Renault Clio: K9K, and JH3 or JR5 - K9K, and 772, and TL4

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / K9K, and JH3 or JR5 - K9K, and 772, and TL4

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).

WARNING

During this operation, secure the vehicle to the lift with a safety strap(s), to prevent it from becoming unbalanced.

• To fit the strap to the vehicle (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Remove the front engine cover.

• Remove:
  • the scuttle panel grille (1) (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scoop under the scuttle panel grille.
• Remove the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery)

• Unclip the power supply fuse board support at (2).
• Move the support from the fuse board as indicated by the arrows.

• Remove the shielding by unclipping at (3).
• Disconnect the air flow sensor connector.

• Loosen the air inlet duct clip on the air filter unit.
• Remove:
  • the air filter unit,
  • the battery tray base.

• Loosen the mounting nut of the air pipe at the intercooler inlet on the alternator.
• Remove the air duct bolt on the rocker cover.
• Move the air duct clips to one side of the turbocharger and the air pipe at the intercooler inlet.
• Unclip the air duct (4) on the turbocharger and the air pipe at the intercooler inlet.
• Disconnect the connector (5) from the inlet air pressure sensor.
• Loosen the air inlet duct clip (6).
• Remove the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection).
• Remove the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection).

• Remove the air duct clips on the intercooler.
• Pull the tab and lift the intercooler from its mounting studs.
• Remove:
  • the intercooler,
  • the nut from the air pipes on the alternator,
  • the turbocharging air ducts.
• Drain:
  • the cooling circuit through the radiator bottom hose,
  • the gearbox,
  • the engine, if necessary.
• Drain the coolant circuit using the refrigerant charging station.
• Remove the " hub carrier - left-hand driveshaft " assembly (see Hub carrier - driveshaft assembly: Removal - Refitting) (MR 392, 31A, Front axle component).
• Remove the " hub carrier - right-hand driveshaft " assembly (see Hub carrier - driveshaft assembly: Removal - Refitting) (MR 392, 31A, Front axle component).
• Check the condition of the lip seal contact surface.
• Disconnect:
  • the engine cooling fan assembly connectors,
  • the top hose on the cylinder head coolant outlet unit,
  • the passenger compartment heater hoses.

• Extract the expansion bottle from its housing by following the direction of the arrow and put it to one side.

• Disconnect the pressure switch connector on the condenser.
• Remove the bolts (7) from the air conditioning pipes.

Note: Plugs must be fitted on the hoses to prevent moisture from entering the system.

• Remove:
  • the left-hand side stiffener bolts (8),
  • the left-hand side stiffener,
  • the lower bolt (9) from the side tie rods.

K9K, and 772, and TL4

• Remove:
  • the bolt (1) mounting the earth on the coolant pump and the heating element unit support,
  • the bolt (2) mounting the coolant pump and the heating element unit support on the radiator mounting cross member.
• Disconnect the connector (3) from the heating element unit.

• Remove:
  • the front cross member bolts (10),
  • the front radiator cross member,
  • the cooling radiator assembly,
  • the earth wiring.
• Disconnect:
  • the preheating unit connector.
  • the coolant temperature sensor.

DELPHI injection

SIEMENS injection

• Disconnect the fuel supply and return pipes on the high-pressure pump (11).
• Move the engine wiring harness to one side.
• Remove the Protection and Switching Unit cover.

• Disconnect:
  • the Protection and Switching Unit connectors,
  • the brake servo pipe,
  • the 30A and 70A engine fuses,
  • the fuse holder on the fuse board,
  • the feed wiring on the fuse board,
  • the feed wiring on the battery protection fuse box.

• Disconnect the injection computer connectors (12).

• Remove:
  • the gear control cables on the gearbox by pushing at (13),
  • the gear control cables from the sleeve stops by pressing at (14),
  • the wiring harness channel mountings on the gearbox.

• Remove:
  • the engine tie-bar,
  • the exhaust downpipe bolts.
• Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe.

• Remove the clip at the wheel end (15).
• Disconnect the clutch pipe from the clutch slave cylinder.
• Support the engine and gearbox assembly on (Mot.1390).
• Mark the positions of the suspended engine mountings on the body.
• Remove:
  • the suspended engine mounting,
  • the gearbox support rubber pad,
  • the gearbox suspended engine mounting.

K9K, and 772, and TL4

• Disconnect the fuel supply union from the diesel injector on the catalytic pre-converter.

II - REMOVAL OF PART CONCERNED

• Raise the vehicle, moving the engine towards the front.

• Extract the engine and gearbox assembly from the engine compartment.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacements (see ) (Technical Note 6006A, 10A, Engine and peripherals).

II - REFITTING PART CONCERNED

• Refit the engine and gearbox assembly in the engine compartment.

III - FINAL OPERATION.

K9K, and 772, and TL4

• Connect the fuel supply union to the diesel injector on the catalytic pre-converter.

• Refit:
  • the gearbox suspended engine mounting,
  • the gearbox support rubber pad,
  • the suspended engine mounting.
• Remove the (Mot. 1390).
• Torque tighten:
  • the bolts for the gearbox suspended mounting (62 Nm),
  • the bolts for the suspended engine mounting on the engine (62 Nm),
  • the bolts for the suspended engine mounting on the body (62 Nm).
• Connect the clutch pipe.
• Bleed the clutch system.
• Refit the exhaust downpipe bolts.
• Refit the lower engine tie-bar.
• Tighten to torque the engine tie-bar bolts (105 Nm).
• Refit the gear control cables.
• Reconnect:
  • the connectors to the injection computer,
  • the feed wiring on the battery protection fuse box,
  • the feed wiring on the fuse board,
  • the fuse holder on the fuse board,
  • the 30A and 70A engine fuses,
  • the brake servo pipe,
  • the Protection and Switching Unit connectors.
• Refit the Protection and Switching Unit cover.
• Refit the engine wiring harness.
• Connect the fuel supply and return pipes on the high-pressure pump.
• Connect:
  • the coolant temperature sensor,
  • the preheating unit connector.
  • the earth wiring.
• Refit:
  • the cooling radiator assembly,
  • the front radiator cross member,
  • the front cross member bolts.
• Tighten to torque the front cross member bolts (105 Nm).

K9K, and 772, and TL4

• Refit:
  • the bolt mounting the earth on the coolant pump and heating element unit support,
  • the bolt mounting the coolant pump and heating element unit support on the radiator mounting cross member.
• Connect the connector to the heating element unit.

• Refit:
  • the side tie-rod lower bolts,
  • the left-hand side stiffener,
  • the air conditioning pipes.
• Tighten to torque the air conditioning pipe bolts (8 Nm).
• Connect the pressure switch connector to the condenser.
• Refit the expansion bottle.
• Connect:
  • the passenger compartment heater hoses,
  • the top hose on the cylinder head coolant outlet unit,
  • the radiator bottom hose,
  • the fan assembly connectors.
• Always replace the differential output lip seal each time the driveshaft is removed (see Differential output seal: Removal - Refitting) (MR 392, 21A, Manual gearbox).
• Refit the " hub carrier - right-hand driveshaft " assembly (see Hub carrier - driveshaft assembly: Removal - Refitting) (MR 392, 31A, Front axle component).
• Refit the " hub carrier - left-hand driveshaft " assembly (see Hub carrier - driveshaft assembly: Removal - Refitting) (MR 392, 31A, Front axle component).
• Refit:
  • the turbocharging pipes,
  • the nut to the turbocharger pipes on the alternator,
  • the intercooler.
• Refit the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection).
• Refit the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection).
• Refit the inlet pipe to the inlet manifold.
• Connect the inlet air pressure sensor
• Fit the air duct between the turbocharger and the intercooler air inlet pipe.
• Clip the air duct on the turbocharger and the air pipe at the intercooler inlet.
• Refit the air duct bolt on the rocker cover.
• Torque tighten the nut mounting the intercooler air inlet pipe on the alternator (8 Nm).
• refit:
  • the battery tray base,
  • the air filter unit.
• Refit the air inlet duct to the air filter unit and tighten the clip.
• Refit the battery protective tray.
• Refit the fuse board.
• Perform the following operations:
  • refill the refrigerant circuit using the refrigerant charging station,
  • refill the engine if necessary,
  • refill the gearbox,
  • refill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16).
• Bleed the cooling system.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Refit:
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the engine cover.

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