Renault Koleos Service Repair Manual: Inlet distributor: 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 on the air filter unit,
  • the battery,
  • the battery tray.

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

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

• Loosen the clip (3) on the intercooler air inlet duct.
• Remove:
  • the air inlet duct assembly (4) from the intercooler,
  • 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
  • the water chamber
  • the exhaust gas recirculation rigid pipe between
    the exhaust manifold and the exhaust gas cooler.

• Disconnect the connector from the damper valve wiring (5) .
• Loosen the clip (6) on the intercooler air inlet duct.
• Remove the bolt (7) from the intercooler air outlet duct.
• Disconnect the intercooler air outlet duct (8) from the damper valve.
• Move the intercooler air outlet duct to one side.

• Remove:
  • the dipstick guide tube bolts (9) ,
  • the dipstick guide tube.
• Plug the opening of the dipstick guide tube on the cylinder block.
• Remove the damper valve.

• Disconnect the connector (10) from the turbocharger pressure sensor.
• Remove:
  • the turbocharger pressure sensor housing (11) ,
  • the exhaust gas recirculation rigid pipe between
    the exhaust gas recirculation solenoid valve and the exhaust gas cooler,
  • the EGR solenoid valve,
  • the starter ,
  • the intercooler,
  • the front right-hand wheel,
  • the front right-hand wheel arch liner,
  • the accessories belt,
  • the alternator,
  • the multifunction support.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the intake distributor bolts (12) ,
  • the intake distributor nuts (13) ,
  • the inlet manifold,
  • the inlet manifold gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

• Clean:
  • the cylinder head joint face,
  • the intake distributor joint face,
  • the exhaust gas recirculation rigid pipe joint faces,
  • the turbocharger pressure sensor housing joint faces,
  • the damper valve seal face.
• Always replace:
  • the inlet manifold gasket,
  • the exhaust gas recirculation rigid pipe between
    the exhaust manifold and the exhaust gas cooler,
  • the exhaust gas recirculation rigid pipe seal on the exhaust manifold,
  • the exhaust gas recirculation rigid pipe seals,
  • the exhaust gas recirculation rigid pipe clip,
  • the rigid exhaust gas recirculation pipe bolts,
  • the coolant outlet unit seal,
  • the gasket between the intake distributor and the EGR solenoid valve.
  • the seal between the turbocharger pressure sensor housing and the EGR solenoid valve,
  • the seal between the damper valve and the turbocharger pressure sensor housing,
  • the intercooler air inlet duct seal.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the new intake distributor seal,
  • the inlet manifold,
  • the inlet manifold nuts and bolts.
• Pretighten to torque and in order the inlet manifold nuts and bolts (15 N.m).
• Torque tighten in order the inlet manifold nuts and bolts (25 N.m).

III - FINAL OPERATION.

• Refit:
  • the multifunction support
  • the alternator
  • the accessories belt
  • the front right-hand wheel arch liner
  • the front right-hand wheel
  • the intercooler
  • the starter
  • the new seal between the EGR solenoid valve and the intake distributor
  • the EGR solenoid valve
  • the new exhaust gas recirculation rigid pipe seals
  • the exhaust gas recirculation rigid pipe between
    the exhaust gas recirculation solenoid valve and the exhaust gas cooler
  • the new seal between the turbocharger pressure sensor housing and the EGR solenoid valve
  • the turbocharger pressure sensor housing.
• Connect the turbocharger pressure sensor connector.
• Refit:
  • the seal between the damper valve and the turbocharger pressure sensor housing,
  • the damper valve.
• Remove the plug from the opening of the dipstick guide tube on the cylinder block.
• Torque tighten the dipstick guide tube bolts (10 N.m).
• Connect the intercooler air outlet duct to the damper valve.
• Refit the intercooler air outlet duct bolt.
• Torque tighten:
  • the intercooler air outlet duct bolt (8 N.m),
  • the intercooler air outlet duct clip (6 N.m) using the tool (Mot. 1608).
• Connect the damper valve wiring connector.
• Refit:
  • the exhaust gas recirculation rigid pipe seal on the exhaust manifold
  • the exhaust gas recirculation rigid pipe between the exhaust manifold and the exhaust gas cooler
  • the coolant outlet unit seal
  • the water chamber
  • 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.
• Refit 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 opening of the oil separator.
• Connect the oil vapour rebreathing hose to the oil separator.
• Fit the intercooler air inlet duct assembly onto the intercooler air inlet pipe.
• Torque tighten the intercooler air inlet hose clip (6 N.m) using the tool (Mot. 1608).

• 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 battery tray
  • the battery
  • the scoop under the scuttle panel grille
  • the windscreen wiper mechanism
  • the scuttle half-grille
  • the windscreen wiper arms
  • 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

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.

• Remove the engine cover.
• Remove the air inlet sleeve.

• Disconnect the cover (1) from the Protection and Switching Unit.

• Remove the fuse (2) of the fuel pump(F13) (15A).
• Release the fuel pressure in the fuel pipe after starting the engine.

• Remove:
  • the battery
  • the battery tray
  • the air filter unit
  • the engine cover
  • the air resonator located on the rocker cover
  • the air inlet duct.

• Remove the plug of the fuel supply union.

• Disconnect the quick-release union (3) using the tool (Mot. 1869) (4) as illustrated.

• Remove the petrol vapour rebreathing pipe clip (6) .
• Disconnect the petrol vapour rebreathing pipe (7) .

• Remove the clips (8) of the oil vapour rebreathing hose.
• Disconnect the oil vapour rebreathing hose (9) .

• Remove the clip (10) from the vacuum pipe of the brake servo.
• Disconnect the vacuum pipe (11) from the brake servo.
• Remove:
  • the windscreen wiper arms
  • the scuttle panel half-grille
  • the windscreen wiper mechanism
  • the scoop under the scuttle panel grille.
• Disconnect the motorised throttle valve connector.

• Remove:
  • in order the motorised throttle valve bolts,
  • the motorised throttle valve without disconnecting the coolant pipes.

• Move aside the throttle valve (12) .

• Remove:
  • the intake distributor support bolts (13) and (14) ,
  • the intake distributor support (15) ,
  • the seal.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • in order, the intake distributor bolts and nuts,
  • the inlet manifold (16) ,
  • the intake distributor seal,
  • the intake distributor adapter (17) ,
  • the intake distributor adapter seal.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the intake distributor seal,
  • the intake distributor adapter seal,
  • the motorised throttle valve seal.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the new intake distributor adapter seal,
  • the intake distributor adapter,
  • the new intake distributor seal,
  • the inlet manifold,
  • the intake distributor nuts and bolts.

• Torque tighten in order the intake distributor nuts and bolts (20 N.m).

III - FINAL OPERATION

• Refit:
  • the new intake distributor support seal,
  • the intake distributor support,
  • the intake distributor support bolts.
• Torque tighten the intake distributor support bolts (20 N.m).
• Refit:
  • the new motorised throttle valve seal,
  • the motorised throttle valve bolts.

• Torque tighten in order the motorised throttle valve bolts (8 N.m).
• Connect the motorised throttle valve connector.
• Refit:
  • the scoop under the scuttle panel grille
  • the windscreen wiper mechanism
  • the scuttle panel half-grille
  • the windscreen wiper arms.
• Connect the brake servo vacuum pipe.
• Refit the clip of the vacuum pipe of the brake servo.
• Connect the oil vapour rebreathing hoses.
• Refit the clips of the oil vapour rebreathing hose.
• Disconnect the petrol vapour rebreathing pipe.
• Refit the petrol vapour rebreathing pipe clip.
• Connect the quick-release union of the fuel supply.

• Remove the fuel supply union plug.
• Refit:
  • the air inlet duct
  • the air resonator located on the rocker cover
  • the engine cover
  • the air filter unit
  • the battery tray
  • the battery
  • the fuel pump fuse
  • the Protection and Switching Unit cover.
• Refit the air intake sleeve.