torque 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

GENERAL
Tightening torques (in daN.m)
30
FRONT
AXLE
DI3035R
30-2

GENERAL
Tightening torques (in daN.m)
30
FRONT
AXLE
DI3034R1*Fitting direction must be observed
30-3

GENERAL
Tightening torques (in daN.m)
30
TUBULAR
REAR AXLE
88507-1R2
30-4

GENERAL
Tightening torques (in daN.m)
30
4 BAR
REAR AXLE
88507-2R2
30-5

GENERAL
Tightening torques (in daN.m)
30
DIMENSIONSTIGHTENING TORQUES
Bleed screw
Hoses for front calipers
Hoses on rear suspension arm
Rear wheel cylinder supply
Master cylinder outlets
Compensator inlet
Compensator outlets-
M 10 × 100
M 10 × 100
M 10 × 100
or
M 12 × 100
M 10 × 100
or
M 12 × 100
M 10 × 100
or
M 12 × 100
M 10 × 100
or
M12 × 1000.6 to 0.8
1.7
1.7
1.7
1.7
1.7
1.7
30-6

FRONT AXLE
Lower wishbone
31
85875R2
12992R
Wheel bolts 9
Lower wishbone nut on sub-frame 9
Key nut on stub-axle carrier 5.5
Anti-roll bar bearing nut 1.5
TIGHTENING TORQUES (in daN.m)
REMOVAL
Put the vehicle on a two post lift.
Remove both wheels.
Remove the mounting nuts for the anti-roll bar on
the lower wishbones.
Release the anti-roll bar downwards.
Remove:
- the nut and key on the stub-axle carrier,
- the two mounting bolts for the wishbone on
the sub-frame,
- the wishbone.
REFITTING
NOTE :
ensure the plastic protective washer ( A ) is
present on the lower ball joint shaft.
Refit:
- the wishbone,
- the two bolts, without tightening them,
- the ball joint shaft in the stub-axle carrier and
tighten the key nut.
Refit the anti-roll bar and fit the mounting nuts
using tool Sus. 1414 (see method in anti-roll bar
section).
This tool allows the rubber mounting to be
compressed to fit the nut.
NOTE : bounce the suspension and tighten the
wishbone and anti-roll bar bearing nuts to the re-
commended torque (tightening position: vehicle
unladen).
31-1

FRONT AXLE
Lower wishbone ball joint
31
85875R1
Remove:
- the two ball joint mounting bolts (4) ,
- the ball joint.
REFITTING
Note : ensure the plastic protective washer ( A ) is
present on the lower ball joint shaft.
Fit the ball joint and torque tighten the
mountings.
Then proceed in the same manner as for refitting
the lower wishbone.
REMOVAL
If the gaiter is damaged, the complete ball joint
must be replaced.
Proceed in the same manner as for removing the
lower wishbone.
Slacken but do not remove the two mounting
bolts (3) for the wishbone on the sub-frame.
31-3

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