RENAULT KANGOO 1997 KC / 1.G Engine And Peripherals Owner's Manual

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 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
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
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.
F8Q engine
13084R
13034R
- the relay plate (4), the connector (5) and the
fuse support (6) by removing the fuse holders
(7),
- the accelerator and clutch cables.
Unclip the power assisted steering reservoir and
place it on the engine.
10-22

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

ENGINE AND ENGINE PERIPHERALS
Sump
10
Sump mounting bolt 1
TIGHTENING TORQUES (in daN.m)
Put the vehicle on a 2 post lift.
Disconnect the battery.
Drain the engine.
Remove:
- the oil level sensor using a 19 mm half-moon
wrench,
- the engine-gearbox undertray.
99900S
Remove the sump mounting bolts.
Rotate the sump towards the rear of the vehicle in
order to release the oil pump strainer from the
sump partitioning.
Clean the sealing surfaces without scratching the
aluminium.
REFITTING
Proceed in the reverse order of removal and fit a
new gasket. D7F engine
10-25

ENGINE AND ENGINE PERIPHERALS
Sump
10
Front sub-frame mounting bolt 6.2
Rear sub-frame mounting bolt 10.5
E7J sump bolt 1
F8Q sump bolt 1.5
Steering shaft yoke mounting bolt 3
Engine tie-bar bolt 6.2
Wheel bolt 9
TIGHTENING TORQUES (in daN.m)
REMOVAL
Put the vehicle on a 2 post lift.
Disconnect the battery.
Drain the engine oil.
Remove:
- the front wheels,
- the nut and the eccentric bolt of the steering
shaft yoke, after pushing back the guard,
97390S1
- the lower ball joint mountings and the track
rod ends for the
E7J engine,
- the sub-frame and body tie rods,
- the gear control on the gearbox side,
- bolt (1), and slacken engine tie-bar bolt (2),
without removing it,
E7J / F8Q
engines
SPECIAL TOOLING REQUIRED
Mot. 1233-01 Threaded rods for lowering the
sub-frame
13359R1
- the bottom mountings of the bumper,
- the exhaust downpipe for the
F8Q engine.
Special notes for the E7J engine
Remove:
- the exhaust manifold heat shield,
- the catalytic converter,
- the engine flywheel guard,
- the power assisted steering pipe mountings
on the cylinder block and the multifunction
mounting.
10-26