Renault Koleos Service Repair Manual: Turbocharger: Removal - Refitting

M9R

REMOVAL

I - REMOVAL PREPARATION OPERATION

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

• Turn the clip (1) on the intercooler air inlet duct.

• Remove the intercooler air inlet duct bolt (2) from the fuel pipe support.
• Move aside the intercooler air inlet duct.

• Remove the turbocharger cooling pipe clips (3) using the tool (Mot. 1448).
• Disconnect:
  • the turbocharger cooling pipes,
  • the connector (4) from the exhaust gas temperature sensor.

• Unclip the exhaust gas temperature sensor wiring (5) from the heat shield.

• Remove:
  • the bolts (6) from the turbocharger heat shield,
  • the turbocharger heat shield,
  • the oxygen sensors,
  • the catalytic converter,
  • the turbocharger oil pipe.

• Disconnect:
  • the turbocharging pressure regulator hose (7) from the turbocharger,
  • the connector (8) from the exhaust gas pressure sensor.
• Remove:
  • the exhaust gas temperature sensor (9) from the turbocharger,
  • the exhaust gas pressure sensor bolt (10) .
  • the bolt (11) from the exhaust gas pressure sensor pipe assembly,
  • the exhaust gas pressure sensor pipe assembly from the lifting eye.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the turbocharger bolt (12) ,
  • the upper turbocharger nut (13) from the exhaust manifold.

• Remove:
  • the lower turbocharger nuts (14) from the exhaust manifold,
  • the turbocharger upwards,
  • the gasket between the turbocharger and the exhaust manifold.

• Remove:
  • the bolts (15) from the turbocharger strut,
  • the turbocharger strut.

• Remove:
  • the turbocharger cooling pipe bolts (16) from the turbocharger,
  • the turbocharger cooling pipe retaining bracket bolt from the turbocharger,
  • the turbocharger cooling pipe,
  • the seal between the turbocharger and the turbocharger cooling pipe,
  • the turbocharger studs from the turbocharger using a roller-type stud removal tool.

REFITTING

I - REFITTING PREPARATION OPERATION

• Clean and degrease the bearing faces:
  • the exhaust manifold,
  • of the turbocharger (if being reused),
  • of the cooling pipe (if being reused).
• Always replace:
  • the intercooler air inlet duct seal,
  • the seal between the turbocharger and the exhaust manifold,
  • the seal between the turbocharger and the catalytic converter,
  • the seal between the turbocharger and the turbocharger cooling pipe,
  • the seal between the catalytic converter and the particle filter,
  • the nuts between the turbocharger and the catalytic converter,
  • the upper turbocharger nut,
  • the lower turbocharger nuts,
  • the turbocharger studs,
  • the exhaust gas temperature sensor.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the new turbocharger cooling pipe seal,
  • the turbocharger cooling pipe,
  • the turbocharger cooling pipe bolts,
  • the turbocharger cooling pipe retaining bracket bolt on the turbocharger.
• Torque tighten:
  • the turbocharger cooling pipe bolts (10 N.m),
  • the turbocharger cooling pipe retaining bracket bolt (10 N.m).
• Refit the new turbocharger studs.
• Torque tighten the turbocharger studs (15 N.m) using the flat surfaces of the studs or a roller-type stud removal tool.

• Fit the turbocharger strut.
• Finger-tighten the bolts (18) and (19) of the turbocharger strut.
• Fit the turbocharger without its seal and hold the turbocharger flat against the exhaust manifold.
• Push the turbocharger strut according to the arrow (20) so that it is resting against the turbocharger on the flywheel end.

• Tighten the turbocharger strut bolt (19) on the timing end slightly.
• Remove the turbocharger.
• Tighten to torque the turbocharger strut bolt on the flywheel end (25 N.m) (18) .
• Position the seal between the turbocharger and the exhaust manifold.
• Refit the turbocharger.
• Tighten the turbocharger bolt (12) by a few turns.
• Refit without tightening:
  • the upper turbocharger nut,
  • the lower turbocharger nuts.
• Pretighten to torque:
  • the turbocharger lower nuts (15 N.m),
  • the turbocharger upper nut (15 N.m).
  • Torque tighten:
  • the turbocharger lower nuts (28 N.m),
  • the turbocharger upper nut (28 N.m).
• Tighten the turbocharger strut bolt (19) on the timing end slightly.
• Torque tighten:
  • the turbocharger bolt (25 N.m) (12) ,
  • the turbocharger strut bolt on the timing end (25 N.m).

III - FINAL OPERATION.

• Fit the exhaust gas pressure sensor pipe assembly.
• Refit:
  • the exhaust gas pressure sensor pipe assembly bolt,
  • the exhaust gas pressure sensor bolt.
• Torque tighten:
  • the exhaust gas pressure sensor pipe assembly bolt (10 N.m),
  • the exhaust gas pressure sensor hollow bolt (16 N.m).
• Refit the exhaust gas temperature sensor on the turbocharger.
• Torque tighten the exhaust gas temperature sensor (44 N.m).
• Clip the exhaust gas temperature sensor wiring onto the heat shield.
• Connect:
  • the exhaust gas pressure sensor connector,
  • the turbocharging pressure regulator hose on the turbocharger,
  • the exhaust gas temperature sensor connector,
  • the turbocharger cooling pipes.
• Refit the turbocharger cooling pipe clips using the tool (Mot. 1448).
• Refit:
  • the turbocharger oil pipe
  • the catalytic converter
  • the oxygen sensors
  • the turbocharger heat shield
  • the turbocharger heat shield bolts.
• Torque tighten the turbocharger heat shield bolts (7 N.m).

• Remove the intercooler air inlet duct seal using a tweezers.

• Refit the new intercooler air inlet duct seal.
• Turn the intercooler air inlet duct to fit the clip in its housing.
• Clip the intercooler air inlet duct onto the turbocharger.
• Refit the intercooler air inlet duct bolt to the fuel pipe support.
• Torque tighten the intercooler air inlet duct bolt (8 N.m).
• Refit:
  • the scoop under the scuttle panel grille
  • the windscreen wiper mechanism
  • the scuttle panel 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 duct clips (5 N.m) using the tool (Mot. 1608).
• Remove the blanking plug from the oil separator opening.
• Connect the oil vapour rebreathing hose to the oil separator.
• Refit:
  • the battery tray
  • the battery
  • the air intake sleeve of 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.