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.
© RENAULT 1997
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)
No
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)
No
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)
No
Multiplex
network
Saudi Arabia,
Bahrain, Dubai, Arab
Emirates, Kuwait,
Oman, Qatar
Renault Clio
Features of Mexican
vehicles
– 5-door Clio
Mexico
No
Multiplex
network
Mexico Renault Clio
Features of Colombian -
Venezuelan vehicles
– 5-door Clio
– 4-door Clio with luggage
compartment
Columbia
(M)
No
Multiplex
network
Columbia
Venezuela
Renault Symbol
Features of Mercosur
country vehicles
– 5-door Clio
– 4-door Clio with luggage
compartment
Argentina (L)
Brazil (J)
No
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
3
)
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)
2
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
0
48
-10
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