Renault Koleos Service Repair Manual: 2TR, and FK0 or FK8

Engine and cylinder block assembly

Engine and cylinder block assembly

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair.

 

IMPORTANT Wear protective gloves during the operation.

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
IMPORTANT To prevent the vehicle from falling, lash it to the vehicle lift using a strap.

Engine and cylinder block assembly

  • To release the fuel pressure, remove:
    • the air inlet sleeve clips (1) ,
    • the air inlet sleeve (2) from the air resonator (3) and the air filter unit (4) .

Engine and cylinder block assembly

  • Remove the cover (5) from the Protection and Switching Unit.

Engine and cylinder block assembly

  • Remove the fuse (6) of the fuel pump(F13) (15A).
  • Release the fuel pressure of the fuel supply pipe.
Note: After switching the engine off, start it again two or three times to fully release the fuel pressure.
  • Drain:
    • the cooling system
    • the automatic gearbox oil
    • the refrigerant circuit using a refrigerant charging station
  • Remove:
    • the engine cover
    • the battery

Engine and cylinder block assembly

  • Disconnect the battery positive terminal wiring connectors (7) .
  • Remove the battery tray .

Engine and cylinder block assembly

  • Remove the engine fuse and relay box cover (8) .

Engine and cylinder block assembly

  • Disconnect the engine fuse and relay box wiring connectors (9) .

Engine and cylinder block assembly

  • Remove:
    • the engine wiring support bolts (10) ,
    • the engine wiring support (11) .
Note: Attach the engine wiring temporarily on the engine side.

Engine and cylinder block assembly

  • Remove:
    • the bolts (12) from the bracket,
    • the bracket (13) ,
    • the air filter unit ,
    • the rocker cover air resonator .

Engine and cylinder block assembly

  • Remove:
    • the breather hose clip (14) ,
    • the breather hose (15) ,
    • the air inlet duct.

Engine and cylinder block assembly

  • Remove the plug of the fuel supply union.
IMPORTANT During this operation, be sure to:
  • refrain from smoking or bringing red hot objects close to the working area,
  • be careful of fuel splashes when disconnecting the union.
  • Disconnect the quick-release union (16) using the tool (Mot. 1869) (17) .
Note: Insert the tool (Mot. 1869) on the second retainer (18) .

Engine and cylinder block assembly

  • Disconnect:
    • the fuel vapour rebreathing hose clip (19) ,
    • the fuel vapour rebreathing hose (20) .

Engine and cylinder block assembly

  • Disconnect:
    • the clip (21) from the brake servo vacuum pipe,
    • the vacuum pipe (22) from the brake servo.

Engine and cylinder block assembly

  • Remove the alternator support earth cable bolt (23) .
  • Disconnect the earth cable (24) from the alternator support.

Engine and cylinder block assembly

  • Remove:
    • the air conditioning pipe nut (25) ,
    • the air conditioning pipe bolt (26) .
  • Disconnect the air conditioning pipes (27) from the air conditioning compressor.
  • Fit plugs into the openings.

Engine and cylinder block assembly

  • Remove:
    • the radiator upper hose clips (28) using the tool (Mot. 1448)
    • the radiator upper hose (29) .

Engine and cylinder block assembly

Note: Take care with the remaining coolant.
  • Remove:
    • the radiator lower hose clips (30) using the tool (Mot. 1448),
    • the radiator lower hose (31) .

Engine and cylinder block assembly

  • Remove the clips (32) from the heater hoses.
  • Disconnect:
    • the heater hoses (33) ,
    • the automatic gearbox control cable (34) .
  • Remove the front wheels.

Engine and cylinder block assembly

  • Unclip the left-hand splash guard clips (35) .
  • Remove the left-hand splash guard (36) .

Engine and cylinder block assembly

  • Remove the automatic gearbox earth cable bolt (37) .
  • Disconnect the automatic gearbox earth wire (38) .

Engine and cylinder block assembly

  • Unclip the right-hand splash guard clips (39) .
  • Remove:
    • the right-hand splash guard (40) ,
    • the connector pipe,
    • the front left-hand driveshaft,
    • the front right-hand driveshaft ,
    • the rear suspended engine mounting,
    • the front axle subframe.

FK8

  • Uncouple the longitudinal driveshaft from the transfer box.
  • Secure the longitudinal driveshaft to the control cable bracket using a cord.
  • Remove the transfer box.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Engine and cylinder block assembly

  • Support the " engine-gearbox " assembly on the tool (Mot. 1390) at (41) .

Engine and cylinder block assembly

  • Remove in order the right-hand suspended engine mounting bolts.

Engine and cylinder block assembly

  • Remove in order the left-hand suspended engine mounting bolts.
Note: Check that no part is interfering with the vehicle side.

Before and during lifting, always check that the wiring remains connected.

During removal, always take care to prevent the vehicle from falling off the lift because of changes in its centre of gravity.

  • Raise the lift to remove the " engine-gearbox " assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

  • For standard engine replacements.
  • Always replace the O-rings on the air conditioning pipes.

II - REFITTING OPERATION FOR PART CONCERNED

Note: Never allow engine oil to come into contact with the suspended engine mounting. Do not damage the suspended engine mountings.

Check that every suspended engine mounting is fitted correctly and tighten the nuts and bolts.

  • Fit the " engine - gearbox " assembly into the engine compartment using the tool (Mot. 1390).

Engine and cylinder block assembly

  • Refit in order the left-hand suspended engine mounting bolts.
  • Torque tighten in order the left-hand suspended engine mounting bolts (50 N.m).

Engine and cylinder block assembly

  • Refit in order the right-hand suspended engine mounting bolts.
  • Torque tighten in order the right-hand suspended engine mounting bolts (55 N.m).

III - FINAL OPERATION.

FK8

  • Refit:
    • the transfer box
    • the longitudinal driveshaft on the transfer box

 

  • Refit:
    • the front right-hand driveshaft
    • the front left-hand driveshaft
    • the connector pipe
    • the front axle subframe
    • the rear suspended engine mounting
    • the right-hand splash guard.
  • Clip on the right-hand splash guard clips.
  • Connect the earth cable on the automatic gearbox.
  • Refit the earth cable bolt on the automatic gearbox.
  • Torque tighten the earth cable bolt on the automatic gearbox (21 N.m).
  • Refit the left-hand splash guard.
  • Clip on the left-hand splash guard clips.
  • Refit the front wheels.
  • Connect:
    • the automatic gearbox control cable
    • the heater hoses.
  • Refit:
    • the heater hose clips,
    • the radiator lower hose,
    • the radiator lower hose clips,
    • the radiator upper hose,
    • the radiator upper hose clips.
  • Remove the caps from the apertures.
  • Connect the air conditioning pipes on the air conditioning compressor.
  • Refit:
    • the bolt from the air conditioning pipe,
    • the air conditioning pipe nut.
  • Torque tighten:
    • the air conditioning pipe bolt (4 N.m).
    • the air conditioning pipe nut (4 N.m).
  • Connect the earth cable on the alternator support.
  • Refit the earth cable bolt on the alternator support.
  • Torque tighten the earth cable bolt on the alternator support (7 N.m).
  • Refit:
    • brake servo vacuum pipe ,
    • the clip on the brake servo vacuum pipe,
    • the fuel vapour rebreathing pipe,
    • the fuel vapour rebreathing hose clip.
  • Connect the quick-release union on the fuel supply pipe.
Note: Check the connection of the quick-release union by pulling on the part.
  • Refit:
    • the plug of the fuel supply union,
    • the air inlet duct,
    • the breather hose,
    • the breather hose clip,
    • The air resonator on the rocker cover .
    • the air filter unit,
    • the bracket (13) ,
    • the bracket bolts.
  • Torque tighten the bracket bolts (21 N.m).
  • Refit:
    • the engine wiring support,
    • the engine wiring support bolts.
  • Torque tighten the engine wiring support bolts (21 N.m).
  • Connect the engine fuse and relay box wiring connectors.
  • Refit:
    • the fuse and relay box cover,
    • the battery tray.
  • Connect the battery positive terminal wiring connectors.
  • Refit:
    • the battery
    • the engine cover,
    • the fuel pump fuse,
    • the Protection and Switching Unit cover,
    • the air inlet sleeve on the air filter unit and on the air resonator,
    • the air inlet sleeve clips.
  • Refill:
    • the refrigerant circuit using a refrigerant charging station.
    • the automatic gearbox oil.
    • the cooling system.
  • Bleed the cooling system.
Note: When replacing the engine, carry out the programming using the Diagnostic tool.
    M9R

    2TR, and ND5 or ND8

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