Renault Koleos Service Repair Manual: M9R

Engine and cylinder block assembly

Engine and cylinder block assembly

Engine and cylinder block assembly

IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair .

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift .
  • Remove:
    • the engine cover,
    • the air inlet sleeve clips,
    • the air inlet sleeve from the air filter unit.

Engine and cylinder block assembly

  • Rotate the intercooler air inlet pipe clip (1) .

Engine and cylinder block assembly

  • Remove the intercooler air inlet pipe bolt (2) from the fuel supply pipe bracket.
  • Move the intercooler air inlet pipe to one side.

Engine and cylinder block assembly

  • Remove the protective plate (3) from the injector rail protector.

Engine and cylinder block assembly

  • Loosen the clip (4) on the intercooler air inlet pipe.
  • Disconnect the " intercooler air inlet pipe - duct " assembly (5) .
  • Remove:
    • the battery
    • the battery tray

AIR CONDITIONING 01 or AIR CONDITIONING 02

  • Drain the refrigerant circuit

 

  • Remove the engine undertray.
  • Drain the cooling system.

6-SPEED MANUAL GEARBOX

  • Drain the manual gearbox

6-SPEED AUTOMATIC GEARBOX

  • Drain the automatic transmission

AIR CONDITIONING 01 or AIR CONDITIONING 02

Engine and cylinder block assembly

  • Remove the compressor pipe union bolts (6) .
  • Disconnect the compressor pipe unions.
  • Plug the openings.

Engine and cylinder block assembly

  • Unclip the fuel pipes from their mounting support (7) .
  • Move the fuel pipes aside.
  • Remove:
    • the fuel pipe bolt (8) ,
    • the fuel pipe support.

Engine and cylinder block assembly

  • Loosen the clip (9) on the intercooler air outlet pipe.
  • Remove the intercooler air outlet pipe bolt (10) .
  • Disconnect the intercooler air outlet pipe (11) from the damper valve.
  • Move the intercooler air outlet pipe to one side.

Engine and cylinder block assembly

  • Remove the clip (12) from the expansion bottle hose using the tool (Mot. 1448).
  • Disconnect the hose from the expansion bottle.

Engine and cylinder block assembly

  • Remove the cooling radiator top hose clip (13) using the (Mot. 1448).
  • Disconnect the cooling radiator top hose.
  • Remove:
    • the fuel filter
    • the manual priming pump
  • Disconnect the fuel return quick-release union leading to the tank.

Engine and cylinder block assembly

  • Unclip the wiring (14) from the manual priming pump support.
  • Remove:
    • the support bolt (15) of the manual priming pump,
    • the manual priming pump support.

Engine and cylinder block assembly

  • Disconnect:
    • the turbocharging pressure regulation valve actuating hose (16) ,
    • the brake servo hose (17) from the non-return valve.
  • Remove the bolt (18) from the turbocharging pressure regulation actuating solenoid valve support.
  • Move aside the turbocharging pressure regulation actuating solenoid valve (19) and the turbocharging pressure regulation valve actuating hoses (16) .
  • Remove the air filter unit .
  • Loosen the air filter unit air outlet pipe clip located on the turbocharger side.
  • Disconnect the air filter unit air outlet pipe (20) from the turbocharger.

LEFT-HAND DRIVE

Engine and cylinder block assembly

  • Disconnect the brake fluid level sensor connector (21) .

RIGHT-HAND DRIVE

Engine and cylinder block assembly

  • Disconnect the brake fluid level sensor connector (22) .
  • Unclip the brake fluid level sensor wiring harness at (23) .

Engine and cylinder block assembly

  • Remove the fuse box cover (24) .

Engine and cylinder block assembly

  • Disconnect:
    • the fuse box wiring connectors (25) ,
    • the pre-postheating unit connector (26) .

Engine and cylinder block assembly

  • Remove the bolts (27) from the wiring bracket.
  • Unclip:
    • the wiring at (28) ,
    • the wiring at (29) .

6-SPEED AUTOMATIC GEARBOX

  • Disconnect the connector (30) from the automatic transmission computer.
  • Remove:
    • the automatic transmission computer mounting bolts (31) ,
    • the earth cable,
    • the " automatic transmission computer - mounting support " assembly.

6-SPEED MANUAL GEARBOX

  • Remove the automatic transmission computer mounting.

Engine and cylinder block assembly

  • Disconnect the battery protection fuse wiring connectors (32) .
  • Unclip the wiring harness from the brackets at (33) .

Engine and cylinder block assembly

  • Remove the heater matrix pipe clips (34) using the (Mot. 1448).
  • Disconnect the heater matrix pipes.

6-SPEED MANUAL GEARBOX

Engine and cylinder block assembly

  • Remove:
    • the heater matrix coolant outlet pipe clips (35) using the tool (Mot. 1448),
    • the heater matrix water outlet pipe bolt (36) .
  • Disconnect the " heater matrix coolant outlet duct - pipe " assembly (37) from the inlet distributor and the heater matrix coolant outlet pipe.
  • Unclip:
    • the selector cable and the gear selector lever cable from the manual gearbox.
    • the gear shift cable and the gear shift lever cable from the manual gearbox.

6-SPEED AUTOMATIC GEARBOX

Engine and cylinder block assembly

  • Remove:
    • the heater matrix coolant outlet pipe clips (38) using the (Mot. 1448).
    • the heater matrix coolant outlet pipe bolt (39) .
  • Disconnect the " heater matrix coolant outlet pipe - duct " assembly (40) from the inlet distributor and the heater matrix coolant outlet pipe.

Engine and cylinder block assembly

  • Remove the heater matrix coolant inlet pipe bolt (41) .
  • Separate the coolant inlet hose from the heater matrix.

Engine and cylinder block assembly

  • Remove:
    • the nut (42) of the automatic gearbox control cable,
    • the stop (43) from the control cable of the automatic gearbox.
  • Unclip:
    • the automatic gearbox control cable from the multifunction switch lever (44) .
    • the automatic gearbox control cable from the control cable upper bracket (45) .

Engine and cylinder block assembly

  • Remove:
    • the bolts (46) from the air filter unit support,
    • the air filter unit support (47) .

6-SPEED MANUAL GEARBOX

Engine and cylinder block assembly

  • Remove:
    • the oil filter unit coolant inlet pipe clip (48) using the (Mot. 1448),
    • the clip (49) from the coolant hose using the tool (Mot. 1448).
  • Disconnect:
    • the oil filter unit coolant inlet pipe,
    • the coolant hose (50) .

6-SPEED AUTOMATIC GEARBOX

Engine and cylinder block assembly

  • Remove the oil filter unit coolant inlet pipe clip (51) using the tool (Mot. 1448).
  • Disconnect the oil filter unit coolant inlet pipe.

 

  • Remove:
    • the front wheels.
    • the front splash guards.
    • the front left-hand wheel driveshaft.
    • the front right-hand wheel driveshaft.
    • the electric coolant pump.
    • the front axle subframe.

6-SPEED MANUAL GEARBOX

Engine and cylinder block assembly

  • Remove:
    • the earth strap bolt (52) ,
    • the earth strap,
    • the clutch control pipe clip (53) .
  • Disconnect the clutch control pipe (54) from the manual gearbox.
  • Unclip the clutch control pipe from its clip (55) .
  • Drain the oil from the clutch control pipe.

6-SPEED AUTOMATIC GEARBOX

Engine and cylinder block assembly

  • Remove:
    • the earth strap bolt (56) ,
    • the earth strap.
  • Remove the automatic gearbox coolant hose clips (57) using the tool.
  • Disconnect the automatic gearbox coolant hoses from the automatic gearbox coolant pipe (58) .
  • Remove:
    • the automatic gearbox coolant pipe bolts (59) ,
    • the automatic gearbox coolant pipe.

 

  • Remove the particle filter.

4X4 TRANSMISSION

  • Remove the transfer box.

II - OPERATION FOR REMOVAL OF PART CONCERNED

6-SPEED MANUAL GEARBOX

Engine and cylinder block assembly

  • Place the engine and the gearbox on the rubber pads of the tool (Mot. 1390) at points (60) .

6-SPEED AUTOMATIC GEARBOX

Engine and cylinder block assembly

  • Place the engine and the gearbox on the rubber pads of the tool (Mot. 1390) at points (61) .

Engine and cylinder block assembly

  • Remove:
    • the upper engine tie-bar bolt and washer (62) ,
    • the upper engine tie-bar bolt (63) from the body,
    • the upper engine tie-bar,
    • the right-hand suspended engine mounting bolts (64) .

6-SPEED MANUAL GEARBOX

Engine and cylinder block assembly

  • Remove the left-hand suspended engine mounting bolts (65) from the manual gearbox.

6-SPEED AUTOMATIC GEARBOX

Engine and cylinder block assembly

  • Remove the left-hand suspended engine mounting bolts (66) from the automatic gearbox.

 

  • Remove the " engine - gearbox assembly " .
  • Raise the vehicle.
  • Move the " engine - gearbox assembly " aside.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the intercooler air inlet pipe seal,
    • the compressor pipe union seals,
    • the engine tie-bar washer,

Engine and cylinder block assembly

  • Remove the intercooler air inlet pipe seal using a .

Engine and cylinder block assembly

  • Refit the new intercooler air inlet pipe seal (67) .
Note: Check that the seal on the intercooler air inlet pipe is fitted the correct way round.

II - REFITTING OPERATION FOR PART CONCERNED

  • Place the " engine-gearbox " assembly in the vehicle.
  • Lower the vehicle.

6-SPEED MANUAL GEARBOX

Engine and cylinder block assembly

  • Refit the left-hand suspended engine bolts located on the manual gearbox.
  • Torque tighten in order the left-hand suspended engine mounting bolts (110 N.m).

6-SPEED AUTOMATIC GEARBOX

Engine and cylinder block assembly

  • Refit the left-hand suspended engine bolts located on the automatic gearbox.
  • Torque tighten in order the left-hand suspended engine mounting bolts (110 N.m) located on the automatic gearbox.

Engine and cylinder block assembly

  • Refit the right-hand suspended engine mounting bolts located on the engine.
  • Torque tighten in order the right-hand suspended engine mounting bolts (55 N.m) located on the engine.
  • Refit:
    • the upper engine tie-bar,
    • the upper engine tie-bar bolt on the body,
    • the new upper engine tie-bar washer,
    • the upper engine tie-bar bolt on the engine.
  • Tighten to torque and in order:
    • the upper engine tie-bar bolt (120 N.m) on the engine,
    • the upper engine tie-bar bolt (120 N.m) on the body.
  • Remove the tool (Mot. 1390).

III - FINAL OPERATION

4X4 TRANSMISSION

  • Refit the transfer box.

 

  • Refit the particle filter.

6-SPEED MANUAL GEARBOX

  • Clip the clutch control pipe onto its clip (55) .
  • Connect the clutch control pipe onto the manual gearbox.
  • Refit
    • the clutch control pipe clip (53)
    • the earth strap,
    • the earth strap bolt (52) .
  • Torque tighten the earth strap bolt (14 N.m).

6-SPEED AUTOMATIC GEARBOX

  • Refit:
    • the automatic gearbox coolant pipe,
    • the automatic gearbox coolant pipe bolts (59) .
  • Torque tighten the automatic gearbox coolant pipes (25 N.m).
  • Connect the automatic gearbox coolant hoses onto the automatic gearbox coolant pipes (58) .
  • Refit the automatic gearbox coolant hose clips using the (Mot. 1448).
  • Refit:
    • the earth strap,
    • the earth strap bolt (56) .
  • Torque tighten the earth strap bolt (14 N.m).

 

  • Refit:
    • the front axle subframe
    • the electric coolant pump
    • the front right-hand wheel driveshaft
    • the front left-hand wheel driveshaft
    • the front splash guards
    • the front wheels

6-SPEED MANUAL GEARBOX

  • Connect:
    • the coolant hose (50) ,
    • the oil filter unit coolant inlet pipe onto the oil filter unit.
  • Refit:
    • the coolant hose clip (49) using the (Mot. 1448),
    • the clip (48) on the oil filter unit coolant inlet pipe using the (Mot. 1448).

6-SPEED AUTOMATIC GEARBOX

  • Connect the oil filter unit coolant inlet pipe onto the oil filter unit.
  • Refit the clip (51) on the oil filter unit coolant inlet pipe using the (Mot. 1448).

 

  • Refit:
    • the air filter unit support (47) ,
    • the air filter unit mounting bolts (46) .
  • Torque tighten the air filter unit support bolts (10 N.m).

6-SPEED MANUAL GEARBOX

  • Clip on:
    • the selector cable and the gear selector lever cable from the manual gearbox
    • the selector cable and the gear selector lever cable from the manual gearbox
  • Connect the " heater matrix coolant outlet pipe - duct assembly " (37) onto the inlet distributor and the heater matrix coolant outlet pipe.
  • Refit the heater matrix coolant outlet pipe bolt (36) .
  • Torque tighten the heater matrix coolant outlet pipe bolt (25 N.m).
  • Refit the heater matrix coolant outlet pipe clips (35) using the (Mot. 1448).

6-SPEED AUTOMATIC GEARBOX

  • Clip on:
    • the automatic gearbox control cable onto the control cable upper bracket,
    • the automatic gearbox control cable onto the multifunction switch lever.
  • Refit:
    • the automatic gearbox control cable nut,
    • the automatic gearbox control cable stop.
  • Torque tighten the automatic gearbox control cable nut (14 N.m).
  • Refit the heater matrix coolant inlet pipe bolt (41) .
  • Torque tighten the heater matrix inlet pipe bolt (25 N.m).
  • Connect the " heater matrix coolant outlet pipe - duct " (40) assembly onto the inlet distributor and the heater matrix coolant outlet hose.
  • Refit the heater matrix coolant outlet pipe bolt (39) .
  • Torque tighten the heater matrix coolant outlet pipe bolt (25 N.m).
  • Refit the heater matrix water outlet hose clips (38) using the tool (Mot. 1448).

 

  • Connect the heater matrix pipes.
  • Refit the heater matrix pipe clips (34) using the (Mot.1448).
  • Clip the wiring onto the brackets (33) .
  • Connect the wiring connectors (32) to the battery protection fuse.

6-SPEED MANUAL GEARBOX

  • Refit the automatic gearbox computer mounting.

6-SPEED AUTOMATIC GEARBOX

  • Fit:
    • the " automatic gearbox computer - mounting support " assembly,
    • the earth cable.
  • Refit the automatic gearbox computer mounting bolts (31) .
  • Torque tighten the automatic gearbox computer mounting bolts (27 N.m).
  • Connect the automatic gearbox computer connector.

 

  • Clip on:
    • the wiring at (30) ,
    • the wiring at (29) .
  • Refit the wiring bracket bolts (28) .
  • Torque tighten the wiring bracket bolts (10 N.m).
  • Connect:
    • the pre-postheating unit connector (26) ,
    • the wiring connectors (25) in the fuse box.
  • Refit the fuse box cover.

LEFT-HAND DRIVE

  • Connect the brake fluid level sensor connector (21) .

RIGHT-HAND DRIVE

  • Clip on the brake fluid level sensor wiring at (23) .
  • Connect the brake fluid level sensor connector (22) .

 

  • Refit the air filter box.
  • Connect the air filter unit air outlet pipe to the turbocharger and the air filter unit.
  • Torque tighten the air filter unit air outlet pipe clips (5 N.m) using the tool (Mot. 1608).
  • Place the turbocharging pressure regulation actuating solenoid valve support on the air filter unit.
  • Refit the bolt on the turbocharging pressure regulation actuating solenoid valve support.
  • Torque tighten the bolt on the turbocharging pressure regulation actuating solenoid valve support (10 N.m)
  • Connect:
    • the brake servo pipe to the non-return valve,
    • the turbocharging pressure regulation valve actuating hose (16) .
  • Refit:
    • the manual priming pump support,
    • the support bolt of the manual priming pump.
  • Torque tighten the support bolt of the manual priming pump (12 N.m).
  • Clip the wiring on the manual priming pump support (14) .
  • Connect the fuel return quick-release union of the fuel pipe leading to the tank.
  • Refit:
    • the manual priming pump.
    • the fuel filter.
  • Connect the cooling radiator top hose.
  • Refit the cooling radiator top hose clip using the tool (Mot. 1448).
  • Connect the expansion bottle hose.
  • Refit the expansion bottle clip (12) using the (Mot.1448).
  • Connect the intercooler air outlet pipe (11) to the damper valve.
  • Refit the intercooler air outlet pipe bolt (10) .
  • Torque tighten:
    • the intercooler air outlet pipe bolt (8 N.m),
    • the clip of the intercooler air outlet pipe clip (6 N.m) using the tool (Mot. 1608).
  • Refit the fuel pipe support.
  • Refit the fuel pipe support bolt (8) .
  • Torque tighten the fuel pipe support bolt (10 N.m).
  • Clip the fuel pipes onto the fuel pipe support (7) .

AIR CONDITIONING 01 or AIR CONDITIONING 02

  • Remove the blanking plugs from the compressor and the compressor pipe unions.
  • Refit the new compressor pipe union seals.
  • Connect the compressor pipe unions onto the compressor.
  • Refit the compressor pipe union bolts.
  • Torque tighten the compressor pipe union bolts (4 N.m).

 

  • Connect the " intercooler air inlet pipe-duct " assembly (5) .
  • Torque tighten the intercooler air inlet pipe clip (6 N.m) using the tool (Mot. 1608).
  • Refit the protector plate on the injector rail protector.
  • Rotate the intercooler air inlet pipe to refit the clip in its housing.
  • Clip the intercooler air inlet pipe onto the turbocharger.
  • Refit the intercooler air inlet pipe bolt to the fuel supply pipe bracket.
  • Torque tighten the intercooler air inlet pipe bolt (8 N.m).

6-SPEED MANUAL GEARBOX

  • Fill with oil:
    • the manual gearbox .
    • the brake fluid reservoir.
  • Bleed the hydraulic clutch control .

6-SPEED AUTOMATIC GEARBOX

  • Fill the automatic gearbox oil.

 

  • Fill the cooling system.
  • Bleed the cooling system.
  • Refit the engine undertray.

AIR CONDITIONING 01 or AIR CONDITIONING 02

  • Fill the refrigerant circuit using a refrigerant charging station.

 

  • Refit:
    • the battery tray
    • the battery
    • the air inlet sleeve to the air filter unit
    • the air inlet sleeve clips
    • the engine cover.
    Engine - gearbox assembly: Removal - Refitting

    2TR, and FK0 or FK8

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