Renault Clio: D4F, and 784, and Right-hand Drive

Renault Clio III (2005-2013) Service Manual / Chassis / Mechanical Component Controls / Brake servo: Removal - Refitting / D4F, and 784, and Right-hand Drive

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Remove the dashboard side face (1).

• Remove:
  • the protective strips from the lower cover (2),
  • the bolts (3),
  • the lower cover (4), disconnecting the various connectors.
• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove:
  • the engine cover,
  • 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).

• Remove:
  • the bolts (5),
  • the turbocharger heat shield (6),
  • the upstream oxygen sensor (7).

• Remove:
  • the clips (8),
  • the bulkhead heat shield (9),
  • the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, 37A-2),
  • the clutch master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, 37A-107),
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (MR 392, 19D, Engine mounting).

• Remove:
  • the radiator mounting cross member bolt (10),
  • the sub-frame rear bolt (11).

• Fit the (Mot. 1672) as shown above.
• Remove the front left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting).
• Fully lower the engine using the (Mot. 1672).

• Remove the petrol vapour rebreathing solenoid valve (12).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the brake servo non-return valve (13) (see 37A, Mechanical component controls, Brake servo non-return valve: Removal - Refitting, 37A-26).

• Remove:
  • the double safety connecting shaft (14) between the brake servo pushrod and the brake pedal by pressing on the ring (15) with a flat-blade screwdriver,
  • the brake servo nuts (16),
  • the brake servo.

Note: To remove the brake servo, the engine must be tilted towards the front of the vehicle.

REFITTING

• It is essential to replace the sub-frame rear bolts.

I - REFITTING PREPARATIONS OPERATION

• Check that the brake servo seal (17) is in place and replace the seal if it is faulty.
• The shaft connecting the brake servo pushrod and the brake pedal must be replaced every time it is removed.

• Check the following dimension before refitting: (X1) = 128 mm.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the brake servo,
  • the brake servo nuts.
• The connecting shaft between the brake servo pushrod and the brake pedal must be refitted from right to left and from top to bottom.
• Torque tighten the brake servo nuts (25 Nm).

III - FINAL OPERATION.

• Fit the petrol vapour rebreathing solenoid valve onto its mounting.
• Refit the front left-hand suspended engine mounting (see Left-hand suspended engine mounting: Removal - Refitting) (MR 392, 19D, Engine mounting).
• Remove the (Mot. 1672).
• Refit:
  • the sub-frame rear bolt,
  • the right-hand side radiator mounting cross member bolt.
• Torque tighten:
  • the sub-frame rear bolt (110 Nm),
  • the right-hand side radiator mounting cross member bolt (105 Nm).
• Refit:
  • the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (MR 392, 19D, Engine mounting),
  • the front bumper (see Front bumper: Removal - Refitting) (MR 393, 55A, Exterior protection),
  • the clutch master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, 37A-107),
  • the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, 37A-2),
  • the bulkhead heat shield,
  • the bulkhead heat shield clips,
  • the upstream oxygen sensor.
• Torque tighten the oxygen sensor (44 Nm).
• Refit:
  • the turbocharger heat shield,
  • the turbocharger heat shield bolts,
  • 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.
• Bleed:
  • the clutch circuit (see 37A, Mechanical component controls, Clutch circuit: Bleed, 37A- 100),
  • the brake circuit (see 30A, General information, Braking circuit: Bleed, 30A-4).
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove the vehicle from the lift.
• Adjust:
  • the brake switch (see 37A, Mechanical component controls, Brake pedal switch: Removal - Refitting, 37A-79),
  • the clutch switch (see 37A, Mechanical component controls, Clutch pedal switch: Removal - Refitting, 37A-97).
• Refit:
  • the lower cover and connect the various connectors,
  • the lower cover bolts,
  • the dashboard side panel,
  • the lower cover protective strips.

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