Renault Koleos Service Repair Manual: Rocker cover: Removal - Refitting

2TR

Top and front of engine

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.
  • Remove:
    • the air intake sleeve
    • the battery
    • the battery tray
    • the air filter unit
    • the air resonator located on the rocker cover
    • the air inlet duct
    • the windscreen wiper arms
    • the scuttle half-grille
    • the windscreen wiper mechanism
    • the scoop under the scuttle panel grille
    • the motorised throttle valve without disconnecting the cooling hoses
    • the intake distributor

Top and front of engine

  • Remove:
    • the earth cable bolts (1) ,
    • the wiring clip (2) .
  • Disconnect the ignition coil connectors.
  • Move aside the wiring (3) .

Top and front of engine

  • Remove:
    • the front resonator support bolts (4) ,
    • the front resonator support (5) ,
    • the pipes on the rocker cover,
    • the engine undertray.

Top and front of engine

Note: To ensure stability, place a wooden block or equivalent on the support surface.

 

Note: To ensure stability, place an object behind the trolley jack or equivalent to provide support.
  • Fit the trolley jack or an equivalent engine support tool under the cylinder block.
  • Remove the right-hand suspended engine mounting.

Top and front of engine

  • Remove:
    • the engine mounting bolts (6) on the right-hand side,
    • the engine mounting on the right-hand side (7) ,
    • the ignition coils.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Top and front of engine

  • Remove:
    • the rocker cover bolts in order,
    • the rocker cover,
    • the rocker cover gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace the rocker cover seal.
WARNING The joint faces must be clean, dry and free from grease (avoid finger marks).
  • Use SUPER CLEANER FOR JOINT FACES.

Top and front of engine

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).
  • Apply a beading (A) of SILICONE ADHESIVE SEALANT.

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the new seal on the rocker cover,
    • the rocker cover.

Top and front of engine

  • Torque tighten in order:
    • rocker cover bolts (initial torque) (2 N.m),
    • rocker cover bolts (8 N.m).

III - FINAL OPERATION

  • Refit:
    • the ignition coils
    • the engine mounting on the right-hand side
    • the engine mounting bolts on the right-hand side.
  • Torque tighten the engine mounting bolts on the right-hand side (48 N.m).
  • Refit the right-hand suspended engine mounting.
  • Remove the trolley jack or equivalent engine supporting tool from the cylinder block.
  • Refit:
    • the engine undertray,
    • the pipes on the rocker cover,
    • the front resonator support,
    • the front resonator support bolts.
  • Torque tighten the front resonator support bolts (10 N.m).
  • Connect the ignition coil connectors.
  • Refit:
    • the wiring clip,
    • the earth cable bolts.
  • Torque tighten the earth cable bolts (7 N.m).
  • Refit:
    • the inlet manifold
    • the motorised throttle valve
    • the scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle half-grille
    • the windscreen wiper arms
    • the air inlet duct
    • the air resonator located on the rocker cover
    • the engine cover
    • the air filter unit
    • the battery tray
    • the battery
    • the air intake sleeve.

M9R

Top and front of engine

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Remove the timing chain.
  • Remove the exhaust gas pressure sensor.
  • Remove:
    • the vacuum pump
    • the high pressure pipe between the pump and the rail
    • the oil decanter
    • the diesel return rail
    • the high pressure pipes between the rail and the injectors
    • the diesel injectors .

Top and front of engine

  • Remove the bolts (1) and (2) of the fuel collector outlet pipe of the cylinder head.
  • Disconnect the fuel collector outlet pipe from the cylinder head at (3) .
  • Move aside the fuel collector outlet pipe from the cylinder head.

II - REMOVAL OF THE ROCKER COVER

Top and front of engine

  • Remove the rocker cover bolts.

Top and front of engine

  • Position a protective shim on the cylinder head.
  • Detach the rocker cover using a flat-blade screwdriver, using the shim for leverage.
  • Remove the rocker cover - camshafts assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Use SUPER CLEANING AGENT FOR JOINT FACES:
    • the joint face on the rocker cover,
    • the joint face on the cylinder head.
WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.

 

WARNING Clean the cylinder head carefully to avoid any foreign bodies entering the oil return and supply pipes.

Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage.

  • Remove the residue using a plastic spatula.
  • Finish cleaning the joint faces using a GREY ABRASIVE PAD.
  • Use SURFACE CLEANER:
    • the joint face on the rocker cover,
    • the joint face on the cylinder head.
WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).

 

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).

II - REFITTING THE ROCKER COVER

Top and front of engine

  • Apply a bead of SILICONE ADHESIVE SEALANT with a diameter of 1.5 +- 1 mm to the cylinder head at (4) , (5) , (6).
  • Fit two studs (M6 - length 60 mm) into the holes (7) and (8) on the cylinder head to guide the rocker cover.

Top and front of engine

  • Position:
    • the groove on the exhaust side of the camshaft (9) horizontally (large clearance (10) facing upwards),
    • the groove on the inlet side of the camshaft (11) facing towards the rocker cover boss (12) .
  • Check that cylinders 1 and 4 are at Top Dead Centre using the (Mot. 1766).
  • Refit the rocker cover - camshafts assembly.

Top and front of engine

  • Tighten in order and successively, the rocker cover bolts (12), (15),(18) and (21) to gradually fit the rocker cover on the cylinder head.
  • Remove the two rocker cover guide studs.
  • Fit without tightening the remaining rocker cover bolts.
  • Loosen bolts (12), (15), (18) and (21).
  • Fit without tightening bolts (12), (15), (18) and (21).
  • Tighten the rocker cover bolts in order.
  • Clean the excess silicone adhesive sealant on the timing and coupling faces using a plastic spatula.

III - FINAL OPERATION

  • Connect the fuel collector outlet pipe of the cylinder head.
  • Tighten the bolts of the fuel collector outlet pipe of the cylinder head.
  • Refit:
    • the diesel injectors
    • the high pressure pipes between the rail and the injectors
    • the diesel return rail
    • the oil decanter
    • the high pressure pipe between the pump and the rail
    • the vacuum pump
  • Refit the exhaust gas pressure sensor.
  • Refit the timing chain.

Camshaft dephaser: Removal - Refitting

2TR

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Remove the engine and gearbox assembly.

II - OPERATION FOR REMOVAL OF PART CONCERNED

  • Remove the camshaft dephaser.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED NL

  • Refit the camshaft dephaser.

II - FINAL OPERATION.

  • Refit the engine and gearbox assembly.
    Crankshaft accessories pulley: Removal - Refitting

    Camshaft dephaser solenoid valve: Removal - Refitting

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