Renault Koleos Service Repair Manual: Rocker cover: Removal - Refitting

2TR

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.

• Remove:
  • the air intake sleeve
  • the battery
  • the battery tray
  • the air filter unit
  • the air resonator located on the rocker cover
  • the air inlet duct
  • the windscreen wiper arms
  • the scuttle half-grille
  • the windscreen wiper mechanism
  • the scoop under the scuttle panel grille
  • the motorised throttle valve without disconnecting the cooling hoses
  • the intake distributor

• Remove:
  • the earth cable bolts (1) ,
  • the wiring clip (2) .
• Disconnect the ignition coil connectors.
• Move aside the wiring (3) .

• Remove:
  • the front resonator support bolts (4) ,
  • the front resonator support (5) ,
  • the pipes on the rocker cover,
  • the engine undertray.

• Fit the trolley jack or an equivalent engine support tool under the cylinder block.
• Remove the right-hand suspended engine mounting.

• Remove:
  • the engine mounting bolts (6) on the right-hand side,
  • the engine mounting on the right-hand side (7) ,
  • the ignition coils.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the rocker cover bolts in order,
  • the rocker cover,
  • the rocker cover gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the rocker cover seal.

• Use SUPER CLEANER FOR JOINT FACES.

• Apply a beading (A) of SILICONE ADHESIVE SEALANT.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the new seal on the rocker cover,
  • the rocker cover.

• Torque tighten in order:
  • rocker cover bolts (initial torque) (2 N.m),
  • rocker cover bolts (8 N.m).

III - FINAL OPERATION

• Refit:
  • the ignition coils
  • the engine mounting on the right-hand side
  • the engine mounting bolts on the right-hand side.
• Torque tighten the engine mounting bolts on the right-hand side (48 N.m).
• Refit the right-hand suspended engine mounting.
• Remove the trolley jack or equivalent engine supporting tool from the cylinder block.
• Refit:
  • the engine undertray,
  • the pipes on the rocker cover,
  • the front resonator support,
  • the front resonator support bolts.
• Torque tighten the front resonator support bolts (10 N.m).
• Connect the ignition coil connectors.
• Refit:
  • the wiring clip,
  • the earth cable bolts.
• Torque tighten the earth cable bolts (7 N.m).
• Refit:
  • the inlet manifold
  • the motorised throttle valve
  • the scoop under the scuttle panel grille
  • the windscreen wiper mechanism
  • the scuttle half-grille
  • the windscreen wiper arms
  • the air inlet duct
  • the air resonator located on the rocker cover
  • the engine cover
  • the air filter unit
  • the battery tray
  • the battery
  • the air intake sleeve.

M9R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Remove the timing chain.
• Remove the exhaust gas pressure sensor.
• Remove:
  • the vacuum pump
  • the high pressure pipe between the pump and the rail
  • the oil decanter
  • the diesel return rail
  • the high pressure pipes between the rail and the injectors
  • the diesel injectors .

• Remove the bolts (1) and (2) of the fuel collector outlet pipe of the cylinder head.
• Disconnect the fuel collector outlet pipe from the cylinder head at (3) .
• Move aside the fuel collector outlet pipe from the cylinder head.

II - REMOVAL OF THE ROCKER COVER

• Remove the rocker cover bolts.

• Position a protective shim on the cylinder head.
• Detach the rocker cover using a flat-blade screwdriver, using the shim for leverage.
• Remove the rocker cover - camshafts assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• Use SUPER CLEANING AGENT FOR JOINT FACES:
  • the joint face on the rocker cover,
  • the joint face on the cylinder head.

• Remove the residue using a plastic spatula.
• Finish cleaning the joint faces using a GREY ABRASIVE PAD.
• Use SURFACE CLEANER:
  • the joint face on the rocker cover,
  • the joint face on the cylinder head.

II - REFITTING THE ROCKER COVER

• Apply a bead of SILICONE ADHESIVE SEALANT with a diameter of 1.5 +- 1 mm to the cylinder head at (4) , (5) , (6).
• Fit two studs (M6 - length 60 mm) into the holes (7) and (8) on the cylinder head to guide the rocker cover.

• Position:
  • the groove on the exhaust side of the camshaft (9) horizontally (large clearance (10) facing upwards),
  • the groove on the inlet side of the camshaft (11) facing towards the rocker cover boss (12) .
• Check that cylinders 1 and 4 are at Top Dead Centre using the (Mot. 1766).
• Refit the rocker cover - camshafts assembly.

• Tighten in order and successively, the rocker cover bolts (12), (15),(18) and (21) to gradually fit the rocker cover on the cylinder head.
• Remove the two rocker cover guide studs.
• Fit without tightening the remaining rocker cover bolts.
• Loosen bolts (12), (15), (18) and (21).
• Fit without tightening bolts (12), (15), (18) and (21).
• Tighten the rocker cover bolts in order.
• Clean the excess silicone adhesive sealant on the timing and coupling faces using a plastic spatula.

III - FINAL OPERATION

• Connect the fuel collector outlet pipe of the cylinder head.
• Tighten the bolts of the fuel collector outlet pipe of the cylinder head.
• Refit:
  • the diesel injectors
  • the high pressure pipes between the rail and the injectors
  • the diesel return rail
  • the oil decanter
  • the high pressure pipe between the pump and the rail
  • the vacuum pump
• Refit the exhaust gas pressure sensor.
• Refit the timing chain.

Camshaft dephaser: Removal - Refitting

2TR

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Remove the engine and gearbox assembly.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the camshaft dephaser.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED NL

• Refit the camshaft dephaser.

II - FINAL OPERATION.

• Refit the engine and gearbox assembly.