belt RENAULT KANGOO 1997 KC / 1.G Engine And Peripherals Workshop Manual

Contents
Consumables
Identification
Oil consumption
Oil pressure
Engine - Gearbox
Engine and transmission assembly
Sump
Crankshaft seal, timing end
Oil pump10-1
10-1
10-2
10-3
10-4
10-9
10-25
10-29
10-30
TOP AND FRONT OF ENGINE
Timing belt
Cylinder head gasket
Replacement of valve adjustersPage Page
11
Engine and
peripherals
11-1
11-11
11-29 ENGINE AND PERIPHERALS
10FUEL SUPPLY -
DIESEL EQUIPMENT
Fuel supply
Fuel cut off in case of an impact
Injector gallery
Fuel filter
Pump flow
Fuel pressure
Antipercolation device
Diesel equipment
General
Specifications
Location of components
Advance solenoid valve
Altimetric corrector
Fast idle LDA
Coded solenoid valve
Load potentiometer
Computer configuration
Injector with sensor (needle
lift)
Injection warning light
Pre-postheating control
Fast idle control
Injection/air conditioning
programming
Computer
Defect modes
Pump
Pump -Timing
Idle speed settings13-1
13-2
13-6
13-7
13-8
13-12
13-13
13-14
13-16
13-19
13-22
13-25
13-26
13-28
13-29
13-31
13-32
13-33
13-35
13-36
13-36
13-37
13-38
13-39
13-41
13-4613
FUEL MIXTURE
Specifications
Throttle body
Inlet manifold
Exhaust manifold
Inlet-exhaust manifolds12-1
12-7
12-15
12-18
12-2012

ENGINE AND ENGINE PERIPHERALS
Engine - Gearbox
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 (bottom hose of the
radiator),
- the gearbox oil,
- the engine oil if necessary.
Remove:
- the battery,
- the bonnet,
- the wheels,
- the air intake pipe,
- the expansion bottle and fix it to the engine. Brake caliper guide bolt 4
Shock absorber base bolts 18
Driveshaft gaiter mounting bolt 2.5
Wheel bolt 9
Left-hand suspended mounting bolt
on gearbox 6.2
Left-hand suspended mounting bolt
and nut on body 2.1
Right hand suspended
engine mounting bolt on engine 6.2
Right hand suspended
engine mounting bolt on body 6.2
TIGHTENING TORQUES (in daN.m)
D7F engine
SPECIAL TOOLING REQUIRED
B. Vi. 31-01 Set of three punches for roll
pins
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1311-06 Tool for removal of fuel pipe
Mot. 1379 Tool for retaining engine on
sub-frame
T. Av. 476 Ball joint extractor
EQUIPMENT REQUIRED
Load positioner
10-4

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
Crankshaft seal, timing end
10
Crankshaft output mounting bolt 2 + 90°
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
Timing belt tension wheel nut 5
TIGHTENING TORQUES (in daN.m)
REPLACEMENT
REMOVAL
Remove the timing belt (see section 11 "Timing
belt").
Use tool Mot. 1374 to remove the crankshaft seal.
99787R
Screw the body of the tool into the seal using nut
(1), then use bolt (2) to extract the seal.
SPECIAL TOOLING REQUIRED
Mot. 1054TDC pin
Mot. 1273 Tool for checking belt tension
Mot. 1289-03 Centring fork for suspended engine
mounting limiter
Mot. 1355 Tool for fitting pump seal
Mot. 1374 Pump seal extractor
Mot. 1379 Tool for maintaining engine on sub-
frame
REFITTING
Refit the new seal onto the crankshaft output wi-
thout damaging it when passing the timing
sprocket drive groove.
Position it using tool Mot. 1355.
99788R
Refit the new timing belt (see the method descri-
bed in section 11 "Timing belt"). D7F engine
10-29

ENGINE AND ENGINE PERIPHERALS
Oil pump
10
Crankshaft output mounting bolt 2 + 90°
Bolt mounting front right suspended
engine mounting on engine 6.2
Bolt mounting front right suspended
engine mounting on body 6.2
Timing belt tension wheel nut 5
TIGHTENING TORQUES (in daN.m)
REMOVAL
Remove:
- the timing belt (see method described in
section 11 "Timing belt"),
- the oil level sensor with the aid of a 19 mm
half-moon wrench,
- the oil dipstick,
- the crankshaft pulley and sprocket,
- the engine flywheel guard.
Lift the engine and gearbox assembly with the aid
of tool Mot. 1379.
Remove the sump bolts.
Rotate the sump towards the rear of the vehicle in
order to release the oil pump strainer from the
sump partitioning.
Remove:
- the oil pump strainer
- the oil pump
Clean the sealing surfaces without scratching the
aluminium.
SPECIAL TOOLING REQUIRED
Mot. 1054TDC pin
Mot. 1273 Tool for checking belt tension
Mot. 1355 Tool for fitting oil pump
Mot. 1379 Tool for maintaining engine on sub-
frame
REFITTING
Systematically replace the oil pressure seal (3).
99790R
Apply a bead of RHODORSEAL 5661 to the sealing
surface.
98964S
IMPORTANT: the oil pump is driven by two studs
located on the crankshaft. D7F engine
10-30

ENGINE AND ENGINE PERIPHERALS
Oil pump
10
Refit:
- the oil pump onto the engine and tighten it to
a torque of 0.9 daN.m,
- the new seal onto the crankshaft output wi-
thout damaging it when passing the timing
sprocket drive groove.
Position it with the aid of tool Mot. 1355..
99788R
Refit the strainer with a new O-ring.
Clean the sealing surfaces (cylinder block, sump).
Refit the sump.
Tighten the bolts to a torque of 1 daN.m.
Refit:
- the timing belt (see method described in
section 11 "Timing belt"),
- the new alternator and power assisted stee-
ring pump belts (see tension values in section
07 "Accessories belt tension"). D7F engine
10-31

TIGHTENING TORQUES (in daN.m)
TOP AND FRONT OF ENGINE
Timing belt
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove :
- the front right hand wheel,
- the belt from the alternator and the power
assisted steering pump if fitted (see section
07),
- the crankshaft accessories pulley.
11
10267R
SPECIAL TOOLING REQUIRED
Crankshaft accessories pulley
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
Mot. 1054TDC pin
Mot. 1135-01 Tool for tensioning timing
belt
Mot. 1273 Tool for checking belt tension
Mot. 1379 Tool for securing engine to
subframe
Mot. 1386 Tool for pre-tensioning timing
belt
Fit tool Mot. 1379. D7F engine
11-1

TOP AND FRONT OF ENGINE
Timing belt
11
Remove the suspended engine mounting.
Remove the timing cover, water pump cover and
suspended engine mounting cover on the cylinder
head .
Turn the engine in the operating direction until
the timing reaches its setting point (the camshaft
and crankshaft markings are aligned), whilst in-
serting pin Mot. 1054 into the flywheel.
12924S1
DI1041R
Remove the timing belt by slackening nut ( 5 ).
99795R
D7F engine
11-2

TOP AND FRONT OF ENGINE
Timing belt
11
REFITTING
Line up the markings of the timing belt with
those of the camshaft and crankshaft sprockets.
10072S
PROCEDURE FOR TENSIONING TIMING BELT
Remove pin Mot. 1054.
Fit the spacer (1) of tool Mot. 1386 and tighten
the crankshaft sprocket bolt.
10881R
a)Fit tool Mot. 1273 and, using tool
Mot. 1135-01, turn the tension wheel anti-
clockwise until the value of 20 US is obtained
(turn the sensor wheel until it is tight, as indi-
cated by three clicks).
10479R1
IMPORTANT: The camshaft sprocket bears five
markings, of which only the rectangular one on
the surface of one of the teeth represents TDC;
the other markings are intended as an aid for ad-
justing the valve rockers.
D7F Engine
11-3