2003 Renault Kangoo Service and Repair Manual

© Renault s.a.s. 2005 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault. 77 11 318 022 FEBRUARY 2003 Edition Anglaise X84, and B84 or C84 or G84 or S84 1 Engine and peripherals 10A ENGINE AND LOWER ENGINE ASSEMBLY 11A TOP AND FRONT OF ENGINE 12A FUEL MIXTURE 12B TURBOCHARGING 13A FUEL SUPPLY 13B DIESEL INJECTION 13C PREHEATING 14A ANTIPOLLUTION 16A STARTING - LOAD 17A IGNITION 17B PETROL INJECTION

© Renault s.a.s. 2005 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault. 77 11 318 022 FEBRUARY 2003 Edition Anglaise X84, and B84 or C84 or G84 or S84 19A COOLING SYSTEM 19B EXHAUST 19C RESERVOIR 19D ENGINE MOUNTING

Mégane II - Section 1 Contents Page Mégane II - Section 1ContentsPage 10A ENGINE AND LOWER ENGINE ASSEMBLY Engine identification 10A-1 Engine oil: Draining - Refilling 10A-2 Oil consumption Check 10A-3 Oil filter: Removal - Refitting 10A-4 Exchanger: Removal - Refitting 10A-10 Oil pressure 10A-16 Oil pressure sensor: Removal - Refitting 10A-17 Oil level sensor: Removal - Refitting 10A-20 Sump: Removal - Refitting 10A-21 Oil pump: Removal - Refitting 10A-42 Multifunction support: Removal - Refitting 10A-45 Engine/gearbox assembly: Removal - Refitting 10A-55 Engine speed and position sensor: Removal - Refitting 10A-131 Crankshaft seal at timing end Removal - Refitting 10A-132 11A TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting 11A-1 Timing belt: Removal - Refitting 11A-11 Timing chain: Removal - Refitting 11A-116 Cylinder head gasket : Removal - Refitting 11A-117 Tightening the cylinder head 11A-199 Cylinder head: Removal - Refitting 11A-205 12A FUEL MIXTURE Specifications 12A-1 Air inlet 12A-11 Air resonator: Removal - Refitting 12A-22 Air filter: Replacement 12A-23 Air filter: Removal - Refitting 12A-25 Air filter unit: Removal - Refitting 12A-26 Air flowmeter: Removal - Refitting 12A-39 Air inlet flap: Removal - Refitting 12A-41 Air inlet duct: Removal - Refitting 12A-49 Inlet manifold: Removal - Refitting 12A-52 Injector holder shim: Removal - Refitting 12A-58 Manifolds: Removal - Refitting 12A-64 11A TOP AND FRONT OF ENGINE

Contents Exhaust manifold: Removal - Refitting 12A-67 Throttle valve: Removal - Refitting 12A-86 Throttle valve: Cleaning 12A-94 Engine stop device 12A-96 12B TURBOCHARGING Turbocharging: Precautions for repair 12B-1 Turbocharger: Removal - Refitting 12B-6 Pressure regulator: Checking 12B-37 Turbocharging pressure regulation valve 12B-43 Intercooler: Removal - Refitting 12B-46 13A FUEL SUPPLY Petrol supply circuit 13A-1 Diesel fuel supply circuit 13A-2 Petrol filter: General information 13A-6 Diesel filter: Removal - Refitting 13A-7 Injector rail - Injectors: Removal - Refitting 13A-14 Electric fuel: Checking 13A-20 13B DIESEL INJECTION Specifications 13B-1 Diesel injection: Specifications 13B-11 12A FUEL MIXTURE Diesel injection: Precautions for repair 13B-16 Description 13B-31 Operation 13B-33 Location of components 13B-36 Immobiliser function 13B-61 Injection warning light 13B-62 Injection / air conditioning programming 13B-64 Idling speed 13B-67 Centralised coolant temperature management 13B-69 Computer configuration 13B-71 High pressure pipe: Checking 13B-73 High pressure pipe: Replacement 13B-76 Diesel injector: check 13B-83 High pressure pump: Removal - Refitting 13B-84 Diesel injector: Removal - Refitting 13B-113 Injectors: Configuration 13B-130 High-pressure pipe between the rail and injector: Removal - Refitting 13B-132 Injector rail: Removal - Refitting 13B-143 Rail pressure sensor 13B-160 Rail pressure sensor: Removal - Refitting 13B-161 Fuel flow actuator: Removal - Refitting 13B-164 Leak flow from injectors: Check 13B-170 Fuel pressure regulator: Removal - Refitting 13B-174 13B DIESEL INJECTION

Contents Diesel temperature sensor: Removal - Refitting 13B-179 Accelerometer: Removal - Refitting 13B-189 Venturi: Removal - Refitting 13B-190 Accelerator pedal potentiometer: General information 13B-194 Accelerator pedal potentiometer: Removal - Refitting 13B-195 Diesel injection computer: Removal - Refitting 13B-196 13C PREHEATING Pre/postheating unit: Removal - Refitting 13C-1 Heater plugs Removal - Refitting 13C-2 Pre-postheating control 13C-11 14A ANTIPOLLUTION Petrol vapour rebreathing: Operation 14A-1 Fuel vapour recirculation circuit: check 14A-3 Fuel vapour canister: Removal - Refitting 14A-4 Fuel vapour canister:Checking 14A-5 Oil vapour rebreathing 14A-6 Exhaust gas recirculation: Operating diagram Exhaust gas recirculation: Description 14A-17 Exhaust gas recirculation unit 14A-23 13B DIESEL INJECTION Exhaust gas recirculation solenoid valve: Removal - Refitting 14A-29 Intercooler: Removal - Refitting 14A-31 Exhaust gas recirculation mounting: Removal - Refitting 14A-36 Exhaust gas recirculation rigid pipe: Removal - Refitting 14A-37 16A STARTING - LOAD Alternator: General information 16A-1 Alternator: Removal - Refitting 16A-2 Alternator pulley: Removal - Refitting 16A-20 Starter: Identification 16A-24 Starter: Removal - Refitting 16A-25 17A IGNITION Coils Removal - Refitting 17A-1 Spark plugs 17A-5 17B PETROL INJECTION Location of components 17B-1 Oxygen sensors: Removal - Refitting 17B-14 Accelerator pedal potentiometer: Removal - Refitting 17B-16 Position and speed sensor 17B-17 14A ANTIPOLLUTION

Contents Petrol injection computer: Removal - Refitting 17B-19 Special notes 17B-21 Injection warning light 17B-24 Immobiliser function 17B-25 Injection - air conditioning programming 17B-26 Throttle valve: Operating 17B-30 Idle speed correction 17B-31 Adaptive idle speed correction 17B-34 Richness regulation 17B-35 Adaptive richness correction 17B-39 Central coolant temperature management 17B-41 Camshaft dephaser: Description 17B-42 Fault finding warning light activation conditions (when driving) 17B-44 Conditions for carrying out fault finding (when driving) 17B-45 Combustion misfire fault finding 17B-46 Catalytic converter fault finding 17B-47 Oxygen sensor fault finding 17B-48 Speed limiter: Operating principle 17B-49 19A COOLING SYSTEM General information 19A-1 Specifications 19A-2 Checking 19A-3 Diagram 19A-4 17B PETROL INJECTION Cooling circuit: Draining - Refilling 19A-12 Engine cooling circuit: Cleaning 19A-14 Cooling circuit: Bleeding 19A-15 Cooling radiator: Removal - Refitting 19A-16 Water pump: Removal - Refitting 19A-22 Plenum chamber: Removal - Refitting 19A-40 19B EXHAUST General information 19B-1 Pipe assembly 19B-5 Catalytic pre-converter: Removal - Refitting 19B-10 Catalytic converter: Removal - Refitting 19B-15 Expansion chamber: Removal - Refitting 19B-29 Silencer: Removal - Refitting 19B-30 Particle filter: Function 19B-31 Particle filter: Removal - Refitting 19B-32 Particle filter pressure sensor: Removal - Refitting 19B-38 Particle filter temperature sensors: Removal - Refitting 19B-42 Connecting hose: Removal - Refitting 19B-45 Particle filter: Cleaning 19B-46 19A COOLING SYSTEM

Contents 19C RESERVOIR Draining the fuel tank 19C-1 Fuel tank: Description 19C-6 Fuel tank: Removal - Refitting 19C-12 Filler neck: Removal - Refitting 19C-15 Sender unit: Removal - Refitting 19C-17 Pump-sender unit-filter: Removal - Refitting 19C-20 Petrol filter: General information 19C-22 Fuel level sensor: Checking 19C-23 19D ENGINE MOUNTING Suspended engine mounting 19D-1 Suspended engine mounting: Tightening torque 19D-9 Left-hand suspended engine mounting: Removal - Refitting 19D-12 Right-hand suspended engine mounting: Removal - Refitting 19D-14 Rear suspended engine mounting: Removal - Refitting 19D-16

10A- 1 ENGINE AND LOWER ENGINE ASSEMBLY Engine identification 10A List of engine Workshop Repair Manuals to be consul- ted depending on the engine type: - K4J and K4M engine, Technical Note 3784A, - K9K engine, Technical note 6006A, - F9Q engine, Technical Note 3652A, - F4R engine, Technical Note 3783 A. Vehicle type Engine type Engine suf- fix Cubic capacity (cc) Bore (mm) Stroke (mm) Compression ratio XM0B XM0H XM1A K4J 730 1390 79.5 70 10/1 XM08 732 XM0C XM0J XM1B K4M 760 1598 79.5 80.5 9.8/1 761 XM05 XM0U XM1M XM1N F4R 770 1998 82.7 93 9.8/1 771 XNOW 776 9.5/1 XM0F XM0T K9K 722 1461 76 80.5 17.9/1 XM02 XM13 728 XM02 729 XM1E 732 15.3/1 XM0G XM1G F9Q 800 1870 80 93 18.4/1 XM0L XM1D 804 17/1 XM00 808 18.4/1

10A- 2 ENGINE AND LOWER ENGINE ASSEMBLY Engine oil: Draining - Refilling M9R, and 700 10A I - OIL SERVICE Remove the oil filler plug and the dipstick. Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine undertray. Remove the drain plug (1) . Let the oil run into a drain tray. Copper seal Refit the new seal on the plug, positioning the groo- ve (2) towards the plug. Tighten to torque the drain plug ( 44 Nm ) . II - FILLING When filling up the engine oil, always leave at least 10 minutes for the oil to drain down before checking with a dipstick. Fill up the engine with oil. Refit the engine undertray. Tightening torques m drain plug 44 Nm Engine Average oil capacity (check and adjust with dipstick) (l) Draining Oil change with oil filter replacement M9R 6.4 6.7 114651 113764 WARNING Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (as this could damage the engine). Correct the engine oil level if necessary before delivering the vehicle to the customer.

10A- 3 ENGINE AND LOWER ENGINE ASSEMBLY Oil consumption Check 10A PROCEDURE FOR MEASURING OIL CONSUMPTION 1 - Filling to the maximum level Turn the engine off. Wait two minutes for all of the oil to flow into the oil sump. Check the level on the dipstick. Top up to the "MAX" mark. Make a paint mark on both the fuel filler cap and the sump drain plug in order to be able to check later that they have not been removed. 2 - Customer driving Ask the customer to drive approximately 1,200 mi- les (2,000 km) in the vehicle without letting the oil level reach the "MIN" mark. 3 - Topping up Turn the engine off. Wait two minutes for all of the oil to flow into the oil sump. Check the level on the dipstick. Top up to the "MAX" mark. Note the quantity of oil added and the mileage cove- red since the last top-up to maximum level. 4 - Measurement of the oil consumption Oil consumption = Quantity of topping up oil (in litres) / number of kilometres (in thousands). Note: The operation should be carried out with the engine warm after the fan unit has started operating. Note: The operation should be carried out with the engine warm after the fan assembly has started operating.

2003 Renault Kangoo Service and Repair Manual

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