torque RENAULT KANGOO 1997 KC / 1.G Electrical Equipment Workshop Manual

INSTRUMENT PANEL
Dashboard
REMOVAL
Disconnect the battery.
Removing the steering wheel (with AIRBAG)
83
PRB5702
12973S
Remove the two airbag cushion bolts behind the
steering wheel.
Disconnect the connectors (airbag, horn).
Remove:
- the airbag cushion,
- the steering wheel bolt (renew it on refitting,
pre-bonded bolt, tightening torque: 4.5
daN.m),
- the steering wheel after setting the wheels
straight.
Removing the steering wheel (without AIRBAG)
Remove:
- the central cushion,
- the steering wheel bolt (renew it on refitting,
pre-bonded bolt, tightening torque: 4.5
daN.m),
- the steering wheel after setting the wheels
straight.
83-1

INSTRUMENT PANEL
Dashboard
83
- the loud speaker grilles,
- the dashboard mountings.
Gently pull the dashboard.
Release the wiring retaining clips.
Disconnect:
- the headlight remote adjustment control
connector and hazard warning light connector,
- the remaining connectors (example : decoder
unit).
Remove the dashboard.REFITTING
When refitting, it is important to ensure the va-
rious wires are correctly routed and have suffi-
cient space so that the dashboard can be correctly
centred.
SPECIAL NOTES FOR REFITTING THE STEERING
WHEEL WITH AIRBAG
Ensure the rotary switch under the steering wheel
is correctly positioned.
If there is any doubt that this switch is correctly
centred follow the method for centring described
in section 88 "driver’s airbag".
Renew the steering wheel bolt each time it is re-
moved (pre-bonded bolt) for a steering wheel
with airbag.
Observe the correct tightening torque (4.5
daN.m).
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 exactly as
described above, refer to the fault finding section
and test the system using the XRBAG (Elé. 1288)
(see section 88).
12964R
83-5

Mot. 1264
Mot. 1264-01
Mot. 1265
Mot. 1265-01Wrench for removing sender unit nut
Pliers for removing quick-release unions
INSTRUMENT PANEL
Fuel level sensor
83
97163R6
Disconnect the battery.
Lift the rear bench seat (depending on
equipment).
Remove the pump and sender unit steel cover.
Disconnect the electrical connector (1).
Release the clips (2).
Then disconnect the fuel supply pipe (3) (green
marking on the quick-release union) and the fuel
return pipe (4) (red marking on the quick-release
union) using the special pliers Mot. 1265 or Mot.
1265-01.
IMPORTANT: When the pipes are removed, fuel
may be splashed out due to the residual pressure
in the pipes. Take appropriate precautions.
IMPORTANT :
During any operation on the fuel level sensor
you must observe the following precautions:
- Do not smoke.
- Keep all flames or incandescent objects away
from the working area.
REMOVAL OF THE PUMP - SENDER ASSEMBLY
The pump and sender unit assembly may be
removed through the inspection cover under the
rear bench seat and the fuel tank does not have to
be removed.
96420R2
SPECIAL TOOLING REQUIRED
TIGHTENING TORQUES (in daN.m)
Sender unit nut 7
83-10

INSTRUMENT PANEL
Fuel level sensor
83
97163R7
Tighten the mounting nut on the fuel and sender
unit assembly to a torque of 3.5 daN.m using the
tool Mot. 1264-01, holding the sender unit to pre-
vent it from rotating.
Make sure that the connector is firmly locked and
that the quick-release unions are securely clipped
on (with 2 O-ring seals)
Reconnect the battery.
CONNECTION
Disconnect the connector and the pipes on the
sender unit side.
Remove the mounting nut (5) of the pump and
sender unit using tool Mot. 1264-01.
Slacken the nut, remove the tool, unscrew the nut
by hand and remove it.
Remove the pump and sender unit assembly.
NOTE : If several hours may pass between
removing and refitting the pump and sender unit
assembly, refit the nut to the fuel tank to prevent
it from distorting.
REFITTING OF THE PUMP AND SENDER UNIT
ASSEMBLY
Special notes
Check that the seal is in good condition and re-
place it if necessary.
Fit the seal on the fuel tank first before fitting the
assembly.
Refit the pump and sender unit assembly in the
fuel tank by aligning it so that the indexing arrow
(F) is positioned in line with the longitudinal axis
of the vehicle, pointing towards the rear of the
vehicle.
DI8307
Track Allocation
A1 Earth
A2 Low fuel level warning light
B1 Sender unit information to instrument
panel
B2 Not used
C1 + pump
C2 - pump
Checking
IndicationValue between
terminals
A1 and B1 (in Ω)
4/4 7 maximum
3/4 54.5 ± 7
1/2 98 ± 10
1/4 155 ± 16
Low fuel 300 ± 20
97162S
83-11

CONTROLS - SIGNALS
Rotary switch under steering wheel
This makes the electrical connection between the
steering column and the steering wheel.
It consists of a strip of conductor tracks (airbag)
whose length is designed to guarantee 2.5
steering wheel turns (steering lock plus safety
margin) on each side.
REMOVAL - REFITTING
84
- the horn connector, if fitted,
- the steering wheel bolt,
- the steering wheel after setting the wheels
straight,
- the half cowlings (3 bolts).
Disconnect the connector for the rotary switch
and remove it after removing the three mounting
bolts (E).
Before removing the rotary switch its position
must be noted:
- by ensuring that the wheels are straight on re-
moval so that the track may be positioned in
the centre,
- by immobilising the rotary switch rotor using
adhesive tape.
If it is being replaced, the new part is supplied rea-
dy centred by an adhesive label which will tear off
as soon as the steering wheel is turned for the first
time (fit with the wheels straight).
12970R3
Disconnect the battery.
Remove:
- the airbag cushion by the two torx T30 bolts
(tightening torque : 0.5 daN.m) located behind
the steering wheel and disconnect the connec-
tor (D),
IMPORTANT: It is not permitted to operate the
pyrotechnical systems (airbags and pretensioners)
near a source of heat or flame as there is a risk of
triggering.
IMPORTANT : If the steering wheel is removed,
the airbag connector (D)
MUST be disconnected.
The airbag has a connector which short circuits if
it is disconnected to prevent incorrect triggering.
12973R
84-4

CONTROLS - SIGNALS
Rotary switch under steering wheel
Special notes for refitting
Ensure the wheels are still straight.
Ensure the rotary switch under the steering wheel
is still immobilised before refitting.
If there is any doubt follow the method for cen-
tring described in section 88 "driver’s airbag".
Renew the steering wheel bolt each time it is re-
moved (pre-bonded bolt).
Observe the correct tightening torque (4.5
daN.m).
84
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 exactly as
described above, refer to the fault finding section
and test the system using the XRBAG (Elé. 1288)
(see section 88).
IMPORTANT: if these instructions are not obser-
ved, the systems may not operate normally and
may be incorrectly triggered.
84-5

WIPERS
Front windscreen wiper
REMOVAL OF THE WIPER MECHANISM WITH
MOTOR
Make sure that the wiper motor is in the park
position.
Disconnect the battery.
Note the position of the wiper arms.
Open the bonnet.
Remove:
- the wiper arms using tool Elé. 1294-01,
- the scuttle panel grille seal,
- the scuttle panel grille after removing the two
side covers and the two bolts and disconnecting
the washer pipe.
85
13069R
Remove the three mechanism mounting bolts (A).
Disconnect the motor and release the assembly.
SPECIAL TOOLING REQUIRED
Elé. 1294-01 Wiper arm removing tool
Special notes for refitting
Check that the motor is in the park position be-
fore refitting the wiper arms.
Clean the splines on the wiper arm pins using a
metal brush.
Refit the wiper arms, locating the blade on the
marks made on removal.
Fit new nuts and torque tighten to 1.8 daN.m (±
15 %) using a torque wrench.
85-1

WIPERS
Front windscreen wiper
85
13069R1
Remove:
- the motor shaft nut (B) and release the linkage
after noting its position,
- the three motor mountings.
Release the motor after disconnecting it.
Special notes for refitting
Refit the linkage to the motor on the mark made
during removal.
Check that the motor is in the park position be-
fore refitting the wiper arms.
Clean the splines on the wiper arm pins using a
metal brush.
Refit the wiper arms, locating the blade on the
marks made on removal.
Fit new nuts and torque tighten to 1.8 daN.m (±
15 %) using a torque wrench.REMOVING THE MOTOR ALONE
Make sure that the wiper motor is in the park po-
sition.
Disconnect the battery.
Note the position of the wiper arms.
Open the bonnet.
Remove:
- the wiper arms using tool Elé. 1294-01,
- the scuttle panel grille seal,
- the scuttle panel grille after removing the two
side covers and the two bolts and disconnecting
the washer pipe.
85-2

WIPERS
Rear screen wiper
85
Tailgate versionREMOVING THE MOTOR
Make sure that the wiper motor is in the park po-
sition.
Disconnect the battery.
Note the position of the wiper arms.
Remove:
- the wiper arm mounting nut,
- the wiper arm from its pin using special tool
Elé. 1294-01,
- the inner door handle on versions with swin-
ging doors (1 bolt),
- the tailgate trim (clipped).
Disconnect connector (A) for the wiper motor.
Remove the three bolts (B) mounting the motor
and release it.
Special notes for refitting
Check that the motor is in the park position be-
fore refitting the wiper arm.
Clean the splines on the wiper arm pin using a me-
tal brush.
Refit the wiper arm, locating the blade on the
marks made on removal.
Fit a new nut and torque tighten to 1.2 daN.m (±
20 %) using a torque wrench.
Version with swinging doors
13071R
13070R
85-3

WIPERS
Electric washer pump
85
This vehicle is fitted with a bidirectional electric
pump (E) which feeds fluid from the same reser-
voir to both the front and rear screen washers ac-
cording to the electrical feed to the two track
connector (D).
Two cases may be considered:
13069R2
Track Feed
A + 12 Volts
B Earth
The pipes are fed via the white end piece (1)
whilst the front windscreen washer is in opera-
tion.
Track Feed
A Earth
B + 12 Volts
The pipes are fed via the black end piece (2) whilst
the rear screen washer is in operation.
DI8503
REMOVAL - REFITTING
To reach the washer pump it is necessary to re-
move:
- the wiper arms using tool Elé. 1294-01 after no-
ting their positions,
- the scuttle panel grille seal,
- the scuttle panel grille after removing the two
side covers and the two bolts and disconnecting
the front washer pipe.
When removing the washer pump (E), mark the
two pipes (1 and 2) before disconnecting them.
Special notes for refitting
Check that the motor is in the park position be-
fore refitting the wiper arms.
Clean the splines on the wiper arm pins using a
metal brush.
Refit the wiper arms, locating the blade on the
marks made on removal.
Fit new nuts and torque tighten to 1.8 daN.m (±
15 %) using a torque wrench.
85-4