torque RENAULT KANGOO 1997 KC / 1.G Chassis Owner's Guide

STEERING ASSEMBLY
Axial ball joint
36
Put the vehicle on a two post lift.
REMOVAL
Disconnect the track rod end using tool T.Av. 476.
Slacken the bolt on the parallelism adjustment
sleeve and slacken the track rod end while
holding the axial ball joint using an open wrench.
Make a mark or count the number of turns of
thread taken up so the parallelism can be pre-
adjusted on refitting.
Remove the plastic retaining clip for the gaiter
and remove the gaiter.
SPECIAL TOOLING REQUIRED
Wheel bolts 9
Track rod end nut 3.7
Bolt on parallelism adjustment sleeve 1.7
Axial ball joint 5
Dir. 1305-01 Tool for removing - refitting
axial ball joint
Dir. 1306 Tool for retaining SMI unit rack
T.Av. 476 Ball joint extractor
TIGHTENING TORQUES (in daN.m)Turn the wheels so the rack teeth are freed on the
valve side.
Fit tool Dir. 1306.
In this position, release the axial ball joint using
tool Dir. 1305-01.
97469R1
36-1

STEERING ASSEMBLY
Axial ball joint
36
REFITTING
Assembly (2) MUST be renewed systematically.
83510-1R3
Refit to the rack (3) :
- the stop washer assembled with the locking
ring (2),
- the new axial ball joint (1) having lightly coated
the threads with
LOCTITE FREN-BLOC, ensuring
that the air evacuation opening is not blocked.
Before finally tightening the axial ball joint using
tool Dir. 1305-01, check that the tabs on the
locking ring (2) align with the flats (B) on the rack.
Tighten the axial ball joint to the recommended
torque.
Centre the steering to equalise the air in the
gaiters.
Fit a new gaiter and secure it with a new clip
(after greasing the gaiter bearing surface on the
axial ball joint).
Checking
Gently press on the gaiter to check the other
gaiter inflates which indicates the air is circulating
correctly.
36-2

STEERING ASSEMBLY
Manual steering rack
36
Put the vehicle on a two post lift.
REMOVAL
Remove the front wheels.
Cut the rubber gaiter retaining clip and push the
gaiter back towards the bulkhead.
Disconnect the ball joints using tool T.Av. 476.
Remove:
- the universal joint eccentric bolt,
- the steering rack mounting bolts on the sub-
frame.
Remove the steering rack.
SPECIAL TOOLING REQUIRED
Wheel bolts 9
Track rod end nut 3.7
Steering rack mounting bolts 5.5
Universal joint eccentric bolt 2.5
T.Av. 476 Ball joint extractor
TIGHTENING TORQUES (in daN.m)REFITTING
Refitting is the reverse of removal. Observe the
recommended tightening torques.
If a new steering rack is being fitted, fit the track
rod ends in the position noted on removal.
To do this, slacken the bolt on the parallelism
adjustment sleeve and slacken the track rod end
while holding the axial ball joint using an open
wrench.
Make a mark or count the number of turns of
thread taken up so the parallelism can be pre-
adjusted on refitting.
Check the parallelism.
NOTE : the markings on the track rod ends MUST
BE OBSERVED
(one mark on right hand joint, two
marks on left hand joint).
36-3

STEERING ASSEMBLY
Power assisted steering rack
36
SPECIAL TOOLING REQUIRED
Mot. 453-01 Hose clamp pliers
T.Av. 476 Ball joint extractor
Wheel bolts 9
Track rod end nut 3.7
Steering rack mounting bolt 5
Universal joint eccentric bolt 2.5
Engine tie bar bolt 6.5
TIGHTENING TORQUES (in daN.m)
Put the vehicle on a two post lift.
REMOVAL
Remove the front wheels.
Fit a clamp Mot. 453-01 to each of the pipes from
the oil reservoir.
NOTE :never clamp the high pressure pipes.
Cut the rubber gaiter retaining clip and push the
gaiter back towards the bulkhead.
Disconnect the ball joints using tool T.Av. 476.
Remove the universal joint eccentric bolt.
Disconnect the oxygen sensor.
Remove the exhaust downpipe.
Remove the bolt (engine side) from the engine tie
bar and pivot the engine and transmission
assembly forwards.
Insert a retaining block.
Special notes for F8Q engine
Remove (from above) :
- the battery,
- the battery mounting,
- the high and low pressure pipes from the
steering valve.
13120S
36-4

STEERING ASSEMBLY
Power assisted steering rack
36
Disconnect the high and low pressure pipes on the
steering rack (take precautions to catch the oil)
and the nut on the pipe retaining bracket.
Remove:
- the two nuts on the heat shield for the right
hand steering rack bearing,
- the steering rack mounting nuts and remove it
from the timing side.
NOTE :
- do not remove the pipes between the valve
and cylinder,
- fit plugs to the steering rack openings to
prevent the introduction of impurities.
12997R
REFITTING
Refitting is the reverse of removal. Observe the
recommended tightening torques.
Fill the circuit with oil.
Turn the wheels from left to right (engine not
running) to distribute the oil in the circuit.
Repeat the operation with the engine running
then top up the level.
If a new steering rack is being fitted, fit the track
rod ends in the position noted on removal.
To do this, slacken the bolt on the parallelism
adjustment sleeve and slacken the track rod end
while holding the axial ball joint using an open
wrench.
Make a mark or count the number of turns of
thread taken up so the parallelism can be pre-
adjusted on refitting.
Check the parallelism.
36-5

STEERING ASSEMBLY
Steering column
36
TIGHTENING TORQUES (in daN.m)
REMOVAL
Disconnect the battery.
Set the vehicle wheels straight.
Remove the steering wheel in the following
manner.
Without airbag option
Remove the plastic cover.
Remove:
- the steering wheel bolt (this
MUST be renewed
on refitting),
- the steering wheel after noting its position.
With airbag option
REMOVAL
Disconnect the battery.
Remove:
- the driver’s airbag cushion by the two Torx T30
bolts (tightening torque 0.5 daN.m) located
behind the steering wheel and disconnect the
connector ( D ),
IMPORTANT: pyrotechnic systems (airbags and
pretensioners) must not be handled near to a heat
source or flame - they may be triggered.
IMPORTANT : whenever the steering wheel is
removed, the airbag connector ( D )
MUST be
disconnected. The airbag is fitted with a
connector which short circuits when it is
connected to avoid any incorrect triggering.
12973S
- the horn connector, if fitted,
- the steering wheel bolt (this
MUST be renewed
on refitting),
- the steering wheel after setting the wheels
straight,
- the half cowlings ( three bolts).
Disconnect the rotary switch connector and
remove it after removing the three mounting
bolts ( E ).
When removing the switch, its position must be
noted:
• either by ensuring the wheels are straight when
removing it so that the track may be positioned
centrally,
• or by immobilising the rotary switch rotor with
adhesive tape.
Steering wheel bolt 4.5
Steering column universal joint
eccentric bolt 2.5
Steering column mounting nuts 2
36-12

STEERING ASSEMBLY
Steering column
36
IMPORTANT : if these instructions are not
followed exactly the system may not operate
normally and could even be triggered incorrectly.
IMPORTANT
Before reconnecting the driver’s airbag cushion,
check to see if the system is operating correctly as
follows:
•check the airbag warning light on the
instrument panel is illuminated when the
ignition is on,
•connect a dummy ignition module to the
driver’s airbag connector and check that the
warning light extinguishes,
•switch the ignition off, connect the airbag
cushion in place of the dummy ignition module
and secure the cushion to the steering wheel,
•switch the ignition on. Check the warning light
illuminates for three seconds when the ignition
is switched on then extinguishes and remains
extinguished.
If the warning light does not operate as described
above, refer to the fault finding section and check
the system using the
XRBAG (Elé. 1288).
SPECIAL NOTES FOR VEHICLES FITTED WITH A
DRIVER’S AIRBAG
Ensure that the wheels are still straight.
Check that the rotary switch is still immobilised
before refitting.
If it is not, follow the method for centring
described in section 88 "driver’s airbag".
Renew the steering wheel bolt each time it is
removed ( pre-bonded bolt).
Observe the correct tightening torque ( 4.5
daN.m).
36-16

MECHANICAL ELEMENT CONTROLS
Master cylinder
37
Hydraulic pipe unions 1.7
Mounting nut on brake servo 1.8
REMOVAL
Disconnect the battery.
Disconnect the brake fluid level detector
connector.
Remove the injection computer (depending on
version).
Release the PAS reservoir and move it to the side,
towards the engine.
Drain and remove, by pulling up, the brake fluid
reservoir (take care to catch the fluid which will
run out).
Remove:
- the pipes and note their positions,
- the two mounting nuts on the brake servo.
REFITTING
Refitting is the reverse of removal.
Check the length of the pushrod.
Dimension X = 22.3 mm.
Depending on model, adjust using pin (P).
91101R
NOTE : these vehicles have a master cylinder
which is integral to the brake servo. Sealing of the
brake servo is directly linked to that of the master
cylinder. During any operation, a new seal (A)
must be fitted.
Fit the master cylinder in alignment with the
brake servo so that pushrod pin (P) enters
correctly into the master cylinder housing.
TIGHTENING TORQUES (in daN.m)
DI3718
37-1

MECHANICAL ELEMENT CONTROLS
Brake servo
TIGHTENING TORQUES (in daN.m)
Mounting nut on brake servo 1.8
Brake servo on bulkhead 2.3
- remove the 4 brake servo mounting nuts,
- remove the brake servo.
REFITTING
Before refitting, check:
-dimension L = 104.8 mm ,
-dimension X = 22.3 mm .The brake servo cannot be repaired. Operations
are only allowed on:
- the air filter,
- the non-return valve.
REMOVAL
Disconnect and remove the battery.
Remove:
- the master cylinder (following the method
described previously),
- the battery protection plate (4 bolts, 1 nut),
- the two mounting nuts for the expansion
bottle and move it towards the engine.
Disconnect the flexible vacuum hose from the
brake servo.
In the passenger compartment:
- remove the pin ( A ) from the clevice
connecting the brake pedal to the pushrod by
moving the clip,
37
91101R2
97860R
Refitting is the reverse of removal.
Bleed the brake circuit.
37-3

96118R
MECHANICAL ELEMENT CONTROLS
Brake pipes
37
These vehicles have brake pipes without a copper seal. The seal is by contact "at the bottom of the cone" of
the shoulder (Y) on the pipe.
X = 1.5
Z= 1.3
TIGHTENING TORQUES (in daN.m)
PRECAUTIONS TO BE TAKEN WHEN REMOVING - REFITTING A BRAKE CYLINDER OR A BRAKE PIPE.
For safety reasons and to ensure that the brake pipe is not twisted and is not liable to touch a suspension
component the following order of operations must be observed:
Remove the hose from the caliper and if necessary
remove the caliper.
REMOVAL
Slacken the union (1) (pipe wrench) between the
rigid pipe and the hose (2) until the spring (3)
becomes slack which releases the hose from the
splines (4).
85536R
REFITTING
Fit the caliper to the brake and screw the hose
onto it, then torque tighten to
1.5 daN.m.
The brake pipes are fitted when the axle assembly
is in position:
• Wheels suspended (suspension in place)
• Axle assembly aligned (wheels straight)
Position the female end of the hose on the
retaining bracket (5), without twisting it and
check that the end piece (4) fits freely into the
splines of the bracket, then fit:
- the spring (3),
- the rigid pipe to the hose, checking that the
hose does not turn when the assembly is
screwed together.
Torque tighten the union.
Bleed the brake circuit.
37-10