Renault Koleos Service Repair Manual: Exhaust manifold: Removal - Refitting

M9R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.
• Remove:
  • the engine cover,
  • the engine undertray,
  • the clips from the air inlet sleeve,
  • the air intake sleeve on the air filter unit,
  • the battery,
  • the battery tray,
  • 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.
• Drain the engine cooling circuit .

• Disconnect:
  • the connector (1) from the EGR bypass solenoid valve,
  • the vacuum hoses (2) from the EGR bypass solenoid valve.
• Remove:
  •  the EGR bypass solenoid valve bolts (3) ,
  •  the EGR bypass solenoid valve,
  •  the coolant outlet unit.

• Remove:
  • the bolts (4) from the exhaust gas recirculation rigid pipe heat shield on the exhaust manifold and on the cylinder head,
  • the heat shield from the exhaust gas recirculation solenoid valve.

• Unclip:
  • the fuel pipes (5) ,
  • the electrical wiring (6) .
• Remove the bolts (7) from the intercooler water inlet pipe.
• Move the intercooler water inlet pipe to one side.

• Remove:
  • the bolts (8) of the exhaust gas cooler coolant inlet pipe support from the intake distributor,
  • the exhaust gas cooler coolant inlet pipe support.

• Unclip the cooling hose (9) from the turbocharger.
• Remove:
  • the exhaust gas recirculation rigid pipe between
    the exhaust manifold and the exhaust gas cooler
  • the catalytic converter
  • the turbocharger

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the nuts and spacers from the exhaust manifold,
  • the exhaust manifold,
  • the exhaust manifold gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the exhaust manifold studs, if they have been loosened during the removal operation,
  • the exhaust manifold nuts,
  • the exhaust manifold gasket.
• Clean and degrease the bearing faces:
  • of the exhaust manifold, if it is to be reused,
  • of the cylinder head,
  • of the exhaust gas recirculation rigid pipe heat shield.
• Check if the exhaust manifold studs are torque tightened to 9 N.m. Otherwise replace the exhaust manifold studs which are loosened.
• Torque tighten the exhaust manifold studs (9 N.m) using a roller-type stud removal tool.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the new exhaust manifold gasket,
  • the exhaust manifold,
  • the spacers.
• Finger tighten the new exhaust manifold nuts until they are in contact.

• Pretighten to torque and in order the exhaust manifold nuts (18 N.m).
• Torque tighten in order the exhaust manifold nuts (30 N.m).

III - FINAL OPERATION

• Refit:
  • the turbocharger
  • the catalytic converter
  • the exhaust gas recirculation rigid pipe between
    the exhaust manifold and the exhaust gas cooler
• Clip the cooling hose (9) onto the turbocharger.
• Fit the exhaust gas cooler coolant inlet pipe support onto the intake distributor.
• Refit the exhaust gas cooler coolant inlet pipe support bolts.
• Torque tighten the exhaust gas cooler coolant inlet pipe support bolts (10 N.m).
• Position the intercooler water inlet pipe.
• Refit the intercooler water inlet pipe bolts.
• Torque tighten the intercooler water inlet pipe bolts (10 N.m).
• Clip:
  • the electrical wiring (6) ,
  • the fuel pipes (5) .
• Position the heat shield for the exhaust gas recirculation rigid pipe.
• Refit the EGR rigid pipe heat shield bolts
• Torque tighten the exhaust gas recirculation rigid pipe heat shield bolts (10 N.m).
• Refit:
  • the coolant outlet unit
  • 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.
• Remove:
  • the scoop under the scuttle panel grille
  • the windscreen wiper mechanism
  • the scuttle 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 pipe 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 pipe to the oil decanter.
• Refit:
  • the battery tray
  • the battery
  • 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.
• Disconnect the battery.
• Remove the engine undertray.

• Remove:
  • the exhaust connecting pipe rubber mounting bush support nuts (1) ,
  • the exhaust connecting pipe nuts (2) ,
  • the connector pipe (3) ,
  • the seal,
  • the front right-hand wheel,
  • the front wheel arch liner.

• Disconnect the oxygen sensor connectors .

• Remove:
  • the oxygen sensors (4)
  • the accessories belt (5)
  • the windscreen washer bottle neck
  • the alternator (6)
  • the dipstick (7)
  • the dipstick guide tube bolt (8)
  • the dipstick guide tube (9)
  • the O-ring.

• Remove:
  • the bolts (10) from the exhaust manifold upper heat shield,
  • the upper heat shield (11) from the exhaust manifold.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the exhaust manifold nuts in order,
  • the exhaust manifold (12) .

• Remove:
  • the bolts (13) from the exhaust manifold lower heat shield,
  • the lower heat shield (14) from the exhaust manifold.

• Remove:
  • the bolts (15) from the catalytic pre-converter heat shield,
  • the catalytic pre-converter heat shield (16) .

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the seals,
  • the O-ring.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the catalytic pre-converter heat shield,
  • the catalytic pre-converter heat shield bolts.
• Torque tighten the catalytic pre-converter heat shield bolts (6 N.m).
• Refit:
  • the exhaust manifold lower heat shield,
  • the exhaust manifold lower heat shield bolts.
• Torque tighten the exhaust manifold lower heat shield bolts (6 N.m).
• Refit:
  • the new exhaust manifold gasket,
  • the exhaust manifold,
  • the exhaust manifold nuts.

• Torque tighten in order:
  • the exhaust manifold nuts (initial torque) (15 N.m),
  • the exhaust manifold nuts (42 N.m).

III - FINAL OPERATION

• Refit:
  • the exhaust manifold upper heat shield,
  • the exhaust manifold upper heat shield bolts.
• Torque tighten the exhaust manifold upper heat shield bolts (6 N.m).
• Refit:
  • the new O-ring,
  • the dipstick guide tube,
  • the dipstick guide tube bolt,
  • the dipstick.
• Torque tighten the dipstick guide tube bolt (22 N.m).
• Refit:
  • the alternator
  • the windscreen washer bottle neck
  • the accessories belt
  • the oxygen sensors
• Connect the oxygen sensor connectors.
• Refit:
  • the front wheel arch liner
  • the front right-hand wheel
  • the new seal
  • the connector pipe
  • the exhaust connecting pipe nuts
  • the exhaust connecting pipe rubber mounting bush support nuts.
• Torque tighten:
  • the exhaust connecting pipe nuts (65 N.m),
  • the exhaust connecting pipe rubber mounting bush support nuts (14 N.m).
• Refit the engine undertray.
• Connect the battery.