Renault Koleos Service Repair Manual: 2TR, and ND5 or ND8

REMOVAL

I - OPERATION FOR REMOVAL OF PART CONCERNED

• Position the vehicle on a two-post lift.

• To release the fuel pressure, remove:
  • the air inlet sleeve clips (1) ,
  • the air inlet sleeve (2) from the air resonator (3) and the air filter unit (4) .

• Remove the cover (5) from the Protection and Switching Unit.

• Remove the fuse (6) of the fuel pump(F13) (15A).
• Release the fuel pressure of the fuel supply pipe.

• Drain:
  • the cooling system
  • the manual gearbox oil
  • the refrigerant circuit using a refrigerant charging station
• Remove:
  • the engine cover,
  • the battery.

• Disconnect the battery positive terminal wiring connectors (7) .
• Remove the battery tray.

• Remove the engine fuse and relay box cover (8) .

• Disconnect the engine fuse and relay box wiring connectors (9) .

• Remove:
  • the engine wiring support bolts (10) ,
  • the engine wiring support (11) .
  • the air filter box .

• Remove:
  • the bolts (12) from the bracket,
  • the bracket (13) ,
  • the rocker cover air resonator.

• Remove:
  • the breather hose clip (14) ,
  • the breather hose (15) ,
  • the air inlet duct.

• Remove the plug of the fuel supply union.

• Disconnect the quick-release union (16) from the fuel supply pipe using the tool (Mot. 1869) (17) .

• Disconnect:
  • the fuel vapour rebreathing hose clip (19) ,
  • the fuel vapour rebreathing hose (20) .

• Disconnect:
  • the clip (21) from the brake servo vacuum pipe,
  • the vacuum pipe (22) from the brake servo.

• Remove the alternator support earth cable bolt (23) .
• Disconnect the alternator support cable (24) .

• Remove:
  • the air conditioning pipe nut (25) ,
  • the air conditioning pipe bolt (26) .
• Disconnect the air conditioning pipes (27) from the air conditioning compressor.
• Fit plugs into the openings.

• Remove:
  • the radiator upper hose clips (28) using the tool (Mot. 1448)
  • the radiator upper hose (29) .

• Remove:
  • the radiator lower hose clips (30) using the tool (Mot. 1448),
  • the radiator lower hose (31) .

• Remove the clips (32) from the heater hoses.
• Disconnect:
  • the heater hoses (33)
  • the gear lever cable (34)
  • the selector lever cable (35).
• Remove the front wheels.

• Unclip the left-hand splash guard clips (36) .
• Remove the left-hand splash guard (37) .

• Remove the manual gearbox earth cable bolt (38) .
• Disconnect the manual gearbox earth cable (39) .

• Unclip the right-hand splash guard clips (40) .
• Remove:
  • the right-hand splash guard (41) ,
  • the connector pipe ,
  • the front left-hand driveshaft ,
  • the front right-hand driveshaft,
  • the rear suspended engine mounting,
  • the front axle subframe.

ND5

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

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Support the " engine-gearbox " assembly on the (Mot. 1390) at (42) .

• Remove in order the right-hand suspended engine mounting bolts.

• Remove the left-hand suspended engine mounting nut (43) from the gearbox.

• Remove:
  • the nuts (44) and bolts from the left-hand suspended engine mounting,
  • the rubber pad (45) from the left-hand suspended engine mounting.

• Raise the lift to remove the " engine-gearbox " assembly.

REFITTING

I - REFITTING PREPARATION OPERATION

• For standard engine replacement.
• Always replace the O-rings on the air conditioning pipes.

II - REFITTING OPERATION FOR PART CONCERNED

• Fit the " engine - gearbox " assembly into the engine compartment using the tool (Mot. 1390).
• Refit the rubber pad on the left-hand suspended engine mounting.

• Refit:
  • the left-hand suspended engine mounting nut (43) on the gearbox.
  • the bolts and the nuts of the left-hand suspended engine mounting.
• Torque tighten:
  • the bolts and nuts of the left-hand suspended engine mounting (105 N.m),
  • the left-hand suspended engine mounting nut (65 N.m).

• Refit in order the right-hand suspended engine mounting bolts.
• Torque tighten in order the right-hand suspended engine mounting bolts (55 N.m).

III - FINAL OPERATION.

ND5

• Refit:
  • the transfer box
  • the longitudinal driveshaft on the transfer box

• Refit:
  • the front right-hand driveshaft
  • the front left-hand driveshaft
  • the connector pipe
  • the front axle subframe
  • the rear suspended engine mounting
  • the right-hand splash guard.
• Clip on the right-hand splash guard clips.
• Connect the earth cable on the manual gearbox.
• Refit the earth cable bolt on the manual gearbox.
• Torque tighten the earth cable bolt on the manual gearbox (14 N.m).
• Refit the left-hand splash guard.
• Clip on the left-hand splash guard clips.
• Refit the front wheels.
• Connect:
  • the selector lever cable
  • the gear lever cable
  • the heater hoses.
• Refit:
  • the heater hose clips,
  • the radiator lower hose,
  • the radiator lower hose clips,
  • the radiator upper hose,
  • the radiator upper hose clips.
• Remove the caps from the apertures.
• Connect the air conditioning pipes on the air conditioning compressor.
• Refit:
  • the bolt from the air conditioning pipe,
  • the air conditioning pipe nut.
• Torque tighten:
  • the air conditioning pipe bolt (4 N.m).
  • the air conditioning pipe nut (4 N.m).
• Connect the earth cable on the alternator support.
• Refit the earth cable bolt on the alternator support.
• Torque tighten the earth cable bolt on the alternator support (7 N.m).
• Refit:
  • brake servo vacuum pipe ,
  • the clip on the brake servo vacuum pipe,
  • the fuel vapour rebreathing hose.
  • the fuel vapour rebreathing hose clip.
• Connect the quick-release union on the fuel supply pipe.

• Refit:
  • the plug of the fuel supply union,
  • the air inlet duct,
  • the breather hose,
  • the breather hose clip,
  • The air resonator on the rocker cover .
  • the air filter unit ,
  • the bracket (13) ,
  • the bracket bolts.
• Torque tighten the bracket bolts (21 N.m).
• Refit:
  • the engine wiring support,
  • the engine wiring support bolts.
• Torque tighten the engine wiring support bolts (21 N.m).
• Connect the engine fuse and relay box wiring connectors.
• Refit:
  • the engine fuse and relay box cover,
  • the battery tray.
• Connect the battery positive terminal wiring connectors.
• Refit:
  • the battery,
  • the engine cover,
  • the fuel pump fuse,
  • the Protection and Switching Unit cover,
  • the air inlet sleeve on the air filter unit and on the air resonator.
• Clip on the air inlet sleeve clips.
• Refill:
  • the refrigerant circuit using a refrigerant charging station
  • the manual gearbox oil
  • the cooling system .
• Bleed the cooling system .