Renault Clio: Pump assembly: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Transmission / Sequential Gearbox / Pump assembly: Removal - Refitting

K9K, and JA5

REMOVAL

I - REMOVAL PREPARATION OPERATION

Note: When replacing the electric pump assembly, always replace the control relay.

IMPORTANT

Before any operation on the sequential system, discharge the accumulator using the Diagnostic tool.

• To discharge the accumulator, run command " Discharge pressure accumulator " AC081.

  To confirm the pressure drop, read the " Hydraulic pressure " parameter for the resulting value.

  If there is still pressure in the accumulator, re-run the " Discharge pressure accumulator " command until the pressure is negligible and will not pose a risk when the high pressure pipes are removed.

  The pressure reading must be close to zero.

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Remove:
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter unit (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture).
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the diesel injection computer (see Diesel injection computer: Removal - Refitting) (MR 392, 13B, Diesel injection),
  • the wiring harness nut under the injection computer.

• Remove the Protection and Switching Unit bolts (1).
• Remove:
  • the Protection and Switching Unit,
  • the wiring harness under the injection computer.

• Fit the (Mot. 1453) with a safety strap(s).
• Remove:
  • the front left-hand wheel (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres),
  • the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection).
  • the side stiffener bolts on the left-hand side of the vehicle,
  • the side stiffener on the left-hand side of the vehicle,
  • the engine undertray,
  • the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting).

• Disconnect:
  • the connector (2) from the actuator module,
  • the connector (3) from the pump assembly.

• Remove:
  • the clutch pipe (4),
  • the clutch pipe bracket (5).
• Cut the clip on the clutch pipe (6).

• Remove the high pressure pump pipe (7) and (8).

• Remove the low pressure pump pipe (9).

• Disconnect the clutch control pipe (10) on the hydraulic cylinder by pushing on the clip.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Drain the pump assembly reservoir using a syringe.
• Remove:
  • the earth strap on the pump assembly (11),
  • the lower bolts from the pump assembly (12),
  • the upper bolt from the pump assembly (13).

• Disconnect the connector from the pump assembly (14).

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

• Position the pump assembly.
• Refit:
  • the pump assembly upper bolt,
  • the pump assembly lower bolts,
  • the earth strap on the pump assembly.
• Tighten to torque:
  • the pump assembly lower bolts (24 N.m),
  • the pump assembly upper bolt (24 N.m).
• Connect the clutch control pipe on the hydraulic cylinder.
• Refit:
  • the low pressure pump pipe,
  • the high pressure pump pipe,
  • the clutch pipe,
  • the clutch pipe bracket,
  • a new clip on the clutch pipe.
• Tighten to torque:
  • the low pressure pump pipe (14 N.m),
  • the high pressure pump pipe (14 N.m).
• Connect:
  • the actuator module connector,
  • the pump assembly connector.
• Refit the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting).
• Remove the (Mot. 1453) and the safety strap(s).
• Refit:
  • the side stiffener bolts on the left-hand side of the vehicle,
  • the side stiffener on the left-hand side of the vehicle,
  • the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection).
• Connect the electrohydraulic unit connector.
• Fill the oil reservoir (see 21B, Sequential gearbox, Sequential gearbox oil: Specifications, 21B-82) (Technical Note 6012, 04A, Lubricants) to between 32 and 38 mm above the MIN mark.
• Refit:
  • the Protection and Switching Unit,
  • the wiring harness under the injection computer,
  • the diesel injection computer (see Diesel injection computer: Removal - Refitting) (MR 392, 13B, Diesel injection),
  • 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 air filter box (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the front left-hand wheel (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres),
  • the engine undertray.

II - FINAL OPERATION

• Perform the following operations:
  • bleed the clutch circuit (see 21B, Sequential gearbox, Sequential gearbox: Bleeding, 21B- 84),
  • the necessary programming (see Fault finding - Replacement of components (MR 394, 21B, Sequential gearbox).

WARNING

After the accumulator has been fully filled (15 seconds after the ignition has been switched on): the oil is at the MIN mark.

D4F, and JA3

REMOVAL

I - REMOVAL PREPARATION OPERATION

Note: When replacing the electric pump assembly, always replace the control relay.

IMPORTANT

Before any operation on the sequential system, discharge the accumulator using the Diagnostic tool.

• To discharge the accumulator, run command " Discharge pressure accumulator " AC081.

  To confirm the pressure drop, read the " Hydraulic pressure " parameter for the resulting value.

  If there is still pressure in the accumulator, re-run the " Discharge pressure accumulator " command until the pressure is negligible and will not pose a risk when the high pressure pipes are removed.

  The pressure reading must be close to zero.

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Remove:
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the air filter unit (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture).
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the diesel injection computer (see Diesel injection computer: Removal - Refitting) (MR 392, 13B, Diesel injection),
  • the wiring harness nut under the injection computer.

• Remove the Protection and Switching Unit bolts (1).
• Remove:
  • the Protection and Switching Unit,
  • the wiring harness under the injection computer.

• Fit the (Mot. 1453) with a safety strap(s).
• Remove:
  • the front left-hand wheel (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres),
  • the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection).
  • the side stiffener bolts on the left-hand side of the vehicle,
  • the side stiffener on the left-hand side of the vehicle,
  • the engine undertray,
  • the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting).

• Disconnect:
  • the connector (2) from the actuator module,
  • the connector (3) from the pump assembly.

• Remove:
  • the clutch pipe (4),
  • the clutch pipe bracket (5).
• Cut the clip on the clutch pipe (6).

• Remove the high pressure pump pipe (7) and (8).

• Remove the low pressure pump pipe (9).

• Disconnect the clutch control pipe (10) on the hydraulic cylinder by pushing on the clip.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Drain the pump assembly reservoir using a syringe.
• Remove:
  • the earth strap on the pump assembly (11),
  • the lower bolts from the pump assembly (12),
  • the upper bolt from the pump assembly (13).

• Disconnect the connector from the pump assembly (14).

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

• Position the pump assembly.
• Refit:
  • the pump assembly upper bolt,
  • the pump assembly lower bolts,
  • the earth strap on the pump assembly.
• Tighten to torque:
  • the pump assembly lower bolts (24 N.m),
  • the pump assembly upper bolt (24 N.m).
• Connect the clutch control pipe on the hydraulic cylinder.
• Refit:
  • the low pressure pump pipe,
  • the high pressure pump pipe,
  • the clutch pipe,
  • the clutch pipe bracket,
  • a new clip on the clutch pipe.
• Tighten to torque:
  • the low pressure pump pipe (14 N.m),
  • the high pressure pump pipe (14 N.m).
• Connect:
  • the actuator module connector,
  • the pump assembly connector.
• Refit the left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting).
• Remove the (Mot. 1453) and the safety strap(s).
• Refit:
  • the side stiffener bolts on the left-hand side of the vehicle,
  • the side stiffener on the left-hand side of the vehicle,
  • the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 393, 55A, Exterior protection).
• Connect the electrohydraulic unit connector.
• Fill the oil reservoir (see 21B, Sequential gearbox, Sequential gearbox oil: Specifications, 21B-82) (Technical Note 6012, 04A, Lubricants) to between 32 and 38 mm above the MIN mark.
• Refit:
  • the Protection and Switching Unit,
  • the wiring harness under the injection computer,
  • the diesel injection computer (see Diesel injection computer: Removal - Refitting) (MR 392, 13B, Diesel injection),
  • 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 air filter box (see Air filter unit: Removal - Refitting) (MR 392, 12A, Fuel mixture),
  • the battery tray (see Battery tray: Removal - Refitting) (MR 392, 80A, Battery),
  • the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery),
  • the front left-hand wheel (see Wheel: Removal - Refitting) (MR 392, 35A, Wheels and tyres),
  • the engine undertray.

II - FINAL OPERATION

• Perform the following operations:
  • bleed the clutch circuit (see 21B, Sequential gearbox, Sequential gearbox: Bleeding, 21B- 84)
  • the necessary programming (see Fault finding - Replacement of components (MR 394, 21B, Sequential gearbox).

WARNING

After the accumulator has been fully filled (15 seconds after the ignition has been switched on): the oil is at the MIN mark.

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