wheel 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 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
Disconnect:
- the accelerator cable,
- the canister pipe,
- the brake servo pipe,
- the heater hoses,
- the oxygen sensor connector,
- the fuel pipes.
Remove:
- the shock absorber base bolts,
- the steering shaft yoke bolt.
10
97390-1R
SPECIAL NOTES FOR VEHICLES FITTED WITH
DRIVER’S AIR BAG
WARNING
In order to avoid any risk of damage to the rotary
switch beneath the steering wheel, the following
instructions should be followed:
• Before disconnecting the steering column from
the rack, the steering wheel MUST be immobi-
lised with the wheels straight with the aid of a
"steering wheel lock" throughout the opera-
tion.
• If there is any doubt about the rotary switch
being properly centred, the steering wheel
must be removed in order to apply the centring
method described in the Technical Note cove-
ring the 2nd generation air bag.
REMINDER: this kind of work must only be carried
out by properly trained and qualified staff.
Remove:
- both the sub-frame reinforcements,
- the earth strap mounting bolt on the body
side,
- the exhaust downpipe nuts. D7F engine
10-10

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

ENGINE AND ENGINE PERIPHERALS
Sump
10
Front sub-frame mounting bolt 6.2
Rear sub-frame mounting bolt 10.5
E7J sump bolt 1
F8Q sump bolt 1.5
Steering shaft yoke mounting bolt 3
Engine tie-bar bolt 6.2
Wheel bolt 9
TIGHTENING TORQUES (in daN.m)
REMOVAL
Put the vehicle on a 2 post lift.
Disconnect the battery.
Drain the engine oil.
Remove:
- the front wheels,
- the nut and the eccentric bolt of the steering
shaft yoke, after pushing back the guard,
97390S1
- the lower ball joint mountings and the track
rod ends for the
E7J engine,
- the sub-frame and body tie rods,
- the gear control on the gearbox side,
- bolt (1), and slacken engine tie-bar bolt (2),
without removing it,
E7J / F8Q
engines
SPECIAL TOOLING REQUIRED
Mot. 1233-01 Threaded rods for lowering the
sub-frame
13359R1
- the bottom mountings of the bumper,
- the exhaust downpipe for the
F8Q engine.
Special notes for the E7J engine
Remove:
- the exhaust manifold heat shield,
- the catalytic converter,
- the engine flywheel guard,
- the power assisted steering pipe mountings
on the cylinder block and the multifunction
mounting.
10-26

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