Renault CLIO II (1997) phase 2 Workshop Manual

Brand: Renault

Model: CLIO II (1997) phase 2

Type: Workshop Manual

General vehicle information

SPECIFICATIONS

LIFTING EQUIPMENT

TOWING

LUBRICANTS

CONSUMABLES

DRAINING/FILLING

ENGINE AND TRANSMISSION ASSEMBLY

VALUES AND SETTINGS

VALUES AND SETTINGS OF AXLE

ASSEMBLIES

77 11 315 102

"The repair methods given by the manufacturer in this document are based on the

technical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer

in the production of the various component units and accessories from which his

vehicles are constructed.

FEBRUARY 2002

All copyrights reserved by Renault.

EDITION ANGLAISE

Copying or translating, in part or in full, of this document or use of the service part

reference numbering system is forbidden without the prior written authorisation of

Renault.

This Workshop Repair Manual includes CLIO II phase 2

(1.6 16V K4M engine) vehicles specified below:

(1) Manufacture: country of manufacture.

The letter in brackets is the factory code which appears as the first character on the vehicle fabrication number label.

For more information on the selection of Workshop Repair Manuals on the CLIO II range refer to Technical Note

3627A.

Vehicle type

Country of

manufacture

(1)

Technical

Specifications

Market Sales reference

Features of Turkish

vehicles

– 4-door Clio with luggage

compartment

Turkey (R)

Multiplex

network

World

Renault Symbol

(Russia)

Renault Clio

for the rest of the world

Features of CEEC country

vehicles

– 4-door Clio with luggage

compartment

Turkey (R)

Multiplex

network

●

Central Europe:

Hungary, Slovenia,

Slovakia, Czech

Republic, Poland

●

Greece

●

DOM TOM (French

overseas

territories)

Renault Thalia

(Eastern and central

European countries and

Greece)

Renault Symbol

(DOM TOM)

Features of Persian Gulf

vehicles

– 4-door Clio with luggage

compartment

Turkey (R)

Multiplex

network

Saudi Arabia,

Bahrain, Dubai, Arab

Emirates, Kuwait,

Oman, Qatar

Renault Clio

Features of Mexican

vehicles

– 5-door Clio

Mexico

Multiplex

network

Mexico Renault Clio

Features of Colombian -

Venezuelan vehicles

– 5-door Clio

– 4-door Clio with luggage

compartment

Columbia

(M)

Multiplex

network

Columbia

Venezuela

Renault Symbol

Features of Mercosur

country vehicles

– 5-door Clio

– 4-door Clio with luggage

compartment

Argentina (L)

Brazil (J)

Multiplex

network

Argentina

Brazil

Renault Clio

General

Information

Contents

Page

01A

02A

03A

04A

04B

05A

SPECIFICATIONS

Engine - Gearbox 01A-1

Vehicle identification 01A-2

LIFTING APPARATUS

Trolley jack - Axle stands 02A-1

Underbody lift 02A-2

TOWING

All types 03A-1

LUBRICANTS

Packaging 04A-1

CONSUMABLES

Packaging 04B-1

FLUID CHANGE AND FLUID

REFILLING

Engine 05A-1

Gearbox 05A-2

Power assisted steering 05A-3

Page

07A

07B

ENGINE AND TRANSMISSION

ASSEMBLY VALUES AND

SETTINGS

Capacities - Grades 07A-1

Accessories belt tension 07A-2

Tightening the cylinder head 07A-3

VALUES AND SETTINGS OF AXLE

ASSEMBLIES

Wheels and tyres 07B-1

Brakes 07B-2

Brake limiter 07B-3

Underbody height 07B-4

Front axle geometry checking values 07B-8

Rear axle geometry checking values 07B-11

SPECIFICATIONS

Engine - Gearbox

01A

01A-1

101A

SPECIFICATIONS

Engine - Gearbox

VEHICLE IDENTIFICATION

Example:

X : Bodywork type

B : Project code

1R : Engine suffix

Vehicle type

Engine

Gearbox type

Type Cubic capacity (cc

)

XB1R K4M 1598 JB3/DP0

SPECIFICATIONS

Vehicle identification

01A

01A-2

Vehicle identification

LOCATION OF VEHICLE IDENTIFICATION PLATE

1 Vehicle type mine and chassis number

This information is recorded on marking (B)

(depending on country)

2 MGVW (Maximum Gross Vehicle Weight)

3 GTW (Gross Train Weight - loaded vehicle with

trailer)

4 Front axle MGVW

5 Rear axle MGVW

6 Technical specifications of the vehicle

7 Vehicle paint reference

8 Equipment level

9 Vehicle type

10 Trim code

11 Additional equipment details

12 Fabrication number

13 Interior trim code

LIFTING APPARATUS

Trolley jack - Axle stands

02A

02A-1

102A

LIFTING APPARATUS

Trolley jack - Axle stands

Safety symbol (special precautions to be taken when carrying out operations).

IMPORTANT:

The subframe of this vehicle is protected by products

with an anti-corrosion warranty.

Never use equipment which is not fitted with rubber

pads, in order to avoid the direct contact of metal with

metal which could damage the protection originally

fitted.

The vehicle must not be raised by placing the jack

beneath the front suspension arm or under the rear

axle.

To raise a front or a rear wheel, place the jack under

the subframe body flange.

To raise both the front and rear wheels laterally, use

the Cha. 280-02 beam.

Place the jack under the sill body flange in the centre

of the front door.

IMPORTANT:

Position the flange correctly in the groove of the beam.

To mount the vehicle on axle stands, the entire vehicle

must be lifted laterally and axle stands must be placed

under the body flange reinforcements which are used

as jacking points at (A).

SPECIAL TOOLING REQUIRED

Cha. 280-02 Trolley jack support beam

If a trolley jack is used, appropriate axle

stands must always be used.

LIFTING APPARATUS

Underbody lifts

02A

02A-2

Underbody lifts

SAFETY ADVICE REMINDER

It is preferable to use a four-post lift, if possible, if

heavy components need to be removed from the

vehicle.

When a large component (for example: engine and

transmission assembly, rear axle, fuel tank, etc.) is

removed, the vehicle loses a large proportion of its

load and there is a risk that it can become unstable on

two-post lift supports (see notes on the position of the

arms further on).

This is even more dangerous when the vehicle is

raised to a high level.

When the vehicle is lifted from underneath the body by

a two-post lift, it is necessary to fit safety straps which

are available at Parts Stores Part no: 77 11 172 554.

FITTING STRAPS

For obvious safety reasons, these straps must be in

perfect condition (replace them as soon as they begin

to fray).

When fitting the straps, check that the protectors are

located on the seats and the fragile parts of the

vehicle. Do not overtighten the straps.

Place the straps under the post-lift arms and pass

them around the vehicle.

The following example demonstrates the vehicle

lashing for an operation on the front of the vehicle.

LIFTING APPARATUS

Underbody lifts

02A

02A-3

POSITIONING THE LIFTING ARMS

Position the lifting arm on the subframe body flange.

FRONT

REAR

TOWING

All types

03A

03A-1

103A

TOWING

All types

OBSERVE THE TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.

NEVER USE THE DRIVESHAFTS AS AN ATTACHMENT POINT.

The towing points may only be used for towing the vehicle on the road. They should never be used for removing the

vehicle from a ditch or to lift the vehicle, either directly or indirectly.

FRONT REAR

LUBRICANTS

Packaging

04A

04A-1

104A

LUBRICANTS

Packaging

DESCRIPTION PACKAGING PART NUMBER

GREASES

●

MOLYKOTE "BR2"

for main bearing journal faces, thrust pad guide

tubes, clutch fork pads, lower suspension arm

bearings, torsion bar splines, steering box and

driveshaft splines.

1 kg tin 77 01 421 145

●

MOLYKOTE "33 Medium"

bushes, tubular rear axle, anti-roll bar bushes.

100 g tube 77 01 028 179

●

ANTI-SEIZE

(high temperature grease) Turbo, etc.

80 ml tube 77 01 422 307

●

"MOBIL CVJ" 825 Black Star or MOBIL EXF57C

for driveshaft seals.

180 g sachet 77 01 366 100

●

MULTIPURPOSE GREASE

wheel sensor.

Aerosol 77 01 422 308

MECHANICAL SEALANTS

●

Mastic

for sealing exhaust pipe unions.

1.5 kg tin 77 01 421 161

●

RHODORSEAL 5661 – Cartridge

– 100 g tube

77 01 421 042

77 01 404 452

●

HARDENER KIT (RHODORSEAL 5661)

for side sealing of bearing caps.

Kit 77 01 421 080

●

AUTO blue seal

sealing paste.

100 g tube 77 01 396 227

VARNISHES

●

"CIRCUIT PLUS"

varnish for repairing heated rear screens.

Bottle 77 01 421 135

BRAKES

●

Brake fluid. 0.5 litre bottle DOT 4 77 11 172 381

●

"Low viscosity" brake fluid. 0.5 litre bottle DOT 4 77 11 218 589

CONSUMABLES

Packaging

04B

04B-1

204B

CONSUMABLES

Packaging

DESCRIPTION PACKAGING PART NUMBER

MECHANICAL SEALANTS

●

AUTO grey seal

sealing paste.

100 g tubes 77 01 422 750

●

LOCTITE 518

for sealing the gearbox housing.

24 ml syringe 77 01 421 162

●

Leak detector Aerosol 77 11 143 071

ADHESIVES

●

"LOCTITE-FRENETANCH"

stops bolts loosening and allows them to be released.

24 cc bottle 77 01 394 070

●

"LOCTITE-FRENBLOC"

locks bolts.

24 cc bottle 77 01 394 071

●

"LOCTITE SCELBLOC"

for bonding bearings.

24 cc bottle 77 01 394 072

LUBRICANT CLEANING AGENTS

●

"NETELEC"

unseizing agent, lubricant.

Aerosol 77 11 171 287

●

Carburettor cleaner. 300 ml aerosol 77 11 171 437

●

Injector cleaner. 355 ml can 77 01 423 189

●

Super-concentrated unseizing agent. 500 ml aerosol 77 01 408 466

●

DECAPJOINT (FRAMET)

for cleaning the faces of aluminium cylinder heads.

Aerosol 77 01 405 952

●

Brake cleaner. 400 ml aerosol 77 11 171 911

FLUID CHANGE AND FLUID REFILLING

Engine

05A

05A-1

105A

FLUID CHANGE AND FLUID REFILLING

Engine

DRAINING: plug (1) FILLING: plug (2)

K4M engine

TOOLING REQUIRED

Engine drain plug spanner

FLUID CHANGE AND FLUID REFILLING

Gearbox

05A

05A-2

Gearbox

DRAINING: plug (1)

FILLING and LEVEL: cap (2)

Manual gearbox JB3

Automatic gearbox DP0

Draining

Filling

FLUID CHANGE AND FLUID REFILLING

Power assisted steering

05A

05A-3

Power assisted steering

CHECKING THE LEVEL

POWER ASSISTED STEERING PUMP LEVEL

For topping up or filling, use ELF RENAULTMATIC D2

or MOBIL ATF 220 oil.

The level, when correct, should be visible between the

MIN and MAX marks on the reservoir (1).

ALL ENGINES TYPES

ENGINE AND TRANSMISSION ASSEMBLY VALUES AND

ADJUSTMENT

07A

07A-1

107A

ENGINE AND TRANSMISSION ASSEMBLY VALUES AND ADJUSTMENT

Capacities - Grades

Components

Average capacity* in litres

After an oil change,

check using the dipstick

After replacing the oil

filter

Petrol engine (oil)

K4M 4.7 4.85

Manual gearbox

JB3 3.4

Automatic transmission

DP0 6

* Check with dipstick.

NOTE: never exceed the maximum mark on the dipstick.

Components Capacity in litres Grade

Brake circuit

Standard: 0.7

ABS: 1

SAE J 1703 and DOT 4

Brake fluids must be approved by the Technical Department.

Components Capacity in litres Grade

Fuel tank Approximately 50 Unleaded petrol

Power assisted steering

Separate reservoir

1.1

ELF RENAULT MATIC

D2 or MOBIL ATF 220

Cooling circuit

5.7 GLACEOL RX

(type D)

ENGINE AND TRANSMISSION ASSEMBLY VALUES AND

ADJUSTMENT

07A

07A-2

WITHOUT AIR

CONDITIONING

ENGINE AND TRANSMISSION ASSEMBLY VALUES AND ADJUSTMENT

Accessories belt tensioning

ALTERNATOR AND POWER ASSISTED STEERING

The belt tension is set with bolt (1) (with the two

tensioner mounting bolts already having been

unscrewed) then tighten nut (2).

A Crankshaft

B Power assisted steering pump

C Alternator

T Tension wheel

→ Point for checking belt tension

NOTE: the accessories belt has five teeth whilst

the alternator, power assisted steering pump, and

the crankshaft pulleys all have six. Therefore,

when fitting the belt, ensure that the tooth at edge

of the pulleys (E) is kept free.

SPECIAL TOOLING REQUIRED

Mot. 1505 Tool for checking belt tension

Tension

(Hertz)

Multitooth power

assisted steering belt

Fit 190 ± 10

ENGINE AND TRANSMISSION ASSEMBLY VALUES AND

ADJUSTMENT

07A

07A-3

ENGINE AND TRANSMISSION ASSEMBLY VALUES AND ADJUSTMENT

Tightening the cylinder head

METHOD FOR TIGHTENING THE CYLINDER HEAD

The bolts can be reused if the length under the head does not exceed 117.7 mm

(otherwise replace all the bolts).

Cylinder head tightening procedure

REMINDER: Use a syringe to remove any oil which may have entered the cylinder head

mounting bolt holes to achieve correct tightening of the bolts.

Do not oil the new bolts. However, the bolts must be oiled if they are being reused.

Tighten all the bolts to 2 daNm in the order recommended below.

Check that all the bolts are tightened to 2 daNm then, bolt by bolt, tighten to an angular torque

of 240°°

°°

±±

6°°

°°

Do not retighten the cylinder head bolts after applying this procedure.

VALUES AND ADJUSTMENT OF AXLE ASSEMBLIES

Tyres and wheels

07B

07B-1

207B

VALUES AND ADJUSTMENT OF AXLE ASSEMBLIES

Tyres and wheels

(1) Under full load and/or on motorway

(2) With air conditioning

Wheel bolt tightening torque: 9 daNm

Rim run-out: 0.8 mm

Vehicle type Rim Tyres

Tyre pressure when

cold (in bar) (1)

Front Rear

B / L B1R 5.5 J 14

185/60 R 14 H

175/65 R 14 T

2.4 2.1

VALUES AND ADJUSTMENT OF AXLE ASSEMBLIES

Brakes

07B

07B-2

Brakes

(1) Drum: maximum wear diameter

The disc run-out is 0.07 maximum.

(1) Leading lining

(2) Secondary lining

Vehicle type

Disc thickness

(in mm)

Diameter of drums

(in mm)

Normal Minimum Normal Maximum

B/LB 1R 20.6 17.6 203.2 204.2

Vehicle type

Lining thickness (in mm)

Brake fluidFront (including mounting) Rear

New Minimum New Minimum

B/LB 1R 18.2 6

3.3 (2)

4.6 (1)

SAE J1703

DOT 4

VALUES AND ADJUSTMENT OF AXLE ASSEMBLIES

Brake compensator

07B

07B-3

Brake compensator

BRAKING PRESSURE

(1) The test is performed using two pressure gauges in an X arrangement.

Vehicle type

Amount of fuel in tank

(driver on board)

Check pressure (1) (in bar)

Front Rear

BB1 R

LB 1R

100

-10

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Renault CLIO II (1997) phase 2 Workshop Manual

Renault CLIO II (1997) phase 2 Workshop Manual

Renault CLIO II (1997) phase 2 Workshop Manual

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