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

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 heater hoses on the bulkhead side (with
plastic unions),
10
Disconnect the gear control at the position of the
gearbox output lever after releasing the gaiter.
93912R1
Slacken bolt (A) without removing it and remove
bolt (B) from the engine tie-bar.
92661R1
Disconnect:
- the accelerator cable,
- the canister pipe,
- the brake servo vacuum pipe,
- the hoses between the radiator and the
engine block, on the engine block side,
13085R
(with metal unions),
13084R
- the connectors of the oxygen sensor and fan,
- the fuel pipes. D7F engine
10-6

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 and transmission assembly
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 (disconnect the bottom
hose of the radiator),
- the gearbox oil if necessary,
- the engine oil if necessary.
Remove:
- the battery,
- the wheels,
- the air intake pipe,
- the upper radiator mountings,
- the expansion bottle and fix it to the engine,
- the power assisted steering fluid reservoir,
and secure it onto the engine. Shock absorber base bolts 18
Track rod end 3.7
Front sub-frame mounting bolt 6.2
Rear sub-frame mounting bolt 10.5
Driveshaft gaiter mounting bolt 2.5
Wheel bolt 9
Mounting nut for rubber engine mounting
pad on left suspended engine mounting 6.2
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
Steering shaft yoke bolt 2.5
TIGHTENING TORQUES (in daN.m)
D7F engine
SPECIAL TOOLING REQUIRED
B. Vi. 31-01 Set of punches for roll pins
Mot. 1040-01 Dummy sub-frame for
removing and refitting engine
and transmission assembly
Mot. 1202 Hose clip pliers
Mot. 1311-06 Tool for removal of fuel pipe
Mot. 1379 Tool for retaining engine on
sub-frame
T. Av. 476 Ball joint extractor
T. Av. 1233-01 Tool for sub-frame and axle
assembly
10-9

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
- the relay plate (4), the connector (5) and the
fuse support (6) by removing the fuse holder
(7),
13034R
- the canister pipe,
- the fuel supply and return pipes with the aid
of tool Mot. 1311-06, after removing the co-
ver,
- the accelerator and clutch cables.
Unclip the power assisted steering reservoir and
place it on the engine.
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
99024R2
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.
Fit tool Mot. 1159 between the sub-frame and the
cylinder block. E7J engine
10-16

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
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

TOP AND FRONT OF ENGINE
Cylinder head gasket
11
SPECIAL TOOLING REQUIRED
REMOVAL
Place the vehicle on a two post lift .
Disconnect the battery.
Remove :
- the bonnet,
- the timing belt (see method described in
section 11 "Timing belt").
Drain the cooling circuit via the lower radiator
hose.
EQUIPMENT REQUIRED
Engine support tool
55mm torx socket
Mot. 251-01 Dial gauge support tool
Mot. 252-01 Plate for measuring piston
protrusion
Mot. 591-02 Index
Mot. 591-04 Angular tightening wrench
Mot. 1054
TDC pin
Mot. 1159 Tool for mounting engine on
subframe
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1311-06 Tool for removing fuel pipe
Tension wheel nut 5
Crankshaft pulley bolt 2 + 115° ± 15°
Bolt for suspended engine mounting cover 6.2
Nut for suspended engine mounting cover 4.4
Wheel bolts 9
TIGHTENING TORQUES (in daN.m or/and°)
99024R2
Fit tool Mot. 1159 between the subframe and
the cylinder block. F8Q Engine
11-23

COOLING
Diagram
19
1 Engine
2 Radiator
3 ”Hot” bottle with permanent degassing
4 Heater matrix
5 3 mm diameter restriction
The fan assembly is controlled at high speed by
the injection computer if the coolant tempera-
ture is greater than 99°C.
If the coolant temperature is lower than 96°C, the
fan assembly stops operating.Water pump
Thermostat
Bleed screw
The expansion bottle valve is brown, and its rating
is 1.2 bar.
10070-2R
D7F Engine
19-4