Renault Koleos Service Repair Manual: 2TR, and 6-SPEED MANUAL GEARBOX

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift.

• Remove the engine undertray.
• Drain the manual gearbox.
• Remove:
  • the battery
  • the battery tray

• Unclip the breather hose clip (1) .
• Remove:
  • the breather hose clip (2) ,
  • the breather hose (3) ,
  • the engine cover,
  • the air inlet sleeve ,
  • the air resonator,
  • the air filter box.

• Remove:
  • the bolts (4) from the battery tray bracket,
  • the battery tray bracket (5) ,
  • the bolts (5) from the wiring harness channel.
• Remove the wiring harness channel (7) .
• Disconnect:
  • the selector cable
  • the gear lever cable

• Disconnect:
  • the neutral switch (8) ,
  • the reverse gear switch (9) .
• Unclip:
  • the clip (10) from the reverse gear switch wiring,
  • the gearbox wiring clips (11) .

ELECTRONIC STABILITY PROGRAM 2 or ELECTRONIC STABILITY PROGRAM

• Disconnect the 1st gear position switch (12) .
• Unclip the clips from the 1st gear position switch wiring (13) .

• Remove:
  • the front left-hand wheel
  • the front left-hand wheel arch liner
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the intermediate pipe
  • the rear suspended engine mounting
  • the front axle subframe .

4X4 TRANSMISSION

• Disconnect the propshaft from the transfer box.
• Secure the propshaft to the control cable bracket using a strap.
• 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.
• Remove the starter.

• Remove the engine wiring harness nuts (18) .
• Move the engine wiring to one side.

• Fit:
  • the lifting eye (19) ,
  • the lifting eye bolts (20) .
• Torque tighten the lifting eye bolts (28 N.m).

• Remove the hood seals (21) .

• Fit the (Mot. 1453) (22) .
• Remove the left-hand suspended engine mounting.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the gearbox mounting bolt A (23) ,
  • the gearbox mounting bolts B (24) ,
  • the gearbox mounting bolt C (25) .

• Remove:
  • the gearbox mounting bolt B (26) ,
  • the gearbox mounting bolts D (27) ,
  • the gearbox mounting bolts E (28) .
• Fit the component jack underneath the manual gearbox.
• Remove the manual gearbox.

III - FINAL OPERATION

• Remove the clutch thrust bearing.

• Remove:
  • the selector cable bracket bolts (29) ,
  • the selector cable bracket (30) ,
  • the gear lever cable bracket bolts (31) ,
  • the gear lever cable bracket (32) ,
  • the clutch pipe bracket bolt (33) ,
  • the clutch pipe bracket (34) .

ELECTRONIC STABILITY PROGRAM 2 or ELECTRONIC STABILITY PROGRAM

• Remove:
  • the switch wiring bolt (35) ,
  • the switch wiring bracket (36) .

REFITTING

I - REFITTING PREPARATION OPERATION

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

• Check that the centring dowels (37) are in place.
• Refit:
  • the clutch pipe bracket,
  • the clutch pipe bracket bolt,
  • the gear lever cable bracket,
  • the gear lever cable bracket bolts,
  • the selector cable bracket,
  • the selector cable bracket bolts,
  • the earth bracket,
  • the earth strap bolt.
• Torque tighten:
  • the clutch pipe bracket bolt (14 N.m),
  • the gear lever cable bracket bolts (17 N.m), the selector cable bracket bolts (17 N.m), the earth strap bracket bolt (25 N.m).

ELECTRONIC STABILITY PROGRAM 2 or ELECTRONIC STABILITY PROGRAM

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

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the manual gearbox,
  • the gearbox mounting bolt A,
  • the gearbox mounting bolt B,
  • the gearbox mounting bolt C,
  • the gearbox mounting bolt D,
  • the gearbox mounting bolt E.
• Torque tighten:
  • the gearbox mounting bolt A (35 N.m),
  • the gearbox mounting bolt B (75 N.m),
  • the gearbox mounting bolt C (75 N.m),
  • the gearbox bolt D (43 N.m),
  • the gearbox bolt E (43 N.m).

III - FINAL OPERATION

• Refit the left-hand suspended engine mounting.
• Remove:
  • tool (Mot. 1453)
  • the lifting eye bolts,
  • the lifting eye.
• Torque tighten the engine wiring harness nuts (10 N.m).
• Refit the bonnet seals.

4X4 TRANSMISSION

• Refit:
  • the transfer box
  • the propshaft

• Refit:
  • the earth strap,
  • the earth strap bolt.
• Torque tighten the earth strap bolt (14 N.m).
• Refit:
  • the clutch control pipe,
  • the clutch control pipe clip,
  • the starter .
• Connect:
  • the neutral switch,
  • the reverse gear position switch.
• Clip:
  • the reverse gear position switch wiring clip,
  • the neutral switch wiring clips.

4X4 TRANSMISSION

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

• Refit:
  • the intermediate pipe
  • the front left-hand driveshaft
  • the front right-hand driveshaft
  • the front axle subframe
  • the rear suspended engine mounting
• Connect:
  • the selector cable
  • the gear lever cable
• Refit:
  • the battery tray bracket,
  • the battery tray bracket bolts,
  • the wiring bracket,
  • the wiring bracket bolts.
• Torque tighten:
  • the battery tray bracket bolts (28 N.m),
  • the wiring bracket bolts28 (N.m).
• Refit:
  • the air filter box,
  • the air resonator,
  • the air inlet sleeve,
  • the engine cover,
  • the breather hose,
  • the breather hose clip.
• Clip on the breather hose clip.
• Refit:
  • the battery tray
  • the battery
• Refill:
  • the brake fluid,
  • the manual gearbox with oil
• Bleed the hydraulic clutch control .
• Refit:
  • the front left-hand wheel arch liner
  • the front left-hand wheel
  • the engine undertray.