Renault Koleos Service Repair Manual: Fuel tank: Removal - Refitting

M9R

REMOVAL

I - OPERATION FOR REMOVAL OF PART CONCERNED

• Position the vehicle on a two-post lift .
• Disconnect the battery.
• Lift up:
  • the rear bench seat base
  • partially, the floor carpet under the rear bench seat base
• Drain the fuel tank.

• Remove the inspection flap blanking cover (1) .

• Disconnect:
  • the fuel sender connector (2) ,
  • the quick-release union (3) from the fuel supply pipe,
  • the quick-release union (4) from the fuel return pipe.

• Fit blanking plugs on the unions.

• Remove:
  • the silencer bracket bolts (5) on the particle filter,
  • the silencer from the rubber mounting bushes (6) and (7) .

4X4 TRANSMISSION

• Remove the longitudinal driveshaft (8).

• Remove:
  • the fuel tank heat shield (9) ,
  • the rear right-hand wheel ,
  • the rear right-hand wheel arch liner.

• Remove the fuel filler neck bolts (10) .

• Remove the fuel filler neck bracket (11) .
• Disconnect the filler neck from the fuel tank.

• Remove:
  • the breather pipe bolt (12) ,
  • the breather pipe bracket (13) .
• Disconnect the breather pipe.

• Remove:
  • the clips (14) ,
  • the covers (15) ,
  • the rear final drive subframe strut bolts (16) ,
  • the rear final drive subframe struts,
  • the parking brake cable.

4X4 TRANSMISSION

• Disconnect the connector (17) from the electric coupler.
• Unclip the wiring clip (18) .

• Loosen the rear final drive nut (19) .

• Remove the rear final drive bolts (20) .

• Tilt the rear final drive downwards.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Place a component jack beneath the fuel tank.

• Remove:
  • the fuel tank retaining strap bolts (21) ,
  • the fuel tank retaining straps,
  • the fuel tank.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the clips,
  • the fuel filler neck bracket,
  • the breather pipe bracket.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the fuel tank,
  • the fuel tank retaining straps,
  • the fuel tank retaining strap bolts.
• Torque tighten the fuel tank retaining strap bolts (31 N.m)
• Remove the component jack.

III - FINAL OPERATION

4X4 TRANSMISSION

• Refit the rear axle in its original position.
• Torque tighten:
  • the rear axle bolts (63 N.m),
  • the rear axle nut (78 N.m).
• Clip on the wiring clip.
• Connect the electric coupler connector.

• Refit:
  • the parking brake cable,
  • the rear final drive subframe struts,
  • the rear final drive subframe strut bolts,
  • the covers (15) ,
  • the new clips (14) .
• Torque tighten the rear final drive subframe strut bolts (53 N.m).
• Connect the breather pipe.
• Refit:
  • the new breather pipe bracket,
  • the breather pipe bolt.
• Torque tighten the breather pipe bolt (9 N.m).
• Connect the fuel filler neck onto the fuel tank.
• Refit:
  • the new fuel filler neck bracket,
  • the fuel filler neck bolts.
• Torque tighten the fuel filler neck bolts (9 N.m).
• Refit:
  • the rear right-hand wheel arch liner,
  • the rear right-hand wheel,
  • the fuel tank heat shield.

4X4 TRANSMISSION

• Refit the longitudinal driveshaft.

• Refit:
  • the silencer on the rubber mounting bushes,
  • the silencer bracket bolts on the particle filter.
• Torque tighten the silencer bracket bolts on the particle filter (45 N.m).
• Remove the blanking plugs.
• Connect:
  • the fuel return pipe quick-release union,
  • the fuel supply pipe quick-release union,
  • the fuel tank sender unit connector.
• Refit the blanking cover on the inspection flap.
• Refit:
  • the floor carpet under the rear bench seat base.
  • the rear bench seat base.
• Connect the battery.

2TR

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.
• Disconnect the battery .
• Lift up:
  • the rear bench seat base
  • partially, the floor carpet under the rear bench seat base
• Drain the fuel tank.

• Remove the inspection flap blanking cover (1) .

• Disconnect:
  • the fuel sender connector (2) ,
  • the quick-release union (3) from the fuel supply pipe.

• Fit blanking plugs on the unions.

• Remove:
  • the silencer bracket bolts (4) on the catalytic converter,
  • the silencer from the rubber mounting bushes (5) and (6) .

4X4 TRANSMISSION

• Remove the longitudinal driveshaft (7).

• Remove:
  • the fuel tank heat shield,
  • the rear right-hand wheel,
  • the rear right-hand wheel arch liner.

• Remove the fuel filler neck bolts (8) .

• Remove the fuel filler neck bracket (9) .
• Disconnect the filler neck from the fuel tank.

• Remove:
  • the breather pipe bracket (10) ,
  • the fuel vapour rebreather pipe bracket (11) .
• Disconnect:
  • the breather pipe,
  • the petrol vapour rebreather pipe.

• Remove:
  • the clips (12) ,
  • the covers (13) ,
  • the rear axle subframe strut bolts (14) ,
  • the rear axle subframe struts,
  • the parking brake cable.

4X4 TRANSMISSION

• Disconnect the connector (15) from the electric coupler.
• Unclip the wiring clip (16) .

• Loosen the nut (17) on the rear axle.

• Remove the rear axle bolts (18) .

• Tilt the rear axle downwards.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Fit a component jack under the fuel tank.

• Remove:
  • the fuel tank retaining strap bolts (19) ,
  • the fuel tank retaining straps,
  • the fuel tank.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the fuel filler neck bracket,
  • the clips,
  • the breather pipe bracket,
  • the petrol vapour rebreathing pipe bracket.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the fuel tank,
  • the fuel tank retaining straps,
  • the fuel tank retaining strap bolts.
• Torque tighten the fuel tank retaining strap bolts (31 N.m)
• Remove the component jack.

III - FINAL OPERATION

4X4 TRANSMISSION

• Refit the rear axle in its original position.
• Torque tighten:
  • the rear axle bolts (63 N.m),
  • the rear axle nut (78 N.m).
• Clip on the wiring clip.
• Connect the electric coupler connector.

• Refit:
  • the parking brake cable
  • the rear axle subframe struts
  • the rear axle subframe bolts
  • the covers (13)
  • the new clips (12) .
• Torque tighten the rear axle subframe bolts (53 N.m).
• Connect:
  • the petrol vapour rebreathing pipe,
  • the breather pipe.
  • Refit:
  • the new petrol vapour rebreathing pipe bracket,
  • the new breather pipe bracket.
• Connect the fuel filler neck onto the fuel tank.
• Refit:
  • the new fuel filler neck bracket,
  • the fuel filler neck bolts.
• Torque tighten the fuel filler neck bolts (9 N.m).
• Refit:
  • the rear right-hand wheel arch liner
  • the rear right-hand wheel
  • the fuel tank heat shield.

4X4 TRANSMISSION

• Refit the longitudinal driveshaft.

• Refit:
  • the silencer on the rubber mounting bushes,
  • the silencer bracket bolts on the catalytic converter.
• Torque tighten the silencer bracket bolts on the catalytic converter (45 N.m).
• Remove the blanking plugs.
• Connect:
  • the fuel supply pipe quick-release union,
  • the fuel tank sender unit connector.
• Refit the blanking cover on the inspection flap.
• Refit:
  • the floor carpet under the rear bench seat base
  • the rear bench seat base
• Connect the battery.