Nemo clutch replacement guide wanted

[blake7]

Can you please advise on the best way to replace the clutch on the 1.4hdi Marc (GiveMeABreak)

Thanks in advance

[GiveMeABreak]

Pop your VIN up for me - shouldn't take me more than 20 minutes to put you a guide up.

[blake7]

Thanks Marc, greatly appreciated

VF7**************[VIN obfuscated, can be read by forum staff]

[GiveMeABreak]

Ok - It's taking a little longer - due to the gearbox operation also needing to be included.....

[GiveMeABreak]

Clutch Replacement:- Nemo Utiliy VAN 1.4 HDi 70 BVM5

The Gearbox and the Clutch Operations are combined in a single process.

Tools

Clutch mechanism compression tool (-).0217. [1] Clutch mechanism compressor (-).0217-A. [2] Support pin (Ø 8 mm) (-).0217-B2. [3] clutch friction centring rod (-).0217-C3.

Removing Clutch
Note: This method applies to all flywheel models.

Remove the Gearbox

Recommended Tools

[1] Lower engine support crossmember (-).0012: [1a] Transverse engine support bar [1b] support [1c] Safety bolt [1d] Longitudinal engine support bar [1e] bolts [1f] engine support [1g] bolts [1h] bolts [1j] Pliers	[2] workshop hoist. [3] Chain. [4] shackles.

Removing

Place the vehicle on a 2-post lift.
Lift and support the vehicle.
Disconnect the battery.

Remove:

• The battery
• The battery support
• The catalytic converter

Remove: The earth screw (1) The earth cable Disconnect the connector from the reverse gear switch (2).	Uncouple the clutch cable (3) from the clutch control lever (5). Pull the clutch cable (3) (In the direction of the arrow "a"). Release the clutch cable from the cable stop mounting (4). Drain the gearbox . Remove: The front wheels The front left-hand splash-shield The drive shafts The starter motor Disconnect the gear selection controls.
Remove: The tie wrap (8) The clips (9) The (6) bolt The (10) bolt The resonator and air inlet duct assembly (7)	Remove: The nut (12) The bolt (11) The bolts (13) The reaction link (14)
Remove: The stud (16) The (15) bolt	Position: The clamps "1j" of tool [1] on the vehicle floorpan (on each side) The crossbar "1a" of tool [1] on the clamps "1j" of tool [1] Position the support [1b] of the tool [1] in place of a subframe fixing.
Position: The longitudinal bar "1d" of tool [1] on the support "1b" of tool [1] using the screw "1g" The longitudinal bar "1d" of tool [1] on the crossbar "1a" of tool [1] using the screw "1h" Position the support "1f" of tool [1] under the oil sump, using screw "1e". Remove the engine/gearbox lower fixing bolts. Sling the gearbox. using the tools [2], [3], [4].	Remove: The bolts (18) The bolts (17) The gearbox mounting (19)
Disconnect the battery positive lead (20) (at "b"). Remove the top screws coupling the engine/gearbox.	Remove the 2 bolts (21). Release: The venting unit The venting unit pipe Remove the gearbox From below the vehicle.

Gearbox Refitting Follows Clutch Procedure:

Removing the Clutch (continued)

Clutch mechanism (Not re-used)
Remove:

• The securing bolts
• The clutch mechanism
• The clutch disc

Clutch mechanism (Re-used)

CAUTION: The clutch mechanism and disc are paired at the factory and cannot be replaced separately.

N.B.: Mark the clutch plate in relation to the engine flywheel.

Remove 3 bolts (1) (one screw out of two). Position the tools [1], [2]. Compress the clutch mechanism (2) by acting on the central screw (at "a") ; Using tool [1]. Finish removing the remaining bolts (1). Slacken the clutch mechanism (2) by acting on the central screw (at "a") ; Using tool [1]. Remove the tools [1], [2]. Retrieve: The clutch mechanism (2) The clutch disc Visually check: The flywheel face for damage or scores The flywheel for wear The condition of the starter ring gear The clutch mechanism (2) In the case of oil presence in the clutch mechanism: Replace the seal of the crankshaft Replace the output seal of the primary shaft CAUTION: Do not reuse a clutch disc the hub of which bears traces of oxidation.

Refitting
CAUTION: Before fitting either a new or an existing mechanism, make sure that it is correctly in the initial position.

Refit the clutch disc (3). Centre the clutch disc using the tool [3].

Refit the clutch mechanism (2). Position the tools [1] and [2] on the clutch mechanism. Screw in the 3 support pins [2] in place of the screws (1). Screw in the screw ""a"" of the tool [1] to compress the clutch mechanism (2). Refit the 3 bolts (1) (one screw out of two) ; Tighten to 2 ± 0,2 daN.m. Unscrew the screw ""a"" of the tool [1] by a few turns to slacken the clutch mechanism (2). Remove the tools [1], [2], [3]. Fit the remaining screws (1); Tighten to 2 ± 0,2 daN.m.

Refit the Gearbox

Refitting the Gearbox

N.B.: Check the presence of the centring pins on the gearbox.

Check:

• There are no oil leaks at the stop guide seal
• There are no oil leaks at the crankshaft sealing ring
• The state of wear of the clutch
• The state of wear of the declutch bearing

Rectify (if necessary).

ESSENTIAL: Clean the input shaft completely along its entire length, over its entire periphery and in the grooves.

Protect the interior of the clutch housing from splashes of grease.
Apply the recommended grease uniformly on the stop guide and the input shaft.
Grease the fingers of the clutch fork.

N.B.: Use MOLYCOTE G-RAPID PLUS grease.

Remove the surplus grease on the top of the grooves and the end of the input shaft using a cloth.

N.B.: An excess of grease will contaminate the clutch friction plate and cause noise in neutral, slipping or juddering of the clutch.

CAUTION: If the clutch disc is reused, the disc hub must be free of traces of oxidation.

Clean the bolt threads.
Set the gearbox in neutral.
Attach the gearbox to the engine.
Refit:

• The upper engine/gearbox coupling bolts
• The gearbox mounting (19)
• The bolts (17) ; Tighten to 6 ± 0,6 daN.m
• The bolts (18) ; Tighten to 8 ± 0,4 daN.m

Remove the tools [2], [3], [4].
Refit: The lower engine/gearbox coupling screws.

Remove the nut (22).
Refit:

• The venting unit pipe (23)
• The nut (22)
• The venting unit
• The bolts (21)

Tighten the engine/gearbox coupling fixings to 5,5 ± 0,5 daN.m.
Clip the battery positive cable (20) ( as "b").
Refit:

• The stud (16)
• The reaction link (14)
• The bolts (13) ; Tighten to 6 ± 0,6 daN.m
• The (11) bolt
• The nut (12) ; Tighten to 3,5 ± 0,3 daN.m
• The catalytic converter

Engage the clutch cable in the cable stop mounting (4).
Pull the clutch cable (3); Connect the clutch cable to the clutch lever .
Refit:

• The resonator and air inlet duct assembly (7)
• The (10) bolt
• The (6) bolt
• The clips (9)
• The tie wrap (8)

Couple the gear selection controls.
Disconnect the connector from the reverse gear switch (2).
Refit:

• The earth cable
• The earth screw (1)
• The starter motor
• The drive shafts
• The front left-hand splash-shield
• The front wheels
• The battery support
• The battery

Top up the oil in the gearbox.
Reconnect the battery.
CAUTION: Perform the operations to be carried out following reconnection of the battery.

Lower the vehicle to the ground.

[blake7]

Thank you very much!