Renault Clio: Exhaust gas cooler: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Antipollution / Exhaust gas cooler: Removal - Refitting

K9K, and 764 or 766 or 768 or 772

REMOVAL

I - REMOVAL PREPARATION OPERATION

• 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 scuttle panel grille (see Scuttle panel grille: Removal - Refitting).

• Remove the inlet duct (1) between the turbocharger and the intercooler.
• Disconnect the inlet duct (2).

K9K, and 764 or 772

• Remove the oil vapour rebreathing pipe (3).

• Disconnect the connector (4) from the exhaust gas recirculation solenoid valve.
• Disconnect the vacuum pump pipe.

K9K, and 764 or 772

• Disconnect the connector from the cut-off valve (if equipped).
• Remove:
  • the bolts (5) mounting the damper valve retaining bracket,
  • the damper valve mounting bolts (6),
  • the damper valve (7) (if equipped).

K9K, and 766 or 768

• Disconnect the oil vapour recirculation pipe (11).
• Remove:
  • the oil vapour recirculation valve bolts (10),
  • the oil vapour recirculation valve,
  • the mounting bolts (12) of the oil vapour recirculation valve retaining bracket.

• Position the tools (Ms. 583) or the hose clamps on the coolant inlet and outlet hoses (13) of the exhaust gas cooler.
• Remove the mounting bolts (8) of the coolant circulation cover.
• Detach the coolant circulation cover.

Note: Be prepared for the escape of coolant.

K9K, and 764 or 766 or 768

• Remove the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, 19B-29).

K9K, and 772

• Remove the catalytic pre-converter (see 19B, Exhaust, Catalytic pre-converter: Removal - Refitting, 19B-23).

• Remove:
  • the exhaust gas recirculation rigid pipe (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting, 14A-20),
  • the exhaust gas recirculation assembly .

II - OPERATION FOR REMOVAL OF PART CONCERNED

1 - First fitting of the exhaust gas cooler recirculation assembly

• Using the workbench, remove:
  • the bolts (19) mounting the exhaust gas cooler on its two supports,
  • the exhaust gas cooler.

2 - Second fitting of the exhaust gas cooler recirculation assembly

• Remove:
  • the bolts (29) of the cooler on the support,
  • the seal of the cooler on the support,
  • the cooler.

REFITTING

I - REFITTING PREPARATION OPERATION

• All the supporting surfaces on each removed part must be carefully cleaned.

WARNING

Take care not to damage the bearing faces to prevent any risk of coolant leaks.

WARNING

Always replace:

• the air inlet metal tube and its O-rings,
• the exhaust gas inlet pipe, its mounting bolts, its seal and its snap-on clip,
• the cooler seals on its mountings,
• the coolant circulation cover seals within the exhaust gas cooler,
• the seal between the cut-off valve downstream duct and the exhaust gas cooler mounting,
• the seal between the catalytic converter and the turbocharger.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit the exhaust gas cooler on its two mountings with new seals.

1 - First fitting of the exhaust gas cooler recirculation assembly

• Position the cooler mounting bolts (22), avoiding contact so that the cooler can move.
• Refit the exhaust gas recirculation unit assembly on the cylinder head with its cooler.
• Tighten the two mounting bolts on the exhaust gas cooler mountings until contact is made.
• Adjust the exhaust gas cooler in relation to its two mountings.
• Tighten the exhaust gas cooler mounting bolts on to its two mountings until contact is made and so that it is locked into place.
• Remove the exhaust gas recirculation unit and its cooler.
• On the workbench, torque tighten:
  • the bolts mounting the exhaust gas cooler on the timing end support (12 N.m),
  • the bolts mounting the exhaust gas cooler on the flywheel end support (12 N.m).

WARNING

Ensure that the seals between the cooler and its two supports are correctly positioned to avoid any coolant leaks.

2 - Second fitting of the exhaust gas cooler recirculation assembly

• Position the cooler mounting bolts on its support, avoiding contact so that the cooler can move.
• Refit the exhaust gas recirculation assembly equipped with the old exhaust gas recirculation rigid pipe on the cylinder head.
• Tighten the mounting bolts of the exhaust gas recirculation assembly on the cylinder head until contact is made.
• Adjust the exhaust gas cooler in relation to its support.
• Tighten the bolts mounting the exhaust gas cooler on its support until contact is made, in order to immobilise it.
• Remove the exhaust gas recirculation assembly.
• Remove the old exhaust gas recirculation rigid pipe and dispose of it in a waste bin.
• On the workbench, torque tighten the mounting bolts of the exhaust gas cooler on the support at the flywheel end (12 N.m).

WARNING

Ensure that the seal between the cooler and its support is correctly positioned to avoid any coolant leaks.

III - FINAL OPERATION

• Refit:
  • the exhaust gas recirculation assembly ,
  • the exhaust gas recirculation rigid pipe (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting, 14A-20).

K9K, and 764 or 766 or 768

• Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, 19B-29).

K9K, and 772

• Refit the catalytic pre-converter (see 19B, Exhaust, Catalytic pre-converter: Removal - Refitting, 19B-23).

• Torque tighten:
  • the coolant circulation cover mounting bolts (10 N.m),
  • the mounting bolts of the lifting bracket at the timing end (10 N.m).

WARNING

Make sure that the exhaust gas cooler coolant inlet and outlet hoses are correctly fitted so that they do not bend.

• Proceed in the reverse order to removal.
• Loosen the mounting nut of the air pipe at the intercooler inlet on the alternator.
• Fit the air duct between the turbocharger and the intercooler air inlet pipe.
• Snap the air duct to the turbocharger and to the air pipe at the intercooler inlet.
• Tighten the bolt of the air duct on the rocker cover.
• Torque tighten the mounting nut of the pipe at the intercooler inlet on the alternator (8 N.m).
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Bleed the cooling circuit .
• Clear any faults stored by the computer using the Diagnostic tool.

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