Torque tighten the water chamber bolts (12 N.m).

III - FINAL OPERATION

• Connect:
  • the coolant temperature sensor connector,
  • the water chamber hoses.
• Fit the water chamber hose clips using the (Mot.1448) or (Mot. 1202-01) or (Mot. 1202-02).
• Disconnect the coolant hose.
• Fit the coolant hose clip using the (Mot. 1448) or (Mot. 1202-01) or (Mot. 1202-02).
• Clip the coolant hose.
• Connect the vacuum pipe to the vacuum pump.
• Refit:
  • the engine undertray,
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17) (MR 392, 12A, Fuel mixture),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter inlet air pipe,
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Perform the following operations:
  • fill the engine cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A- 16) (MR 392, 19A, Cooling),
  • bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).
• Refit the engine cover.

K4J or K4M

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 battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the air intake ducts,
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17).
• Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

• Disconnect:
  • the top hose (1) on the water chamber,
  • the passenger compartment heating hoses (2),
  • the coolant temperature sensor (3).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove
  • the mounting bolts (4) from the water chamber,
  • the water chamber.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

• Refit the water chamber.

• Tighten the water chamber mounting bolts,
• Pre-tighten the following mounting bolts in order and to torque: mounting bolts no. 9, 2, 8, 1, 4, 5, 6, 7, 3, 1 (4 N.m).
• Tighten to torque and in order mounting bolts no. 9, 2, 8, 1, 4, 5, 6, 7, 3, 1 (11 N.m).

II - FINAL OPERATION

• Connect:
  • the coolant temperature sensor,
  • the passenger compartment heating hoses,
  • the top hose to the water chamber.
• Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16).
• Refit:
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air intake ducts,
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

M4R

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 cover.
• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove:
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the engine undertray.
• Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

• Remove the gearbox breather mounting bracket (1).
• Disconnect:
  • the coolant temperature sensor connector (2),
  • the hoses from the plenum chamber.

II - REMOVAL OF PART CONCERNED

• Remove:
  • the mounting bolts (3) from the water chamber,
  • the water chamber,
  • the water chamber seal.

REFITTING

I - REFITTING PREPARATION OPERATION

• The water chamber seal must be replaced.

II - REFITTING PART CONCERNED

• Torque tighten the water chamber mounting bolts (25 N.m).

III - FINAL OPERATION

• Connect:
  • the coolant temperature sensor connector,
  • the hoses from the plenum chamber.
• Refit:
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the engine undertray.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).
• Refit the engine cover.

F4R

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 undertray.
• Perform the following operations:
  • drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling),
  • flush the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

• Remove the air inlet duct (A) :
  • unclip it from the front end panel,
  • turn it and disconnect it.
• Disconnect the duct (B) :
  • air resonator side,
  • air filter unit side.
• Remove:
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery).
• Unclip the breather pipe from the gearbox.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Disconnect:
  • the coolant temperature sensor connector (1),
  • the cooling hose (2) on the unit, separating the clip (3) using the (Mot. 1448).
• Remove the thermostat cover mounting bolts (4).
• Move the thermostat cover to one side.
• Remove the thermostat.

• Remove the wiring harness channel mounting bolts (5).

• Remove:
  • the coolant outlet unit mounting bolts,
  • the water chamber.

REFITTING

I - REFITTING PREPARATION OPERATION

• Clean the joint faces.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the water chamber fitted with a new seal,
  • the plenum chamber mounting bolts.
• Torque tighten the coolant outlet unit mounting bolts (13 N.m).
• Refit:
  • the thermostat fitted with a new seal,
  • the thermostat cover,
  • the thermostat cover mounting bolts,
  • the coolant hose mounting bolts.
• Connect the coolant hose to the coolant outlet unit.
• Fit the hose clip using the (Mot. 1448).
• Connect the coolant temperature sensor connector.

III - FINAL OPERATION

• Clip the breather pipe to the gearbox.
• Refit:
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Connect the duct (B) :
  • to air filter unit,
  • to the air resonator.
• Refit the air inlet duct (A) :
  • rotate it and connect it,
  • clip it to the front end panel.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Perform the following operations:
  • fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling),
  • bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).
• Check that there are no leaks.
• Refit the engine undertray.

D4F, and 764

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 battery (see ) (MR 392, 80A, Battery),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the engine undertray.
• Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

II - OPERATION FOR REMOVAL OF PART CONCERNED

Note: Protect the TDC sensor with a cloth to prevent coolant entering the gearbox aperture.

• Disconnect the thermostat control connector (1).

• Remove using the (Mot. 1448) :
  • the engine cooling radiator hose clip (2),
  • the heater matrix hose clip (4).
• Disconnect:
  • the engine cooling radiator hose (3),
  • the heater matrix hose (5).
• Disconnect the coolant temperature sensor connector (6).
• Remove:
  • the water chamber bolts (7),
  • the water chamber.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING

Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.

IMPORTANT

Wear protective gloves during the operation.

IMPORTANT

Wear goggles with side protectors for this operation.

WARNING

The joint faces must be clean, dry and free from grease (avoid finger marks).

• The water chamber seal must be replaced.

II - REFITTING OPERATION FOR PART CONCERNED

• Position the water chamber with a new seal.
• Screw on the water chamber bolts without tightening them.
• Torque tighten the cylinder head water chamber bolts (10 N.m).
• Connect:
  • the coolant temperature sensor connector,
  • the heater matrix hose,
  • the cooling radiator hose.
• Using the (Mot. 1448), fit:
  • the heater matrix hose clip,
  • the engine cooling radiator hose clip.
• Connect the thermostat control connector.

III - FINAL OPERATION

• Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).
• Refit:
  •  the engine undertray,
  • the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery (see ) (MR 392, 80A, Battery).
• Bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16) (MR 392, 19A, Cooling).

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