Renault Koleos Service Repair Manual: M9R, and 6-SPEED MANUAL GEARBOX

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.

• Remove the engine undertray.
• Drain:
  • the cooling system
  • the manual gearbox
• Remove:
  • the engine cover
  • the air inlet sleeve
  • the battery
  • the battery tray

• Unclip the breather hose clip (1) from the air filter.
• Remove:
  • the breather hose clip (2) ,
  • the breather hose (3) ,
  • the air filter box.

• Remove the bolts (4) from the engine wiring harness channel.
• Remove the wiring harness channel (5) .

• Remove:
  • the heater matrix coolant hose clips (6) ,
  • the bolt (7) from the heater matrix water outlet pipe,
  • the heater matrix coolant outlet pipe (8) .
• Disconnect:
  • the selector cable
  • the gear lever cable

• Remove the bolt (9) from the heater matrix inlet pipe.

• Disconnect:
  • the neutral switch (10) ,
  • the reverse gear switch (11) .
• Unclip:
  • the reverse gear switch wiring clips (12) ,
  • the gearbox wiring clips (13) .
• Remove:
  • the front wheels
  • the front left-hand wheel arch liner
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the particle filter
  • the rear suspended engine mounting
  • the front axle subframe.

4X4 TRANSMISSION

• Disconnect the propshaft from the transfer box.
• Secure the longitudinal driveshaft to the control cable bracket using a cord.
• Remove the transfer box.

• Remove:
  • the earth strap bolt (14) ,
  • the clip (15) from the clutch pipe.
• Disconnect:
  • the clutch control pipe (16) from the manual gearbox,
  • the clutch control pipe (16) from the clip (17) .
• Drain the clutch oil.

4X4 TRANSMISSION

• Unclip:
  • the 1st gear switch (18) ,
  • the 1st gear switch wiring clips (19) .

• Remove:
  • the diesel fuel drainage pipe bolts (20) ,
  • the diesel fuel drainage pipe (21) .

• Remove the hood seals (22) .

• Fit the (Mot. 1453) (23) .

• Remove:
  • the air filter unit bracket bolts (24) ,
  • the air filter unit support (25) ,
  • the left-hand suspended engine mounting bolt A (26) ,
  • the left-hand suspended engine mounting bolt B (27) ,
  • the starter.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the gearbox nuts (28) ,
  • the gearbox support studs (29) .
• Fit the component jack underneath the gearbox.

• Remove the lower bolts (30) from the gearbox.

• Remove:
  • the gearbox side bolts (31) ,
  • the manual gearbox.

III - FINAL REMOVAL OPERATION

• Remove the clutch thrust bearing.

• Remove:
  • the left-hand suspended engine mounting bolts (32) ,
  • the left-hand suspended engine mounting (33)
  • the selector cable bracket bolts (34) ,
  • the selector cable bracket (35) ,
  • the gear lever cable bracket bolts (36) ,
  • the gear lever cable bracket (37) ,
  • the heater matrix coolant pipe bracket bolts (38) ,
  • the heater matrix coolant pipe bracket (39) ,
  • the clutch pipe bracket bolt (40) ,
  • the clutch pipe bracket (41) .

4X4 TRANSMISSION

• Remove:
  • the switch wiring bracket bolt (42) ,
  • the switch wiring bracket (43) .

• Remove: - the earth strap bracket bolt (44) , - the earth strap bracket (45) .

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace the clutch thrust bearing.
• Refit the clutch thrust bearing.

• Check that the centring dowel (46) is in position.

• Check that the centring dowel (47) is in position.
• Refit:
  • the clutch pipe bracket,
  • the clutch pipe bracket bolt,
  • the heater matrix coolant pipe bracket,
  • the heater matrix coolant pipe bracket bolts,
  • the gear lever cable bracket,
  • the gear lever cable bracket bolts,
  • the selector cable bracket,
  • the selector cable bracket bolts,
  • the left-hand suspended engine mounting,
  • the left-hand suspended engine mounting bolts,
  • the earth bracket,
  • the earth strap bolt.
• Torque tighten:
  • the clutch pipe bracket bolt (14 N.m),
  • the heater matrix coolant pipe bracket bolts (25 N.m),
  • the gear lever cable bracket bolts (17 N.m),
  • the gear selector cable bracket bolts (17 N.m),
  • the left-hand suspended engine mounting bolts (45 N.m),
  • the earth strap bracket bolt (25 N.m).

4X4 TRANSMISSION

• Refit:
  • the switch wiring bracket,
  • the switch wiring bracket bolt.
• Torque tighten the switch wiring bracket bolt14 (N.m).

II - REFITTING OPERATION FOR THE PART CONCERNED

• Refit:
  • the manual gearbox,
  • the gearbox lower bolts,
  • the gearbox side bolts,
  • the gearbox mounting studs,
  • the gearbox nuts.
• Torque tighten:
  • the gearbox lower bolts (48 N.m),
  • the gearbox side bolts (48 N.m),
  • the gearbox mounting studs (20 N.m),
  • the gearbox nuts (48 Nm).

III - FINAL OPERATION

• Refit and tighten to torque:
  • the left-hand suspended engine mounting bolt A (110 N.m),
  • the left-hand suspended engine mounting bolt B (110 N.m),
• Refit:
  • the air filter box mounting,
  • the air filter unit bracket bolts.
• Torque tighten the air filter unit bracket bolts (10 N.m).
• Refit the starter.
• Remove the tool (Mot. 1453).
• Refit:
  • the hood seals,
  • the diesel drain pipe,
  • the diesel fuel drainage pipe bolts.
• Torque tighten the diesel fuel drainage pipe bolts (25 N.m).
• Connect:
  • the neutral switch,
  • the reverse gear switch.
• Clip:
  • the reverse gear switch wiring clips,
  • the gearbox wiring clips.

4X4 TRANSMISSION

• Connect the 1st gear switch.
• Clip on the 1st gear switch wiring clips.

• Refit:
  • the earth strap,
  • the earth strap bolt.
• Torque tighten the earth strap bolt (14 N.m).
• Connect:
  • the clutch control pipe to the manual gearbox,
  • the clutch control pipe onto the clip.
• Refit the clutch control pipe clip.

4X4 TRANSMISSION

• Refit:
  • the transfer box
  • the propshaft

• Refit:
  • the front axle subframe
  • the rear suspended engine mounting
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the particle filter
• Torque tighten the heater matrix water inlet pipe bolt (25 N.m).
• Connect:
  • the selector cable
  • the gear lever cable
• Refit:
  • the heater matrix water outlet pipe,
  • the heater matrix coolant outlet pipe bolt,
  • the heater matrix coolant hose clip.
• Torque tighten the heater matrix water outlet pipe bolt (25 N.m).
• Refit:
  • the air filter box
  • the breather hose,
  • the breather hose clip.
• Clip on the breather hose clip.
• Refit:
  • the wiring channel,
  • the wiring channel bolts.
• Torque tighten the wiring harness channel bolts (5 N.m).
• Refit:
  • the battery tray
  • the battery
  • the air inlet sleeve
  • the engine cover.
• Refill:
  • the brake fluid
  • the manual gearbox with oil
  • the cooling system
• Bleed the hydraulic clutch control .
• Refit:
  • the front left-hand wheel arch liner
  • the front wheels
  • the engine undertray.