Mount RENAULT ESPACE 2000 J66 / 3.G Technical Note 3426A Workshop Manual

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Page
07
10
11
12
16
VALUES AND SETTINGS
Capacities - Grades 07-1
Tightening the cylinder head 07-2
ENGINE AND PERIPHERALS
Identification 10-1
Oil pressure 10-2
Engine and transmission assembly 10-3
TOP AND FRONT OF ENGINE
Accessories belt 11-1
Timing belt 11-2
Cylinder head gasket 11-8
TURBOCHARGING - FUEL
MIXTURE
Turbocharger 12-1
Air inlet 12-3
Exhaust manifold 12-7
Inlet manifold 12-8
STARTING - CHARGING
Alternator 16-1
Starter 16-4Page
19
21
61
62
COOLING SYSTEM
Filling - bleeding 19-1
Diagram 19-2
Coolant pump 19-3
Suspended mountings 19-4
Cooling system 19-5
MANUAL GEARBOX
Identification 21-1
Gears 21-2
Lubricants 21-3
Remove and refit 21-4
HEATING
Additional heating 61-1
AIR CONDITIONING
Air conditioning compressor 62-1

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Engine and transmission assembly
10
10-3
Engine and transmission assembly
Parts to order: high pressure circuit plugs kit
Part No.: 77 01 206 381. SPECIAL TOOLING REQUIRED
Mot. 1390 Universal mounting
Mot. 1410 Tool for unlocking the snap
couplings in the refrigerant
circuit
Dir. 1282 -01 Spanner for undoing the
steering rack union
Dir. 1282 -02 Spanner for undoing the
steering rack union
ESSENTIAL SPECIAL TOOLING
Two-post lift
Safety pad or belts
TIGHTENING TORQUES (in daN.m)
Shock absorber base mounting bolts
Ø M16 x 200 20
Driveshaft gaiter mounting bolt 2.5
Wheel bolts 10
Engine tie-bar bolts 10
Suspended mounting bolt to gearbox 5.5 to 6.5
Rubber suspended mounting nut to
the front left side member 5.5 to 8
Mounting bolt for front right
suspended mounting cover to engine 6.2
Mounting bolt for the movement
limiter of the upper front right hand
suspended engine mounting 10.5
Mounting nut for the rubber pad on
the front right suspended engine
mounting cover 3 to 4.5

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Engine and transmission assembly
10
10-7
Disconnect the lead from the engine compartment
connection unit; be sure to mark the location of the
various connections correctly.
Separate:
–a connector from the battery tray,
–the control solenoid valve from the turbocharger
regulation valve.
Fit hose pliers on the clutch master cylinder supply
pipe (on the brake fluid tank side).
Open the clutch slave cylinder bleed screw
(WARNING: you must use a counter-spanner at (C)
to compensate the effort of loosening/retightening
the bleed screw (A); see Technical Note 3345A).Disconnect:
Left side:
–the clutch slave cylinder high pressure union and
release the pipe from its clips,
–the water hoses connecting the engine to the tank
and the heater matrix element.
Right side:
–the diesel supply (1) and return (2) element from the
injection pump to the filter. It is essential that you plug
the openings with the appropriate plugs from kit
Part No.: 77 01 206 381,
–the inertia switch connector (3),
–the air conditioning circuit low pressure pipe on the
mounting bracket on the throttle body.
Under the vehicle:
–the booster pump connector; refit the electric wiring
harness to the engine.
15583R
18240-1M2
17527M1

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Engine and transmission assembly
10
10-8
Prepare the universal mounting tool Mot. 1390 and
position it beneath the engine and transmission
assembly (two people).Remove:
–the right-hand suspended mounting cover,
–the travel limiter linkage located just behind this
cover,
–the left-hand suspension axis mounting nut.
Gently raise the vehicle in relation to the engine (two-
person operation).
IMPORTANT: when lifting, hold on to the gearbox
control cables to prevent them from becoming trapped
and being damaged.
14935M1

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Engine and transmission assembly
10
10-9
REFITTING - Special points
Pre-position the gearbox control cables.
Position the engine/gearbox assembly in its
compartment. Check the rear of the gearbox in relation
to the sub-frame.
Fitting suspended mountings: see section 19
"Suspended mountings".
Tighten all the bolts, nuts and studs to the
recommended torques.
Refitting is the reverse of removal.
Press the brake pedal several times to bring the
pistons into contact with the brake pads.
Reprogram all the components deprogrammed by
disconnecting the battery.
Fill the refrigerant circuit using the filling station (see
section 62 "Air conditioning").
Refrigerant fluid R134a: 800 ± 20 g.
Carry out:
–filling and bleeding of the cooling circuit (see
section 19),
–filling and bleeding of the power assisted steering
circuit,–bleed the hydraulic clutch circuit.
Damage to the union leads to replacement of the
master cylinder, and thus removal/refitting of the
gearbox.IT IS ESSENTIAL THAT YOU FOLLOW THE
BLEEDING METHOD GIVEN BELOW
VERY IMPORTANT:
When bleeding use a 19 mm ring spanner to
immobilise the rotating union (C) while tightening
and loosening the bleed screw (A) so as not to
damage the slave cylinder and the union.
15583R

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Timing belt
11
11 - 2
Timing belt
REMOVAL
Disconnect the battery.
If necessary, place the vehicle on a two-post lift.
Remove the right-hand side member soundproofing.
Remove the travel limiter linkage.
Turn the steering to full right-hand lock.
Remove the front right wheel arch cover. Adjust the engine cylinder n˚ 1 to top dead centre
(marking (1) on the crankshaft pulley) and pin the
crankshaft after removing the cap (A). SPECIAL TOOLING REQUIRED
Mot. 1390 Engine and transmission
assembly mounting tool
Mot. 1536 TDC setting pin
Mot. 1534 Inlet camshaft timing/locking
tool
Mot. 1537 Exhaust camshaft timing/
locking tool
TIGHTENING TORQUES (in daN.m)
Tensioner nut 2.6
Fixed roller nut 3.3
Timing cover bolt 1
Suspended mounting limiter bolt 10.5
Suspended mounting cover bolt 6.2
Wheel bolts 10
15854M1

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Timing belt
11
11 - 3
Insert the mounting tool Mot. 1390 under the engine
and transmission assembly, positioning the right-hand
pads only underneath the engine. Lower the two
unused left-hand pads.
Remove the right-hand suspended engine mounting
cover.Remove the timing belt cover and the lower plastic
cover.
Check the position of the camshaft grooves as shown
below.
15394M2
17533M1
15850-6M1
17942R

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Timing belt
11
11 - 4
Fit the camshaft locking tools and tighten them
carefully to the cylinder head.
Release the tension in the timing belt by undoing the
timing tension wheel bolt.Remove:
–the exhaust camshaft sprocket by undoing the three
mounting bolts on the sprocket on the hub),
–the timing belt.
Remove tool Mot. 1537.
Remove the gear tensioner.
17943M1
15850M1
17553-2M

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Timing belt
11
11 - 5
–the pulley; remove the nut and take the pulley out
without removing the stud.
REFITTING
Fit:
–the pulley,
–the automatic tension wheel without tightening it and
position the groove (7) of the tension wheel correctly
in the pin,
–the three bolts at the centre of the inlet camshaft
sprocket holes (this must be free),
–the exhaust camshaft timing tool Mot. 1537.
Check that the crankshaft is at top dead centre.
Fit the timing belt at the same time as the exhaust
camshaft sprocket, and position the sprocket mounting
bolts at the centre of the holes.
Operation of the exhaust camshaft timing/locking tool
repeater: mobile mark (1) on the tension wheel pushes
the repeater (2) to the lower section (3). The upper
section has two edges (4) and (5) which, repeat the
position of the tension wheel index by aligning with the
edge (6) of the fixed section of the tool.Adjust the position of the tension wheel (by pivoting
the tension wheel eccentric anticlockwise) plus
approximately 5˚ by aligning sections (5) and (6).
16026M
17551M

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Timing belt
11
11 - 7
Tighten:
–bolt (8) of the tension wheel to a torque of 2.5 daN.m,
–the camshaft timing sprocket bolts (9) to a torque of
1 daN.m.Remove the camshaft timing tools Mot. 1534 and
Mot. 1537 and the TDC pin Mot. 1536.
Refit the cap in the TDC pin opening applying
RHODORSEAL 5661 to the thread and by tightening
to a torque of 2.2 daN.m.
Refitting is the reverse of removal.
To refit the right-hand suspended mounting, you must
consult section 19 "Suspended mountings".
17553M4
15854M