Renault Koleos Service Repair Manual: Exhaust manifold: Removal - Refitting

Renault Koleos Service Repair Manual / Engine and peripherals / Fuel mixture / Exhaust manifold: Removal - Refitting

M9R

Fuel mixture

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
  • Remove:
    • the engine cover,
    • the engine undertray,
    • the clips from the air inlet sleeve,
    • the air intake sleeve on the air filter unit,
    • the battery,
    • the battery tray,
    • the air filter unit.
  • Loosen the air filter unit air outlet duct clip on the turbocharger.
  • Disconnect:
    • the oil vapour rebreathing pipe from 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 half-grille,
    • the windscreen wiper mechanism,
    • the scoop under the scuttle panel grille.
  • Drain the engine cooling circuit .

Fuel mixture

  • Disconnect:
    • the connector (1) from the EGR bypass solenoid valve,
    • the vacuum hoses (2) from the EGR bypass solenoid valve.
  • Remove:
    •  the EGR bypass solenoid valve bolts (3) ,
    •  the EGR bypass solenoid valve,
    •  the coolant outlet unit.

Fuel mixture

  • Remove:
    • the bolts (4) from the exhaust gas recirculation rigid pipe heat shield on the exhaust manifold and on the cylinder head,
    • the heat shield from the exhaust gas recirculation solenoid valve.

Fuel mixture

  • Unclip:
    • the fuel pipes (5) ,
    • the electrical wiring (6) .
  • Remove the bolts (7) from the intercooler water inlet pipe.
  • Move the intercooler water inlet pipe to one side.

Fuel mixture

  • Remove:
    • the bolts (8) of the exhaust gas cooler coolant inlet pipe support from the intake distributor,
    • the exhaust gas cooler coolant inlet pipe support.

Fuel mixture

  • Unclip the cooling hose (9) from the turbocharger.
  • Remove:
    • the exhaust gas recirculation rigid pipe between
      the exhaust manifold and the exhaust gas cooler
    • the catalytic converter
    • the turbocharger

II - OPERATION FOR REMOVAL OF PART CONCERNED

Fuel mixture

  • Remove:
    • the nuts and spacers from the exhaust manifold,
    • the exhaust manifold,
    • the exhaust manifold gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING The joint faces must be clean, dry and free from grease (avoid finger marks).
  • Always replace:
    • the exhaust manifold studs, if they have been loosened during the removal operation,
    • the exhaust manifold nuts,
    • the exhaust manifold gasket.
  • Clean and degrease the bearing faces:
    • of the exhaust manifold, if it is to be reused,
    • of the cylinder head,
    • of the exhaust gas recirculation rigid pipe heat shield.
  • Check if the exhaust manifold studs are torque tightened to 9 N.m. Otherwise replace the exhaust manifold studs which are loosened.
  • Torque tighten the exhaust manifold studs (9 N.m) using a roller-type stud removal tool.

II - REFITTING OPERATION FOR PART CONCERNED

Fuel mixture

Fuel mixture

Note: Check if the manifold seal is correctly positioned.

The tab must be positioned at (10) .

  • Refit:
    • the new exhaust manifold gasket,
    • the exhaust manifold,
    • the spacers.
  • Finger tighten the new exhaust manifold nuts until they are in contact.

Fuel mixture

  • Pretighten to torque and in order the exhaust manifold nuts (18 N.m).
  • Torque tighten in order the exhaust manifold nuts (30 N.m).

III - FINAL OPERATION

  • Refit:
    • the turbocharger
    • the catalytic converter
    • the exhaust gas recirculation rigid pipe between
      the exhaust manifold and the exhaust gas cooler
  • Clip the cooling hose (9) onto the turbocharger.
  • Fit the exhaust gas cooler coolant inlet pipe support onto the intake distributor.
  • Refit the exhaust gas cooler coolant inlet pipe support bolts.
  • Torque tighten the exhaust gas cooler coolant inlet pipe support 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).
  • Clip:
    • the electrical wiring (6) ,
    • the fuel pipes (5) .
  • Position the heat shield for the exhaust gas recirculation rigid pipe.
  • Refit the EGR rigid pipe heat shield bolts
  • Torque tighten the exhaust gas recirculation rigid pipe heat shield bolts (10 N.m).
  • Refit:
    • the coolant outlet unit
    • the water chamber hoses and pipes
  • Fit the EGR bypass solenoid valve.
  • Refit the EGR bypass solenoid valve bolts.
  • Torque tighten the EGR bypass solenoid valve bolts (10 N.m).
  • Connect:
    • the vacuum hoses on the EGR bypass solenoid valve and on the exhaust gas cooler,
    • the EGR bypass solenoid valve connector.
  • Remove:
    • the scoop under the scuttle panel grille
    • the windscreen wiper mechanism
    • the scuttle 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 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.
  • Refit:
    • the battery tray
    • the battery
    • the air intake sleeve on 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.

2TR

Fuel mixture

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
  • Disconnect the battery.
  • Remove the engine undertray.

Fuel mixture

  • Remove:
    • the exhaust connecting pipe rubber mounting bush support nuts (1) ,
    • the exhaust connecting pipe nuts (2) ,
    • the connector pipe (3) ,
    • the seal,
    • the front right-hand wheel,
    • the front wheel arch liner.

Fuel mixture

  • Disconnect the oxygen sensor connectors .
Note: Do not damage the oxygen sensor.

If the oxygen sensor falls on hard ground, for example concrete, replace the sensor.

  • Remove:
    • the oxygen sensors (4)
    • the accessories belt (5)
    • the windscreen washer bottle neck
    • the alternator (6)
    • the dipstick (7)
    • the dipstick guide tube bolt (8)
    • the dipstick guide tube (9)
    • the O-ring.

Fuel mixture

Note: The engine must remain covered to prevent impurities from entering inside.
  • Remove:
    • the bolts (10) from the exhaust manifold upper heat shield,
    • the upper heat shield (11) from the exhaust manifold.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Fuel mixture

Note: The engine must remain covered to prevent impurities from entering inside.
  • Remove:
    • the exhaust manifold nuts in order,
    • the exhaust manifold (12) .

Fuel mixture

  • Remove:
    • the bolts (13) from the exhaust manifold lower heat shield,
    • the lower heat shield (14) from the exhaust manifold.

Fuel mixture

  • Remove:
    • the bolts (15) from the catalytic pre-converter heat shield,
    • the catalytic pre-converter heat shield (16) .

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the seals,
    • the O-ring.

II - REFITTING OPERATION FOR PART CONCERNED

  • Refit:
    • the catalytic pre-converter heat shield,
    • the catalytic pre-converter heat shield bolts.
  • Torque tighten the catalytic pre-converter heat shield bolts (6 N.m).
  • Refit:
    • the exhaust manifold lower heat shield,
    • the exhaust manifold lower heat shield bolts.
  • Torque tighten the exhaust manifold lower heat shield bolts (6 N.m).
  • Refit:
    • the new exhaust manifold gasket,
    • the exhaust manifold,
    • the exhaust manifold nuts.

Fuel mixture

  • Torque tighten in order:
    • the exhaust manifold nuts (initial torque) (15 N.m),
    • the exhaust manifold nuts (42 N.m).

III - FINAL OPERATION

  • Refit:
    • the exhaust manifold upper heat shield,
    • the exhaust manifold upper heat shield bolts.
  • Torque tighten the exhaust manifold upper heat shield bolts (6 N.m).
  • Refit:
    • the new O-ring,
    • the dipstick guide tube,
    • the dipstick guide tube bolt,
    • the dipstick.
  • Torque tighten the dipstick guide tube bolt (22 N.m).
  • Refit:
    • the alternator
    • the windscreen washer bottle neck
    • the accessories belt
    • the oxygen sensors
  • Connect the oxygen sensor connectors.
  • Refit:
    • the front wheel arch liner
    • the front right-hand wheel
    • the new seal
    • the connector pipe
    • the exhaust connecting pipe nuts
    • the exhaust connecting pipe rubber mounting bush support nuts.
  • Torque tighten:
    • the exhaust connecting pipe nuts (65 N.m),
    • the exhaust connecting pipe rubber mounting bush support nuts (14 N.m).
  • Refit the engine undertray.
  • Connect the battery.
    Inlet distributor: Removal - Refitting

    Turbocharging

    See More:

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    Note: The information contained in the following describes the general repair procedure for all vehicles having the same design for this part. Before reading this general information, check that there are no special notes associated with this vehicle. These special notes are specified if necessary ...

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