Renault Koleos Service Repair Manual: Exhaust manifold: Removal - Refitting

Renault Koleos Service Repair Manual / Engine and peripherals / Fuel mixture / Exhaust manifold: 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,
    • the clips from the air inlet sleeve,
    • the air intake sleeve on the air filter unit,
    • the battery,
    • the battery tray,
    • 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.
  • Drain the engine cooling circuit .

Fuel mixture

  • Disconnect:
    • the connector (1) from the EGR bypass solenoid valve,
    • the vacuum hoses (2) from the EGR bypass solenoid valve.
  • Remove:
    •  the EGR bypass solenoid valve bolts (3) ,
    •  the EGR bypass solenoid valve,
    •  the coolant outlet unit.

Fuel mixture

  • Remove:
    • the bolts (4) from the exhaust gas recirculation rigid pipe heat shield on the exhaust manifold and on the cylinder head,
    • the heat shield from the exhaust gas recirculation solenoid valve.

Fuel mixture

  • Unclip:
    • the fuel pipes (5) ,
    • the electrical wiring (6) .
  • Remove the bolts (7) from the intercooler water inlet pipe.
  • Move the intercooler water inlet pipe to one side.

Fuel mixture

  • Remove:
    • the bolts (8) of the exhaust gas cooler coolant inlet pipe support from the intake distributor,
    • the exhaust gas cooler coolant inlet pipe support.

Fuel mixture

  • Unclip the cooling hose (9) from the turbocharger.
  • Remove:
    • the exhaust gas recirculation rigid pipe between
      the exhaust manifold and the exhaust gas cooler
    • the catalytic converter
    • the turbocharger

II - OPERATION FOR REMOVAL OF PART CONCERNED

Fuel mixture

  • Remove:
    • the nuts and spacers from the exhaust manifold,
    • the exhaust manifold,
    • the exhaust manifold gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING The joint faces must be clean, dry and free from grease (avoid finger marks).
  • Always replace:
    • the exhaust manifold studs, if they have been loosened during the removal operation,
    • the exhaust manifold nuts,
    • the exhaust manifold gasket.
  • Clean and degrease the bearing faces:
    • of the exhaust manifold, if it is to be reused,
    • of the cylinder head,
    • of the exhaust gas recirculation rigid pipe heat shield.
  • Check if the exhaust manifold studs are torque tightened to 9 N.m. Otherwise replace the exhaust manifold studs which are loosened.
  • Torque tighten the exhaust manifold studs (9 N.m) using a roller-type stud removal tool.

II - REFITTING OPERATION FOR PART CONCERNED

Fuel mixture

Fuel mixture

Note: Check if the manifold seal is correctly positioned.

The tab must be positioned at (10) .

  • Refit:
    • the new exhaust manifold gasket,
    • the exhaust manifold,
    • the spacers.
  • Finger tighten the new exhaust manifold nuts until they are in contact.

Fuel mixture

  • Pretighten to torque and in order the exhaust manifold nuts (18 N.m).
  • Torque tighten in order the exhaust manifold nuts (30 N.m).

III - FINAL OPERATION

  • Refit:
    • the turbocharger
    • the catalytic converter
    • the exhaust gas recirculation rigid pipe between
      the exhaust manifold and the exhaust gas cooler
  • Clip the cooling hose (9) onto the turbocharger.
  • Fit the exhaust gas cooler coolant inlet pipe support onto the intake distributor.
  • Refit the exhaust gas cooler coolant inlet pipe support bolts.
  • Torque tighten the exhaust gas cooler coolant inlet pipe support bolts (10 N.m).
  • Position the intercooler water inlet pipe.
  • Refit the intercooler water inlet pipe bolts.
  • Torque tighten the intercooler water inlet pipe bolts (10 N.m).
  • Clip:
    • the electrical wiring (6) ,
    • the fuel pipes (5) .
  • Position the heat shield for the exhaust gas recirculation rigid pipe.
  • Refit the EGR rigid pipe heat shield bolts
  • Torque tighten the exhaust gas recirculation rigid pipe heat shield bolts (10 N.m).
  • Refit:
    • the coolant outlet unit
    • 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.
  • Remove:
    • the scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle half-grille
    • the windscreen wiper arms
    • 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 pipe 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 pipe to the oil decanter.
  • Refit:
    • the battery tray
    • the battery
    • 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

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
  • Disconnect the battery.
  • Remove the engine undertray.

Fuel mixture

  • Remove:
    • the exhaust connecting pipe rubber mounting bush support nuts (1) ,
    • the exhaust connecting pipe nuts (2) ,
    • the connector pipe (3) ,
    • the seal,
    • the front right-hand wheel,
    • the front wheel arch liner.

Fuel mixture

  • Disconnect the oxygen sensor connectors .
Note: Do not damage the oxygen sensor.

If the oxygen sensor falls on hard ground, for example concrete, replace the sensor.

  • Remove:
    • the oxygen sensors (4)
    • the accessories belt (5)
    • the windscreen washer bottle neck
    • the alternator (6)
    • the dipstick (7)
    • the dipstick guide tube bolt (8)
    • the dipstick guide tube (9)
    • the O-ring.

Fuel mixture

Note: The engine must remain covered to prevent impurities from entering inside.
  • Remove:
    • the bolts (10) from the exhaust manifold upper heat shield,
    • the upper heat shield (11) from the exhaust manifold.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Fuel mixture

Note: The engine must remain covered to prevent impurities from entering inside.
  • Remove:
    • the exhaust manifold nuts in order,
    • the exhaust manifold (12) .

Fuel mixture

  • Remove:
    • the bolts (13) from the exhaust manifold lower heat shield,
    • the lower heat shield (14) from the exhaust manifold.

Fuel mixture

  • Remove:
    • the bolts (15) from the catalytic pre-converter heat shield,
    • the catalytic pre-converter heat shield (16) .

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the seals,
    • the O-ring.

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the catalytic pre-converter heat shield,
    • the catalytic pre-converter heat shield bolts.
  • Torque tighten the catalytic pre-converter heat shield bolts (6 N.m).
  • Refit:
    • the exhaust manifold lower heat shield,
    • the exhaust manifold lower heat shield bolts.
  • Torque tighten the exhaust manifold lower heat shield bolts (6 N.m).
  • Refit:
    • the new exhaust manifold gasket,
    • the exhaust manifold,
    • the exhaust manifold nuts.

Fuel mixture

  • Torque tighten in order:
    • the exhaust manifold nuts (initial torque) (15 N.m),
    • the exhaust manifold nuts (42 N.m).

III - FINAL OPERATION

  • Refit:
    • the exhaust manifold upper heat shield,
    • the exhaust manifold upper heat shield bolts.
  • Torque tighten the exhaust manifold upper heat shield bolts (6 N.m).
  • Refit:
    • the new O-ring,
    • the dipstick guide tube,
    • the dipstick guide tube bolt,
    • the dipstick.
  • Torque tighten the dipstick guide tube bolt (22 N.m).
  • Refit:
    • the alternator
    • the windscreen washer bottle neck
    • the accessories belt
    • the oxygen sensors
  • Connect the oxygen sensor connectors.
  • Refit:
    • the front wheel arch liner
    • the front right-hand wheel
    • the new seal
    • the connector pipe
    • the exhaust connecting pipe nuts
    • the exhaust connecting pipe rubber mounting bush support nuts.
  • Torque tighten:
    • the exhaust connecting pipe nuts (65 N.m),
    • the exhaust connecting pipe rubber mounting bush support nuts (14 N.m).
  • Refit the engine undertray.
  • Connect the battery.
    Inlet distributor: Removal - Refitting

    Turbocharging

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