Renault Koleos Service Repair Manual: Exhaust gas recirculation rigid pipe: Removal - Refitting

M9R

REMOVAL

I - REMOVAL PREPARATION OPERATION

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

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

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

• 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 battery
  • the battery tray
  • the air filter unit
• 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 windscreen wiper arms
  • the scuttle panel grille
  • the windscreen wiper mechanism
  • the scoop under the scuttle panel grille.
• Drain the cooling system.

• Disconnect:
  • the connector (3) from the EGR cooling bypass solenoid valve,
  • the vacuum hoses (4) from the EGR cooling bypass solenoid valve.
• Remove:
  • the EGR cooling bypass solenoid valve bolts (5) ,
  • the EGR cooling bypass solenoid valve,
  • the water chamber.

• Remove:
  • the bolts (6) from the exhaust gas recirculation rigid pipe heat shield on the exhaust manifold and the cylinder head,
  • the heat shield from the rigid exhaust gas recirculation pipe.

• Unclip:
  • the fuel pipes (7) ,
  • the wiring (8) .
• Remove the bolt (9) from the intercooler water inlet pipe.
• Move the intercooler water inlet pipe to one side.

• Remove:
  • the exhaust gas recirculation exchanger water inlet pipe bracket bolts (10) from the inlet manifold,
  • the exhaust gas recirculation exchanger water inlet pipe bracket.

• Unclip the turbocharger cooling hose (11) .

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

• Remove the front engine cover.
• Remove the battery.
• Remove the damper valve.

• Disconnect the turbocharger pressure sensor connector (12) .
• Remove:
  • the turbocharger pressure sensor housing (13) ,
  • the seal between the turbocharger pressure sensor housing and the exhaust gas recirculation solenoid valve.

II - OPERATION FOR REMOVAL OF PART CONCERNED

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

• Remove the clip (14) from the exhaust gas recirculation rigid pipe.

• Remove:
  • the bolt (15) securing the exhaust gas recirculation rigid pipe on the cylinder head,
  • the bolts (16) securing the exhaust gas recirculation rigid pipe on the exhaust manifold,
  • the exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger,
  • the exhaust gas recirculation exchanger rigid pipe seal.

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

• Remove:
  • the bolts (17) from the exhaust gas recirculation
    rigid pipe between the exhaust gas recirculation
    solenoid valve and the exhaust gas recirculation
    exchanger.
  • the exhaust gas recirculation rigid pipe between
    the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger,
  • the exhaust gas recirculation exchanger rigid pipe seals.

REFITTING

I - REFITTING PREPARATION OPERATION

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

• Clean the gasket faces.
• Always replace:
  • the exhaust gas recirculation exchanger rigid pipe,
  • the exhaust gas recirculation exchanger rigid pipe seal,
  • the exhaust gas recirculation exchanger rigid pipe clip,
  • the bolts securing the exhaust gas recirculation rigid pipe on the exhaust manifold,
  • the intercooler inlet pipe seal.

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

• Clean the gasket faces.
• Always replace:
  • the exhaust gas recirculation exchanger rigid pipe seals,
  • 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

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

• Refit:
  • the new exhaust gas recirculation rigid pipe with the new seal,
  • the exhaust gas recirculation exchanger rigid pipe clip,
  • the new bolts securing the exhaust gas recirculation rigid pipe on the exhaust manifold,
  • the bolt securing the exhaust gas recirculation rigid pipe on the cylinder head.
• Tighten to torque:
  • the exhaust gas recirculation rigid pipe clip (5 N.m) using tool (Mot. 1608),
  • the exhaust gas recirculation rigid pipe bolts on the exhaust manifold (35 N.m),
  • the bolt securing the EGR rigid pipe on the cylinder head (10 N.m).

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

• Refit:
  • the exhaust gas recirculation rigid pipe with the new seals,
  • the EGR rigid pipe bolts.
• Torque tighten the EGR rigid pipe bolts (25 N.m).

III - FINAL OPERATION.

1 - Exhaust gas recirculation exchanger rigid pipe between the exhaust manifold and the exhaust gas recirculation exchanger

• Unclip the turbocharger cooling hose.
• Position the exhaust gas recirculation exchanger water inlet pipe bracket on the inlet manifold.
• Refit the exhaust gas recirculation exchanger water inlet pipe bracket bolts.
• Torque tighten the exhaust gas recirculation exchanger water inlet pipe bracket 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).
• Refit:
  • the wiring harness,
  • the fuel pipes.
• Position the heat shield for the exhaust gas recirculation rigid pipe.
• Refit the rigid EGR pipe heat shield bolts.
• Torque tighten the exhaust gas recirculation rigid pipe heat shield bolts (10 N.m).
• Refit:
  • the water chamber
  • the water chamber hoses and pipes
• Position the exhaust gas recirculation cooling bypass solenoid valve.
• Refit the exhaust gas recirculation cooling bypass solenoid valve bolts.
• Torque tighten the exhaust gas recirculation cooling bypass solenoid valve bolts (10 N.m).
• Connect:
  • the vacuum hoses to the exhaust gas recirculation cooling bypass solenoid valve,
  • the exhaust gas recirculation cooling bypass solenoid valve connector.
• Refit:
  • the scoop under the scuttle panel grille
  • the windscreen wiper mechanism
  • the scuttle panel grille
  • the windscreen wiper arms
  • the air filter unit .
• Connect the air filter unit air outlet pipe to the turbocharger and the air filter unit.
• Torque tighten the air filter unit air outlet pipe clip (s5 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.

• Remove the intercooler inlet pipe seal using tweezers.

• Refit the new intercooler inlet pipe seal.
• Rotate the intercooler inlet pipe to refit the clip in its housing.
• Refit:
  • the intercooler inlet pipe on the turbocharger,
  • the intercooler air inlet pipe bolt on the fuel supply pipe bracket.
• Torque tighten the intercooler air inlet pipe bolt (8 N.m).
• Refit:
  • the air inlet sleeve to the air filter unit,
  • the air inlet sleeve clips,
  • the engine cover.
• Fill the cooling system .
• Bleed the cooling circuit.
• Refit the engine undertray.

2 - Exhaust gas recirculation rigid pipe between the exhaust gas recirculation solenoid valve and the exhaust gas recirculation exchanger.

• Refit:
  • the new seal between the turbocharger pressure sensor housing and the exhaust gas recirculation solenoid valve,
  • the turbocharger pressure sensor housing.
• Connect the turbocharger pressure sensor connector.
• Refit:
  • the new seal between the damper valve and the turbocharger pressure sensor housing,
  • the damper valve.
• Connect the battery.
• Refit the engine cover.