Renault Clio: K9K, and JA5

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Engine And Cylinder Block Assembly / Engine - gearbox assembly: Removal - Refitting / 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.

• Remove the fuses (17).

• 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.

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