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

Contents
Consumables
Identification
Oil consumption
Oil pressure
Engine - Gearbox
Engine and transmission assembly
Sump
Crankshaft seal, timing end
Oil pump10-1
10-1
10-2
10-3
10-4
10-9
10-25
10-29
10-30
TOP AND FRONT OF ENGINE
Timing belt
Cylinder head gasket
Replacement of valve adjustersPage Page
11
Engine and
peripherals
11-1
11-11
11-29 ENGINE AND PERIPHERALS
10FUEL SUPPLY -
DIESEL EQUIPMENT
Fuel supply
Fuel cut off in case of an impact
Injector gallery
Fuel filter
Pump flow
Fuel pressure
Antipercolation device
Diesel equipment
General
Specifications
Location of components
Advance solenoid valve
Altimetric corrector
Fast idle LDA
Coded solenoid valve
Load potentiometer
Computer configuration
Injector with sensor (needle
lift)
Injection warning light
Pre-postheating control
Fast idle control
Injection/air conditioning
programming
Computer
Defect modes
Pump
Pump -Timing
Idle speed settings13-1
13-2
13-6
13-7
13-8
13-12
13-13
13-14
13-16
13-19
13-22
13-25
13-26
13-28
13-29
13-31
13-32
13-33
13-35
13-36
13-36
13-37
13-38
13-39
13-41
13-4613
FUEL MIXTURE
Specifications
Throttle body
Inlet manifold
Exhaust manifold
Inlet-exhaust manifolds12-1
12-7
12-15
12-18
12-2012

12mm torx socket
Angular tightening wrench
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
SPECIAL TOOLING REQUIRED
Mot. 591-04 Angle wrench for tightening
cylinder head and index
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1379 Tool for securing engine to
subframe
EQUIPMENT REQUIRED
TIGHTENING TORQUES (in daN.m)
Crankshaft output mounting bolt 2 + 90°
Mounting bolt for front right suspended
engine mounting on engine 6.2
Mounting bolt for front right suspended
engine mounting on vehicle body 6.2
Timing belt tension wheel nut 5
Wheel bolts 9
REMOVAL
Put the vehicle on a 2 post lift.
Remove the bonnet, and the right hand wheel .
Disconnect the battery.
Drain the cooling circuit.
Fit the engine support tool, Mot. 1379.Remove:
- the timing belt (see method described in
section 11 "Timing belt"),
- the dipstick,
- the brake servo pipe,
- the air filter,
- the accelerator cable,
- the fuel supply and return pipes level with the
timing belt cover on the cylinder head
D7F Engine
11-11

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
- the canister pipe along with the fuel vapour
rebreathing hoses on the solenoid valve,
- the connectors :
• of the ignition module,
• of the injectors,
• of the idle speed regulation stepping
motor,
• of the throttle position potentiometer,
• of the air temperature sensor.
Extract the hose connecting the water pump to
the heater matrix, and the electrical wiring loom
from the heat shield on the rocker cover.
99940R
Disconnect :
- the spark plug leads using tool (3) which is in-
tegrated to the plastic cover (4),
99894R1
D7F Engine
11-12

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
Remove :
- the mounting bolts (5) for the throttle body retaining bracket on the
cylinder head,
- the mounting nuts (3) for the manifold on the cylinder head
- the mounting bolts (4) of the manifold on the valve rocker cover
- the inlet manifold, throttle body and injector gallery assembly.
- the thermostat hoses,
- the valve rocker covers,
- the cylinder head mounting bolts,
- the cylinder head.
99937R1
D7F Engine
11-13

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
99902S
Tighten the cylinder head using an angular tighte-
ning wrench (see section 07 "Tightening the cy-
linder head").
Tighten using tool Mot. 591-04.
Line up the reference marks on the timing belt
with the markings on the sprockets.
10072S
Remove the TDC pin .
Refit the timing belt (see method described in
chapter 11 "Timing belt "). D7F Engine
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.
11-15

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

- the heat shield along with the exhaust down-
pipe,
- the alternator,
- the mounting at (8) along with connector (9)
of the pressostat,
- the mounting bolt for the power assisted
steering pump and move this to one side ,
- the mounting bolts for the multi-function sup-
port and move this to one side,
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
13365S
13364R1
13360R
- the connectors and hoses on the thermostat
support , - the connectors of the ignition coils, along
with the connector at (1),
- the coil (2),
- the pipes at (3) along with the connector (4),
- the pipe at (5),
- the lifting bracket (6),
- the fuel supply and return pipes (7) using tool
Mot. 1311-06,
- the injector connectors,
- the cylinder head cover , E7J Engine
11-19