Renault Koleos Service Repair Manual: Exhaust gas recirculation rigid pipe: Removal - Refitting

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

M9R

Antipollution

REMOVAL

I - REMOVAL PREPARATION OPERATION

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

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

Antipollution

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

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 battery
    • the battery tray
    • the air filter unit
  • 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 windscreen wiper arms
    • the scuttle panel grille
    • the windscreen wiper mechanism
    • the scoop under the scuttle panel grille.
  • Drain the cooling system.

Antipollution

  • Disconnect:
    • the connector (3) from the EGR cooling bypass solenoid valve,
    • the vacuum hoses (4) from the EGR cooling bypass solenoid valve.
  • Remove:
    • the EGR cooling bypass solenoid valve bolts (5) ,
    • the EGR cooling bypass solenoid valve,
    • the water chamber.

Antipollution

  • Remove:
    • the bolts (6) from the exhaust gas recirculation rigid pipe heat shield on the exhaust manifold and the cylinder head,
    • the heat shield from the rigid exhaust gas recirculation pipe.

Antipollution

  • Unclip:
    • the fuel pipes (7) ,
    • the wiring (8) .
  • Remove the bolt (9) from the intercooler water inlet pipe.
  • Move the intercooler water inlet pipe to one side.

Antipollution

  • Remove:
    • the exhaust gas recirculation exchanger water inlet pipe bracket bolts (10) from the inlet manifold,
    • the exhaust gas recirculation exchanger water inlet pipe bracket.

Antipollution

  • Unclip the turbocharger cooling hose (11) .

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

  • Remove the front engine cover.
  • Remove the battery.
  • Remove the damper valve.

Antipollution

  • Disconnect the turbocharger pressure sensor connector (12) .
  • Remove:
    • the turbocharger pressure sensor housing (13) ,
    • the seal between the turbocharger pressure sensor housing and the exhaust gas recirculation solenoid valve.

II - OPERATION FOR REMOVAL OF PART CONCERNED

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

Antipollution

  • Remove the clip (14) from the exhaust gas recirculation rigid pipe.

Antipollution

  • Remove:
    • the bolt (15) securing the exhaust gas recirculation rigid pipe on the cylinder head,
    • the bolts (16) securing the exhaust gas recirculation rigid pipe on the exhaust manifold,
    • the exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger,
    • the exhaust gas recirculation exchanger rigid pipe seal.

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

Antipollution

  • Remove:
    • the bolts (17) from the exhaust gas recirculation
      rigid pipe between the exhaust gas recirculation
      solenoid valve and the exhaust gas recirculation
      exchanger.
    • the exhaust gas recirculation rigid pipe between
      the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger,
    • the exhaust gas recirculation exchanger rigid pipe seals.

REFITTING

I - REFITTING PREPARATION OPERATION

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

WARNING The joint faces must be clean, dry and free from grease (avoid finger marks).
  • Clean the gasket faces.
  • Always replace:
    • the exhaust gas recirculation exchanger rigid pipe,
    • the exhaust gas recirculation exchanger rigid pipe seal,
    • the exhaust gas recirculation exchanger rigid pipe clip,
    • the bolts securing the exhaust gas recirculation rigid pipe on the exhaust manifold,
    • the intercooler inlet pipe seal.

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

WARNING The joint faces must be clean, dry and free from grease (avoid finger marks).
  • Clean the gasket faces.
  • Always replace:
    • the exhaust gas recirculation exchanger rigid pipe seals,
    • 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

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

  • Refit:
    • the new exhaust gas recirculation rigid pipe with the new seal,
    • the exhaust gas recirculation exchanger rigid pipe clip,
    • the new bolts securing the exhaust gas recirculation rigid pipe on the exhaust manifold,
    • the bolt securing the exhaust gas recirculation rigid pipe on the cylinder head.
  • Tighten to torque:
    • the exhaust gas recirculation rigid pipe clip (5 N.m) using tool (Mot. 1608),
    • the exhaust gas recirculation rigid pipe bolts on the exhaust manifold (35 N.m),
    • the bolt securing the EGR rigid pipe on the cylinder head (10 N.m).

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

  • Refit:
    • the exhaust gas recirculation rigid pipe with the new seals,
    • the EGR rigid pipe bolts.
  • Torque tighten the EGR rigid pipe bolts (25 N.m).

III - FINAL OPERATION.

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

  • Unclip the turbocharger cooling hose.
  • Position the exhaust gas recirculation exchanger water inlet pipe bracket on the inlet manifold.
  • Refit the exhaust gas recirculation exchanger water inlet pipe bracket bolts.
  • Torque tighten the exhaust gas recirculation exchanger water inlet pipe bracket 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).
  • Refit:
    • the wiring harness,
    • the fuel pipes.
  • Position the heat shield for the exhaust gas recirculation rigid pipe.
  • Refit the rigid EGR pipe heat shield bolts.
  • Torque tighten the exhaust gas recirculation rigid pipe heat shield bolts (10 N.m).
  • Refit:
    • the water chamber
    • the water chamber hoses and pipes
  • Position the exhaust gas recirculation cooling bypass solenoid valve.
  • Refit the exhaust gas recirculation cooling bypass solenoid valve bolts.
  • Torque tighten the exhaust gas recirculation cooling bypass solenoid valve bolts (10 N.m).
  • Connect:
    • the vacuum hoses to the exhaust gas recirculation cooling bypass solenoid valve,
    • the exhaust gas recirculation cooling bypass solenoid valve connector.
  • Refit:
    • the scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle panel grille
    • the windscreen wiper arms
    • the air filter unit .
  • Connect the air filter unit air outlet pipe to the turbocharger and the air filter unit.
  • Torque tighten the air filter unit air outlet pipe clip (s5 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.

Antipollution

  • Remove the intercooler inlet pipe seal using tweezers.

Antipollution

Note: Check that the seal (18) on the intercooler 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.
  • Refit:
    • the intercooler inlet pipe on the turbocharger,
    • the intercooler air inlet pipe bolt on the fuel supply pipe bracket.
  • Torque tighten the intercooler air inlet pipe bolt (8 N.m).
  • Refit:
    • the air inlet sleeve to the air filter unit,
    • the air inlet sleeve clips,
    • the engine cover.
  • Fill the cooling system .
  • Bleed the cooling circuit.
  • Refit the engine undertray.

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

  • Refit:
    • the new seal between the turbocharger pressure sensor housing and the exhaust gas recirculation solenoid valve,
    • the turbocharger pressure sensor housing.
  • Connect the turbocharger pressure sensor connector.
  • Refit:
    • the new seal between the damper valve and the turbocharger pressure sensor housing,
    • the damper valve.
  • Connect the battery.
  • Refit the engine cover.
    Exhaust gas cooler: Removal - Refitting

    Starting - charging

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