Renault Koleos Service Repair Manual: M9R

REMOVAL

I - REMOVAL PREPARATION OPERATION

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

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

• 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 protective plate (3) from the injector rail protector.

• Loosen the clip (4) on the intercooler air inlet pipe.
• Disconnect the " intercooler air inlet pipe - duct " assembly (5) .
• Remove:
  • the battery
  • the battery tray

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Drain the refrigerant circuit

• Remove the engine undertray.
• Drain the cooling system.

6-SPEED MANUAL GEARBOX

• Drain the manual gearbox

6-SPEED AUTOMATIC GEARBOX

• Drain the automatic transmission

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Remove the compressor pipe union bolts (6) .
• Disconnect the compressor pipe unions.
• Plug the openings.

• Unclip the fuel pipes from their mounting support (7) .
• Move the fuel pipes aside.
• Remove:
  • the fuel pipe bolt (8) ,
  • the fuel pipe support.

• Loosen the clip (9) on the intercooler air outlet pipe.
• Remove the intercooler air outlet pipe bolt (10) .
• Disconnect the intercooler air outlet pipe (11) from the damper valve.
• Move the intercooler air outlet pipe to one side.

• Remove the clip (12) from the expansion bottle hose using the tool (Mot. 1448).
• Disconnect the hose from the expansion bottle.

• Remove the cooling radiator top hose clip (13) using the (Mot. 1448).
• Disconnect the cooling radiator top hose.
• Remove:
  • the fuel filter
  • the manual priming pump
• Disconnect the fuel return quick-release union leading to the tank.

• Unclip the wiring (14) from the manual priming pump support.
• Remove:
  • the support bolt (15) of the manual priming pump,
  • the manual priming pump support.

• Disconnect:
  • the turbocharging pressure regulation valve actuating hose (16) ,
  • the brake servo hose (17) from the non-return valve.
• Remove the bolt (18) from the turbocharging pressure regulation actuating solenoid valve support.
• Move aside the turbocharging pressure regulation actuating solenoid valve (19) and the turbocharging pressure regulation valve actuating hoses (16) .
• Remove the air filter unit .
• Loosen the air filter unit air outlet pipe clip located on the turbocharger side.
• Disconnect the air filter unit air outlet pipe (20) from the turbocharger.

LEFT-HAND DRIVE

• Disconnect the brake fluid level sensor connector (21) .

RIGHT-HAND DRIVE

• Disconnect the brake fluid level sensor connector (22) .
• Unclip the brake fluid level sensor wiring harness at (23) .

• Remove the fuse box cover (24) .

• Disconnect:
  • the fuse box wiring connectors (25) ,
  • the pre-postheating unit connector (26) .

• Remove the bolts (27) from the wiring bracket.
• Unclip:
  • the wiring at (28) ,
  • the wiring at (29) .

6-SPEED AUTOMATIC GEARBOX

• Disconnect the connector (30) from the automatic transmission computer.
• Remove:
  • the automatic transmission computer mounting bolts (31) ,
  • the earth cable,
  • the " automatic transmission computer - mounting support " assembly.

6-SPEED MANUAL GEARBOX

• Remove the automatic transmission computer mounting.

• Disconnect the battery protection fuse wiring connectors (32) .
• Unclip the wiring harness from the brackets at (33) .

• Remove the heater matrix pipe clips (34) using the (Mot. 1448).
• Disconnect the heater matrix pipes.

6-SPEED MANUAL GEARBOX

• Remove:
  • the heater matrix coolant outlet pipe clips (35) using the tool (Mot. 1448),
  • the heater matrix water outlet pipe bolt (36) .
• Disconnect the " heater matrix coolant outlet duct - pipe " assembly (37) from the inlet distributor and the heater matrix coolant outlet pipe.
• Unclip:
  • the selector cable and the gear selector lever cable from the manual gearbox.
  • the gear shift cable and the gear shift lever cable from the manual gearbox.

6-SPEED AUTOMATIC GEARBOX

• Remove:
  • the heater matrix coolant outlet pipe clips (38) using the (Mot. 1448).
  • the heater matrix coolant outlet pipe bolt (39) .
• Disconnect the " heater matrix coolant outlet pipe - duct " assembly (40) from the inlet distributor and the heater matrix coolant outlet pipe.

• Remove the heater matrix coolant inlet pipe bolt (41) .
• Separate the coolant inlet hose from the heater matrix.

• Remove:
  • the nut (42) of the automatic gearbox control cable,
  • the stop (43) from the control cable of the automatic gearbox.
• Unclip:
  • the automatic gearbox control cable from the multifunction switch lever (44) .
  • the automatic gearbox control cable from the control cable upper bracket (45) .

• Remove:
  • the bolts (46) from the air filter unit support,
  • the air filter unit support (47) .

6-SPEED MANUAL GEARBOX

• Remove:
  • the oil filter unit coolant inlet pipe clip (48) using the (Mot. 1448),
  • the clip (49) from the coolant hose using the tool (Mot. 1448).
• Disconnect:
  • the oil filter unit coolant inlet pipe,
  • the coolant hose (50) .

6-SPEED AUTOMATIC GEARBOX

• Remove the oil filter unit coolant inlet pipe clip (51) using the tool (Mot. 1448).
• Disconnect the oil filter unit coolant inlet pipe.

• Remove:
  • the front wheels.
  • the front splash guards.
  • the front left-hand wheel driveshaft.
  • the front right-hand wheel driveshaft.
  • the electric coolant pump.
  • the front axle subframe.

6-SPEED MANUAL GEARBOX

• Remove:
  • the earth strap bolt (52) ,
  • the earth strap,
  • the clutch control pipe clip (53) .
• Disconnect the clutch control pipe (54) from the manual gearbox.
• Unclip the clutch control pipe from its clip (55) .
• Drain the oil from the clutch control pipe.

6-SPEED AUTOMATIC GEARBOX

• Remove:
  • the earth strap bolt (56) ,
  • the earth strap.
• Remove the automatic gearbox coolant hose clips (57) using the tool.
• Disconnect the automatic gearbox coolant hoses from the automatic gearbox coolant pipe (58) .
• Remove:
  • the automatic gearbox coolant pipe bolts (59) ,
  • the automatic gearbox coolant pipe.

• Remove the particle filter.

4X4 TRANSMISSION

• Remove the transfer box.

II - OPERATION FOR REMOVAL OF PART CONCERNED

6-SPEED MANUAL GEARBOX

• Place the engine and the gearbox on the rubber pads of the tool (Mot. 1390) at points (60) .

6-SPEED AUTOMATIC GEARBOX

• Place the engine and the gearbox on the rubber pads of the tool (Mot. 1390) at points (61) .

• Remove:
  • the upper engine tie-bar bolt and washer (62) ,
  • the upper engine tie-bar bolt (63) from the body,
  • the upper engine tie-bar,
  • the right-hand suspended engine mounting bolts (64) .

6-SPEED MANUAL GEARBOX

• Remove the left-hand suspended engine mounting bolts (65) from the manual gearbox.

6-SPEED AUTOMATIC GEARBOX

• Remove the left-hand suspended engine mounting bolts (66) from the automatic gearbox.

• Remove the " engine - gearbox assembly " .
• Raise the vehicle.
• Move the " engine - gearbox assembly " aside.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the intercooler air inlet pipe seal,
  • the compressor pipe union seals,
  • the engine tie-bar washer,

• Remove the intercooler air inlet pipe seal using a .

• Refit the new intercooler air inlet pipe seal (67) .

II - REFITTING OPERATION FOR PART CONCERNED

• Place the " engine-gearbox " assembly in the vehicle.
• Lower the vehicle.

6-SPEED MANUAL GEARBOX

• Refit the left-hand suspended engine bolts located on the manual gearbox.
• Torque tighten in order the left-hand suspended engine mounting bolts (110 N.m).

6-SPEED AUTOMATIC GEARBOX

• Refit the left-hand suspended engine bolts located on the automatic gearbox.
• Torque tighten in order the left-hand suspended engine mounting bolts (110 N.m) located on the automatic gearbox.

• Refit the right-hand suspended engine mounting bolts located on the engine.
• Torque tighten in order the right-hand suspended engine mounting bolts (55 N.m) located on the engine.
• Refit:
  • the upper engine tie-bar,
  • the upper engine tie-bar bolt on the body,
  • the new upper engine tie-bar washer,
  • the upper engine tie-bar bolt on the engine.
• Tighten to torque and in order:
  • the upper engine tie-bar bolt (120 N.m) on the engine,
  • the upper engine tie-bar bolt (120 N.m) on the body.
• Remove the tool (Mot. 1390).

III - FINAL OPERATION

4X4 TRANSMISSION

• Refit the transfer box.

• Refit the particle filter.

6-SPEED MANUAL GEARBOX

• Clip the clutch control pipe onto its clip (55) .
• Connect the clutch control pipe onto the manual gearbox.
• Refit
  • the clutch control pipe clip (53)
  • the earth strap,
  • the earth strap bolt (52) .
• Torque tighten the earth strap bolt (14 N.m).

6-SPEED AUTOMATIC GEARBOX

• Refit:
  • the automatic gearbox coolant pipe,
  • the automatic gearbox coolant pipe bolts (59) .
• Torque tighten the automatic gearbox coolant pipes (25 N.m).
• Connect the automatic gearbox coolant hoses onto the automatic gearbox coolant pipes (58) .
• Refit the automatic gearbox coolant hose clips using the (Mot. 1448).
• Refit:
  • the earth strap,
  • the earth strap bolt (56) .
• Torque tighten the earth strap bolt (14 N.m).

• Refit:
  • the front axle subframe
  • the electric coolant pump
  • the front right-hand wheel driveshaft
  • the front left-hand wheel driveshaft
  • the front splash guards
  • the front wheels

6-SPEED MANUAL GEARBOX

• Connect:
  • the coolant hose (50) ,
  • the oil filter unit coolant inlet pipe onto the oil filter unit.
• Refit:
  • the coolant hose clip (49) using the (Mot. 1448),
  • the clip (48) on the oil filter unit coolant inlet pipe using the (Mot. 1448).

6-SPEED AUTOMATIC GEARBOX

• Connect the oil filter unit coolant inlet pipe onto the oil filter unit.
• Refit the clip (51) on the oil filter unit coolant inlet pipe using the (Mot. 1448).

• Refit:
  • the air filter unit support (47) ,
  • the air filter unit mounting bolts (46) .
• Torque tighten the air filter unit support bolts (10 N.m).

6-SPEED MANUAL GEARBOX

• Clip on:
  • the selector cable and the gear selector lever cable from the manual gearbox
  • the selector cable and the gear selector lever cable from the manual gearbox
• Connect the " heater matrix coolant outlet pipe - duct assembly " (37) onto the inlet distributor and the heater matrix coolant outlet pipe.
• Refit the heater matrix coolant outlet pipe bolt (36) .
• Torque tighten the heater matrix coolant outlet pipe bolt (25 N.m).
• Refit the heater matrix coolant outlet pipe clips (35) using the (Mot. 1448).

6-SPEED AUTOMATIC GEARBOX

• Clip on:
  • the automatic gearbox control cable onto the control cable upper bracket,
  • the automatic gearbox control cable onto the multifunction switch lever.
• Refit:
  • the automatic gearbox control cable nut,
  • the automatic gearbox control cable stop.
• Torque tighten the automatic gearbox control cable nut (14 N.m).
• Refit the heater matrix coolant inlet pipe bolt (41) .
• Torque tighten the heater matrix inlet pipe bolt (25 N.m).
• Connect the " heater matrix coolant outlet pipe - duct " (40) assembly onto the inlet distributor and the heater matrix coolant outlet hose.
• Refit the heater matrix coolant outlet pipe bolt (39) .
• Torque tighten the heater matrix coolant outlet pipe bolt (25 N.m).
• Refit the heater matrix water outlet hose clips (38) using the tool (Mot. 1448).

• Connect the heater matrix pipes.
• Refit the heater matrix pipe clips (34) using the (Mot.1448).
• Clip the wiring onto the brackets (33) .
• Connect the wiring connectors (32) to the battery protection fuse.

6-SPEED MANUAL GEARBOX

• Refit the automatic gearbox computer mounting.

6-SPEED AUTOMATIC GEARBOX

• Fit:
  • the " automatic gearbox computer - mounting support " assembly,
  • the earth cable.
• Refit the automatic gearbox computer mounting bolts (31) .
• Torque tighten the automatic gearbox computer mounting bolts (27 N.m).
• Connect the automatic gearbox computer connector.

• Clip on:
  • the wiring at (30) ,
  • the wiring at (29) .
• Refit the wiring bracket bolts (28) .
• Torque tighten the wiring bracket bolts (10 N.m).
• Connect:
  • the pre-postheating unit connector (26) ,
  • the wiring connectors (25) in the fuse box.
• Refit the fuse box cover.

LEFT-HAND DRIVE

• Connect the brake fluid level sensor connector (21) .

RIGHT-HAND DRIVE

• Clip on the brake fluid level sensor wiring at (23) .
• Connect the brake fluid level sensor connector (22) .

• Refit the air filter box.
• 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 clips (5 N.m) using the tool (Mot. 1608).
• Place the turbocharging pressure regulation actuating solenoid valve support on the air filter unit.
• Refit the bolt on the turbocharging pressure regulation actuating solenoid valve support.
• Torque tighten the bolt on the turbocharging pressure regulation actuating solenoid valve support (10 N.m)
• Connect:
  • the brake servo pipe to the non-return valve,
  • the turbocharging pressure regulation valve actuating hose (16) .
• Refit:
  • the manual priming pump support,
  • the support bolt of the manual priming pump.
• Torque tighten the support bolt of the manual priming pump (12 N.m).
• Clip the wiring on the manual priming pump support (14) .
• Connect the fuel return quick-release union of the fuel pipe leading to the tank.
• Refit:
  • the manual priming pump.
  • the fuel filter.
• Connect the cooling radiator top hose.
• Refit the cooling radiator top hose clip using the tool (Mot. 1448).
• Connect the expansion bottle hose.
• Refit the expansion bottle clip (12) using the (Mot.1448).
• Connect the intercooler air outlet pipe (11) to the damper valve.
• Refit the intercooler air outlet pipe bolt (10) .
• Torque tighten:
  • the intercooler air outlet pipe bolt (8 N.m),
  • the clip of the intercooler air outlet pipe clip (6 N.m) using the tool (Mot. 1608).
• Refit the fuel pipe support.
• Refit the fuel pipe support bolt (8) .
• Torque tighten the fuel pipe support bolt (10 N.m).
• Clip the fuel pipes onto the fuel pipe support (7) .

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Remove the blanking plugs from the compressor and the compressor pipe unions.
• Refit the new compressor pipe union seals.
• Connect the compressor pipe unions onto the compressor.
• Refit the compressor pipe union bolts.
• Torque tighten the compressor pipe union bolts (4 N.m).

• Connect the " intercooler air inlet pipe-duct " assembly (5) .
• Torque tighten the intercooler air inlet pipe clip (6 N.m) using the tool (Mot. 1608).
• Refit the protector plate on the injector rail protector.
• Rotate the intercooler air inlet pipe to refit the clip in its housing.
• Clip the intercooler air 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).

6-SPEED MANUAL GEARBOX

• Fill with oil:
  • the manual gearbox .
  • the brake fluid reservoir.
• Bleed the hydraulic clutch control .

6-SPEED AUTOMATIC GEARBOX

• Fill the automatic gearbox oil.

• Fill the cooling system.
• Bleed the cooling system.
• Refit the engine undertray.

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Fill the refrigerant circuit using a refrigerant charging station.

• Refit:
  • the battery tray
  • the battery
  • the air inlet sleeve to the air filter unit
  • the air inlet sleeve clips
  • the engine cover.