RENAULT KANGOO 1997 KC / 1.G Engine And Peripherals User Guide

ENGINE AND ENGINE PERIPHERALS
Engine - Gearbox
- the mounting bolts (2) of the rubber engine
mounting pad (1).
Note the position of the engine mounting pad(1)
in relation to the body.
10
99893S
12924R1
Remove:
- the gearbox side support,Remove the engine and transmission assembly
after taking the power assisted steering unit out
of the engine compartment and protecting the
radiator. Remove:
- the computer support plate.
- the power assisted steering pipe mountings
on the engine,
- the power assisted steering pump belt (see
section 07),
- the power assisted steering pulley,
- the power assisted steering bolts.
Release the power assisted steering unit.
Attach the load positioner to the engine lifting
rings.
12924R2
D7F engine
10-7

ENGINE AND ENGINE PERIPHERALS
Engine - Gearbox
10
12924R3
Apply Rhodorseal 5661 to the driveshaft roll pin hole.
Press the brake pedal several times to bring the pistons into contact with the brake pads.
Refit the power assisted steering pump belt (see section 07).
Fill:
- the gearbox with oil,
- the engine with oil (if necessary),
- the cooling circuit and bleed it (see section 19).
REFITTING (special notes)
Refitting is the reverse of removal.
Tighten the suspended engine mounting bolts to the recommended torque.
NOTE : tighten the suspended engine mounting bolts on the body in the order recommended below:
-1⇒bolt A to a torque of 2.1 daNm.
-2⇒bolt B to a torque of 2.1 daNm.
-3⇒bolt C to a torque of 2.1 daNm. D7F engine
10-8

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
REMOVAL
Put the vehicle on a 2 post lift.
Disconnect:
- the battery,
- the electrical connectors from the engine
connection unit and its environment.
13034S
Drain:
- the cooling circuit (disconnect the bottom
hose of the radiator),
- the gearbox oil if necessary,
- the engine oil if necessary.
Remove:
- the battery,
- the wheels,
- the air intake pipe,
- the upper radiator mountings,
- the expansion bottle and fix it to the engine,
- the power assisted steering fluid reservoir,
and secure it onto the engine. Shock absorber base bolts 18
Track rod end 3.7
Front sub-frame mounting bolt 6.2
Rear sub-frame mounting bolt 10.5
Driveshaft gaiter mounting bolt 2.5
Wheel bolt 9
Mounting nut for rubber engine mounting
pad on left suspended engine mounting 6.2
Mounting bolt for front right suspended
engine mounting on the engine 6.2
Mounting bolt for front right suspended
engine mounting on the body 6.2
Steering shaft yoke bolt 2.5
TIGHTENING TORQUES (in daN.m)
D7F engine
SPECIAL TOOLING REQUIRED
B. Vi. 31-01 Set of punches for roll pins
Mot. 1040-01 Dummy sub-frame for
removing and refitting engine
and transmission assembly
Mot. 1202 Hose clip pliers
Mot. 1311-06 Tool for removal of fuel pipe
Mot. 1379 Tool for retaining engine on
sub-frame
T. Av. 476 Ball joint extractor
T. Av. 1233-01 Tool for sub-frame and axle
assembly
10-9

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
Disconnect:
- the accelerator cable,
- the canister pipe,
- the brake servo pipe,
- the heater hoses,
- the oxygen sensor connector,
- the fuel pipes.
Remove:
- the shock absorber base bolts,
- the steering shaft yoke bolt.
10
97390-1R
SPECIAL NOTES FOR VEHICLES FITTED WITH
DRIVER’S AIR BAG
WARNING
In order to avoid any risk of damage to the rotary
switch beneath the steering wheel, the following
instructions should be followed:
• Before disconnecting the steering column from
the rack, the steering wheel MUST be immobi-
lised with the wheels straight with the aid of a
"steering wheel lock" throughout the opera-
tion.
• If there is any doubt about the rotary switch
being properly centred, the steering wheel
must be removed in order to apply the centring
method described in the Technical Note cove-
ring the 2nd generation air bag.
REMINDER: this kind of work must only be carried
out by properly trained and qualified staff.
Remove:
- both the sub-frame reinforcements,
- the earth strap mounting bolt on the body
side,
- the exhaust downpipe nuts. D7F engine
10-10

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
Insert a wooden block between the gearbox and
the sub-frame.
Diagram showing the holes drilled in tool Mot.
1040-01 (dimensions in mm).
10
Disconnect the gear control:
- at the position of the gearbox output lever af-
ter releasing the gaiter,
- at the level of the gear lever after removing
the central heat shield.
Pull the control lever (2) towards the rear of the
vehicle.
10621R
Fit tool Mot. 1379 onto the sub-frame and take
the weight off the right-hand engine mounting,
using the threaded rod (1).
10267R1
93912R2
Fix tool Mot. 1040-01 underneath the sub-frame,
having first fitted the shims Mot. 1379 onto this
tool.
92442-1R2
D7F engine
10-11

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
Remove:
- the gearbox suspended mounting nut, then
tap it with a copper hammer to release the
suspended mounting stud,
- the suspended engine mounting bolts on the
engine.
Lower the lift until the tool touches the ground.
Remove the four mounting bolts of the sub-
frame.
Take out the engine and transmission assembly by
lifting the body.
98755R
D7F engine
10-12

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
12924R4
Apply Rhodorseal 5661 to the driveshaft roll pin hole.
Press the brake pedal several times to bring the pistons into contact with the brake pads.
Fill:
- the gearbox with oil (if necessary),
- the engine with oil (if necessary),
- the cooling circuit and bleed it (see section 19).
REFITTING (special notes)
Use tool T. Av. 1233-01 to position the engine and transmission assembly in relation to the body.
Refitting is the reverse of removal.
Tighten the suspended engine mounting bolts and nuts to the recommended torque.D7F engine
10-13

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
Front sub-frame mounting bolt 6.2
Rear sub-frame mounting bolt 10.5
Mounting bolt for front right suspended
engine mounting cover on engine 6.2
Mounting nut for front right suspended
engine mounting cover 4.4
Mounting nut for rubber engine mounting pad
on front left-hand side member support 6.2
Shock absorber base bolt 18
Brake caliper mounting bolt 4
Steering shaft yoke bolt 3
Wheel bolt 9
TIGHTENING TORQUES (in daN.m)
REMOVAL
Put the vehicle on a 2 post lift.
Disconnect the battery.
Drain:
- the cooling circuit through the bottom hose
of the radiator,
- the gearbox and the engine if necessary.
Remove:
- the bonnet,
- the front wheels,
- the tie-rods between sub-frame and body,- the mounting bolts (1); pull away the brake
calipers as shown in the diagram below and
attach them to the suspension springs,
12994R1
- the shock absorber base bolts, E7J engine
SPECIAL TOOLING REQUIRED
Mot. 1040-01 Dummy sub-frame for removing
and refitting engine and
transmission assembly
Mot. 1159 Tool for maintaining engine on
sub-frame
Mot. 1202
Mot. 1448
Mot. 1311-06 Tool for removing fuel pipe
Hose clip pliers
10-14

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
13085R
- the exhaust heat shield and the gear control
on the lever and gearbox sides,
12988R
- the exhaust pipe clamp between the catalytic
converter and the expansion chamber,
- the earth strap on the gearbox,
- the front bumper,
- the air intake pipe from the air filter,
- the injection computer support after dis-
connecting the 55 track connector and that of
the impact switch.
13088R2
Disconnect:
- the wiring connections and the hoses on the
thermostat support,
- the hoses on the expansion bottle,
- the brake servo pipe,
- the heater hoses (there are two types of as-
sembly to be disconnected, as shown in the
diagrams below),
13084R
E7J engine
10-15

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
- the relay plate (4), the connector (5) and the
fuse support (6) by removing the fuse holder
(7),
13034R
- the canister pipe,
- the fuel supply and return pipes with the aid
of tool Mot. 1311-06, after removing the co-
ver,
- the accelerator and clutch cables.
Unclip the power assisted steering reservoir and
place it on the engine.
Remove:
- the upper mountings of the radiator and at-
tach it to the engine,
- the nut and the eccentric bolt of the steering
shaft yoke, after pushing back the guard.
97390S1
SPECIAL NOTES FOR VEHICLES FITTED WITH
DRIVER’S AIR BAG
99024R2
WARNING
In order to prevent any risk of damage to the ro-
tary switch beneath the steering wheel, the follo-
wing instructions should be observed:
• Before disconnecting the steering column and
the rack, the steering wheel MUST be immobi-
lised with the wheels straight, using a "stee-
ring wheel lock", throughout the operation.
• If there is any doubt that the rotary switch is
properly centred, the steering wheel must be
removed in order to apply the centring method
described in section 88 "Air bag".
REMINDER: this kind of work must only be carried
out by properly trained and qualified staff.
Fit tool Mot. 1159 between the sub-frame and the
cylinder block. E7J engine
10-16