1997-2003 Renault Master Van Service & Repair Manual

General SPECIFICATIONS LIFTING EQUIPMENT TOWING LUBRICANTS - CONSUMABLES DRAINING - REFILLING VALUES AND SETTINGS Renault 1997 "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 by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed". All copyrights reserved by Renault. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault. C 77 11 195 432 AUGUST 1997 Edition Anglaise FD0A - FD0C - UD0A - UD0C

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TOWING All types Contents SPECIFICATIONS Engine - Clutch - Gearbox Vehicle identification 01-1 01-2 LIFTING EQUIPMENT Trolley jack - Axle stands Pages 01 02 03 General 02-1 03-1 LUBRICANTS - CONSUMABLES Packaging 04-1 DRAINING - REFILLING Engine Gearbox Power assisted steering 04 05 05-1 05-2 05-3 VALUES AND SETTINGS Dimensions Capacities - Grades Belt tension Accessories drive belt tension Cylinder head tightening Tyres - Wheels Brakes Brake compensator Front axle checking values Rear axle checking values 07 07-1 07-2 07-4 07-6 07-8 07-9 07-10 07-11 07-12 07-13 Pages

The MASTER Workshop Repair Manual has been written by specialists in repair methods and fault finding. The manual includes methods and fault finding procedures necessary to repair this vehicle to a high standard. However, if a removal - refitting operation does not present any particular points or diffi- culties nor requires the use of any special tools, a description is considered unnecessary for an automobile repair specialist. The repair times are those for operations actually carried out in our workshop, even if some procedures are not described in the Workshop Repair Manual. UNITS OF MEASUREMENT • All dimensions are expressed in millimetres (mm) unless otherwise stated. • Tightening torques are expressed in deca Newton metres (daN.m ). • Pressures are in bars (reminder: 1 bar = 100 000 Pa ). • Electrical resistances are in ohms (Ω). • Voltages are in Volts (V). TOLERANCES Tightening torques expressed without tolerances must observe: • In degrees : ± 3 °. • In daN.m : ± 10 %.

SPECIFICATIONS Engine - Clutch - Gearbox 01 Vehicle type Engine Type Cubic capacity (cm 3 ) Clutch type Manual gearbox type FD0A UD0A S8U 2499 242 DNG 4700 PF1 FD0C UD0C S9W 2799 242 DNG 5500 PF1 01-1

SPECIFICATIONS Vehicle identification 01 LOCATION OF THE VEHICLE IDENTIFICATION PLATE e0-00/00-0000-000-000-00 VF000000000000000 0000 kg 0000 kg 1 - 0000 kg 2 - 0000 kg 000000000000000 RENAULT S.A. 1 2 3 4 5 8 7 6 9 10 13 12 11 1 Vehicle type mine and chassis number 2 MPTW (vehicle Maximum Permitted Total Weight) 3 GTW (Gross Train Weight - Loaded vehicle with trailer) 4 MPTW on front axle 5 MPTW on rear axle 6 Technical specifications of the vehicle 7 Paint identification code 8 Equipment level 9 Vehicle type 10 Upholstery identification code 11 Additional equipment details 12 Production number 13 Interior trim identification code Manufacturer’s plate The information shown on the manufacturer’s plate (right hand section) must be given in all correspondence or orders. 13682S 01-2

LIFTING EQUIPMENT Trolley jack - Axle stands 02 Safety symbol (special precautions to be taken when carrying out work). Suitable axle stands must be used with a trolley jack. The vehicle must not be lifted taking the load under the front suspension arm or under the rear axle. The use of a four or two post lift is permitted if the lifting capacity is greater than or equal to 5 tonnes. 02-1

LIFTING EQUIPMENT Trolley jack - Axle stands 02 13445S 13444S 13443S 13442S Trolley jack and axle stand positions 1 - Front 2 - Rear 1 2 2 02-2

TOWING All types FRONT 03 FOR TOWING, REFER TO THE LEGISLATION IN FORCE IN THE COUNTRY CONCERNED. NEVER USE THE DRIVESHAFT TUBES AS ATTACHMENT POINTS. The towing points are only be used for towing the vehicle on the road. In no circumstances are they to be used for pulling the vehicle out of a ditch, for any similar operation or for lifting the vehicle directly or indi- rectly. REAR 13685S 13684S 03-1

DESCRIPTION PACKAGING PART NUMBER 1 kg box 100 g tube 80 ml tube 180 g sachet 400 ml aerosol 77 01 421 145 77 01 028 179 77 01 422 307 77 01 366 100 77 01 422 308 GREASES LUBRICANTS - CONSUMABLES Packaging 04 • MOLYKOTE "BR2" for bushing surfaces, thrust pad guide tubes, clutch fork pads, lower suspension arm bea- rings, torsion bar splines, steering box, drive shaft splines. • MOLYKOTE "33 Medium" tubular rear axle bushes, anti-roll bar bushes. • ANTI-SEIZE (high temperature grease) Turbo etc. • "MOBIL CVJ" 825 Black star or MOBIL EXF57C for drive shaft seals. • MULTI-PURPOSE GREASE wheel sensors. • Mastic for sealing exhaust pipe joints. • RHODORSEAL 5661 • HARDENER KIT ("CAF 4/60 THIXO") for sealing the sides of bearing caps • AUTO joint blue jointing paste 1.5 kg box 310 ml container 100 g tube Set 100 g tube 77 01 421 161 77 01 421 042 77 01 404 452 77 01 421 080 77 01 396 227 MECHANICAL SEALING COMPOUNDS 04-1

1997-2003 Renault Master Van Service & Repair Manual

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