Renault Koleos Service Repair Manual: Exhaust gas cooler: Removal - Refitting

M9R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.
• Remove:
  • the engine cover
  • the windscreen wiper arms
  • the scuttle panel half grille
  • the windscreen wiper mechanism
  • the scoop under the scuttle panel grille

• Rotate the intercooler air inlet pipe clip (1) on the turbocharger.

• Remove the intercooler air inlet pipe bolt (2) from the fuel supply pipe bracket.
• Move the intercooler air inlet pipe to one side.
• Remove the engine undertray.
• Drain the cooling system.
• Remove:
  • the air inlet sleeve clips,
  • the air inlet sleeve from the air filter unit,
  • the battery,
  • the battery tray,
  • the air filter box.
• Loosen the air filter unit air outlet pipe clip on the turbocharger.
• Disconnect:
  • the oil vapour rebreathing pipe from the oil separator,
  • the air filter unit air outlet pipe from the turbocharger.
• Fit a blanking plug into the oil separator opening.
• Remove:
  • the intake distributor,
  • the exhaust gas recirculation rigid pipe between the exhaust manifold and the exhaust gas cooler.

• Disconnect the connector (3) from the damper valve wiring.
• Loosen the clip (4) on the intercooler air outlet pipe.
• Remove the intercooler air outlet pipe bolt (5) .
• Disconnect the intercooler air outlet pipe (6) from the damper valve.
• Move the intercooler air outlet pipe to one side.

• Remove:
  • the bolts (7) from the dipstick tube,
  • the dipstick tube.
• Fit a blanking plug on the opening of the dipstick guide tube on the cylinder block.
• Remove the damper valve.

• Disconnect the turbocharger pressure sensor connector (8) .
• Remove:
  • the turbocharger pressure sensor housing (9) ,
  • the exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation cooler,
  • the starter motor.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the vacuum hose (10) from the exhaust gas cooler,
  • the clip (11) from the exhaust gas cooler water outlet pipe using the tool (Mot. 1448),
  • the clip (12) from the exhaust gas cooler water inlet hose using the tool (Mot. 1448).
• Disconnect:
  • the exhaust gas cooler water outlet pipe from the exhaust gas cooler,
  • the exhaust gas cooler water inlet hose from the exhaust gas cooler.
• Remove:
  • the bolts (13) from the exhaust gas cooler,
  • the exhaust gas intercooler.

REFITTING

I - REFITTING PREPARATION OPERATION

• Clean:
  • the exhaust gas recirculation rigid pipe joint faces,
  • the exhaust gas recirculation solenoid valve seal face,
  • the turbocharger pressure sensor housing seal faces,
  • the damper valve seal face.
• Always replace:
  • the exhaust gas recirculation rigid pipe between
    the exhaust manifold and the exhaust gas cooler,
  • the exhaust gas recirculation rigid pipe seals,
  • the exhaust gas recirculation rigid pipe clip,
  • the bolts securing the exhaust gas recirculation rigid pipe on the exhaust manifold,
  • the inlet manifold gasket,
  • the seal between the turbocharger pressure sensor housing and the exhaust gas recirculation solenoid valve,
  • the seal between the damper valve and the turbocharger pressure sensor housing.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the exhaust gas cooler,
  • the exhaust gas cooler bolts.
• Torque tighten the exhaust gas cooler bolts (25 N.m).
• Connect:
  • the exhaust gas cooler water inlet pipe to the exhaust gas cooler,
  • the exhaust gas cooler water outlet pipe to the exhaust gas cooler.
• Refit:
  • the clip on the exhaust gas cooler water inlet pipe using the tool (Mot. 1448),
  • the clip on the exhaust gas cooler water outlet pipe using the tool (Mot. 1448),
  • the vacuum hose on the exhaust gas cooler.

III - FINAL OPERATION.

• Refit:
  • the starter,
  • the new seals on the exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas cooler,
  • 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 exhaust gas recirculation solenoid valve,
  • the turbocharger pressure sensor housing.
• Refit:
  • the new seal between the damper valve and the turbocharger pressure sensor housing,
  • the damper valve .
• Remove the blanking plug from the opening of the dipstick guide tube on the cylinder block.
• Refit:
  • dipstick guide ,
  • the dipstick guide tube bolts.
• Torque tighten the dipstick guide tube bolts (10 N.m).
• Connect the intercooler air outlet pipe to the damper valve.
• Torque tighten:
  • the intercooler air outlet pipe bolt (8 N.m),
  • the intercooler air outlet pipe clip (6 N.m) using the tool (Mot. 1608).
• Connect the damper valve wiring connector.
• Refit:
  • the new 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 new seal on the inlet manifold,
  • the inlet manifold,
  • the inlet manifold hoses and pipes.
• Refit the air filter unit.
• Connect the air filter unit air outlet pipe 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.

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

• Refit the new intercooler inlet pipe seal.
• Rotate the intercooler inlet pipe to refit the clip in its housing.
• Clip the intercooler inlet pipe onto the turbocharger.
• Refit the intercooler air inlet pipe bolt to the fuel supply pipe bracket.
• Torque tighten the intercooler air inlet pipe bolt (8 N.m).
• Refit:
  • the battery tray
  • the battery
  • the scoop under the scuttle panel grille
  • the windscreen wiper mechanism
  • the scuttle panel grille
  • the windscreen wiper arms
  • the air inlet sleeve to the air filter unit
  • the air inlet sleeve clips.
• Fill the cooling system.
• Bleed the cooling system .
• Refit:
  • the engine cover,
  • the engine undertray.