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

Contents
Page
Chassis
GENERAL
General diagram of braking circuits
Tightening torques (in daN.m)
Dimensions of the main braking
components
Bar specifications:
- front anti-roll bar
- rear anti-roll bar
- rear suspension bars
Brake unions and pipes
Brake fluid30
30-1
30-2
30-7
30-8
30-8
30-8
30-9
30-9
31-1
31-2
31-3
31-4
31-5
31-6
31-7
31-9
31-10
31-12
ENSEMBLE MOTEUR ET BAS
Lower wishbone
Lower wishbone rubber bushes
Lower wishbone ball joint
Brake pads
Front brake calipers
Brake discs
Stub axle carrier bearing
Spring and shock absorber assembly
Anti-roll bar
Engine sub-frameFRONT AXLE31
35-1
35-4Specifications
Wheel balancing
WHEELS AND TYRES35
33-1
33-2
33-4
33-5
33-7
33-8
33-9
33-10
33-11
33-15
33-16
33-20Rear axle assembly
Brake drum
Brake cylinder
Brake linings (drum)
Bearing
Shock absorber
Anti-roll bar, tubular rear axle
Half suspension arms, tubular rear
axle
Bushes, tubular rear axle
Suspension bars, tubular rear axle
Four bar rear axle
Suspension arm bearings
REAR AXLE33

Master cylinder
Brake servo
Air filter - Brake servo non-return
valve
Vacuum pump
Handbrake control lever
Handbrake control
Brake pipes
Braking compensator
Clutch control cable
Clutch automatic wear take-up
system
External gear control37-1
37-3
37-5
37-6
37-7
37-8
37-10
37-11
37-22
37-23
37-24
Contents
Page
MECHANICAL ELEMENT CONTROLS37
38-1
38-2
38-3
38-4
38-5
38-6
38-7
38-8
38-9
BOSCH ABS
Presentation of BOSCH ABS 5.3
Location of components
Presentation of the hydraulic
regulation assembly
Wiring diagram
Wiring diagram key
31 track connector
Diagnostic socket
Hydraulic assembly
Hydraulic braking test
ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEMS38STEERING ASSEMBLY
Axial ball joint
Manual steering rack
Power assisted steering rack
Gaiter
Steering rack pinion
Manual steering assistance pump
Steering column
36-1
36-3
36-4
36-6
36-7
36-8
36-12
36

91563S
GENERAL
General diagram of braking circuits
30
NOTE : the diagram below shows the general principle ; in no case should it be taken as reference for the
circuit connections and allocations. When replacing one of the components of the brake circuit on a vehicle,
always mark the pipes before removing them so that they can be connected back in their original positions.
"X" PATTERN BRAKING
with load sensitive compensator
30-1

FRONT BRAKES (in mm)
Diameter of wheel cylinders
Diameter of discs
Thickness of discs
Minimum disc thickness
Pad thickness (including backing)
Minimum pad thickness (including backing)
Maximum disc run-out
REAR BRAKES (in mm)
Diameter of wheel cylinders
Diameter of drums
Maximum drum wear diameter
Diameter of discs
Thickness of discs
Minimum disc thickness
Lining size
Secondary
Lining thickness (including backing)
Primary
Minimum lining thickness (including backing)
MASTER CYLINDER (in mm)
Diameter
GENERAL
Dimensions of the main braking components
30
FC0X
KC0X
CUS
FC0X
KC0X
CUA
54
238.2
20
17.7
17.8
5.5
0.07
22
203.2
204.45
-
-
-
38
3.15 (ABS) - 2.8(no ABS)
4.6 (ABS) - 4.2(no ABS)
2
22.254
238.2
20
17.7
17,8
5.5
0.07
22
228.3
229.5
-
-
-
40
4.8 (ABS) - 4.5(no ABS)
2
22.2
CUS : Standard payload
CUA : Increased payload
30-7

Brake fluid
78491R
GENERAL
Brake unions and pipes
30
The connection of the pipes between the master
cylinder, calipers, compensator and the hydraulic
assembly is made using threaded unions with a
METRIC THREAD.
Consequently, only parts specified in the Parts
Catalogue for this vehicle should be used.
Identification of parts
- SHAPE of the ends of PIPES in steel or copper
(A),
- SHAPE of the THREADED LOCATIONS on
components (B),
- pipe UNIONS coloured GREEN or BLACK:
HEXAGONAL OUTSIDE 11 mm or 12 mm (C).
BRAKE FLUID RENEWAL FREQUENCY
Braking technology, in particular for disc brakes (hollow pistons which transmit little heat, low volume of
fluid in the cylinder, sliding calipers avoiding the need for a fluid reservoir in the least cooled area of the
wheel), has allowed us to avoid the risk of vapour lock as far as possible, even if the brakes are used
intensively (in mountainous areas).
Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of
humidity and replacement of the fluid is therefore recommended (refer to vehicle’s Warranty and Servicing
Handbook).
Topping up the level:
Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should
not be compensated for since the level will rise again when the pads are changed. The level should not
however be allowed to fall below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to
deterioration of the cups. To avoid such risks, it is important to use only those brake fluids which have been
tested and approved by our Technical Department and which conform to standard SAE J 1703 dot 4.
30-9

FRONT AXLE
Brake pads
31
REMOVAL
Disconnect the wear warning light wire (if fitted).
Push the piston back, sliding the caliper by hand.
Remove the lower brake caliper guide bolt.
SPECIAL TOOLING REQUIRED
Fre. 823 Tool for pushing piston back
Wheel bolts 9
Brake caliper guide bolt 4
12994R
REFITTING
Push back the caliper piston using tool Fre. 823.
Fit new brake pads.
The brake pad with the wear warning light wire
(if fitted) is fitted to the inside.
Refit the caliper into position and fit the lower
guide bolt.
Tighten the guide bolt to the recommended
torque 4 daN.m.
Reconnect the wear warning light wire (if fitted).
Press the brake pedal several times to bring the
piston into contact with the pads.
TIGHTENING TORQUES (in daN.m)
Pivot the caliper around the upper bolt.
Remove the brake pads.
Check:
- the condition and mounting of the piston dust
cover,
- the condition of the guide dust cover.
31-4

FRONT AXLE
Front brake calipers
31
REPAIR
NOTE :
if there are any scratches in the caliper
bore, the complete caliper must be replaced.
To do this:
- remove the brake caliper,
- remove the rubber dust cover,
- remove the piston using compressed air,
inserting a wooden block between the caliper
and the piston to prevent damage to the
piston: any trace of damage to the piston skirt
will render it unusable
- remove the seal from the caliper groove using
a flexible rounded edge blade (eg feeler
gauge).
Clean the parts using methylated spirits.
Replace any faulty parts using original parts and
then refit the seal, piston and dust seal.
REMOVAL
In the passenger compartment, fit a pedal press
(limits the amount of brake fluid which will run
out).
Release the brake pipe at the wheel cylinder end.
Remove the brake pads (see previous page).
Remove the two mounting bolts for the caliper on
the stub axle carrier.
Completely release the brake pipe by turning the
caliper.
Check the condition of the pipe and replace it if
necessary.
REFITTING
Fit the pipe onto the caliper.
Remove the pedal press.
To check the correct operation of the caliper
cylinder, slacken the bleed screw and wait for
brake fluid to run out.
Retighten the bleed screw.
Refit the caliper on the stub axle carrier and
tighten the bolts to the recommended torque.
Refit the pads and the wheel cylinder (follow the
method described previously).
Wheel bolts 9
Brake caliper guide bolt 4
Brake caliper mounting bolt 10
TIGHTENING TORQUES (in daN.m)
31-5

FRONT AXLE
Brake discs
31
Brake discs cannot be reground. If they are too
heavily worn or are scratched they must be repla-
ced.
Wheel bolts 9
Brake caliper mounting bolt 10
REMOVAL
Remove:
- the two brake assembly mounting bolts
(attach the assembly to the spring),
- the two mounting bolts securing the disc to
the hub,
- the disc.
REFITTING
Refitting is the reverse of removal.
NOTE : when a brake disc is replaced, the pads
must also be renewed.
TIGHTENING TORQUES (in daN.m)
31-6

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

REAR AXLE
Rear axle assembly
TIGHTENING TORQUES (in daN.m)
Bearing mounting nut 11
Wheel bolt 9
Shock absorber base bolt 8.5
REMOVAL
Put the vehicle on a two post lift.
Fit the pedal press.
Remove:
- the two lower shock absorber mountings,
- the brake pipes,
- the compensator control,
- the central heat shield,
- the handbrake cables, disconnecting them
from the central control,
Unclip the cables from the fuel tank.
Support the rear axle assembly and remove the
nuts ( 1 ).
Remove the rear axle assembly.
NOTE : the bolts can be reached under the rear
bench seat (depending on version) after
removing the blanking covers.
REFITTING
Refitting is the reverse of removal.
Bleed the brake circuit.
Adjust the handbrake (see section 37).
Check and if necessary adjust the braking
compensator ( see section 37 ).
33
13132R
33-1