Renault Koleos Service Repair Manual: Exhaust gas cooler: Removal - Refitting

Renault Koleos Service Repair Manual / Engine and peripherals / Antipollution / Exhaust gas cooler: Removal - Refitting

M9R

Antipollution

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
  • Remove:
    • the engine cover
    • the windscreen wiper arms
    • the scuttle panel half grille
    • the windscreen wiper mechanism
    • the scoop under the scuttle panel grille

Antipollution

  • Rotate the intercooler air inlet pipe clip (1) on the turbocharger.

Antipollution

  • Remove the intercooler air inlet pipe bolt (2) from the fuel supply pipe bracket.
  • Move the intercooler air inlet pipe to one side.
  • Remove the engine undertray.
  • Drain the cooling system.
  • Remove:
    • the air inlet sleeve clips,
    • the air inlet sleeve from the air filter unit,
    • the battery,
    • the battery tray,
    • the air filter box.
  • Loosen the air filter unit air outlet pipe clip on the turbocharger.
  • Disconnect:
    • the oil vapour rebreathing pipe from the oil separator,
    • the air filter unit air outlet pipe from the turbocharger.
  • Fit a blanking plug into the oil separator opening.
  • Remove:
    • the intake distributor,
    • the exhaust gas recirculation rigid pipe between the exhaust manifold and the exhaust gas cooler.

Antipollution

  • Disconnect the connector (3) from the damper valve wiring.
  • Loosen the clip (4) on the intercooler air outlet pipe.
  • Remove the intercooler air outlet pipe bolt (5) .
  • Disconnect the intercooler air outlet pipe (6) from the damper valve.
  • Move the intercooler air outlet pipe to one side.

Antipollution

  • Remove:
    • the bolts (7) from the dipstick tube,
    • the dipstick tube.
  • Fit a blanking plug on the opening of the dipstick guide tube on the cylinder block.
  • Remove the damper valve.

Antipollution

  • Disconnect the turbocharger pressure sensor connector (8) .
  • Remove:
    • the turbocharger pressure sensor housing (9) ,
    • the exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation cooler,
    • the starter motor.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Antipollution

  • Remove:
    • the vacuum hose (10) from the exhaust gas cooler,
    • the clip (11) from the exhaust gas cooler water outlet pipe using the tool (Mot. 1448),
    • the clip (12) from the exhaust gas cooler water inlet hose using the tool (Mot. 1448).
  • Disconnect:
    • the exhaust gas cooler water outlet pipe from the exhaust gas cooler,
    • the exhaust gas cooler water inlet hose from the exhaust gas cooler.
  • Remove:
    • the bolts (13) from the exhaust gas cooler,
    • the exhaust gas intercooler.

REFITTING

I - REFITTING PREPARATION OPERATION

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

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the exhaust gas cooler,
    • the exhaust gas cooler bolts.
  • Torque tighten the exhaust gas cooler bolts (25 N.m).
  • Connect:
    • the exhaust gas cooler water inlet pipe to the exhaust gas cooler,
    • the exhaust gas cooler water outlet pipe to the exhaust gas cooler.
  • Refit:
    • the clip on the exhaust gas cooler water inlet pipe using the tool (Mot. 1448),
    • the clip on the exhaust gas cooler water outlet pipe using the tool (Mot. 1448),
    • the vacuum hose on the exhaust gas cooler.

III - FINAL OPERATION.

  • Refit:
    • the starter,
    • the new seals on the exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas cooler,
    • 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 exhaust gas recirculation solenoid valve,
    • the turbocharger pressure sensor housing.
  • Refit:
    • the new seal between the damper valve and the turbocharger pressure sensor housing,
    • the damper valve .
  • Remove the blanking plug from the opening of the dipstick guide tube on the cylinder block.
  • Refit:
    • dipstick guide ,
    • the dipstick guide tube bolts.
  • Torque tighten the dipstick guide tube bolts (10 N.m).
  • Connect the intercooler air outlet pipe to the damper valve.
  • Torque tighten:
    • the intercooler air outlet pipe bolt (8 N.m),
    • the intercooler air outlet pipe clip (6 N.m) using the tool (Mot. 1608).
  • Connect the damper valve wiring connector.
  • Refit:
    • the new 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 new seal on the inlet manifold,
    • the inlet manifold,
    • the inlet manifold hoses and pipes.
  • Refit the air filter unit.
  • Connect the air filter unit air outlet pipe 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.

Antipollution

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

Antipollution

Note: Check that the new seal (14) on the intercooler air inlet pipe is fitted the right way round.
  • Refit the new intercooler inlet pipe seal.
  • Rotate the intercooler inlet pipe to refit the clip in its housing.
  • Clip the intercooler inlet pipe onto the turbocharger.
  • Refit the intercooler air inlet pipe bolt to the fuel supply pipe bracket.
  • Torque tighten the intercooler air inlet pipe bolt (8 N.m).
  • Refit:
    • the battery tray
    • the battery
    • the scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle panel grille
    • the windscreen wiper arms
    • the air inlet sleeve to the air filter unit
    • the air inlet sleeve clips.
  • Fill the cooling system.
  • Bleed the cooling system .
  • Refit:
    • the engine cover,
    • the engine undertray.
    Exhaust gas recirculation solenoid valve: Removal - Refitting

    Exhaust gas recirculation rigid pipe: Removal - Refitting

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