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

ENGINE AND ENGINE PERIPHERALS
Oil consumption
10
OIL CONSUMPTION MEASUREMENT PROCEDURE
a) Filling to the maximum level
The operation must be carried out with the engine hot (one rotation of the cooling fan assembly) and af-
ter settling for 15 minutes to allow all the oil to drain into the sump.
Check visually using the dipstick.
Top up to the maximum level.
Seal the drain plug (with a paint mark on both the filler plug and the sump’s drain plug) in order to be
able to check later that it has not been removed.
b) Customer driving
Ask the customer to drive the vehicle for a period corresponding to about 1250 miles (2,000 km) or before
the minimum level is reached.
c) Refilling to the maximum level
The operation must be carried out with the engine hot (one rotation of the cooling fan assembly) and af-
ter a settling time of 15 minutes.
Check visually using the dipstick.
Top up to the maximum level.
Note the quantity of oil and the mileage covered since the last filling to the maximum level.
d) Measurement of the oil consumption
Quantity of topping up oil (in litres)
OIL CONSUMPTION =----------------------------------------
km (in thousands)
10-2

87363R1
ENGINE AND ENGINE PERIPHERALS
Oil pressure
10
SPECIAL TOOLING REQUIRED
Mot. 836 -05 Oil pressure measuring kit
EQUIPMENT REQUIRED
22 mm long socket
CHECKING
The oil pressure should be checked when the en-
gine is warm (approximately 80°C).
Contents of kit Mot. 836-05.
USE
ENGINE CHECKING
D engine
Idling0.8 bar
4 000 rpm3.5 bars
E engine
Idling1 bar
3 000 rpm3 bars
F engine
1 000 rpm1.2 bars
3 000 rpm3.5 bars
D engine E engine F engine
C + F C + E + F B + F
10-3

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
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

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
Tighten the tension wheel nut.
Turn the engine at least twice (never in the op-
posite direction to normal operation).
Insert the pin in the engine at TDC, then remove
the pin .
Check that the timing is correct on the crankshaft
and camshaft side.
Slacken the tension wheel nut and turn it slightly
clockwise using tool Mot. 1135-01 until the two
holes of the tension wheel are lined up
horizontally.
Retighten the tension wheel nut.
b)Turn the engine at least twice (never in the
opposite direction to normal operation).
Insert the pin in the engine at
TDC then re-
move the pin.
Using tool Mot. 1386, apply a pretensioning
torque of 1 daN.m between the crankshaft
sprocket and the water pump.
Fit tool Mot. 1273 and note the tension measure-
ment, which should be 20±
3 US (fitting tension),
or simply adjust by varying the position of the
tension wheel using Mot. 1135-01 and repeat the
tensioning process in (b).
Tighten the tension wheel nut to a torque of
5 daN.m.
IMPORTANT
Following each variation of the tension wheel
position, turn the engine at least twice before
proceeding to measure the tension .
Apply the pretensioning of 1 daN.m which allows
all belt play to be eliminated.
Refitting is the reverse of removal.
Fit the suspended engine mounting .
12924S1
10881R
D7F Engine
11-4

TOP AND FRONT OF ENGINE
Timing belt
REMOVAL
Place the vehicle on a 2 post lift.
Disconnect the battery.
Fit the engine support tool.
11
13370S
SPECIAL TOOLING REQUIRED
Mot. 591-02 Index pin
Mot. 591-04 Angle tightening wrench
Mot. 1135-01 Tool for tensioning timing
belt
Mot. 1273 Tool for checking belt tension
Wheel bolts 9
Crankshaft pulley bolts 2 + 68° ± 6°
Tension wheel nut 5
Bolt for suspended engine mounting cover 6.2
Nut for suspended engine mounting cover 4.4
13359R
Remove :
- the front right wheel along with the mud-
guard,
- the suspended engine mounting cover,
EQUIPMENT REQUIRED
Engine support tool
- the belts for the alternator and the power
assisted steering pump.
TIGHTENING TORQUES (In daN.m or /and°)
E7J Engine
11-5

TOP AND FRONT OF ENGINE
Timing belt
11
REFITTING
An arrow indicating the direction of rotation and
two dashes for setting are marked on the surface
of the belt .
Check that the engine is at the setting point.
Bring the belt markings in line with the sprocket
markings .
Observe the mounting direction for the belt and
begin to position it on the crankshaft sprocket.
Carry out the tensioning of the belt using tool
Mot. 1135-01, until the fitting value is obtained
(see section 07 "Timing belt tension ").
Tighten the nut (O) of the tension wheel to a tor-
que of 5 daN.m.
It is essential to tighten the nut of the tension
wheel to a torque of 5 daN. to avoid any slacke-
ning which may cause a deterioration in the en-
gine .
Refitting is the reverse of removal.
Refit the crankshaft pulley, being sure to tighten
the bolt to a torque of 2 daN.m with an angle of
68° ± 6°.
Refit and tension the accessories belts (see section
07 "Accessories belt tension").
Never refit a belt once removed , but replace it. E7J Engine
11-7

TOP AND FRONT OF ENGINE
Timing belt
11
REMOVAL
Place the vehicle on a 2 post lift.
Disconnect the battery.
Remove :
- the front right hand wheel and the mud-
guard,
- the protective plastic covering over the sus-
pended engine mounting cover .
Fit the engine support tool.
SPECIAL TOOLING REQUIRED
Mot. 1054TDC pin
Mot. 1273 Tool for checking belt tension
EQUIPMENT REQUIRED
Engine support tool
14mm torx socket
13370S
Remove :
- the accessories belt,
- the suspended engine mounting cover.
13086R1
Wheel bolts 9
Crankshaft pulley bolt 2 + 115° ± 15°
Tension wheel nut 5
Bolt for suspended engine mounting
cover 6.2
Nut for suspended engine mounting cover 4.4
TIGHTENING TORQUES (in daN.m or/and°)
F8Q Engine
11-8