brake fluid 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

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
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

REAR AXLE
Suspension arm bearings
This operation is carried out after removing the
rear arms and the suspension bars.
REMOVAL
Totally immerse the bearing in brake fluid to
soften the rubber bush.
Using a two or three claw extractor, remove the
external part of the bearing by tearing off the
rubber.
Saw through the inner ring taking care not to
scratch in the tube of the arm.
REFITTING
The bearing is fitted in the arm on the press,
ensuring the correct alignment is observed and
the clearance between the bearing and the arm is
correct.
Alignment
Observe dimension "X" between the bearing
pressure face and the stub axle shaft:
X = 156 mm ± 3.5
TUBULAR REAR
AXLE
33
DI3303
85909S
75362S
DI3310
33-20

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
Master cylinder
37
Fill the brake fluid reservoir and bleed the brake
circuit.
MASTER CYLINDER (EXCHANGE)
The kit sold by the Parts Department comprises :
- one master cylinder (4 outlets or 2 outlets for
ABS),
- two plugs (A),
- two mounting nuts (B).
DI3719
37-2

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
BOSCH ABS
38
PRN3818
LOCATION OF THE BOSCH ABS COMPONENTS
1Hydraulic assembly
2Master cylinder
3Brake servo4Brake fluid level warning light
5Braking compensator
38-2

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

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
BOSCH ABS
38
2)Bleeding the hydraulic assembly.
IMPORTANT : the bleeding order must be observed, beginning with the rear right , then the rear left, front
left and then front right.
a)Bleed the rear right brake by bleeding the hydraulic assembly secondary circuit using the XR25:
- position the bleed container and the hose, open the brake bleed screw,
- pump the brake pedal (approximately ten times),
- start the bleed command on the
XR25,
- pump the brake pedal during the diagnostic bleed phase,
- at the end of the bleed cycle on the
XR25, continue to pump the brake pedal and close the brake
bleed screw.
b)Carry out the procedure described at a) for the rear left, front left and front right brakes.
c)Check the pedal travel and if it is incorrect, restart the bleeding procedure.
IMPORTANT : ensure there is sufficient brake fluid in the reservoir.
CHECKING THE WHEEL SPEED SENSORS
a)Check the resistance of the sensor connections (from the computer connector to the 2 track speed sensor
connector).
b)Visually inspect the teeth ( 26 teeth) on the target and if they are faulty, replace the target.
c)Check the air gap using a set of shims. Only the front sensors can be checked.
PRN3820
Front: 0.13 < Z < 1.96 mm
38-10