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

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
SPECIAL TOOLING REQUIRED
Mot. 1040-01 Dummy sub-frame for removing -
refitting the 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
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 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, F8Q engine
Hose clip pliers
10-19

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
Remove the computer support.
13088R1
Disconnect:
- 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),
13085R
F8Q engine
11734R
For the locking of the quick release unions, refer
to the diagrams below:
11733R
10-21

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
REFITTING
The alignment of the sub-frame with the body
will be made easier by positioning two threaded
rods Mot. 1233-01 in the two front mountings of
the sub-frame on the body.
Tighten the sub-frame mounting bolts to a torque
of:
- 6.2 daN.m at the front,
-10.5 daN.m at the rear.
Refitting is the reverse of removal.
Fit the heat shields correctly.
Apply
Loctite FRENBLOC to the caliper mounting
bolts and tighten them to the recommended tor-
que.
Press the brake pedal several times to bring the
pistons into contact with the brake pads.
Fill:
- the engine and gearbox with oil, if necessary,
- the cooling circuit and bleed it (see section 19
"Filling - bleeding"). F8Q engine
Fix tool Mot. 1040-01 underneath the sub-frame.
98755R1
Lower the lift until the tool touches the ground.
Remove the sub-frame mounting bolts and take
out the engine and transmission assembly by lif-
ting the body.
NOTE : for any operation requiring separation of
the engine, gearbox and sub-frame assembly,
take care to mark the position of Mot. 1159 on the
sub-frame.
Remove the mounting bolts (3).
12993-1R3
10-24

12mm torx socket
Angular tightening wrench
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
SPECIAL TOOLING REQUIRED
Mot. 591-04 Angle wrench for tightening
cylinder head and index
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1379 Tool for securing engine to
subframe
EQUIPMENT REQUIRED
TIGHTENING TORQUES (in daN.m)
Crankshaft output mounting bolt 2 + 90°
Mounting bolt for front right suspended
engine mounting on engine 6.2
Mounting bolt for front right suspended
engine mounting on vehicle body 6.2
Timing belt tension wheel nut 5
Wheel bolts 9
REMOVAL
Put the vehicle on a 2 post lift.
Remove the bonnet, and the right hand wheel .
Disconnect the battery.
Drain the cooling circuit.
Fit the engine support tool, Mot. 1379.Remove:
- the timing belt (see method described in
section 11 "Timing belt"),
- the dipstick,
- the brake servo pipe,
- the air filter,
- the accelerator cable,
- the fuel supply and return pipes level with the
timing belt cover on the cylinder head
D7F Engine
11-11

TANK
Fuel Tank
19
REMOVAL OF THE TANK (petrol or diesel ver-
sions)
Disconnect the battery.
Place the vehicle on a two post lift.
Disconnect the electrical connector (2) and the
quick release unions, tool Mot. 1265 or Mot.
1265-01.
97163R4
Disconnect the petrol filter.
Remove the heat shields at (3) and (4) , which are
situated below the tank and beneath the hand-
brake cables.
Remove the exhaust mounting bracket (5).
Lift the vehicle.
Separate the exhaust pipe from the exhaust
down pipe.
Remove the exhaust mounting bracket from the
middle of the vehicle.
12866R
Tilt the exhaust towards the right hand side of the
vehicle.
19-19

FUEL TANK
Fuel tank
19
Before the handbrake adjuster is disengaged, di-
mension X must be noted.
Disengage the adjuster in such a way that both
the left and right hand cables can be easily relea-
sed (carefully release the plastic cable stop (6)).
Disconnect the two unions at (7) and (8) using
tool Mot. 1265.
Disconnect the pipe at (9).
Separate the tank from the filler neck (10).
Unclip the handbrake cables from under the tank
(11).Unclip the hydraulic brake pipes on the fuel tank
side.
Unclip the fuel pipes from the tank.
Position a component jack under the fuel tank.
Remove the four bolts mounting the tank.
Tilt the tank slightly forwards, then remove it.
REFITTING
Refitting is the reverse of removal.
Take care not to pinch any pipes (risk of leaks).
Fit the quick release unions by hand and ensure
they connect correctly.
Take care to ensure the heat shields are correctly
refitted.
12873R
99091R1
19-20