lock RENAULT KANGOO 1997 KC / 1.G Engine And Peripherals User Guide

ENGINE AND ENGINE PERIPHERALS
Oil pump
10
Refit:
- the oil pump onto the engine and tighten it to
a torque of 0.9 daN.m,
- the new seal onto the crankshaft output wi-
thout damaging it when passing the timing
sprocket drive groove.
Position it with the aid of tool Mot. 1355..
99788R
Refit the strainer with a new O-ring.
Clean the sealing surfaces (cylinder block, sump).
Refit the sump.
Tighten the bolts to a torque of 1 daN.m.
Refit:
- the timing belt (see method described in
section 11 "Timing belt"),
- the new alternator and power assisted stee-
ring pump belts (see tension values in section
07 "Accessories belt tension"). D7F engine
10-31

TOP AND FRONT OF ENGINE
Timing belt
11
REFITTING
Line up the markings of the timing belt with
those of the camshaft and crankshaft sprockets.
10072S
PROCEDURE FOR TENSIONING TIMING BELT
Remove pin Mot. 1054.
Fit the spacer (1) of tool Mot. 1386 and tighten
the crankshaft sprocket bolt.
10881R
a)Fit tool Mot. 1273 and, using tool
Mot. 1135-01, turn the tension wheel anti-
clockwise until the value of 20 US is obtained
(turn the sensor wheel until it is tight, as indi-
cated by three clicks).
10479R1
IMPORTANT: The camshaft sprocket bears five
markings, of which only the rectangular one on
the surface of one of the teeth represents TDC;
the other markings are intended as an aid for ad-
justing the valve rockers.
D7F Engine
11-3

TOP AND FRONT OF ENGINE
Timing belt
11
Tighten the tension wheel nut.
Turn the engine at least twice (never in the op-
posite direction to normal operation).
Insert the pin in the engine at TDC, then remove
the pin .
Check that the timing is correct on the crankshaft
and camshaft side.
Slacken the tension wheel nut and turn it slightly
clockwise using tool Mot. 1135-01 until the two
holes of the tension wheel are lined up
horizontally.
Retighten the tension wheel nut.
b)Turn the engine at least twice (never in the
opposite direction to normal operation).
Insert the pin in the engine at
TDC then re-
move the pin.
Using tool Mot. 1386, apply a pretensioning
torque of 1 daN.m between the crankshaft
sprocket and the water pump.
Fit tool Mot. 1273 and note the tension measure-
ment, which should be 20±
3 US (fitting tension),
or simply adjust by varying the position of the
tension wheel using Mot. 1135-01 and repeat the
tensioning process in (b).
Tighten the tension wheel nut to a torque of
5 daN.m.
IMPORTANT
Following each variation of the tension wheel
position, turn the engine at least twice before
proceeding to measure the tension .
Apply the pretensioning of 1 daN.m which allows
all belt play to be eliminated.
Refitting is the reverse of removal.
Fit the suspended engine mounting .
12924S1
10881R
D7F Engine
11-4

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
92076S
CLEANING
It is very important not to scratch the gasket faces
of the aluminium components.
Use the Décapjoint product to dissolve any part of
the gasket which remains attached.
Apply the product to the parts to be cleaned; wait
about ten minutes, then remove it using a
wooden spatula.
Wear gloves whilst carrying out this operation.
Care must be taken whilst carrying out this ope-
ration in order to avoid any foreign bodies ente-
ring the oilways supplying oil under pressure to
the camshaft (oilways are located both in the cy-
linder block and the cylinder head).
Failure to follow to this advice could lead to the
blocking of the jets and thus cause rapid deterio-
ration of the cams and tappets.
CHECKING THE GASKET FACE
Check for gasket face bow using a straight edge
and a set of shims .
Maximum deformation : 0.05 mm.
No regrinding of the cylinder head is permitted.
REFITTING
The cylinder head is centred by two dowels at the
rear of the engine.
REMINDER: in order to obtain the correct tighte-
ning of the bolts, use a syringe to remove any oil
which may have entered the cylinder head moun-
ting bolt holes .
Grease the threads and under the bolt heads with
engine oil.
Adjustment of the valve rockers and tightening
of the cylinder head should be carried out when
the engine is cold. D7F Engine
11-14

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
ADJUSTMENT OF VALVE ROCKERS (IF
NECESSARY)
Partly refit the suspended engine mounting ti-
ming cover on the engine using two bolts.
Bring the engine to TDC , cylinder n. 1 in ignition
phase .
Turn the crankshaft clockwise (viewed from the
timing side ) to reach the first reference mark.
ADJUST :exhaust 1
exhaust 3
move forward to the second mark :
ADJUST:inlet 1
inlet 3
third mark :
ADJUST: exhaust 2
exhaust 4
fourth mark :
ADJUST:inlet 2
inlet 4
10072S
99905S
Refitting is the reverse of removal.
Remove the tool retaining the engine on the sub-
frame, Mot. 1379.
NOTE : tightening the inlet manifold :
- progressively hand tighten the six nuts until
the inlet manifold comes into contact with the
cylinder head, then tighten them to a torque
of 1.5 daN.m,
- fit the upper bolts and tighten them to a tor-
que of 0.9 daN.m.
Fill and bleed the cooling circuit.
Adjust the accelerator cable.
VALVE CLEARANCE ADJUSTMENT VALUE
(in mm)
Inlet0.05
Exhaust0.15 D7F Engine
11-16

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
SPECIAL TOOLING REQUIRED
DEPOSE
Place the vehicle on a 2 post lift .
Disconnect the battery.
Remove :
- the bonnet ,
- the timing belt (see method described in sec-
tion 11, "Timing belt ").
Drain the cooling circuit through the lower radia-
tor hose.
Fit tool Mot. 1159 between the engine subframe
and the cylinder block.
99024R2
EQUIPMENT REQUIRED
Engine support tool
55mm torx socket
Mot. 588 Retaining bracket
Mot. 591-02 Index
Mot. 591-04 Angle tightening angular
wrench
Mot. 1159 Tool for retaining engine on
subframe
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1311-06 Tool for removing fuel pipe
Tension wheel nut 5
Crankshaft pulley bolt 2 + 68° ± 6°
Bolt for suspended engine mounting 6.2
cover
Nut for suspended engine mounting cover 4.4
Wheel bolts 9
TIGHTENING TORQUES (in daN.m or /and °)
E7J Engine
11-17

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
13339S
- the cover on the air filter assembly,
- the air filter assembly,
13338S
99310R
Remove :
- the connector along with the pipe on the ab-
solute pressure sensor,
- the stepping motor connector, Fit the bracket Mot. 1159 in place of the coolant
pipe mounting on the cylinder block, then remove
the engine support tool.- the throttle position potentiometer connec-
tor,
- the accelerator cable
- the air intake pipe, having disconnected the
air temperature connector, E7J Engine
11-18

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
Unhook the wiring loom at (14).
Remove :
- the cylinder head bolts except for (F) which
must simply be loosened, then pivot the cylin-
der head around the bolt.
92106R
- the cylinder head .
Fit the cylinder liner retaining brackets, tool
Mot. 588.
92062R
- the mounting at (10),
- the bolt (11) of the strut and slacken the nut
at (12),
- the mounting bolt (13) of the dipstick guide
tube,
13336-1R1
E7J Engine
CLEANING
It is very important not to scratch the gasket faces
of the aluminium components.
Use the Décapjoint product to dissolve any part of
the gasket which remains attached.
Apply the product to the parts to be cleaned; wait
about ten minutes, then remove it using a
wooden spatula.
Wear gloves whilst carrying out this operation.
Care must be taken whilst carrying out this ope-
ration in order to avoid any foreign bodies ente-
ring the oilways supplying oil under pressure to
the camshaft (oilways are located both in the cy-
linder block and the cylinder head).
Failure to follow to this advice could lead to the
blocking of the jets and thus cause rapid deterio-
ration of the cams and tappets.
11-20

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
SPECIAL TOOLING REQUIRED
REMOVAL
Place the vehicle on a two post lift .
Disconnect the battery.
Remove :
- the bonnet,
- the timing belt (see method described in
section 11 "Timing belt").
Drain the cooling circuit via the lower radiator
hose.
EQUIPMENT REQUIRED
Engine support tool
55mm torx socket
Mot. 251-01 Dial gauge support tool
Mot. 252-01 Plate for measuring piston
protrusion
Mot. 591-02 Index
Mot. 591-04 Angular tightening wrench
Mot. 1054
TDC pin
Mot. 1159 Tool for mounting engine on
subframe
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1311-06 Tool for removing fuel pipe
Tension wheel nut 5
Crankshaft pulley bolt 2 + 115° ± 15°
Bolt for suspended engine mounting cover 6.2
Nut for suspended engine mounting cover 4.4
Wheel bolts 9
TIGHTENING TORQUES (in daN.m or/and°)
99024R2
Fit tool Mot. 1159 between the subframe and
the cylinder block. F8Q Engine
11-23

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
Remove :
- the exhaust downpipe,
- the hoses and connectors of the cylinder head
coolant pipe housing outlet,
- the connection at (1) using tool Mot. 1311-06,
13097R
99461R
- the air filter assembly by disconnecting the
EGR solenoid valve and the air temperature
sensor (unclip the fuel supply pipes from the
air filter housing),
- the air inlet pipe
- the accelerator cable
- the feeds for the heater plugs ,
- the connector of the injector with sensor,
along with the fast idle solenoid valve connec-
tor (5),
- the fuel supply and return unions at (A) and
(B).
Disconnect connector (6) from the diesel fuel fil-
ter, remove it from its support and move the die-
sel fuel filter pipe assembly to one side. Place bracket Mot. 1159 at the mounting of the
coolant pipe on the cylinder block, then remove
the engine support tool.
99310R
F8Q Engine
11-24