1997 RENAULT KANGOO gearbox

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
Insert a wooden block between the gearbox and
the sub-frame.
Diagram showing the holes drilled in tool Mot.
1040-01 (dimensions in mm).
10
Disconnect the gear control:
- at the position of the gearbox output lever af-
ter releasing the gaiter,
- at the level of the gear lever after removing
the central heat shield.
Pull the control lever (2) towards the rear of the
vehicle.
10621R
Fit tool Mot. 1379 onto the sub-frame and take
the weight off the right-hand engine mounting,
using the threaded rod (1).
10267R1
93912R2
Fix tool Mot. 1040-01 underneath the sub-frame,
having first fitted the shims Mot. 1379 onto this
tool.
92442-1R2
D7F engine
10-11

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
Remove:
- the gearbox suspended mounting nut, then
tap it with a copper hammer to release the
suspended mounting stud,
- the suspended engine mounting bolts on the
engine.
Lower the lift until the tool touches the ground.
Remove the four mounting bolts of the sub-
frame.
Take out the engine and transmission assembly by
lifting the body.
98755R
D7F engine
10-12

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
12924R4
Apply Rhodorseal 5661 to the driveshaft roll pin hole.
Press the brake pedal several times to bring the pistons into contact with the brake pads.
Fill:
- the gearbox with oil (if necessary),
- the engine with oil (if necessary),
- the cooling circuit and bleed it (see section 19).
REFITTING (special notes)
Use tool T. Av. 1233-01 to position the engine and transmission assembly in relation to the body.
Refitting is the reverse of removal.
Tighten the suspended engine mounting bolts and nuts to the recommended torque.D7F engine
10-13

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
13085R
- the exhaust heat shield and the gear control
on the lever and gearbox sides,
12988R
- the exhaust pipe clamp between the catalytic
converter and the expansion chamber,
- the earth strap on the gearbox,
- the front bumper,
- the air intake pipe from the air filter,
- the injection computer support after dis-
connecting the 55 track connector and that of
the impact switch.
13088R2
Disconnect:
- the wiring connections and the hoses on the
thermostat support,
- the hoses on the expansion bottle,
- the brake servo pipe,
- the heater hoses (there are two types of as-
sembly to be disconnected, as shown in the
diagrams below),
13084R
E7J engine
10-15

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
Fit retaining lug Mot. 1159 in place of the coolant
pipe mounting on the cylinder block.
99310R
Remove the suspended engine mounting cover.
13359R
13086R
Insert a wooden block between the gearbox and
the sub-frame.
Remove:
- the nut (1), then tap it with a copper hammer
to release the suspended engine mounting
stud.- the mounting bolts (3).
E7J engine
12993-1R3
10-17

ENGINE AND ENGINE PERIPHERALS
Engine and transmission assembly
10
REFITTING
The alignment of the sub-frame with the body
will be made easier by positioning two threaded
rods Mot. 1233-01 in the two front mountings of
the sub-frame on the body.
Tighten the sub-frame mounting bolts to a torque
of:
- 6.2 daN.m at the front,
-10.5 daN.m at the rear.
Refitting is the reverse of removal.
Fit the heat shields correctly.
Apply
Loctite FRENBLOC to the caliper mounting
bolts and tighten them to the recommended tor-
que.
Press the brake pedal several times to bring the
pistons into contact with the brake pads.
Fill:
- the engine and gearbox with oil, if necessary,
- the cooling circuit and bleed it (see section 19
"Filling - bleeding"). E7J engine
Fix tool Mot. 1040-01 underneath the sub-frame.
98755R1
Lower the lift until the tool touches the ground.
Remove the sub-frame mounting bolts and take
out the engine and transmission assembly by lif-
ting the body.
NOTE : for any operation requiring separation of
the engine, gearbox and sub-frame assembly,
take care to mark the position of Mot. 1159 on the
sub-frame.
10-18