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

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
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

FUEL SUPPLY
Fuel cut off in case of an impact
13
OBJECTIVE
The main function of this feature is to avoid any
fires that may result from the leakage of fuel du-
ring an accident. In order to achieve this, all
components pumping fuel from the fuel tank will
automatically stop functioning during and imme-
diately after the impact. They can then only be
made to operate again by a mechanical action car-
ried out by the driver or the repairer.
DESCRIPTION
The system consists simply of an inertia switch (1),
which:
- detects the impact,
- and thus cuts off the electrical circuit.
13051R
This is fitted:
• in petrol engines, between track 1 of the
pump relay (236) and the + 12 V supply ,
• in diesel engines, between the + supply and
the electrical solenoid (or the coded solenoid
valve if the vehicle is fitted with an engine im-
mobiliser).
OPERATING PRINCIPLE
During the impact, the ball of the inertia switch
moves up and interrupts the electrical connec-
tion.
In petrol engines, the + supply of the pump relay
control circuit (236) is cut. Neither the pump or
the injectors will receive any further supply of
electricity .
The fuel contained in the tank is actually isolated.
In diesel engines, the + supply of the electrical
solenoid or of the coded solenoid is cut off.
The pump can no longer take in fuel, and there is
no longer any high pressure. All risk of fire due to
the outlet of diesel fuel at high pressure onto the
engine is removed.
RESETTING AND OPERATING THE SWITCH
In order to reset the inertia switch, it is sufficient
to press it down in order to replace the ball bea-
ring in its original position .
IMPORTANT: for petrol engines, , having reset
the switch, it is
VITAL to erase the memory of the
computer, using the
XR25. The injection compu-
ter will memorise a pump relay fault once the
system has gone into operation .
13-1

FUEL SUPPLY
Pump flow
13
Petrol
engines
96093R2
SPECIAL TOOLING REQUIRED
Mot. 1265 Pliers for removing quick release
unions
EQUIPMENT REQUIRED
2 000 ml measuring cylinder
It is advised to check the pump supply flow
through the fuel return pipe connected to the
pump-fuel sender unit assembly.
IMPORTANT
During this operation, it is essential :
• to refrain from smoking and handling incan-
descent objects close to the working area,
• to take precautions against possible fuel
projections which may occur due to the resi-
dual pressure in the supply pipes when they
are removed.

CHECKING THE PUMP FLOW
Disconnect the fuel return pipe (1) (Mot. 1265).
Connect a piece of pipe to the hose and place this
into a 0-2 000 ml graduated measuring cylinder.
Shunt terminals (3) and (5) of relay (K) on the DF7
engine, or for the
E7J engine shunt at (L) on the
fuel pump relay (which is located in the engine
fuse box ). In one minute, the pump flow must be
a minimum of 1.3 litres with a voltage of 12
volts.
If the fuel flow is low, check the pump feed vol-
tage (approximately 10 % reduction in flow for a
voltage drop of 1 Volt)
12839S
13-7

FUEL SUPPLY
Fuel pressure
13
Connect pressure gauge 0 ; 10 bars along with
the flexible hose, Mot. 1311-01.
Shunt terminals (3) and (5) on the pump relay (K) ,
which is situated in the engine fuse box.
99938-1R
12839S
The pressure must be 3 bars ± 0,2.
By applying a pressure of 500 mbars to the
pressure regulator, a fuel pressure of 2.5 bars ±
0.2 should be obtained. DF7 Engine
13-9

FUEL SUPPLY
Fuel pressure
13E7J Engine
Shunt terminals (3) and(5) of the fuel pump relay
(L) located in the engine fuse box .
12839S
The pressure must be 3 bars ± 0.2.
By applying a pressure of 500 mbars to the
pressure regulator, a fuel pressure of 2.5 bars ±
0.2 should be obtained.
13-11

DIESEL EQUIPMENT
General
13
The use of electronic injection in Diesel engines has allowed the operational power of these engines to be
optimised, thus reducing the emission rate of pollutant gases.
The system consists of a computer, which receives information from:
- the coolant temperature sensor,
- the air temperature sensor,
- the engine speed sensor,
- the vehicle speed sensor,
- the load potentiometer,
- the injection start sensor, which forms part of the injector of cylinder n° 3 (injector with sensor).
It controls :
- the injection pump :
• the altimetric corrector (F8Q 630) via a relay
• the advance solenoid valve.
- the cold engine starting system (heater plugs and pre-postheating unit),
- the exhaust gas recycling system (EGR),
- the diesel injection fault warning light,
- the preheating warning light,
- the solenoid valve controlling the fast idle speed LDA,
- the relay controlling the power assisted steering electric pump assembly (for vehicles with air conditio-
ning), the pump assembly is supplied once the engine speed exceeds 650 rpm.
It carries out a self diagnosis procedure which may be visualised through the
XR25.
SPECIAL FEATURES
On the injection pump it is possible to replace:
- the load potentiometer,
- the advance solenoid valve,
- the altimetric corrector,
- the electrical solenoid.
13-13

DIESEL EQUIPMENT
Specifications
13
DESCRIPTIONMAKE/TYPESPECIAL NOTES
Computer LUCAS 25 track (in case of computer replacement,
programme the new computer to memorise the
full load position of the load potentiometer)
Injection - Indirect
Injection pump
LUCAS DIESEL
8448B171 A/231A
(F8Q 630)
8448B152 B/241B
(F8Q 662)Rotary pump fitted with :
- an advance solenoid valve,
- an altimetric corrector (F8Q 630).
Pump setting (obtain TDC
point using ∅ 8 mm pin) - Dimension ( X ) on pump
Injector holders
LUCAS DIESEL
LCR 6735 405Tightening torque: 7 daN.m (injector on injector
holder and injector holder on cylinder head )
Holder for injector with sensor
(needle lift)
LUCAS DIESEL
LDCR020011AA1Tightening torque : 7 daN.m
Resistance ≈ 105 Ω
Injectors
LUCAS DIESEL
RDN OSDC 6902Opening pressure : 130 bars
Maximum pressure difference: 8 bars
EGR solenoid valve
-Voltage: 12 volts
Resistance : 46 ± 5 Ω
Injector pipes
-Ø interior : 2.5 mm
Length: 330 ± 5 mm
Preheating relay housing
-With pre-postheating function (command
controlled by the computer)
Plugs BERU
Pencil type plugResistance : 0.8 Ω
Tightening torque : 2 daN.m
TDC sensor - Resistance : 220 Ω
Fast idle solenoid valve
-Voltage: 12 V
Resistance : 46 Ω
Advance corrector
-Voltage: 12 V
Resistance : 11.5 Ω
Load potentiometer
-Voltage : 5 V
Resistance : (in K Ω, approximately )
Altimetric corrector
-Voltage : 12 V
Resistance : 15.5 Ω
Fault finding Fiche n° 43
Code D34
Selector S8-+5
- 5
Track
(10 track connector)no load full load
5-4
3-4
3-54.5
5.6
2.84.5
2.8
5.6
13-15

DIESEL EQUIPMENT
Location of components
13
1 EGR valve and solenoid valve
2 Air temperature sensor (white connector)
3 Coolant temperature sensor (white connector)
4 Diesel injection computer
5 Fuel filter
6 Pre-postheating plug relay housing
7 TDC sensor
8 Fast idle solenoid valve
9 Electrical solenoid / coded solenoid
10 Digital DPC injection pump
11 Load potentiometer
12 Advance solenoid valve
13 Altimetric corrector
14 Injector with sensor (needle lift)
12874
13-16

DIESEL EQUIPMENT
Location of components
13
12Advance solenoid valve
14Injector with sensor
13Altimetric corrector
11Load potentiometer
9Electrical solenoid / coded solenoid valve
8Idle speed solenoid valve
12869-1R
3Coolant temperature sensor
2Air temperature sensor
6Pre-postheating plug relay housing
5Fuel filter
16Inertia switch
4Injection computer
13083R
12872R
19 EGR solenoid valve
12871R
13-17