RENAULT KANGOO 1997 KC / 1.G Engine And Peripherals Workshop Manual

COOLING
Water pump
CLEANING
It is very important not to scratch the gasket faces
of all aluminium components.
Use the product Décapjoint to dissolve the part
of the gasket which remains attached.
Apply the product to the part to be cleaned, wait
approximately 10 minutes, then remove it using a
wooden spatula.
The wearing of gloves is recommended during
this operation.
19
SPECIAL TOOLING REQUIRED
Mot. 1054TDC pin
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1289-03 Tool for centring the suspended en-
gine movement limiter
Mot. 1379 Tool for retaining engine on sub-
frame
10478S
D7F Engine
Crankshaft output mounting bolts 2 + 90°
Bolt for mounting front right suspended
engine mounting on engine 6.2
Bolt for mounting front right suspended
engine mounting on vehicle body 6.2
Timing belt tension wheel nut 5
Water pump mounting bolt 0.9
TIGHTENING TORQUES (in daN.m)
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove:
- the timing belt (see method described in
section 11 "Timing belt),
- the power assisted steering pump pulley (if fit-
ted),
- the upper alternator mounting bolt and
slacken the lower bolt,
- the bolts for mounting the power assisted
steering pipe on the cylinder block,
- the bolts for mounting the power assisted
steering pump on its support (move the po-
wer assisted steering pump-pipe assembly to
one side),
- the power assisted steering pump support,
- the water pump hose,
- the tension wheel along with the water pump
itself.
19-7

COOLING
Water pump
Refitting is the reverse of removal.
Refit the timing belt (see method described in
section 11 "Timing belt").
Remember to remove the TDC pin.
19
10272R
D7F Engine
REFITTING
Special notes
Sealing of the water pump is carried out using
RHODORSEAL 5661, the bead (J) must be applied
following the illustration below.
Apply a bead of
LOCTITE 518 on the sealing sur-
face (L) between the inlet pipe elbow and the wa-
ter pump.
19-8

COOLING
Water pump
Refit the timing belt (see method described in
chapter 11 "Timing belt").
Fill and bleed the cooling circuit (see section 19
"Filling - Bleeding").
19
SPECIAL TOOLING REQUIRED
Mot. 591-02 Index
Mot. 591-04 Angle tightening wrench
Mot. 1135-01 Tool for tensioning the timing belt
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
92068R
E7J Engine
Tension wheel nut 5
Crankshaft pulley bolt 2 + 68° + 6°
Bolt for suspended engine mounting cover 6,2
Nut for suspended engine mounting cover 4,4
Water pump bolt 2,2
Water pump nut 1
Wheel bolts 9
TIGHTENING TORQUES (in daN.m)
EQUIPMENT REQUIRED
Engine support tool
REFITTING
The sealing of the water pump is carried out using
the product
LOCTITE 518; the bead (H) must be
applied following the diagram below.
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Drain the cooling circuit from the lower radiator
hose.
Remove:
- the timing belt (see method described in
section 11 "Timing belt),
- the timing tension wheel,
- the water pump, and extract this from above.
CLEANING
It is very important not to scratch the gasket faces
of all aluminium components.
Use the product Décapjoint to dissolve the part
of the gasket which remains attached.
Apply the product to the part to be cleaned, wait
approximately 10 minutes, then remove it using a
wooden spatula.
The wearing of gloves is recommended during
this operation.
19-9

COOLING
Water pump
19
SPECIAL TOOLING REQUIRED
Mot. 1202 Hose clip pliers
13090R
F8Q Engine
Water pump bolt 1.6
Bolt for water pump pulley 2
Bolt for crankshaft pulley 2 + 115° ± 15°
TIGHTENING TORQUES (in daN.m)
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Drain the cooling circuit through the lower radia-
tor hose.
Fit the engine support tool.
Remove :
- the plastic protector for the suspended engine
mounting cover,
- the suspended engine mounting cover,
EQUIPMENT REQUIRED
Engine support tool
- the front right wheel arch,
- the accessories belt,
- the crankshaft pulley (A),
- the water pump pulley (B) , lowering the en-
gine as far as possible,
- the injection pump housing (C),
- the bolt at (1) and move the alternator to the
right.
13086R1
19-10

COOLING
Water pump
CLEANING
It is very important not to scratch the gasket faces
of all aluminium components.
Use the product Décapjoint to dissolve the part
of the gasket which remains attached.
Apply the product to the part to be cleaned, wait
approximately 10 minutes, then remove it using a
wooden spatula.
The wearing of gloves is recommended during
this operation.
REFITTING
Refitting is the reverse of removal.
Refit and tension the accessories belt. (see section
07 "Accessories belt tension").
Fill and bleed the cooling circuit (see section 19
"Filling and bleeding").
19F8Q Engine
- the bolts mounting the water pump and extract
this from above.
13089S
19-11

EXHAUST
General
19
ATTACHMENT OF THE PIPE UNDER THE BODY
The attachment of the pipe under the body is by
the rubber mounting at (1).
This can generally be unhooked by hand by ta-
king the weight off the exhaust pipe.
However, in certain cases, it may be necessary to
slacken the bolts retaining the support ( 2) under
the body in order to more easily unhook the rub-
ber mountings. During operation, the catalytic converter reaches
high temperatures, and consequently, it is vital
not to park the vehicle in a place where combusti-
ble materials could come into contact with it, and,
as a result, ignite.
Under certain conditions, these materials could
ignite.
IMPORTANT:
- the seal, between the exhaust manifold gas-
ket face and the catalytic converter (inclu-
sive), must be in perfect condition,
_ it is imperative that every gasket removed be

REPLACED (especially at the catalytic converter
flange)
- during removal and refitting, the catalytic
converter must not undergo repeated mecha-
nical shocks, as it will be damaged.
CUTTING THE EXHAUST PIPE
The exhaust pipes are of the monoblock type.
There is no join from the beginning of the cataly-
tic converter or the expansion box, to the end of
the silencer.
It will therefore be necessary, when replacing one
of the components in After Sales, to cut the
exhaust pipe.
For this, it is absolutely essential to accurately :
- mark the area to be cut,
- use the cutting tool Mot. 1199-01,
- fit the after sales sleeve .
12847-1R
19-12

EXHAUST
General
19
MARKING THE AREA TO BE CUT
The area to be cut is defined by two punch marks
on the exhaust pipe.
99226-1R
Depending on engine, there are a maximum of
two cutting areas on the exhaust pipe, situated
between the catalytic converter and the
expansion box and between the expansion box
and the silencer.
The distance between the two markings is 90 mm.
To cut the tube, mark the central point (D) bet-
ween the two markings (P
1 and P2).
DI1901
90 mm
P
1P
2 D
IMPORTANT: to cut the exhaust pipe, it is essen-
tial to use tool Mot. 1199-01; this tool allows
2mm thick pipes to be cut.
19-13

EXHAUST
General
19
FITTING THE AFTER SALES SLEEVE
95478R1
Once a collar has been used once, renew it.
The nut on the collar has a groove (A) to ensure it
is tightened to the correct torque. When the nut is
tightened and the groove disappears, it causes a
distinct clicking sound and the nut is then tighte-
ned to the correct torque (2.5 daN.m).
NOTE : there are two different diameters of
sleeve available:
-∅ 50 mm,
-∅ 45 mm .
IMPORTANT:
- check that there is no point of contact bet-
ween the exhaust pipe and the vehicle body,
- check for the presence and correct positioning
of all heat shields for the exhaust pipe,
- check that the two cutting marks are correctly
aligned.
99227S
To avoid any leaks in the exhaust pipe, the sleeve
must be correctly positioned over the two exhaust
pipe sections. The pipe must be against the stops
inside the sleeve.
Begin by positioning the sleeve over the used sec-
tion of the pipe, adjust the collar by tightening
gently.
Check the position of the pipe in relation to the
stops.
Fit the new section of the pipe.
Before fitting the sleeve on the pipe, apply a little
mastic to the inner ring on the sleeve to prevent
leaks.
(Exhaust mastic, Part Number. 77 01 421 161
SODICAM).
IMPORTANT : the bolt and nut used for tighte-
ning the sleeve must be aligned vertically to
avoid any risks of touching the underside of the
body.
19-14

EXHAUST
Pipe assembly
19
DIAGRAM OF EXHAUST PIPES AND LOCATION OF CUTTING AREAS
1 Expansion box
2 Silencer
3 Catalytic converter
ZC Pipe cutting area
13124R
E7J Engine D7F Engine
13126R
19-15

EXHAUST
Pipe assembly
19
DIAGRAM OF EXHAUST PIPES AND LOCATION OF CUTTING AREAS
13125R
1 Catalytic converter
2 Silencer
ZC Pipe cutting area F8Q Engine
19-16