Renault Clio: K9K, and 772

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Top And Front Of Engine / Rocker cover: Removal - Refitting / K9K, and 772

• Detach the turbocharger front temperature sensor wiring harness on the injector rail protector mounting.

• Remove:
  • the injector rail protector mounting bolts (13),
  • the injector rail protector support.
• Disconnect:
  • the damper valve connector (14) (if equipped),
  • the camshaft position sensor connector (15).
• Remove:
  • the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting, 12A-31) (if equipped),
  • the camshaft position sensor.

• Disconnect the oil vapour rebreathing pipe (16) on the rocker cover side.

• Unclip the tab (17).
• Swivel the timing cover in the direction of the arrow.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the rocker cover bolts (18),
  • the rocker cover (19).

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the rocker cover seal.

WARNING

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

WARNING

Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).

• Apply RESIN ADHESIVE (diameter 2 mm).

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the rocker cover,
  • the rocker cover bolts.

• Tighten to torque and in order the rocker cover bolts (11 N.m).

III - FINAL OPERATION

• Fit the timing cover.
• Clip on the tab.
• Connect the oil vapour rebreathing pipe on the rocker cover side.
• Refit:
  • the cylinder marking sensor,
  • the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting, 12A-31) (if equipped).
• Connect:
  • the damper valve connector (14) (if equipped),
  • the camshaft position sensor connector (15).
• Refit:
  • the injector rail protector support,
  • the injector rail protector mounting bolts.

K9K, and 772

• Clip on the turbocharger front temperature sensor wiring harness on the rail protector mounting.

• Clip on the diesel return pipe.
• Connect the injector connectors (12).
• Position the injector wiring harness.
• Refit:
  • the injector rail protector cover,
  • the injector rail protector cover nut,
  • the injector rail protector cover bolt.
• Torque tighten:
  • the injector rail protector cover bolt (8 N.m),
  • the injector rail protector cover nut (8 N.m).
• Fasten the clips of the injector rail protector cover.
• Refit:
  • the intercooler air inlet pipe,
  • the clips to the intercooler inlet air pipe,
  • the bolt on the rocker cover.
• Fit the intercooler outlet air pipe.
• Torque tighten the intercooler outlet air pipe clip (5.5 N.m).

K9K, and 764

• Connect the turbocharger pressure regulation pipe.

• Refit the intercooler inlet and outlet pipe nut on the alternator.
• Torque tighten the intercooler inlet and outlet pipe nut on the alternator (8 N.m).
• Refit:
  • the air filter unit air inlet pipe,
  • the engine cover.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).

M4R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Disconnect the battery (see Battery: Removal - Refitting).
• Remove the ignition coils (see 17A, Ignition, Coils: Removal - Refitting, 17A-2).

• Unclip:
  • the wiring harness at (1),
  • the atmospheric pressure sensor (2).
• Move the wiring harness to one side.

II - REMOVAL OF PART CONCERNED

• Remove:
  • in order, the rocker cover mounting bolts,
  • the rocker cover,
  • the rocker cover seal.

REFITTING

I - REFITTING PREPARATION OPERATION

• The rocker cover seal must always be replaced.

II - REFITTING THE PART CONCERNED

• Fit the rocker cover.
• Tighten to torque and in order the rocker cover mounting bolts (2 Nm).
• Tighten to torque and in order the rocker cover mounting bolts (8 Nm).

III - FINAL OPERATION

• Clip:
  • the atmospheric pressure sensor,
  • the wiring harness.
• Refit the ignition coils (see 17A, Ignition, Coils: Removal - Refitting, 17A-2).
• Connect the battery (see Battery: Removal - Refitting).

F4R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see 02A, Lifting equipment, Vehicle: Towing and lifting).
• Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting)
• Remove:
  • the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, 12A-33),
  • the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45),
  • the ignition coils (see 17A, Ignition, Coils: Removal - Refitting, 17A-2),
  • the oil decanter (see 11A, Top and front of engine, Oil decanter: Removal - Refitting, 11A-302),
  • the battery (see 80A, Battery, Battery: Removal - Refitting),
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the front right-hand wheel (see 35A, Wheels and tyres: Wheel: Removal - Refitting),
  • the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, 11A-5),
  • the timing belt (see 11A, Top and front of engine, Special tooling required Timing belt: Removal - Refitting, 11A-48).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Undo all the mounting bolts from the rocker cover.
• Remove the rocker cover bolts.

• Using a clean cloth (1), protect:
  • the injector holder plate pipe openings to prevent any impurities from entering,
  • the injector rail,
  • the camshaft position sensor location.

• Remove the rocker cover centring devices (2) using a hammer and a drift to knock them out from above.

Note: The centring device (3) must not be removed under any circumstances. Not following these instructions could damage the cylinder head.

• Press a flat-blade screwdriver onto the injector holder plate and use it to gently remove the adhesive from the rocker cover.

• Remove the rocker cover using the (Mot. 1716).
• Remove the rocker cover.

REFITTING

I - REFITTING PREPARATION OPERATION

• Refit the centring devices on the cylinder head using a hammer and drift.

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

Excess sealant could be squeezed out when the parts are tightened. The product-fluid mix may damage some components (engine, radiator).

II - REFITTING OPERATION FOR PART CONCERNED

• Apply some RESIN ADHESIVE to the rocker cover gasket face using a stipple roller.

Note: Use a cloth to remove any RESIN ADHESIVE on the rocker cover bearings

• Fit the rocker cover.

mounting bolt location

1. short bolts
2. medium bolts
3. long bolts

• Insert all the rocker cover mounting bolts.

tightening order for rocker cover mounting bolts

• Tighten in order and to torque the rocker cover mounting bolts (22), (23), (20), (13) (8 Nm) to correctly fit the rocker cover.
• Tighten in order and to torque the rocker cover mounting bolts (1) to (12), (14) to (19), (21) and (24) (12 Nm).
• Loosen rocker cover mounting bolts (22), (23), (20) and (13).
• Tighten in order and to torque rocker cover mounting bolts (22), (23), (20), (13) (12 Nm).

III - FINAL OPERATION

• Refit:
  • the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, 11A-48),
  • the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, 11A-5),
  • the front right-hand wheel (see 35A, Wheels and tyres: Wheel: Removal - Refitting),
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the oil decanter (see 11A, Top and front of engine, Oil decanter: Removal - Refitting, 11A-302),
  • the ignition coils (see 17A, Ignition, Coils: Removal - Refitting, 17A-2),
  • the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45),
  • the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, 12A-33).
• Connect the battery (see 80A, Battery, Battery: Removal - Refitting),
• Using the Diagnostic tool, check that there are no faults stored by the injection computer and clear them if necessary.

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