Renault Koleos Service Repair Manual: Turbocharger: Removal - Refitting

M9R

Turbocharging

Turbocharging

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 engine undertray.
  • Drain the engine cooling circuit.
  • Remove:
    • the clips from the air inlet sleeve
    • the air intake sleeve from the air filter unit
    • the battery
    • the battery tray
    • the air filter unit
  • Undo the air filter unit air outlet duct clip on the turbocharger.
  • Disconnect:
    • the oil vapour rebreathing hose on 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 panel half-grille
    • the windscreen wiper mechanism
    • the scoop under the scuttle panel grille.

Turbocharging

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

Turbocharging

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

Turbocharging

  • Remove the turbocharger cooling pipe clips (3) using the tool (Mot. 1448).
  • Disconnect:
    • the turbocharger cooling pipes,
    • the connector (4) from the exhaust gas temperature sensor.

Turbocharging

  • Unclip the exhaust gas temperature sensor wiring (5) from the heat shield.

Turbocharging

  • Remove:
    • the bolts (6) from the turbocharger heat shield,
    • the turbocharger heat shield,
    • the oxygen sensors,
    • the catalytic converter,
    • the turbocharger oil pipe.

Turbocharging

  • Disconnect:
    • the turbocharging pressure regulator hose (7) from the turbocharger,
    • the connector (8) from the exhaust gas pressure sensor.
  • Remove:
    • the exhaust gas temperature sensor (9) from the turbocharger,
    • the exhaust gas pressure sensor bolt (10) .
    • the bolt (11) from the exhaust gas pressure sensor pipe assembly,
    • the exhaust gas pressure sensor pipe assembly from the lifting eye.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Turbocharging

  • Remove:
    • the turbocharger bolt (12) ,
    • the upper turbocharger nut (13) from the exhaust manifold.

Turbocharging

  • Remove:
    • the lower turbocharger nuts (14) from the exhaust manifold,
    • the turbocharger upwards,
    • the gasket between the turbocharger and the exhaust manifold.

Turbocharging

  • Remove:
    • the bolts (15) from the turbocharger strut,
    • the turbocharger strut.

Turbocharging

  • Remove:
    • the turbocharger cooling pipe bolts (16) from the turbocharger,
    • the turbocharger cooling pipe retaining bracket bolt from the turbocharger,
    • the turbocharger cooling pipe,
    • the seal between the turbocharger and the turbocharger cooling pipe,
    • the turbocharger studs from the turbocharger using a roller-type stud removal tool.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Clean and degrease the bearing faces:
    • the exhaust manifold,
    • of the turbocharger (if being reused),
    • of the cooling pipe (if being reused).
  • Always replace:
    • the intercooler air inlet duct seal,
    • the seal between the turbocharger and the exhaust manifold,
    • the seal between the turbocharger and the catalytic converter,
    • the seal between the turbocharger and the turbocharger cooling pipe,
    • the seal between the catalytic converter and the particle filter,
    • the nuts between the turbocharger and the catalytic converter,
    • the upper turbocharger nut,
    • the lower turbocharger nuts,
    • the turbocharger studs,
    • the exhaust gas temperature sensor.

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the new turbocharger cooling pipe seal,
    • the turbocharger cooling pipe,
    • the turbocharger cooling pipe bolts,
    • the turbocharger cooling pipe retaining bracket bolt on the turbocharger.
  • Torque tighten:
    • the turbocharger cooling pipe bolts (10 N.m),
    • the turbocharger cooling pipe retaining bracket bolt (10 N.m).
  • Refit the new turbocharger studs.
  • Torque tighten the turbocharger studs (15 N.m) using the flat surfaces of the studs or a roller-type stud removal tool.

Turbocharging

Note: The turbocharger strut must move freely.
  • Fit the turbocharger strut.
  • Finger-tighten the bolts (18) and (19) of the turbocharger strut.
  • Fit the turbocharger without its seal and hold the turbocharger flat against the exhaust manifold.
  • Push the turbocharger strut according to the arrow (20) so that it is resting against the turbocharger on the flywheel end.
Note: Do not tighten the bolt too quickly to prevent the turbocharger strut from rotating.
  • Tighten the turbocharger strut bolt (19) on the timing end slightly.
  • Remove the turbocharger.
  • Tighten to torque the turbocharger strut bolt on the flywheel end (25 N.m) (18) .
  • Position the seal between the turbocharger and the exhaust manifold.
  • Refit the turbocharger.
  • Tighten the turbocharger bolt (12) by a few turns.
  • Refit without tightening:
    • the upper turbocharger nut,
    • the lower turbocharger nuts.
  • Pretighten to torque:
    • the turbocharger lower nuts (15 N.m),
    • the turbocharger upper nut (15 N.m).
    • Torque tighten:
    • the turbocharger lower nuts (28 N.m),
    • the turbocharger upper nut (28 N.m).
  • Tighten the turbocharger strut bolt (19) on the timing end slightly.
  • Torque tighten:
    • the turbocharger bolt (25 N.m) (12) ,
    • the turbocharger strut bolt on the timing end (25 N.m).

III - FINAL OPERATION.

  • Fit the exhaust gas pressure sensor pipe assembly.
  • Refit:
    • the exhaust gas pressure sensor pipe assembly bolt,
    • the exhaust gas pressure sensor bolt.
  • Torque tighten:
    • the exhaust gas pressure sensor pipe assembly bolt (10 N.m),
    • the exhaust gas pressure sensor hollow bolt (16 N.m).
  • Refit the exhaust gas temperature sensor on the turbocharger.
  • Torque tighten the exhaust gas temperature sensor (44 N.m).
  • Clip the exhaust gas temperature sensor wiring onto the heat shield.
  • Connect:
    • the exhaust gas pressure sensor connector,
    • the turbocharging pressure regulator hose on the turbocharger,
    • the exhaust gas temperature sensor connector,
    • the turbocharger cooling pipes.
  • Refit the turbocharger cooling pipe clips using the tool (Mot. 1448).
  • Refit:
    • the turbocharger oil pipe
    • the catalytic converter
    • the oxygen sensors
    • the turbocharger heat shield
    • the turbocharger heat shield bolts.
  • Torque tighten the turbocharger heat shield bolts (7 N.m).

Turbocharging

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

Turbocharging

Note: Check whether the intercooler air inlet duct seal (21) 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 scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle panel 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 duct clips (5 N.m) using the tool (Mot. 1608).
  • Remove the blanking plug from the oil separator opening.
  • Connect the oil vapour rebreathing hose to the oil separator.
  • Refit:
    • the battery tray
    • the battery
    • the air intake sleeve of 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.
    Turbocharging: Precautions for the repair

    Turbocharger oil pipe: Removal - Refitting

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