Renault Koleos Service Repair Manual: M9R, and 6-SPEED MANUAL GEARBOX

Manual gearbox

IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair.

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Position the vehicle on a two-post lift.
IMPORTANT To prevent the vehicle from falling, lash it to the vehicle lift using a strap.
  • Remove the engine undertray.
  • Drain:
    • the cooling system
    • the manual gearbox
  • Remove:
    • the engine cover
    • the air inlet sleeve
    • the battery
    • the battery tray

Manual gearbox

  • Unclip the breather hose clip (1) from the air filter.
  • Remove:
    • the breather hose clip (2) ,
    • the breather hose (3) ,
    • the air filter box.

Manual gearbox

  • Remove the bolts (4) from the engine wiring harness channel.
  • Remove the wiring harness channel (5) .

Manual gearbox

  • Remove:
    • the heater matrix coolant hose clips (6) ,
    • the bolt (7) from the heater matrix water outlet pipe,
    • the heater matrix coolant outlet pipe (8) .
  • Disconnect:
    • the selector cable
    • the gear lever cable

Manual gearbox

  • Remove the bolt (9) from the heater matrix inlet pipe.

Manual gearbox

  • Disconnect:
    • the neutral switch (10) ,
    • the reverse gear switch (11) .
  • Unclip:
    • the reverse gear switch wiring clips (12) ,
    • the gearbox wiring clips (13) .
  • Remove:
    • the front wheels
    • the front left-hand wheel arch liner
    • the front left-hand driveshaft
    • the front right-hand driveshaft
    • the particle filter
    • the rear suspended engine mounting
    • the front axle subframe.

4X4 TRANSMISSION

  • Disconnect the propshaft from the transfer box.
  • Secure the longitudinal driveshaft to the control cable bracket using a cord.
  • Remove the transfer box.

Manual gearbox

  • Remove:
    • the earth strap bolt (14) ,
    • the clip (15) from the clutch pipe.
  • Disconnect:
    • the clutch control pipe (16) from the manual gearbox,
    • the clutch control pipe (16) from the clip (17) .
  • Drain the clutch oil.

4X4 TRANSMISSION

Manual gearbox

  • Unclip:
    • the 1st gear switch (18) ,
    • the 1st gear switch wiring clips (19) .

Manual gearbox

  • Remove:
    • the diesel fuel drainage pipe bolts (20) ,
    • the diesel fuel drainage pipe (21) .

Manual gearbox

  • Remove the hood seals (22) .

Manual gearbox

  • Fit the (Mot. 1453) (23) .

Manual gearbox

  • Remove:
    • the air filter unit bracket bolts (24) ,
    • the air filter unit support (25) ,
    • the left-hand suspended engine mounting bolt A (26) ,
    • the left-hand suspended engine mounting bolt B (27) ,
    • the starter.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Manual gearbox

  • Remove:
    • the gearbox nuts (28) ,
    • the gearbox support studs (29) .
  • Fit the component jack underneath the gearbox.

Manual gearbox

  • Remove the lower bolts (30) from the gearbox.

Manual gearbox

  • Remove:
    • the gearbox side bolts (31) ,
    • the manual gearbox.

III - FINAL REMOVAL OPERATION

  • Remove the clutch thrust bearing.

Manual gearbox

  • Remove:
    • the left-hand suspended engine mounting bolts (32) ,
    • the left-hand suspended engine mounting (33)
    • the selector cable bracket bolts (34) ,
    • the selector cable bracket (35) ,
    • the gear lever cable bracket bolts (36) ,
    • the gear lever cable bracket (37) ,
    • the heater matrix coolant pipe bracket bolts (38) ,
    • the heater matrix coolant pipe bracket (39) ,
    • the clutch pipe bracket bolt (40) ,
    • the clutch pipe bracket (41) .

4X4 TRANSMISSION

  • Remove:
    • the switch wiring bracket bolt (42) ,
    • the switch wiring bracket (43) .

Manual gearbox

  • Remove: - the earth strap bracket bolt (44) , - the earth strap bracket (45) .

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace the clutch thrust bearing.
  • Refit the clutch thrust bearing.

Manual gearbox

  • Check that the centring dowel (46) is in position.

Manual gearbox

  • Check that the centring dowel (47) is in position.
  • Refit:
    • the clutch pipe bracket,
    • the clutch pipe bracket bolt,
    • the heater matrix coolant pipe bracket,
    • the heater matrix coolant pipe bracket bolts,
    • the gear lever cable bracket,
    • the gear lever cable bracket bolts,
    • the selector cable bracket,
    • the selector cable bracket bolts,
    • the left-hand suspended engine mounting,
    • the left-hand suspended engine mounting bolts,
    • the earth bracket,
    • the earth strap bolt.
  • Torque tighten:
    • the clutch pipe bracket bolt (14 N.m),
    • the heater matrix coolant pipe bracket bolts (25 N.m),
    • the gear lever cable bracket bolts (17 N.m),
    • the gear selector cable bracket bolts (17 N.m),
    • the left-hand suspended engine mounting bolts (45 N.m),
    • the earth strap bracket bolt (25 N.m).

4X4 TRANSMISSION

  • Refit:
    • the switch wiring bracket,
    • the switch wiring bracket bolt.
  • Torque tighten the switch wiring bracket bolt14 (N.m).

II - REFITTING OPERATION FOR THE PART CONCERNED

  • Refit:
    • the manual gearbox,
    • the gearbox lower bolts,
    • the gearbox side bolts,
    • the gearbox mounting studs,
    • the gearbox nuts.
  • Torque tighten:
    • the gearbox lower bolts (48 N.m),
    • the gearbox side bolts (48 N.m),
    • the gearbox mounting studs (20 N.m),
    • the gearbox nuts (48 Nm).

III - FINAL OPERATION

  • Refit and tighten to torque:
    • the left-hand suspended engine mounting bolt A (110 N.m),
    • the left-hand suspended engine mounting bolt B (110 N.m),
  • Refit:
    • the air filter box mounting,
    • the air filter unit bracket bolts.
  • Torque tighten the air filter unit bracket bolts (10 N.m).
  • Refit the starter.
  • Remove the tool (Mot. 1453).
  • Refit:
    • the hood seals,
    • the diesel drain pipe,
    • the diesel fuel drainage pipe bolts.
  • Torque tighten the diesel fuel drainage pipe bolts (25 N.m).
  • Connect:
    • the neutral switch,
    • the reverse gear switch.
  • Clip:
    • the reverse gear switch wiring clips,
    • the gearbox wiring clips.

4X4 TRANSMISSION

  • Connect the 1st gear switch.
  • Clip on the 1st gear switch wiring clips.

 

  • Refit:
    • the earth strap,
    • the earth strap bolt.
  • Torque tighten the earth strap bolt (14 N.m).
  • Connect:
    • the clutch control pipe to the manual gearbox,
    • the clutch control pipe onto the clip.
  • Refit the clutch control pipe clip.

4X4 TRANSMISSION

  • Refit:
    • the transfer box
    • the propshaft

 

  • Refit:
    • the front axle subframe
    • the rear suspended engine mounting
    • the front left-hand driveshaft
    • the front right-hand driveshaft
    • the particle filter
  • Torque tighten the heater matrix water inlet pipe bolt (25 N.m).
  • Connect:
    • the selector cable
    • the gear lever cable
  • Refit:
    • the heater matrix water outlet pipe,
    • the heater matrix coolant outlet pipe bolt,
    • the heater matrix coolant hose clip.
  • Torque tighten the heater matrix water outlet pipe bolt (25 N.m).
  • Refit:
    • the air filter box
    • the breather hose,
    • the breather hose clip.
  • Clip on the breather hose clip.
  • Refit:
    • the wiring channel,
    • the wiring channel bolts.
  • Torque tighten the wiring harness channel bolts (5 N.m).
  • Refit:
    • the battery tray
    • the battery
    • the air inlet sleeve
    • the engine cover.
  • Refill:
    • the brake fluid
    • the manual gearbox with oil
    • the cooling system
  • Bleed the hydraulic clutch control .
  • Refit:
    • the front left-hand wheel arch liner
    • the front wheels
    • the engine undertray.
    Manual gearbox: Removal - Refitting

    2TR, and 6-SPEED MANUAL GEARBOX

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