Renault Koleos Service Repair Manual: Inlet distributor: Removal - Refitting

Renault Koleos Service Repair Manual / Engine and peripherals / Fuel mixture / Inlet distributor: Removal - Refitting

M9R

Fuel mixture

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
  • Remove:
    • the engine cover,
    • the engine undertray.
  • Drain the engine cooling circuit.
  • Remove:
    • the clips from the air inlet sleeve,
    • the air intake sleeve on the air filter unit,
    • the battery,
    • the battery tray.

Fuel mixture

  • Turn the clip (1) on the intercooler air inlet duct.

Fuel mixture

  • Remove the intercooler air inlet duct bolt (2) from the fuel pipe support.

Fuel mixture

  • Loosen the clip (3) on the intercooler air inlet duct.
  • Remove:
    • the air inlet duct assembly (4) from the intercooler,
    • the air filter unit.
  • Loosen the air filter unit air outlet duct clip on the turbocharger.
  • Disconnect:
    • the oil vapour rebreathing pipe from the oil separator,
    • the air filter unit air outlet duct from the turbocharger.
  • Fit a blanking plug in the opening of the oil separator.
  • Remove:
    • the windscreen wiper arms
    • the scuttle half-grille
    • the windscreen wiper mechanism
    • the scoop under the scuttle panel grille
    • the water chamber
    • the exhaust gas recirculation rigid pipe between
      the exhaust manifold and the exhaust gas cooler.

Fuel mixture

  • Disconnect the connector from the damper valve wiring (5) .
  • Loosen the clip (6) on the intercooler air inlet duct.
  • Remove the bolt (7) from the intercooler air outlet duct.
  • Disconnect the intercooler air outlet duct (8) from the damper valve.
  • Move the intercooler air outlet duct to one side.

Fuel mixture

  • Remove:
    • the dipstick guide tube bolts (9) ,
    • the dipstick guide tube.
  • Plug the opening of the dipstick guide tube on the cylinder block.
  • Remove the damper valve.

Fuel mixture

  • Disconnect the connector (10) from the turbocharger pressure sensor.
  • Remove:
    • the turbocharger pressure sensor housing (11) ,
    • the exhaust gas recirculation rigid pipe between
      the exhaust gas recirculation solenoid valve and the exhaust gas cooler,
    • the EGR solenoid valve,
    • the starter ,
    • the intercooler,
    • the front right-hand wheel,
    • the front right-hand wheel arch liner,
    • the accessories belt,
    • the alternator,
    • the multifunction support.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Fuel mixture

  • Remove:
    • the intake distributor bolts (12) ,
    • the intake distributor nuts (13) ,
    • the inlet manifold,
    • the inlet manifold gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING The joint faces must be clean, dry and free from grease (avoid finger marks).
  • Clean:
    • the cylinder head joint face,
    • the intake distributor joint face,
    • the exhaust gas recirculation rigid pipe joint faces,
    • the turbocharger pressure sensor housing joint faces,
    • the damper valve seal face.
  • Always replace:
    • the inlet manifold gasket,
    • the exhaust gas recirculation rigid pipe between
      the exhaust manifold and the exhaust gas cooler,
    • the exhaust gas recirculation rigid pipe seal on the exhaust manifold,
    • the exhaust gas recirculation rigid pipe seals,
    • the exhaust gas recirculation rigid pipe clip,
    • the rigid exhaust gas recirculation pipe bolts,
    • the coolant outlet unit seal,
    • the gasket between the intake distributor and the EGR solenoid valve.
    • the seal between the turbocharger pressure sensor housing and the EGR solenoid valve,
    • the seal between the damper valve and the turbocharger pressure sensor housing,
    • the intercooler air inlet duct seal.

II - REFITTING OPERATION FOR PART CONCERNED

Fuel mixture

  • Refit:
    • the new intake distributor seal,
    • the inlet manifold,
    • the inlet manifold nuts and bolts.
  • Pretighten to torque and in order the inlet manifold nuts and bolts (15 N.m).
  • Torque tighten in order the inlet manifold nuts and bolts (25 N.m).

III - FINAL OPERATION.

  • Refit:
    • the multifunction support
    • the alternator
    • the accessories belt
    • the front right-hand wheel arch liner
    • the front right-hand wheel
    • the intercooler
    • the starter
    • the new seal between the EGR solenoid valve and the intake distributor
    • the EGR solenoid valve
    • the new exhaust gas recirculation rigid pipe seals
    • the exhaust gas recirculation rigid pipe between
      the exhaust gas recirculation solenoid valve and the exhaust gas cooler
    • the new seal between the turbocharger pressure sensor housing and the EGR solenoid valve
    • the turbocharger pressure sensor housing.
  • Connect the turbocharger pressure sensor connector.
  • Refit:
    • the seal between the damper valve and the turbocharger pressure sensor housing,
    • the damper valve.
  • Remove the plug from the opening of the dipstick guide tube on the cylinder block.
  • Torque tighten the dipstick guide tube bolts (10 N.m).
  • Connect the intercooler air outlet duct to the damper valve.
  • Refit the intercooler air outlet duct bolt.
  • Torque tighten:
    • the intercooler air outlet duct bolt (8 N.m),
    • the intercooler air outlet duct clip (6 N.m) using the tool (Mot. 1608).
  • Connect the damper valve wiring connector.
  • Refit:
    • the exhaust gas recirculation rigid pipe seal on the exhaust manifold
    • the exhaust gas recirculation rigid pipe between the exhaust manifold and the exhaust gas cooler
    • the coolant outlet unit seal
    • the water chamber
    • the water chamber hoses and pipes
  • Fit the EGR bypass solenoid valve.
  • Refit the EGR bypass solenoid valve bolts.
  • Torque tighten the EGR bypass solenoid valve bolts (10 N.m).
  • Connect:
    • the vacuum hoses on the EGR bypass solenoid valve and on the exhaust gas cooler,
    • the EGR bypass solenoid valve connector.
  • Refit the air filter unit.
  • Connect the air filter unit air outlet duct to the turbocharger and to the air filter unit.
  • Torque tighten the air filter unit air outlet duct clips (5 N.m) using the tool (Mot. 1608).
  • Remove the blanking plug from the opening of the oil separator.
  • Connect the oil vapour rebreathing hose to the oil separator.
  • Fit the intercooler air inlet duct assembly onto the intercooler air inlet pipe.
  • Torque tighten the intercooler air inlet hose clip (6 N.m) using the tool (Mot. 1608).

Fuel mixture

  • Remove the intercooler air inlet duct seal using a tweezers.

Fuel mixture

Note: Check whether the intercooler air inlet duct seal (14) is correctly positioned.
  • Refit the new intercooler air inlet duct seal.
  • Turn the intercooler air inlet duct to fit the clip in its housing.
  • Clip the intercooler air inlet duct onto the turbocharger.
  • Refit the intercooler air inlet duct bolt to the fuel pipe support.
  • Torque tighten the intercooler air inlet duct bolt (8 N.m).
  • Refit:
    • the battery tray
    • the battery
    • the scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle half-grille
    • the windscreen wiper arms
    • the air intake sleeve on the air filter unit
    • the clips of the air inlet sleeve.
  • Fill the engine cooling system .
  • Bleed the engine cooling system .
  • Refit:
    • the engine undertray,
    • the engine cover.

2TR

Fuel mixture

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 engine cover.
  • Remove the air inlet sleeve.

Fuel mixture

  • Disconnect the cover (1) from the Protection and Switching Unit.

Fuel mixture

  • Remove the fuse (2) of the fuel pump(F13) (15A).
  • Release the fuel pressure in the fuel pipe after starting the engine.
Note: After switching the engine off, start it again two or three times to fully relieve the fuel pressure.
  • Remove:
    • the battery
    • the battery tray
    • the air filter unit
    • the engine cover
    • the air resonator located on the rocker cover
    • the air inlet duct.

Fuel mixture

  • 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 (3) using the tool (Mot. 1869) (4) as illustrated.
Note: Insert the tool (Mot. 1869) (4) into the second retaining part (5) .

Fuel mixture

  • Remove the petrol vapour rebreathing pipe clip (6) .
  • Disconnect the petrol vapour rebreathing pipe (7) .

Fuel mixture

  • Remove the clips (8) of the oil vapour rebreathing hose.
  • Disconnect the oil vapour rebreathing hose (9) .

Fuel mixture

  • Remove the clip (10) from the vacuum pipe of the brake servo.
  • Disconnect the vacuum pipe (11) from the brake servo.
  • Remove:
    • the windscreen wiper arms
    • the scuttle panel half-grille
    • the windscreen wiper mechanism
    • the scoop under the scuttle panel grille.
  • Disconnect the motorised throttle valve connector.

Fuel mixture

  • Remove:
    • in order the motorised throttle valve bolts,
    • the motorised throttle valve without disconnecting the coolant pipes.

Fuel mixture

  • Move aside the throttle valve (12) .

Fuel mixture

  • Remove:
    • the intake distributor support bolts (13) and (14) ,
    • the intake distributor support (15) ,
    • the seal.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Fuel mixture

  • Remove:
    • in order, the intake distributor bolts and nuts,
    • the inlet manifold (16) ,
    • the intake distributor seal,
    • the intake distributor adapter (17) ,
    • the intake distributor adapter seal.
Note: The engine must remain covered to prevent impurities from entering inside.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the intake distributor seal,
    • the intake distributor adapter seal,
    • the motorised throttle valve seal.

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the new intake distributor adapter seal,
    • the intake distributor adapter,
    • the new intake distributor seal,
    • the inlet manifold,
    • the intake distributor nuts and bolts.

Fuel mixture

  • Torque tighten in order the intake distributor nuts and bolts (20 N.m).
Note: Mark (6) indicates retightening of the bolt to a torque of 20 N.m.

III - FINAL OPERATION

  • Refit:
    • the new intake distributor support seal,
    • the intake distributor support,
    • the intake distributor support bolts.
  • Torque tighten the intake distributor support bolts (20 N.m).
  • Refit:
    • the new motorised throttle valve seal,
    • the motorised throttle valve bolts.

Fuel mixture

  • Torque tighten in order the motorised throttle valve bolts (8 N.m).
  • Connect the motorised throttle valve connector.
  • Refit:
    • the scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle panel half-grille
    • the windscreen wiper arms.
  • Connect the brake servo vacuum pipe.
  • Refit the clip of the vacuum pipe of the brake servo.
  • Connect the oil vapour rebreathing hoses.
  • Refit the clips of the oil vapour rebreathing hose.
  • Disconnect the petrol vapour rebreathing pipe.
  • Refit the petrol vapour rebreathing pipe clip.
  • Connect the quick-release union of the fuel supply.
Note: Check the condition of the quick-release union connection again.
  • Remove the fuel supply union plug.
  • Refit:
    • 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 fuel pump fuse
    • the Protection and Switching Unit cover.
  • Refit the air intake sleeve.
    Inlet duct: Removal - Refitting

    Exhaust manifold: Removal - Refitting

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