battery RENAULT KANGOO 1997 KC / 1.G Chassis Workshop Manual

FRONT AXLE
Stub axle carrier bearing
31
SPECIAL TOOLING REQUIRED
Rou. 15 -01 Shaft protector
Rou. 604 -01 Hub locking tool
T.Av.476 Ball joint extractor
T.Av. 1050-02 Tool for pushing driveshaft back
Driveshaft nut 28
Wheel bolts 9
Shock absorber base nut 18
Brake caliper mounting bolt 10
Track rod end nut 3.7
Key nut on stub axle carrier 5.5
83348G
REMOVAL
Disconnect the battery.
Remove:
- the wheel,
- the brake caliper and attach it to the spring so
the pipe is not damaged,
- the track rod end using tool
T.Av. 476,
- the driveshaft nut.
Push back the driveshaft using tool :
T. Av. 1050-02.
Remove:
- the brake disc,
- the lower ball joint nut and key,
- the two shock absorber base bolts,
- the hub / stub axle carrier / bearing assembly.
TIGHTENING TORQUES (in daN.m)Remove the hub on the press.
Remove the lower bush from the hub using an ex-
tractor with jaws and tool Rou. 15-01.
Remove the locking spring ring from the stub axle
carrier.
On the press remove the remainder of the bea-
ring, taking care to take the weight on the inner
bush using a tube of the same diameter.
31-7

FRONT AXLE
Engine sub-frame
Remove:
- the two nuts for the steering rack heat shield,
- the mounting nuts for the steering rack and
attach it to the exhaust manifold.
31
12988R
SPECIAL TOOLING REQUIRED
Mot. 1040 -01 Dummy sub-frame for removing/refitting engine/transmission assembly
T. Av. 476 Ball joint extractor
REMOVAL
Disconnect the battery.
Put the vehicle on a two post lift.
Remove the wheels.
Disconnect the track rod ends using tool T. Av.
476.
Remove the key on the stub axle carrier.
Release but do not remove the mudguards to
reach the upper bolt on the sub-frame - side mem-
ber tie rod and remove it.
Remove:
- the exhaust downpipe and attach the catalytic
converter,
- the bolt (engine side) for the engine tie bar.
- the gear control by removing the two bolts at
the ends of the control. To do this, the cataly-
tic converter heat shield must be removed and
the gaiter on the gearbox side must also be re-
moved.
TIGHTENING TORQUES (in daN.m)
Wheel bolts 9
Track rod end nut 3.7
Steering universal joint bolt 2.5
Sub-frame mounting bolt front Ø10 6
rear Ø 12 10.5
Sub-frame - side member tie rod nut 3
Key nut on stub axle carrier 5.5
Engine tie bar 6.5
Steering box mounting bolt 5
Fit tool Mot. 1040-01 under the engine sub-frame.
12993-1R1
31-12

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
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

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

MECHANICAL ELEMENT CONTROLS
External gear control
37
Mounting nut for unit on body 1.5
Linkage mounting clip bolt on clevice 2
Linkage mounting bolt on clevice 3
Linkage - lever mounting nut 3
TIGHTENING TORQUES (in daN.m)
REMOVAL
Disconnect the battery.
In the vehicle, remove the gaiter from the console
and remove the two mounting bolts.
12985R
Under the vehicle:
- release the primary exhaust pipe,
- remove the bolts from the heat shield cover.
12988R
Remove:
- the lever - linkage mounting nut,
- the four nuts mounting the control unit.
12987R
37-24

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
BOSCH ABS
38
DIAGNOSTIC SOCKET
PRN3807
4Chassis earth
5Electronic earth
7Diagnostic line K
15Diagnostic line L
16+ battery
38-7

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
BOSCH ABS
38
13138R
Pipe unions M10 × 100 1.7
M12 × 100 1.7
TIGHTENING TORQUES (in daN.m)
REMOVAL
Put the vehicle on a two post lift.
Disconnect the battery.
Remove the front right hand wheel.
Fit a pedal press to limit the amount of brake
fluid which will run out.
From above:
Disconnect the computer connector.
Remove the two earth bolts.
Disconnect the six pipes from the hydraulic assem-
bly, marking their position for refitting.
From below:
Remove:
- the exhaust downpipe,
- the exhaust manifold heat shield ( 3 bolts),
- the two lower mounting bolts for the hydraulic
assembly,HYDRAULIC ASSEMBLY
13139R
- the hydraulic assembly via the wheel arch.
Remove the upper hydraulic assembly mounting
bolt ( 1 ).
REFITTING
Refitting is the reverse of removal.
NOTE : the computer must not be removed. If
there is a fault, replace the complete hydraulic as-
sembly.
38-8