Renault Clio: K4J or K4M or K9K or M4R, and Left-hand Drive

Renault Clio III (2005-2013) Service Manual / Chassis / Mechanical Component Controls / Brake servo: Removal - Refitting / K4J or K4M or K9K or M4R, and Left-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).

• Remove:
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
  • the air filter box (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture),
  • the non-return valve (1) from the servo,
  • the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, 37A-2),
  • the lower cover strip,
  • the side section of the lower cover.

• Remove:
  • the bolts (2),
  • the clip (3),
  • the lower cover (4), disconnecting the various connectors.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the double safety connecting shaft (5) from between the brake servo pushrod and the brake pedal, and, after tilting the connecting shaft upwards, move ring (6) using a flat-blade screwdriver.
  • the connector (7) from the accelerator pedal,
  • the accelerator pedal connector wiring harness clip,
  • the blanking cover (8) from the brake servo mounting nut,
  • the brake servo mounting nuts (9),
  • the brake servo.

• Remove:
  • the mounting bolts (10) from the brake servo spacer,
  • the brake servo spacer.

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.

• Check the following dimension before refitting: (X1) = 171 mm.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the brake servo spacer,
  • the brake servo spacer mounting bolts.
• Torque tighten the spacer mounting bolts (21 Nm).
• Refit:
  • the brake servo,
  • the brake servo mounting 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 mounting nuts (21 Nm).
• Refit:
  • the brake servo mounting nut blanking cover,
  • the accelerator pedal connector wiring harness clip,
  • the accelerator pedal connector.

III - FINAL OPERATION.

• Refit:
  • the lower cover, connecting the various connectors.
  • the clip,
  • the bolts,
  • the side section of the lower cover.
  • the lower cover strip,
  • the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, 37A-2),
  • the air filter box (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Reconnect the non-return valve at the servo.
• Bleed the brake circuit (see 30A, General information, Braking circuit: Bleed, 30A-4).

IMPORTANT

Check that the brake servo pushrod-brake pedal connecting shaft is locked in place.

• Adjust the brake light switch (see 37A, Mechanical component controls, Brake pedal switch: Removal - Refitting, 37A-79).

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