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

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

• Discharge the pressure in the fuel supply circuit of the exhaust fuel injector (see 19B, Exhaust, Exhaust fuel injector: Removal - Refitting, 19B-66).

• Remove:
  • the scuttle panel grille (1) (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the scoop under the scuttle panel grille.
• Remove the battery (see Battery: Removal - Refitting) (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 connector from the air flowmeter (if equipped).

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

• Loosen the intercooler air inlet pipe nut on the alternator.
• Remove the air duct bolt on the rocker cover.
• Separate the clips on the turbocharger air duct and on the intercooler air inlet pipe.
• Unclip the air duct (4) on the turbocharger and the intercooler air inlet pipe.
• Disconnect the connector (5) from the inlet air pressure sensor.
• Loosen the clip (6) on the damper valve air inlet pipe.
• Remove the air pipe.
• Remove:
  • 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).

K9K, and 764 or 772

• Disconnect the electrical connector from the damper valve (if equipped).

• 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 ducts on the alternator,
  • the turbocharging air ducts.
• Drain:
  • the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, 19A-16),
  • the manual gearbox oil (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox),
  • the engine oil if necessary (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12),
  • the refrigerant fluid circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).
• Remove:
  • the front left-hand driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front right-hand driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts).
• Disconnect:
  • the engine cooling fan assembly connectors,
  • the top hose on the coolant outlet unit,
  • the passenger compartment heating 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.

WARNING

To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air.

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

K9K, and 772

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

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

DELPHI injection

SIEMENS injection

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

• Disconnect:
  • the Protection and Switching Unit connectors,
  • the brake servo pipe from the vacuum pump,
  • the engine fuses 30A and 70A,
  • the fuse holder on the fuse board,
  • the supply wiring on the fuse board,
  • the supply 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.

K9K/TL4

K9K/JH3, JR5

• 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-gearbox assembly " on the (Mot. 1390).
• Mark the positions of the suspended engine mountings on the body.
• Remove the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, 19D-22).

• Remove the left-hand suspended engine mounting shaft nut (16).

K9K, and 772

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

II - OPERATION FOR REMOVAL OF PART CONCERNED

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

• Extract the " engine - gearbox " assembly from the engine compartment.

REFITTING

I - REFITTING PREPARATION OPERATION

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

II - REFITTING OPERATION FOR PART CONCERNED

• Position the " engine - gearbox " assembly in the engine compartment.

III - FINAL OPERATION

K9K, and 772

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

• Fit the left-hand suspended engine mounting shaft.
• Refit:
  • the left-hand suspended engine mounting shaft nut,
  • the right-hand suspended engine mounting.
• Remove the tool (Mot. 1390).
• Torque tighten the left-hand suspended engine mounting shaft nut (62 N.m).
• Connect the clutch pipe.
• Bleed the clutch circuit (see Clutch circuit: Bleed) (37A, Mechanical component control).
• Refit:
  • the exhaust downpipe bolts,
  • the lower engine tie-bar.
• Torque tighten the engine tie-bar bolts (105 N.m).
• Refit the gear control cables.
• Connect:
  • the injection computer connectors,
  • the supply wiring on the battery protection fuse box,
  • the supply wiring on the fuse board,
  • the fuse holder on the fuse board,
  • the engine fuses 30A and 70A,
  • the brake servo pipe on the vacuum pump,
  • the Protection and Switching Unit connectors.

K9K, and 764 or 772

• Disconnect the electrical connector from the damper valve (if equipped).

• Fit the engine wiring.
• Connect the fuel supply and return pipes on the high-pressure pump.
• Connect:
  • the coolant temperature sensor,
  • the pre-postheating 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 N.m).

TL4

• Refit:
  • the bolt mounting the earth on the thermoplunger unit and the coolant pump mounting,
  • the bolt on the thermoplunger unit and the coolant pump mounting on the radiator mounting cross member.
• Connect the thermoplunger unit connector.

• Refit:
  • the side tie-rod lower bolts,
  • the left-hand side reinforcement,
  • the air conditioning pipes.
• Torque tighten the air conditioning pipe bolts (8 N.m).
• Connect the pressure switch connector to the condenser.
• Position the expansion bottle.
• Connect:
  • the passenger compartment heating hoses,
  • the top hose on the coolant outlet unit,
  • the bottom radiator hose,
  • the fan assembly connectors.
• Refit:
  • the front left-hand driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the front right-hand driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the turbocharging ducts,
  • the nut to the turbocharger pipes on the alternator,
  • the intercooler,
  • the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection),
  • the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
  • 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 onto 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 inlet air pipe on the alternator (8 N.m).
• Refit:
  • the battery tray base,
  • the air filter unit.
• Fit the air inlet duct on the air filter unit and tighten the clip.
• Refit the battery protective tray.
• Fit the fuse board.
• Refit the battery (see Battery: Removal - Refitting) (80A, Battery).
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Perform the following operations:
  • fill the refrigerant circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning),
  • top up the engine oil (if necessary) (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, 10A-12),
  • fill the manual gearbox oil (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox),
  • fill and bleed the coolant circuit (see 19A, Cooling, Cooling system: Draining - Refilling, 19A- 16).
• Refit:
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the engine cover.

K9K, and 772

• Carry out a sealing test on the fuel supply circuit of the exhaust fuel injector (see 19B, Exhaust, Exhaust fuel injector: Removal - Refitting, 19B-66).

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