1997 RENAULT KANGOO brake

MECHANICAL ELEMENT CONTROLS
Handbrake control lever
37
REMOVAL
Release the handbrake.
Remove the lower bolts from the exhaust
downpipe.
Remove the rear rubber mounting for the exhaust
pipe.
NOTE : attach the exhaust pipe to the body.
Remove the heat shields.
12998S
98826-2R
Note the handbrake adjustment dimen-
sion,between the end of the nut (1) and the rod.
Slacken nut ( 1 )to release the two cables.
Remove the linkage from the clip (2).
Remove the two handbrake control lever
mounting nuts.
Remove the handbrake lever and disconnect the
connector.
REFITTING
Refitting is the reverse of removal.
Refit the heat shields.
Remember to reconnect the handbrake
connector.
Reset the handbrake control linkage to the
dimension noted on removal.
If necessary, adjust the lever travel (see section
"Adjusting the control").
37-7

MECHANICAL ELEMENT CONTROLS
Handbrake control
37
ADJUSTMENT
Incorrect adjustment of the handbrake where the
cable is too tight:
- prevents the correct operation of the automa-
tic compensation system for the brake shoes ,
- causes long brake pedal travel.
The cables should not be re-tensioned to correct
this fault since it will quickly occur again.
The handbrake should not be used to adjust play,
it should only be adjusted when replacing :
- brake linings,
- cables,
- the control lever.
Any other adjustment except in the above cases is
not permitted.
With the vehicle on a lift supported under the bo-
dy, slacken the nut (1) so the central adjuster is
completely free.
Remove:
- the two rear wheels,
- the two drums.
Check the operation of the compensation system
by rotating the notched sector (D) (ensure it turns
in both directions), then turn it back by 5 to 6
teeth.
98992-1R3
98826-1R
37-8

MECHANICAL ELEMENT CONTROLS
Handbrake control
37
98992-1R2
Ensure :
- the cables slide correctly,
- the handbrake levers (B) are in the correct
position against the brake shoes.
Progressively tighten the cables at the central
adjuster so that levers (B) start to move between
the 1st and 2nd notch of the control lever travel
and remain applied from the 2nd notch.
Tighten the lock nuts.
Fit the drums.
With the vehicle on its wheels, adjust the brake
linings by pressing the brake pedal firmly and
progressively for a number of times while
listening for the automatic compensation system
clicking.
37-9

96118R
MECHANICAL ELEMENT CONTROLS
Brake pipes
37
These vehicles have brake pipes without a copper seal. The seal is by contact "at the bottom of the cone" of
the shoulder (Y) on the pipe.
X = 1.5
Z= 1.3
TIGHTENING TORQUES (in daN.m)
PRECAUTIONS TO BE TAKEN WHEN REMOVING - REFITTING A BRAKE CYLINDER OR A BRAKE PIPE.
For safety reasons and to ensure that the brake pipe is not twisted and is not liable to touch a suspension
component the following order of operations must be observed:
Remove the hose from the caliper and if necessary
remove the caliper.
REMOVAL
Slacken the union (1) (pipe wrench) between the
rigid pipe and the hose (2) until the spring (3)
becomes slack which releases the hose from the
splines (4).
85536R
REFITTING
Fit the caliper to the brake and screw the hose
onto it, then torque tighten to
1.5 daN.m.
The brake pipes are fitted when the axle assembly
is in position:
• Wheels suspended (suspension in place)
• Axle assembly aligned (wheels straight)
Position the female end of the hose on the
retaining bracket (5), without twisting it and
check that the end piece (4) fits freely into the
splines of the bracket, then fit:
- the spring (3),
- the rigid pipe to the hose, checking that the
hose does not turn when the assembly is
screwed together.
Torque tighten the union.
Bleed the brake circuit.
37-10

MECHANICAL ELEMENT CONTROLS
Braking compensator
37
NOTE
the braking compensators differ depending on the type of rear axle:
-standard load rear axle: red reference mark,
-increased load rear axle: green reference mark,
REMOVAL
Put the vehicle on a two post lift.
Disconnect the brake pipes.
Disconnect rod ( 2 ) from the compensator by
slackening bolt ( 1 ).
Remove the compensator (two bolts).
12865-1R
TIGHTENING TORQUES (in daN.m)
Hydraulic unions 1.7
Compensator mounting bolt 1.8
Rod adjustment bolt 1
NOTE : do not alter the position of nut (3).
REFITTING
Refitting is the reverse of removal.
Bleed and check the circuit (see section "Checking
- Adjusting").
SPECIAL TOOLING REQUIRED
Fre. 244 -03
or
Fre. 1085-01
CHECKING
Connect two pressure gauges Fre. 244-03 or
Fre. 1085-01 :
- one at the front right hand side,
- one at the rear left hand side.
Bleed the pressure gauges via screw (P).
98828R
Progressively press the brake pedal until the
pressure at the front wheels is the setting
pressure (see table of values). Read the
corresponding pressure at the rear wheels;
correct it if necessary.Pressure gauge for checking
compensator rating
37-12

12865-1R
MECHANICAL ELEMENT CONTROLS
Braking compensator
37
Carry out the same operation on the other circuit:
- one at the front left hand side,
- one at the rear right hand side.
If there is a large difference (values exceed
tolerance ranges), replace the compensator since
no repair is permitted.ADJUSTMENT
The method for adjusting the compensators used
today in After Sales is simple and only involves
using two pressure gauges which must be
connected to the braking circuit (front right
wheel and rear left wheel, then front left wheel
and rear right wheel).
Checking and adjustment is carried out with the
vehicle unladen, the fuel tank full and the driver
on board.
After imposing a certain pressure at the front by
pressing the brake pedal, just read off the
pressure at the rear and compare the value with
that given in section 07. Then move the
compensator rod by releasing the bolt ( 1 ), so rod
( 2 ) may be adjusted.
NOTE : do not alter the position of nut (3).
This method is difficult to carry out when the
vehicle is loaded, as is often the case for a utility
vehicle fitted out with shelves full of spare parts
and tools.
The special case of utility vehicles has led to the
development of a different method for
adjustment which uses a deflection calculation
(index of crushing) for the tyres (this is
inexpensive but must be carried out with care).
The graphs for rear pressure as a function of tyre
deflection must be consulted.
37-13

MECHANICAL ELEMENT CONTROLS
Braking compensator
37
Tooling required:
- one measuring tape mounted on a base (used
for measuring underbody heights),
- an accurate pressure gauge.
1• Preparation of the vehicle:
- the vehicle must be left loaded,
- the person in charge of pressing the brake
pedal when the compensator is being adjusted
must be in the vehicle when the radius under
load is measured at the rear wheels,
- the vehicle must be on a flat horizontal surface,
which is smooth and clean (use a four post lift if
possible).
2• Marking the centre of the rear wheels:
- lift the rear of the vehicle so the rear wheels
may be turned,
- apply a chalk stick to the hub cover or the
wheel embellisher at the approximate centre of
the wheel,
- turn the wheel by hand fairly quickly, pressing
hard on the chalk. This allows concentric circles
to be drawn around the real rotation centre of
the wheel,
- mark the centre using a pencil on the chalk,
- carry out the same operation on the second
rear wheel.3• Adjusting the rear tyre pressure:
- the pressure must be adjusted with the wheels
on the ground and one person in the driver’s
seat,
- deflate the two rear wheels so that the pressure
is brought to 1.2 bar (use an accurate pressure
gauge which has been correctly calibrated),
- wait a few minutes for the air in the tyres to
return to ambient temperature since it is
cooled when the tyres are deflated and the
pressure will therefore have changed,
- adjust the pressure to 1.2 bar as accurately as
possible.
4• Measuring the radius with the vehicle
unladen:
- lift the rear wheels so that the tyres are no
longer crushed by the load on the axle (as soon
as the wheels leave the ground),
- measure the distance between the ground and
the wheel centre using the measuring tape.
5• Measuring the radius with the rear wheels
loaded:
- return the vehicle to its wheels,
- measure the distance between the ground and
the wheel centre using the measuring tape.
37-14

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
BOSCH ABS
38
PRN3818
LOCATION OF THE BOSCH ABS COMPONENTS
1Hydraulic assembly
2Master cylinder
3Brake servo4Brake fluid level warning light
5Braking compensator
38-2