Renault Koleos Service Repair Manual: Brake servo: Removal - Refitting

LEFT-HAND DRIVE

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

M9R

• Disconnect the turbocharging pressure regulation solenoid valve connector (1) .
• Unclip:
  • the turbocharging pressure regulation solenoid valve from its support (2) ,
  • the hoses of the turbocharging pressure regulation solenoid valve at (3) from the battery tray.
• Remove:
  • the battery (see Battery: Removal - Refitting) (80A, Battery),
  • the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),
  • the air filter box (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the air filter box air outlet pipe,
  • the brake master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Disconnect the hose (5) from the brake servo.

• Remove:
  • the brake pedal circlip (6) ,
  • the connector shaft (7) between the brake pedal and the brake servo pushrod.

• Remove:
  • the brake servo nuts (8) ,
  • the brake servo.

• Remove:
  • the nuts (9) from the brake servo bracket,
  • the bracket (10) from the brake servo.

• Remove the seal (11) from the brake servo.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the brake servo seal.

• Undo the lock nut (12) of the brake servo pushrod.
• Check that dimension L is between 150.7 and 157.7 mm.
• If dimension L is not correct, adjust the pushrod.
• Torque tighten the lock nut of the brake servo pushrod (19 N.m)

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the new seal of the brake servo,
  • the brake servo bracket,
  • the brake servo bracket nuts.
• Torque tighten the brake servo bracket nuts (14 N.m).

• Refit:
  • the brake servo on the vehicle,
  • the brake servo nuts (8) ,
• Torque tighten the brake servo nut (14 N.m).
• Refit:
  • the connector shaft (7) between the brake pedal and the brake servo pushrod,
  • the brake pedal circlip (6) .

AIR CONDITIONING 01

• Connect the vacuum pipe on the brake servo.

III - FINAL OPERATION

• Refit:
  • the brake master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) ,
  • the air filter box air outlet pipe,
  • the air filter box (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the air filter box (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the battery tray (see Battery tray: Removal - Refitting) (80A, Battery).

M9R

• Clip:
  • the hoses of the turbocharging pressure regulation solenoid valve on the battery tray,
  • the turbocharging pressure regulation solenoid valve on its support.
• Connect the turbocharging pressure regulation solenoid valve connector.

• Refit the battery (see Battery: Removal - Refitting) (80A, Battery).
• Bleed the brake circuit (see 30A, General information, Braking circuit: Bleed, page 30A-4) .

6-SPEED MANUAL GEARBOX

• Bleed the clutch circuit (see 37A, Mechanical component controls, Clutch circuit: Bleed, page 37A- 48) .

M9R, and RIGHT-HAND DRIVE

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
• Drain the refrigerant fluid circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).
• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Remove:
  • the engine cover,
  • the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping - Washing),
  • the scuttle half-grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting) (85A, Wiping - Washing).
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the bulkhead insulation (see Bulkhead insulation: Removal - Refitting) (68A, Soundproofing),
  • the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) (37A, Mechanical component controls),
  • the air inlet sleeve (see Air filter unit: Removal - Refitting) (Fuel mixture),
  • the air filter box (see Air filter unit: Removal - Refitting) (Fuel mixture),
  • the brake pipes between the hydraulic unit and the master cylinder (see 31A, Front axle components, Hydraulic unit - master cylinder brake pipe: Removal - Refitting, page 31A-16) .

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Remove the connecting pipe (1) (see Compressor - condenser connecting pipe: Removal - Refitting) .

• Remove:
  • the heat shield from the turbocharger (see Turbocharger: Removal - Refitting) (12B, Turbocharging),
  • the oxygen sensor (see Oxygen sensor: Removal - Refitting) (13B, Diesel injection).

• Disconnect the exhaust gas pressure sensor connector (2) .
• Remove:
  • the pipe (3) of the exhaust gas pressure sensor from the lifting eye (see Turbocharger: Removal - Refitting) (12B, Turbocharging),
  • the lifting eye (4) ,
  • the bolt (5) from the wiring bracket.
• Move aside the electrical wiring with the bracket.

6-SPEED MANUAL GEARBOX

• Remove the clutch master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, page 37A-55) .

• Remove:
  • the dashboard lower cover on the driver's side (see Dashboard: Removal - Refitting) (57A, Interior equipment),
  • the A-pillar air distribution duct (see Front footwell air distribution duct: Removal - Refitting) (61A, Heating system).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the brake pedal circlip (6) ,
  • the connector shaft (7) between the brake pedal and the brake servo pushrod.

• Disconnect:
  • the connector (8) from the brake light switch,
  • the accelerator position sensor connector (9) .

AIR CONDITIONING 01

• Disconnect the connector (10) from the brake switch.

• Remove:
  • the brake servo nuts (11) ,
  • the brake servo.

• Remove the seal (12) from the brake servo.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the brake servo seal.
• Check the condition of the connecting shaft and replace it if it is damaged.

• Loosen the lock nut of the brake servo pushrod.
• Check that dimension L is between 150.7 and 157.7 mm.
• If dimension L is not correct, adjust the pushrod.
• Torque tighten the lock nut of the brake servo pushrod (19 N.m).

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the brake servo with a new seal,
  • the brake servo nuts.
• Torque tighten the brake servo nuts (14 N.m).
• Refit:
  • the connecting shaft between the brake pedal and the brake servo pushrod,
  • the brake pedal circlip.
• Connect:
  • the brake light switch connector,
  • the accelerator position sensor connector.

AIR CONDITIONING 01

• Connect the brake switch connector.

III - FINAL OPERATION.

• Refit:
  • the A-pillar air distribution duct (see Front footwell air distribution duct: Removal - Refitting) (61A, Heating system),
  • the dashboard lower cover on the driver's side (see Dashboard: Removal - Refitting) (57A, Interior equipment).

6-SPEED MANUAL GEARBOX

• Refit the clutch master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, page 37A-55) .

• Refit:
  • the wiring bracket bolts,
  • the lifting eye.
• Torque tighten:
  • the electrical wiring bracket bolts of the exhaust gas pressure sensor (10 N.m),
  • the lifting eye bolts (25 N.m).
• Refit the exhaust gas pressure sensor pipe on the lifting eye (see Turbocharger: Removal - Refitting) (12B, Turbocharging).
• Connect the exhaust gas pressure sensor connector.
• Refit:
  • the oxygen sensor (see Oxygen sensor: Removal - Refitting) (13B, Diesel injection),
  • the heat shield on the turbocharger (see Turbocharger: Removal - Refitting) (12B, Turbocharging).

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Refit the expansion valve connecting pipe (see Expansion valve: Removal - Refitting) (62A, Air conditioning).

• Refit:
  • the brake pipes between the hydraulic unit and the master cylinder (see 31A, Front axle components, Hydraulic unit - master cylinder brake pipe: Removal - Refitting, page 31A-16) ,
  • the air filter box (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the air inlet sleeve (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the brake master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) ,
  • the bulkhead insulation (see Bulkhead insulation: Removal - Refitting) (68A, Soundproofing),
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting) (85A, Wiping - Washing).
  • the scuttle half-grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping - Washing),
  • the engine cover.
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Fill the refrigerant circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).

• Bleed the brake circuit (see 30A, General information, Braking circuit: Bleed, page 30A-4) .

6-SPEED MANUAL GEARBOX

• Bleed the clutch circuit (see 37A, Mechanical component controls, Clutch circuit: Bleed, page 37A- 48) .

2TR, and RIGHT-HAND DRIVE

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
• Drain the refrigerant fluid circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).
• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Remove:
  • the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping - Washing),
  • the scuttle half-grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting) (85A, Wiping - Washing).
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the bulkhead insulation, partially (see Bulkhead insulation: Removal - Refitting) (68A, Soundproofing).

6-SPEED MANUAL GEARBOX

• Remove the supply hose from the clutch master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, page 37A-55) .

• Remove:
  • the brake master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) ,
  • the air inlet sleeve (see Air filter unit: Removal - Refitting) (12A, Fuel mixture).
  • the air filter box (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the brake pipes between the hydraulic unit and the master cylinder (see 31A, Front axle components, Hydraulic unit - master cylinder brake pipe: Removal - Refitting, page 31A-16) .

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Disconnect the connecting pipes from the expansion valve (see Expansion valve: Removal - Refitting) (62A, Air Conditioning).

• Remove:
  • the upper engine tie-bar (see Right-hand suspended engine mounting: Removal - Refitting) (19D, Engine mounting),
  • the dashboard lower cover on the driver's side (see Dashboard: Removal - Refitting) (57A, Interior equipment),
  • the A-pillar air distribution duct (see Front footwell air distribution duct: Removal - Refitting) (61A, Heating system).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  •  the brake pedal circlip (1) ,
  •  the connector shaft (2) between the brake pedal and the brake servo pushrod.

• Remove:
  • the brake pedal circlip (1) ,
  • the connector shaft (2) between the brake pedal and the brake servo pushrod.

AIR CONDITIONING 01

• Disconnect the connector (5) from the brake switch.

• Remove:
  • the brake servo nuts (6) ,
  • the brake servo.

• Remove the seal (7) from the brake servo

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the brake servo seal.
• Check the condition of the connecting shaft and replace it if it is damaged.

• Loosen the lock nut of the brake servo pushrod.
• Check that dimension L is between 150.7 and 157.7 mm.
• If dimension L is not correct, adjust the pushrod.
• Torque tighten the lock nut of the brake servo pushrod (19 N.m)

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the brake servo with a new seal,
  • the brake servo nuts.
• Torque tighten the brake servo nuts (14 N.m).
• Refit:
  • the connecting shaft between the brake pedal and the brake servo pushrod,
  • the brake pedal circlip.
• Connect:
  • the accelerator position sensor connector,
  • the brake light switch connector.

AIR CONDITIONING 01

• Connect the brake switch connector.

III - FINAL OPERATION.

• Refit:
  • the A-pillar air distribution duct (see Front footwell air distribution duct: Removal - Refitting) (61A, Heating system),
  • the dashboard lower cover on the driver's side (see Dashboard: Removal - Refitting) (57A, Interior equipment),
  • the upper engine tie-bar (see Right-hand suspended engine mounting: Removal - Refitting) (19D, Engine mounting).

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Connect the expansion valve connector pipes (see Expansion valve: Removal - Refitting) (62A, Air Conditioning).

• Refit:
  • the brake pipes between the hydraulic unit and the master cylinder (see 31A, Front axle components, Hydraulic unit - master cylinder brake pipe: Removal - Refitting, page 31A-16) ,
  • the air filter box (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the air inlet sleeve (see Air filter unit: Removal - Refitting) (12A, Fuel mixture),
  • the brake master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) .

6-SPEED MANUAL GEARBOX

• Refit the supply hose on the clutch master cylinder (see 37A, Mechanical component controls, Clutch master cylinder: Removal - Refitting, page 37A-55) .

• Refit:
  • the bulkhead insulation, partially (see Bulkhead insulation: Removal - Refitting) (68A, Soundproofing),
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting) (85A, Wiping - Washing).
  • the scuttle half-grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
  • the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping - Washing).
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).

AIR CONDITIONING 01 or AIR CONDITIONING 02

• Fill the refrigerant circuit using the refrigerant charging station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).

• Bleed the brake circuit (see 30A, General information, Braking circuit: Bleed, page 30A-4) .

6-SPEED MANUAL GEARBOX

• Bleed the clutch circuit (see 37A, Mechanical component controls, Clutch circuit: Bleed, page 37A- 48) .