Renault Clio: K9K, and JA5
REMOVAL
I - REMOVAL PREPARATION OPERATION
- Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
- Remove the front engine cover.
- Disconnect the battery (see Battery: Removal - Refitting)
(80A, Battery).
- Remove the air pipe at the air filter unit inlet (1).
- Remove the nut (2) from the protective fuse mounting
wiring.
- Move the protective fuse mounting wiring to one
side.
- Remove:
- the battery (see Battery: Removal - Refitting)
(80A, Battery),
- the engine undertray.
- Drain:
- the cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, 19A-16),
- the sequential gearbox,
- the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Filling)
(62A, Air conditioning).
- Remove:
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the headlights (see ) (80B, Headlights) or (see Xenon
headlight: Removal - Refitting) (80C, Xenon
bulbs),
- the front impact cross member (see Front impact
cross member: Removal - Refitting) (41A, Front
lower structure),
- the intercooler (see 12B, Turbocharging, Intercooler:
Removal - Refitting, 12B-21),
- the expansion bottle (see 19A, Cooling, Expansion
bottle: Removal - Refitting, 19A-101).
- Remove:
- the bolt (3) from the compressor-condenser connecting
pipe, on the condenser,
- the bolt (4) from the compressor-condenser connecting
pipe, on the compressor,
- the compressor-condenser connecting pipe (5),
- the bolt (6) from the dehydrator reservoir-expansion
valve connecting pipe on the dehydrator reservoir.
- Disconnect the dehydrator reservoir-expansion
valve connecting pipe on the dehydrator reservoir.
- Remove the bolt (7) from the compressor-intermediate
pipe connecting pipe on the compressor.
- Disconnect the compressor-intermediate pipe connecting
pipe on the compressor.
WARNING
Plugs must be fitted on the hoses to prevent
moisture from entering the system.
- Remove:
- the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
- the radiator (see 19A, Cooling, Cooling radiator:
Removal - Refitting, 19A-20).
- Remove the nut (8) from intercooler air inlet and outlet
pipes.
- Disconnect the connector (9) from the inlet air pressure
sensor.
- Loosen the clip (10) on the intercooler air outlet pipe.
- Remove the intercooler air outlet pipe.
- Undo the clip of the air filter unit air outlet pipe at the
turbocharger side.
- Disconnect:
- the air filter unit air outlet pipe (11) on the turbocharger
side,
- the oil rebreathing pipe (12) on the air filter unit air
outlet pipe, on the turbocharger side.
- Remove:
- the clip (13) of the turbocharger air outlet pipe,
- the bolt (14) from the turbocharger air outlet pipe,
- the turbocharger air outlet pipe.
- Disconnect the union from the brake servo pipe on
the vacuum pump side.
- Remove:
- the front left-hand wheel driveshaft (see Front left-hand
driveshaft: Removal - Refitting) (29A,
Driveshafts),
- the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts).
- Remove:
- the bolts (15) from the exhaust flange,
- the exhaust bracket gasket,
- the rear suspended engine mounting (see 19D,
Engine mounting, Lower engine tie-bar: Removal
- Refitting, 19D-13).
- Remove the cover (16) from the power supply fuse
unit.
- Unclip the fuse holder (18).
- Remove the nut (19) from the supply wiring of the
power supply fuse unit.
- Disconnect the supply wiring from the power supply
fuse unit.
- Remove the battery tray (see Battery tray: Removal
- Refitting) (80A, Battery).
- Remove:
- the bolts (20) from the Protection and Switching
Unit cover,
- the Protection and Switching Unit cover.
- Disconnect the engine wiring connectors (21) from
the Protection and Switching Unit.
- Disconnect the connectors (22) from the sequential
gearbox computer.
- Disconnect the injection computer connectors (23).
- Disconnect the pre-postheating unit connector (24).
- Remove the nuts (25) from the side member earth
wiring.
- Move the earth wiring away from the side member.
- Remove:
- the bolts (26) from the high pressure pump protector,
- the high pressure pump protector.
- Disconnect:
- the fuel supply pipe (27),
- the fuel return pipe (28).
- Disconnect the quick-release unions (29) from the
heater radiator hoses.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
- Support the (Mot. 1390) on the marks (30) on the
" engine - gearbox " assembly.
- Remove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, 19D-22).
- Separate the neck of the electrical wiring from the
gearbox support.
- Remove:
- the left-hand suspended engine mounting shaft nut (31),
- the nuts (32) from the left-hand suspended engine
mounting rubber pad,
- the left-hand suspended engine mounting rubber
pad.
Note:
Tap the bolt with a copper hammer, if necessary.
- Remove the " engine and gearbox " assembly.
REFITTING
I - REFITTING PREPARATION OPERATION
- For standard engine replacements (see ) (Technical
Note 6006A, 10A, Engine and peripherals).
- parts always to be replaced: seal between catalytic
converter and exhaust downpipe hose.
II - REFITTING OPERATION FOR PART
CONCERNED
- Position the " engine - gearbox " assembly in the
body.
- Refit:
- the left-hand suspended engine mounting rubber
pad,
- the nuts for the left-hand suspended engine mounting
rubber pad,
- the left-hand suspended engine mounting shaft
nut.
- Torque tighten (see 19D, Engine mounting, Suspended
engine mounting: Tightening torque, 19D-1).
- Refit the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, 19D-22).
- Torque tighten (see 19D, Engine mounting, Suspended
engine mounting: Tightening torque, 19D-1).
- Lift the (Mot. 1390) from the " engine - gearbox "
assembly.
III - FINAL OPERATION
- Connect:
- the quick-release unions of the cooling radiator
hoses,
- the fuel return pipe,
- the fuel supply pipe.
- Refit:
- the high pressure pump protector,
- the bolts of the high pressure pump protector.
- Fit the side member earth wiring.
- Refit the side member earth wiring nuts.
- Torque tighten the side member earth wiring nuts
(8 N.m).
- Connect:
- the pre-postheating unit connector,
- the injection computer connectors,
- the connectors to the sequential gearbox computer,
- the engine wiring connectors to the Protection and
Switching Unit.
- Refit:
- the Protection and Switching Unit cover,
- the bolts on the Protection and Switching Unit cover.
- Torque tighten the Protection and Switching Unit
cover bolts (4 N.m).
- Refit:
- the turbocharger air outlet pipe,
- the clip of the turbocharger air outlet pipe,
- the turbocharger air outlet pipe bolt.
- Connect:
- the brake servo union on the vacuum pump,
- the air filter unit air outlet pipe on the turbocharger
side,
- the oil rebreathing pipe on the air filter unit air outlet
pipe, on the turbocharger side.
- Torque tighten the air filter unit air outlet pipe clip,
turbocharger side, on the air filter unit air outlet
pipe, turbocharger side (5.5 N.m).
- Refit:
- the intercooler air outlet pipe,
- the nut from the intercooler air inlet and outlet
pipes.
- Torque tighten the intercooler air outlet pipe clip
(5.5 N.m).
- Connect the air inlet pressure sensor connector.
- Refit the battery tray (see Battery tray: Removal -
Refitting) (80A, Battery).
- Clip on the fuse holder.
- Connect the supply wiring of the power supply fuse
unit.
- Refit the supply wiring nut of the power supply fuse
unit.
- Torque tighten the supply wiring nut of the power
supply fuse unit (8 N.m).
- Refit:
- the fuses,
- the fuse box cover,
- the rear suspended engine mounting (see 19D,
Engine mounting, Lower engine tie-bar: Removal
- Refitting, 19D-13).
- a new exhaust bracket seal,
- the exhaust bracket bolts,
- Torque tighten the exhaust flange bolts (21 N.m).
- Refit:
- the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
- the front left-hand wheel driveshaft (see Front left-hand
driveshaft: Removal - Refitting) (29A,
Driveshafts),
- the radiator (see 19A, Cooling, Cooling radiator:
Removal - Refitting, 19A-20).
- the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
- Connect the compressor-intermediate pipe connecting
pipe on the compressor.
- Refit the bolt to the compressor-intermediate pipe
connecting pipe on the compressor.
- Torque tighten the compressor-intermediate pipe
connecting pipe bolt on the compressor (8 N.m).
- Connect the dehydrator reservoir-expansion valve
connecting pipe on the dehydrator reservoir.
- Refit the dehydrator reservoir-expansion valve connecting
pipe bolt on the dehydrator reservoir.
- Torque tighten the dehydrator reservoir - expansion
valve connecting pipe bolt on the dehydrator
reservoir (8 N.m).
- Refit:
- the compressor-condenser connecting pipe,
- the condenser-compressor connecting pipe bolt on
the compressor,
- the compressor-condenser connecting pipe bolt on
the condenser.
- Tighten to torque:
- the compressor-condenser connecting pipe
bolt on the compressor (8 N.m),
- the compressor-condenser connecting pipe
bolt on the condenser (8 N.m).
- Refit:
- the intercooler (see 12B, Turbocharging, Intercooler:
Removal - Refitting, 12B-21),
- the front impact cross member (see Front impact
cross member: Removal - Refitting) (41A, Front
lower structure),
- the expansion bottle (see 19A, Cooling, Expansion
bottle: Removal - Refitting, 19A-101),
- the headlights (see ) (80B, Headlights) or (see Xenon
headlight: Removal - Refitting) (80C, Xenon
bulbs),
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).
- the battery (see Battery: Removal - Refitting)
(80A, Battery).
- Fit the protective fuse mounting wiring.
- Refit the protective fuse mounting wiring nut.
- Torque tighten the protective fuse mounting wiring
nut (6 N.m).
- Refit the air filter unit air inlet pipe.
- Connect the battery (see Battery: Removal - Refitting)
(80A, Battery).
- Perform the following operations:
- fill the sequential gearbox,
- fill the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining -
Filling) (62A, Air conditioning).
- fill and bleed the coolant circuit (see 19A, Cooling,
Cooling system: Draining - Refilling, 19A- 16).
- Refit:
- the engine cover,
- the engine undertray.
READ NEXT:
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 air filter box (see 12A, Fuel m
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,
the engine unde
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
Remove the front engine cover.
K9K, and 772
Discha
SEE MORE:
Roof: General description
Note:
The information contained in the following
describes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associated
with the vehicle. These spe
DISC BRAKE
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 rear wheel in question (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, 35A-1),
the rear brake pads (see 33A,
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