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

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
Fit retaining lug Mot. 1159 in place of the coolant
pipe mounting on the cylinder block.
99310R
Remove the suspended engine mounting cover.
13359R
13086R
Insert a wooden block between the gearbox and
the sub-frame.
Remove:
- the nut (1), then tap it with a copper hammer
to release the suspended engine mounting
stud.- the mounting bolts (3).
E7J engine
12993-1R3
10-17

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"). E7J 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.
10-18

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
12988R
- the exhaust heat shield and the gear control
on the lever and gearbox sides,
- the exhaust downpipe,
- the earth strap on the gearbox,
- the front bumper,
- the air intake pipe of the air filter,
- the fuel supply and return unions (A) and (B),
- the connectors (2), (3), (4) and (5).
Unclip the fuel pipes from the air filter unit and
the timing cover and unclip the diesel filter from
its support and move the assembly to one side.
13083-1R
F8Q engine
10-20

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
Remove the suspended engine mounting cover.
13086R1
13086R
Insert a wedge between the gearbox and the sub-
frame.
Remove:
- the nut (1), then tap it with a copper hammer
to release the suspended engine mounting
stud. F8Q engine
99024R2
Fit tool Mot. 1159 between the sub-frame and the
cylinder block.
Fit tool Mot. 1159 in place of the coolant pipe
mounting on the cylinder block.
99310R
10-23

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