Renault Clio: K9K

Renault Clio III (2005-2013) Service Manual / Electrical Equipment / Wiring Harness / Engine wiring: Removal - Refitting / K9K

IMPORTANT

Consult the safety and cleanliness advice and operation recommendations before carrying out any repair (see 88A, Wiring harness, Wiring: Precautions for the repair, 88A-5).

WARNING

To prevent damage to the wiring harness when refitting, observe the original routing.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Switch off the ignition.
• Remove:
  • the engine cover,
  • the battery (see 80A, Battery, Battery: Removal - Refitting, 80A-1),
  • the air filter box (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture),
  • the battery tray (see 80A, Battery, Battery tray: Removal - Refitting, 80A-5),
  • the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection).

• Remove:
  • the bolts (1) from the Protection and Switching Unit cover,
  • the Protection and Switching Unit cover,
  • the pre-postheating unit (see Pre-postheating unit: Removal - Refitting) (MR 392, 13C, Preheating).

II - OPERATION FOR REMOVAL OF PART CONCERNED

WARNING

To prevent any risk of noise, premature wear, short circuits, etc. after the refitting operation, mark the wiring routing and how to connect the connectors.

DIESEL SEPARATOR FILTER

• Disconnect the water detection sensor connector (2) from the diesel filter.

• Disconnect:
  • the air conditioning compressor connector (3),
  • the alternator exciter connector (4).
• Remove the nut (5) from the positive terminal of the starter.
• Disconnect:
  • the connector (6) from the oil pressure sensor,
  • the oil level sensor connector (7),
  • the fuel flow actuator connector (8),
  • the fuel pressure regulator connector (9),
  • the fuel temperature sensor connector (10),
  • the connector (11) from each injector,
  • all heater plug connectors (12),
  • the turbocharger pressure sensor connector (13),
  • the turbocharging pressure regulation solenoid valve connector (14),
  • the fuel rail pressure sensor connector (15),
  • the EGR cooler bypass control diaphragm solenoid valve connector (16),
  • the coolant temperature sensor connector (17),
  • the crankshaft position sensor connector (18).

TL4

• Disconnect the connector (41) from the reverse gear switch.

• Disconnect the electric coolant pump (19) connector.

• Disconnect:
  • the damper valve connector (20),
  • the connector (21) from the camshaft position sensor,
  • the connector (22) from the EGR solenoid valve,
  • the connector (23) from the exhaust gas temperature sensor,
  • the air flowmeter connector (24),

K9K, and 772

• Disconnect:
  •  the particle filter pressure sensor connector (25),
  •  the diesel injector connector (26) from the catalytic pre-converter,
  •  the catalytic converter downstream temperature sensor connector (27),
  •  the particle filter upstream temperature sensor connector (28),
  •  the particle filter downstream temperature sensor connector (29),

• Disconnect:
  • the engine cooling fan assembly connector (30),
  • the engine cooling fan assembly resistor connector (31),
  • the refrigerant pressure sensor connector (32),
  • the fuel injection computer connectors (33),
  • the front left-hand wiring connectors (42),
  • the Protection and Switching Unit connectors (34),
• Remove:
  • the nut on the excitation terminal of the starter
  • the nut on the positive terminal of the starter,
  • all earth wiring nuts (35) from the gearbox computer,
  • the engine cooling fan assembly earth cable nut (36) on the front left-hand side member,
  • the gearbox earth wiring bolt (37),
  • the 30 A fuse from the power feed fuse board,
  • the fuse holders (38),
  • the nut (39) from the power feed fuse board cable.

JA5 or JH3 or JR5

• Disconnect the reverse gear switch connector (40).

JA5

• Remove the sequential gearbox computer (see Sequential gearbox converter: Removal - Refitting) (MR 392, 21B, Sequential gearbox).

• Disconnect the sequential gearbox pump assembly connectors (43).

K9K, and 772

• Remove:
  • the heating element nuts (44),
  • the earth wiring (45) from the heating element unit support on the gearbox.

WARNING

To prevent any damage during the removal operation, check that the wiring is free from its mountings (retaining clip, plastic clip, adhesive tape, connector, etc.).

• Unclip:
  • the sub-frame and cylinder block wiring,
  • the engine cooling fan assembly wiring,
  • the cylinder head wiring.
• Remove:
  • the engine wiring harness mounting bolt on the clutch housing,
  • the engine wiring harness.

REFITTING

I - REFITTING PREPARATION OPERATION

• If replacing with more wiring, lock the unused connectors (see Connectors: Sealing and immobilisation) (Technical Note 6015A, 88A, Wiring).

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the engine wiring,
  • the engine wiring mounting bolt on the clutch housing.
• Tighten the engine wiring harness mounting bolt on the clutch housing.

JA5

• Refit the sequential gearbox computer (see Sequential gearbox converter: Removal - Refitting) (MR 392, 21B, Sequential gearbox).
• Connect the sequential gearbox pump assembly connectors.
• Refit the sequential gearbox earth wiring nuts on the front left-hand side member.
• Torque tighten the sequential gearbox earth wiring nuts on the front left-hand side member (8 Nm).

K9K, and 772

• Refit:
  • the heating element nuts,
  • the earth wiring from the heating element unit support on the gearbox.
• Tighten:
  • the heating element nuts (4 Nm),
  • the earth wiring bolt from the heating element unit support on the gearbox (21 Nm).
• Connect:
  • the particle filter downstream temperature sensor connector,
  • the particle filter upstream temperature sensor connector,
  • the catalytic converter downstream temperature sensor connector,
  • the diesel injector connector to the catalytic pre-converter,
  • the particle filter pressure sensor connector.

• Refit the nut from the power feed fuse board cable.
• Torque tighten the nut from the power feed fuse board cable (6 Nm).
• Refit the engine cooling fan assembly earth cable nut on the front left-hand side member.
• Torque tighten the engine cooling fan assembly earth cable nut on the front left-hand side member (8 Nm).
• Refit:
  • the fuse holders,
  • the 30 A fuses from the power feed fuse board.
• Refit the earth wiring bolt on the gearbox.
• Tighten the earth wiring bolt on the gearbox (24 Nm).
• Refit:
  • the nut on the positive terminal of the starter,
  • the nut on the excitation terminal of the starter.
• Tighten:
  • the nut on the positive terminal of the starter (8 Nm),
  • the nut on the positive terminal of the starter (5 Nm).
• Connect:
  • the Protection and Switching Unit connectors,
  • the front left-hand wiring connectors,
  • the diesel injection computer connectors,
  • the refrigerant pressure sensor connector,
  • the engine cooling fan assembly resistor connector,
  • the engine cooling fan assembly connector,
  • the air flowmeter connector,
  • the exhaust gas temperature sensor connector,
  • the exhaust gas recirculation solenoid valve connector,
  • the camshaft position sensor connector,
  • the damper valve connector,
  • the electric coolant pump connector,
  • the reverse gear switch connector,
  • the crankshaft position sensor connector,
  • the coolant temperature sensor connector,
  • the EGR cooler bypass control diaphragm solenoid valve connector,
  • the fuel rail pressure sensor connector,
  • the turbocharging pressure regulation solenoid valve connector,
  • the turbocharger pressure sensor connector,
  • all heater plug connectors,
  • all injector connectors,
  • the fuel temperature sensor connector,
  • the fuel pressure regulator connector,
  • the fuel flow actuator connector,
  • the oil level sensor connector,
  • the oil pressure sensor connector.
• Refit the alternator positive terminal nut.
• Torque tighten the alternator positive terminal nut (24 Nm).
• Connect:
  • the alternator exciter connector,
  • the air conditioning compressor connector.

DIESEL SEPARATOR FILTER

• Connect the water detection sensor connector on the diesel filter.

• Clip:
  • the wiring on the sub-frame and the cylinder block,
  • the wiring on the engine cooling fan assembly,
  • the wiring on the cylinder head.

FINAL OPERATION.

• Refit:
  • the pre-postheating unit (see Pre-postheating unit: Removal - Refitting) (MR 392, 13C, Preheating),
  • the Protection and Switching Unit cover,
  • the bolts on the Protection and Switching Unit cover.
• Tighten the bolts on the Protection and Switching Unit cover.
• Refit:
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the battery tray (see 80A, Battery, Battery tray: Removal - Refitting, 80A-5),
  • the air filter box (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture),
  • the battery (see 80A, Battery, Battery: Removal - Refitting, 80A-1),
  • the engine cover.

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