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

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
11733R
Remove the fuel pipe support (7).
Slacken the mounting bolts for the lower timing
cover, without removing them.
99173-1R
13093R
Remove :
- the accessories belt tensioning system,
- the cylinder head bolts.
Release the cylinder head by setting aside the
lower part of the lower camshaft housing,
without causing the cylinder head to pivot, since
this is centred by the two dowels at ( C ).
Using a syringe, extract any oil which may have
entered the cylinder head mounting holes .
This is necessary in order to obtain the correct
tightening of the bolts.
Protect the oil outlet duct in order to prevent any
foreign bodies from entering the oilways in the
cylinder head.
Failure to take this advice could lead to the
blocking of the oilways, resulting in a rapid dete-
rioration of the camshaft. F8Q Engine
11-26

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
REFITTING (special notes)
Refit the cylinder head gasket selected previous-
ly. This is centred by two dowels at (C).
99173-1R
Bring the pistons to mid-stroke position to
prevent them from coming into contact with the
valves during the tightening of the cylinder head .
Centre the cylinder head on the dowels.
Lubricate the threads and under the heads of the
mounting bolts.
Tighten the cylinder head (see section 07
"Tightening the cylinder head").
Refitting is the reverse of removal.
Refit the timing belt, (see method described in
section 11 "Timing belt").
Fill and bleed the cooling circuit , (see section 9
"Filling -bleeding").
MEASURING THE THICKNESS OF THE CYLINDER
HEAD GASKET
Checking piston protrusion
Clean the piston heads in order to eliminate any
traces of deposits.
Turn the crankshaft in its operating direction
once, to bring piston n° 1 close to
TDC .
Fit tool Mot. 252-01 on the piston.
Fit tool Mot. 251-01, complete with dial gauge
Mot. 252-01. on the plate Ensure that the dial
gauge measuring pin is in contact with the cylin-
der block; then locate the piston
TDC.
NOTE
: All measurements are to be carried out in
the longitudinal axis of the engine, in order to eli-
minate any errors due to tilting of the piston.
99173R
Measure the piston protrusion.
ONLY TAKE INTO CONSIDERATION THE
DIMENSIONS OF THE PISTON WITH THE
GREATEST PROTRUSION.
For a maximum piston protrusion:
- lower than 0.868 mm, use a gasket marked by
a tab with two holes ,
- included between 0.868 mm and 1mm, use a
gasket marked by a tab with one hole,
- greater than 1mm, use a gasket marked by a
tab with three holes. F8Q Engine
11-28

TOP AND FRONT OF ENGINE
Replacement of valve adjusters
11
SPECIAL TOOLING REQUIRED
Mot. 1366-01 Tool for removing valve adjusters
(additional item to Mot. 1366)
TIGHTENING TORQUES (in daN.m)
Studs for mounting manifolds on
cylinder head 1
Nut for mounting manifolds on
cylinder head 2.7
Mounting bolt for strut on inlet manifold 2.5
Mounting bolt for strut on cylinder block 2.5
Place the vehicle on a two-post lift
Disconnect the battery.
CHECKING THE VALVE CLEARANCE
Remove the air filter housing along with the cy-
linder head cover.
Place the valves of the cylinder concerned at the
"end of exhaust - beginning of inlet" position and
check the clearance .
86911-1S
1
3
4
24
2
1
3
Compare the two dimensions noted to the re-
commended dimensions, and replace the adjus-
ters if necessary .
Clearance ( in mm ), when the engine is cold :
- Inlet: 0.10
- Exhaust :0.25 F8Q Engine
11-29

TOP AND FRONT OF ENGINE
Replacement of valve adjusters
11
REPLACEMENT OF VALVE ADJUSTERS
In order to carry out this operation it is necessary
to remove the inlet and exhaust manifolds (see
section 12 Inlet/Exhaust Manifolds) .
Fully open the valve concerned (by turning the
engine in its operating direction).
Insert tool Mot. 1366-01 into the duct concerned .
11231R
For inlet valves
Turn the engine in the operating direction,in
order to bring the valve into contact with tool
Mot. 1366-01 (rotate the camshaft by 90° in
relation to the fully open position).
For the exhaust valves
It is vital to turn the engine in the opposite direc-
tion to normal operation (in order to avoid the
locking of the engine), until the valve comes into
contact with tool Mot. 1366-01 (rotate camshaft
by 90° in the relation to the fully open position).
Extract the valve adjuster using a screwdriver and
a magnetic tool.
11232-1R
NOTE : during the refitting of the valve adjuster,
extract any oil which may be in the bottom of the
pushrod bore ( C ) .
98895R1
REFITTING
Refitting is the reverse of removal. F8Q Engine
11-30

FUEL MIXTURE
Inlet manifold
12
Remove the two bolts (4) mounting the retaining
bracket on the cylinder block. E7J engine
13338R1
Extract the manifold.
REFITTING
Replace the inlet manifold gaskets.
Refitting is then the reverse of removal.
12-11

FUEL MIXTURE
Inlet/Exhaust manifolds
12F8Q engine
Manifold mounting studs on cylinder head 1
Manifold mounting nuts on cylinder head 2.7
Inlet manifold strut mounting bolt 2.5
Cylinder block strut mounting bolt 2.5
TIGHTENING TORQUES (in daN.m)
REMOVAL
Remove the air filter (two mounting bolts at the
top, two mounting nuts at the bottom (1)).
Remove, from above, the two nuts fixing the ex-
haust downpipe to the manifold.
Slacken, without removing it, the nut on the
clamp connecting the downpipe to the exhaust
pipe.
Tilt the exhaust downpipe towards the gearbox.
Remove the nuts securing the manifolds:
- nuts (A) from above,
- nuts (B) from below.
PRO12.1
Special note
To remove nut (C) located above the starter mo-
tor, use a small ratchet (6.35 mm square) and a
universal joint.
13047-1R1
13047R
12-14

DIESEL EQUIPMENT
Location of components
13
20 EGR valve
13047-1R
7Engine speed sensor
13048R
87970R
17Diesel injection fault warning light
18Preheating warning light
Warning light illuminates when ignition is
switched on during preheating phase.
12839S
C Power assisted steering pump assembly relay
HAltimetric corrector relay
LInjection locking relay
MDiesel heating relay
13-18

DIESEL EQUIPMENT
Advance solenoid valve
13
ITB191917
REFITTING
It is VITAL to remove the small filter (3) situated at
the bottom of the system, using a pair of thin-
nose pliers, and replace with a new filter.
The outer part serves as a seal and locks on
tightening the actuator.
Replace, in the following order : the seal at (4) of
the "banjo" return connection (5) ; the new
activator (1) fitted with an external filter, along
with the the two seals at (6) and (7).
Tighten the actuator to a torque of 3 daN.m
using socket Mot. 997-01.
Place the new protective cover (2)on the actuator.
Reconnect the two terminals to the connector.
Reconnect the connector itself.
Replace the protective sheath on the wiring,
along with the retaining clip.Bleed the diesel circuit using the priming pump
before starting the engine.
It is IMPERATIVE to erase the computer memory
by pressing G0**.
It is vital to road test the vehicle after the
operation.
13127R
13-21

DIESEL EQUIPMENT
Load potentiometer
13
In the factory, vehicles are programmed with the full load position. (memorising the voltage delivered by the
potentiometer in the full load position). This value is used to adjust the load potentiometer after it has been
replaced. It is therefore essential, if the diesel injection computer has to be replaced during the vehicle’s li-
fetime , to carry out this programming (G31*).
If it is necessary to replace the load potentiometer, in order to adjust it we compare the voltage delivered by
the potentiometer in full load position, with the value memorised. The new potentiometer is said to be cor-
rectly adjusted when the two voltages are equal. This is displayed on the
XR25. G32* indicates the diffe-
rence in voltage between the value memorised and the one from the potentiometer. The adjustment is cor-
rect if this value is equal to 0 in the full load position.
The potentiometer and the computer cannot be replaced at the same time (if necessary, replace the poten-
tiometer first and then the computer).
REPLACEMENT OF THE LOAD POTENTIOMETER (operation to be carried out by two people)
Remove the three terminals for the load potentiometer from the 10 track pump connector (see method
described in section 13 "Advance solenoid valve").
Remove the two bolts mounting the faulty potentiometer, extract this, and fit the new potentiometer .
Hand tighten the two bolts mounting the potentiometer but do not lock them - it should be possible to turn
the potentiometer body .
Connect the
XR25, and switch on the ignition.
Set the selector to S8.
Enter code
Press down on the accelerator pedal (full load position). Do not act directly on the load lever.
Holding the full load position, turn the potentiometer body until the value 0 appears on the XR25 display (if
you are too far from the 0 value, the screen will display HL , which means "Hors Limite"= "Off limits". Just
to turn the potentiometer body to obtain the display of a decimal value).
Tighten the two bolts mounting the potentiometer in the full load position, when the value read is 0. D
34then
G32*
13-28

DIESEL EQUIPMENT
Pump - Timing
13
IMPORTANT : the engine must only be rotated by
turning a wheel, in 5th gear, and in its operating
direction; if it is accidentally turned in the
opposite direction, repeat the operations for
checking and adjusting the timing.
CHECKING THE SETTING OF INJECTION PUMPS
FITTED WITH RAM PULLEYS
Turn the engine twice in the operating direction
(moving one wheel and having engaged 5th
gear).
Remove the timing shaft plug situated on the
pump cover.
Fit tool Mot. 1079 and zero the dial gauge on
pump cam "rest" zone (this operation will be
made easier by turning the engine in its operating
direction).
NOTE : in order to obtain a precise adjustment,
and to avoid bringing the dial gauge to its limit, it
is advisable to adjust it to 1 mm.
SPECIAL TOOLING REQUIRED
Mot. 1054TDC pin
Mot. 1079 LUCAS pump timing kit
Mot. 1200
Mot. 1317
Mot. 135 Set of tools for operations on a
Mot. 1359 RAM pulley (micrometric adjustment)
91258R2
RAM pulley nut (adjustment locking) 9
TIGHTENING TORQUES (in daN.m)
Pump-pulley retaining tool
13-41