KANGOO II 01D

MR
417
KANGOO II -01D

EDITION ANGLAISE

© Renault s.a.s 2011

"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".

All rights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault.

OCTOBER 2011 EDITION ANGLAISE

X61

0 General vehicle information

01D MECHANICAL INTRODUCTION

KANGOO II - 01DKANGOO II - 01DContentsPages

Contents

01D MECHANICAL INTRODUCTION

Vehicle: Maintenance 01D-1

Vehicle: Precautions for therepair 01D-10

Tightening torques: Generalinformation 01D-13

Illustration key: Description 01D-17

Vehicle: Lockout - Removalof lockout 01D-18

Diagnostic tool : Use 01D-26

Traction battery check-list :Description 01D-27

Pages

MECHANICAL INTRODUCTIONVehicle: Maintenance 01D

The Renault maintenance programme includes allchecks, top-ups, adjustments, and part replacementsnecessary for vehicle maintenance. For information onthe specific service intervals for the vehicle, refer to themaintenance booklet or to the ICM.

I - CONTENT OF THE DIFFERENT TYPES OFSERVICES AND THE ANNUAL INTERMEDIATEVISIT:

Services:

The types of service (Maintenance Service, GeneralService, Renault Service) and the operations to beperformed may vary depending on the vehicle and the

date of manufacture. Thus to know which specificchecks and operations should be performed on the ve-hicle, refer to the vehicle's maintenance booklet.

II - VEHICLES FITTED WITH OCS:

The OCS (Oil Control System) function fitted on cer-tain models detects driving profiles that cause prema-ture degradation of the engine oil. Under certainconditions of use (frequent driving at low speeds, doorto door driving, extended driving at idle speed, drivingtowing a trailer caravan of more than 500 kg), the ve-hicle will alert the driver that a service (in particular, anoil change) is necessary. This service alert is indicatedto the driver via the "service or oil change interval" in-formation provided by the instrument panel.

Models fitted with the OCS:

Equipment required

Diagnostic tool

Model engine Engine suffix Vehicles affected:

TWINGO II D4F 780 All

TWINGO II K9K 718 All

CLIO III andMODUS

D4F 784 All

CLIO III D4F 742 Vehicles manufactured from 24/06/08

MODUS D4F 742 All

MODUS K9K 764 Vehicles manufactured from 23/08/07

CLIO III K9K 764 Vehicles manufactured at FLINS and VALL-ADOLID from 10/09/07

Vehicles manufactured at BURSA from 17/09/07

KANGOO II K9K All All

MEGANE II andSCENIC II

K9K 732 Vehicles manufactured at DOUAI from 19/06/07

Vehicles manufactured at PALENCIA from 27/06/07



M9R 721 Vehicles manufactured from 30/05/07


M9R 722 Vehicles manufactured at DOUAI from 10/07/07


01D-1


III - PROCEDURES FOR PERFORMINGOPERATIONS AND CHECKS DURING THEMAINTENANCE OR SERVICE:

The customer must be warned if a check reveals afault.

Checks marked with an asterisk depend on the vehicleor the country.

1 - Bodywork: anticorrosion check

Visually inspect the condition of the:

- vehicle,

- underside of the vehicle,

- wheel arches.

Indicate any damage to the underbody protection, andall cuts, ruptures, scratches or corrosion anywhere onthe vehicle.

This inspection contributes to the validity of the anti-corrosion warranty. It is therefore necessary to com-plete the maintenance sheets in the maintenancebooklet.

2 - Bodywork: cleaning the deflector arms andpanoramic sunroof mobile panel

MEGANE II M9R 724 Vehicles manufactured from 07/05/2007

MEGANE II F9Q 816 Vehicles manufactured at DOUAI from 25/04/07



MEGANE II F9Q 818 Vehicles manufactured at DOUAI and PALEN-CIA from 30/05/07


MEGANE III K9K 832, 834,836, 837

All

MEGANE III F9Q, F4R All All

LAGUNA III K9K,M9R,V9X

All All

ESPACE IV M9R 740 Vehicles manufactured from 12/03/07



MASTER G9U 632, 650 All

TRAFIC M9R All Vehicles manufactured from 01/12/06

TRAFIC G9U 630 All

109088

01D-2


Use a dry, lint-free cloth to clean the sunroof deflectorarms (1) and the section of the mobile panel withwhich they come into contact.

3 - Bodywork: checking the bonnet lock lubricationand operation

a - Guillotine type lock

As shown in the photo above, apply SILICONE-FREELUBRICANT (see Vehicle: Parts and consumablesfor the repair) (04B, Consumables - Products) be-tween the casing of the catch (2) and the catch seg-ment (3) in the direction of the catch segment hingeshaft (4) .

Let it set for 1 minute, then manoeuvre 10 times fromthe bonnet release catch in the passenger compart-ment.

b - Other types of lock

Apply SILICONE-FREE LUBRICANT (see Vehicle:Parts and consumables for the repair) (04B, Con-sumables - Products) to the catch assembly.

Let it set for 1 minute, then manoeuvre 10 times fromthe bonnet release catch in the passenger compart-ment.

4 - Engine: draining the engine oil

The oil grade is essential for maintaining the servicelife of the engine. Carefully follow the manufacturer'srecommendations specified in the Technical Note (seeEngine oil: Specifications) (Technical Note 6013A,04A, Lubricants).

Use the correct quantity of oil and the correct sumpplug sealing washer (see Engine oil: Draining - Re-filling) (10A, Engine and peripherals).

After topping up, let the oil run for approximately 10minutes before checking the level. The oil level maxi-mum mark on the dipstick must never be exceeded(risk of damage to the engine).

5 - Engine: replacing the oil filter

Replace the engine oil filter after each oil service (seeOil filter: Removal - Refitting) (10A, Engine and pe-ripherals).

125071

125072

01D-3


6 - Engine: checking the exhaust system

Visually inspect:

- that there is no corrosion, piercing or impact to the si-lencer, expansion chamber, catalytic converter andparticle filter*,

- that the rubber mounting bushes are not torn orcracked,

- that the exhaust pipe is not in contact with the under-side of the vehicle.

7 - Engine: bleeding water from the fuel filter* (ifthe part has not reached its replacement interval)

Bleed the water from the fuel filter by unscrewing thewater bleed cap and letting the water run into a suit-able container (see Fuel filter: Removal - Refitting)(13A, Fuel supply).

8 - Engine: checking the clutch play* (except forautomatic compensation)

(Logan and Sandero only) Use the recommendedchecking procedure (see Clutch control: Adjust-ment) (37A, Mechanical component controls).

9 - Checking the levels, condition and sealing ofthe hydraulic circuits: hydraulic power-assistedsteering*

Check the hydraulic steering fluid level: it should bebetween the minimum and maximum level on the res-ervoir.

Visually check the sealing, ensuring that there are noleaks, or any abnormal loss of fluid.

Top up, if necessary.

10 - Checking the level, condition and sealing ofthe hydraulic circuits: cooling

Check the coolant level: it should be between the min-imum and maximum level on the reservoir.

Visually check the circuit sealing, ensuring that thereare no leaks, or any abnormal loss of fluid.


11 - Checking the level, condition and sealing ofthe hydraulic circuits: hydraulic brake/clutch*

Visually check the circuit sealing, checking the condi-tion and that there are no leaks around the enginecompartment, under the vehicle or at the unions.

Check the brake fluid level:

- If the level is between the minimum and maximum,do not add brake fluid as wear on the discs, pads,drums and linings leads to a progressive drop in thebrake fluid level in the tank which will usually be rec-tified once these components are replaced. However,the brake fluid level should never drop below the min-imum mark.

- If there is an abnormal loss of fluid, the cause ofwhich cannot be found with this check, advise thecustomer.

12 - Checking the level, condition and sealing ofthe hydraulic circuits: sequential gearboxhydraulic unit*

Check the hydraulic unit oil level: it should be betweenthe minimum and maximum level on the reservoir.



13 - Checking the level, condition and sealing ofthe hydraulic circuits: sequential gearboxhydraulic clutch*

Check the hydraulic clutch fluid level, it should be atthe middle level of the reservoir.



14 - Checking the chassis: condition of the gaiters,rubber mounting bushes and ball joints

Check the condition of the driveshaft and steering rub-ber gaiters, all ball joints and the rubber mountingbushes. There must not be any signs of tearing orcracks.

15 - Checking the chassis: tyre condition andpressure (including emergency spare wheel orpresence of tyre-repair aerosol)

Check that the tread depth of the tyres has notreached the wear warning strips, explain the degree oftyre wear to the customer.

Check that there is no abnormal tyre wear, and nobulges, blisters, tears or foreign objects (sharp object,screw, etc.).

Check and readjust the tyre inflation pressure whencold according to the type of driving.

01D-4


Check the pressure and condition of the emergencyspare wheel, or if not supplied with the vehicle, checkthat there is a tyre repair aerosol in the vehicle.

Adhere to the recommended pressure shown on thelabel on the door (if the vehicle does not have one, re-fer to the Driver's Handbook or (see Tyre pressure:Identification) (35A, Wheels and tyres).

16 - Checking the chassis: presence of the wheelvalve caps

Check that each valve cap is present.

17 - Checking the chassis: sealing of the front andrear shock absorbers

Visually check that there is no oil leaking along thelength of the shock absorbers.

18 - Checking the chassis: wear on the front andrear brake discs and pads*

When carrying out a quality check, it is essential to re-move the wheels (an impact wrench may only be usedto remove the wheels) (see Wheel: Removal - Refit-ting) (35A, Wheels and tyres).

Check the thickness of the brake pads and compare tothe minimum authorised value (see Brake: Specifica-tions) (30A, General information). In case of partialwear, advise the customer of the degree of wear to thebrake pads.

Check the thickness of the front brake discs (seeFront brake disc: Description) (31A, Front axle com-ponents) and the thickness of the rear brake discs (seeRear brake disc: Description) (33A, Rear axle com-ponents). In case of partial wear, advise the customerof the degree of wear to the brake discs.

19 - Checking visibility: exterior lighting andsignals

Check the side lights, dipped headlights, main beamheadlights, front and rear fog lights, the direction indi-cators and side mounted indicators, the reversinglights, the hazard warning lights, the brake lights, theregistration plate lighting and the additional corneringlights*.

20 - Checking visibility: interior lighting

Checking door lighting, interior lights and sun visors,glovebox and luggage compartment lights.

21 - Checking visibility: condition of thewindscreen and door mirrors

Check that there are no cracks or chips.

22 - Checking visibility: wear on the front and rearwindscreen wiper blades

Check the quality of the wiping function and check thatthe wiper blades are not torn or cracked.

23 - Checking visibility: front and rear windscreenwasher fluid level

Check that there is windscreen washer fluid present.


24 - Labels: checking the airbag safety and enginecompartment labels are present and correctlypositioned

Check that the vehicle has the following original safetylabels:

- airbag, located on the windscreen, sun visor and pas-senger side of the dashboard,

- battery, oil, cooling system, heating and air condition-ing system, engine cooling fan located in the enginecompartment.

25 - Electronic fault finding: battery with test tool

Check the condition of the battery with the MIDTRON-ICS R330 tool (see Battery: Removal - Refitting)(Technical Note 6002A, 80A, Battery).

26 - Electronic fault finding: computers with faultfinding computer

The purpose of this procedure is to see if any of thecomputers are faulty.

The following tools are essential for carrying out faultfinding on these systems:

- a Diagnostic tool,

- a CAN probe.

Running fault finding on the computers shows up pos-sible faults not displayed by the system self-test pro-cedure, and allows them to be cleared, following theprocedure.

Note:

Always check the condition of the battery beforecarrying out fault finding on the computers as insuf-ficient voltage can affect the computers.

01D-5


27 - Electronic fault finding: operation of theinstrument panel warning lights

Check that the following warning lights come on whenthe ignition is switched on:

- STOP warning light,

- SERVICE warning light.

28 - Reinitialisation: maintenance/oil servicedisplay*

Reset the maintenance/oil service interval display (seeDriver's Handbook).

29 - Service sheets: affixing the service label in theengine compartment*

Fill in the étiquette d’entretien and affix it in the en-gine compartment.

IV - SUPPLEMENTARY OPERATIONS:

The removal and refitting procedures and some of thechecks to be carried out during maintenance are setout in the repair manuals or the technical notes. Theinformation and repair procedures given below arespecific to the maintenance programme.

For an exhaustive description of the operations to becarry out during the maintenance operation, refer tothe vehicle's maintenance booklet.

1 - Replacement of the accessories belt, rollers,and pulleys (pulley to be replaced depending onthe vehicle)

When replacing the belt, it is essential to replace thetensioning rollers and fixed rollers across the wholerange. It is also necessary to replace the damper pul-ley (also known as the crankshaft accessories pulley)or the alternator pulley on certain engines, see below.

Table of pulleys to be replaced during maintenanceonly according to the accessories belt replacement fre-quency. The vehicles concerned are those for whichthe maintenance booklets mention a replacement forcertain engines. The detail of the vehicle variants con-cerned is given below (vehicles manufactured afterJune 2006):

a - In Europe

Recommendations for replacing the damper pulley (crankshaft accessories pulley):

Engine type Engine suffix Recommendation forreplacing the damper pul-ley during maintenanceoperations

F4R 714, 715, 720, 760, 761, 762, 763, 764, 765, 766,767, 770, 771, 774, 776, 784, 786, 787, 792, 794,795, 796, 797, 800, 811, 820, 830, 867, 870, 886,887, 896, 897.

To be replaced every timethe accessories belt and itsrollers are replaced

F9Q 260, 262, 264, 660, 664, 670, 674, 680, 755, 757,758, 759, 800, 803, 804, 808, 812, 814, 816, 818,820.

M9R 610, 700, 720, 721, 722, 740, 760, 761, 780, 812.

G9Tequippedwith aircondition-ing

600 ,605, 606, 607, 642, 645, 702, 703, 706, 707,710, 712, 720, 722, 742, 743, 750.

G9Uequippedwith aircondition-ing

630, 632, 650, 720, 724, 730, 750, 754.

01D-6


Recommendations for replacing the alternator pulley:

b - Outside Europe

Recommendations for replacing the damper pulley (crankshaft accessories pulley):

Engine type Engine suffix Recommendations forreplacing the alternatorpulley during maintenance

F4R 813 To be replaced every timethe accessories belt and itsrollers are replaced

Engine type Engine suffix Recommendation forreplacing the damper pul-ley

K4Jequippedwith aircondition-ing

730, 732, 740, 770, 780.


K4Mequippedwith aircondition-ing

680, 690, 694, 697, 698, 716, 760, 761, 762, 764,766, 768, 780, 782, 788.790, 791, 794, 800, 801,804, 812, 813, 814, 824, 830, 831, 844, 848, 856.

K4M 858

01D-7


Recommendations for replacing the alternator pulley:

2 - Replacing the timing belt and rollers

When replacing the belt, it is essential to replace thetensioning and fixed rollers across the whole range.Certain vehicle/engine specifications require associat-ed parts to be replaced, therefore it is necessary toconsult the repair procedure for the vehicle and enginefor further details (see Timing belt: Removal - Refit-ting) (11A, Top and front of engine).

3 - Checking the rear brake linings for vehiclesfitted with drums

Check the wheel cylinders for any possible leaks.

Remove any dust from the brake linings using a brakecleaning product.

Check the thickness of the drum linings and compareit to the minimum authorised thickness (see Brake:Specifications) (30A, General information).

4 - Cleaning the air conditioning system

The air conditioning system is cleaned by cleaning theevaporator (see Evaporator: Cleaning) (62A, Air con-ditioning) or (see Evaporator: Cleaning) (TechnicalNote 6001A, 62A, Air conditioning).

5 - Special notes for LPG vehicles:

Only authorised personnel, i.e. those with specific LPGvehicle training, may work on the LPG system of a ve-hicle.

F4R 714, 715, 720, 760, 761, 762, 763, 764, 765, 766,767, 770, 771, 774, 776, 784, 786, 787, 792, 794,795, 796, 797, 800, 811, 820, 830, 867, 870, 886,887, 896, 897.


K9K 278, 282, 288, 292, 732, 734, 764, 772, 780, 804,806, 832, 836.

F9Q 260, 262, 264, 660, 664, 670, 674, 680, 755, 757,758, 759, 794, 800, 803, 804, 808, 812, 814, 816,818, 820.

G9Tequippedwith aircondition-ing

600 ,605, 606, 607, 642, 645, 702, 703, 706, 707,710, 712, 720, 722, 742, 743, 750.

G9Uequippedwith aircondition-ing

630, 632, 650, 720, 724, 730, 750, 754.

M9R 610, 700, 720, 721, 722, 740, 742, 760, 761, 780,812.

M9R 742, 802, 803, 805, 809, 816, 830, 832, 833. To be replaced every othertime the accessories beltand its rollers are replaced

Engine type Engine suffix Recommendations forreplacing the alternatorpulley during maintenance

F4R 813 To be replaced every timethe accessories belt and itsrollers are replaced

01D-8


a - Checking the safety solenoid valve:

- Put the LPG switch in the LPG position,

- switch on the ignition, the tank solenoid valve should"click".

b - Checking that there is a plastic blanking coveron the safety valve:

Confirm that there is a blanking cover on the LPG tankoverpressure valve.

c - Bleeding the expansion valve:

The operation should be carried out with the enginewarm and stopped:

- Undo the bleed screw of the LPG expansion valveand allow the liquid residue to flow out for approxi-mately a minute into an appropriate container.

6 - Special notes for CNG vehicles

Only authorised personnel, i.e. those with specificCNG vehicle training, may work on the CNG system ofa vehicle.

Visual inspection of the tank and its support:

Check that there is no evidence of corrosion, impact,chips or scratches on the CNG tank. Check that thesupport is in good condition.

01D-9

MECHANICAL INTRODUCTIONVehicle: Precautions for the repair 01D

GENERAL INFORMATION

All information contained in these manuals is intendedexclusively for automotive industry professionals.

The documentation is intended to cover all vehicles inthe RENAULT range throughout the world, but maynot cover equipment designed for use in specific coun-tries.

The procedures and fault finding procedures recom-mended and described in this manual have been de-signed by automotive industry repair professionals.

1 - General recommendations

Observe basic principles of vehicle repair.

The quality of repair depends first and foremost on thecare exercised by the person in carrying it out.

To ensure good repair:

- protect the sensitive areas of the vehicle (seats,steering wheel, wings, etc.),

- unless otherwise indicated, all repairs must be donewith the ignition off,

- when welding on the vehicle, it is advisable to re-move or disconnect components near the repair areathat could be affected by the heat,

- use recommended professional products and originalparts,

- observe the tightening torques,

- replace roll pins, self-locking or bonded nuts or boltsevery time they are removed,

- take care with electrical and electronic componentswhich cannot withstand excess voltage and improperhandling; replace any electrical and electronic com-ponents which have experienced a voltage drop,

- make sure that the connectors are correctly clipped,

- do not pull on the wiring,

Take care not to damage orange high-voltage cables.

Systematicly replace damaged high-voltage cables.

For any prolonged disconnection of connectors of theorange high-voltage circuit, verify the presence ofplugs or protection plastic bags.

Do not splash any liquid, regardless of its type (oil,cleaner, etc.), on the electric and electronic compo-nents (charger, converter, electric engine, wirings andconnectors, traction battery and 12V battery, comput-ers, sensors, etc.).

To ensure good repair:

- check for the sealing plugs on the connectors,

- do not just replace parts one after the other, carry outdetailed fault finding beforehand,

- carry out a final check before returning the vehicle tothe customer (set the clock, check the alarm opera-tion, check the lights and indicators etc.),

- clean and degrease the sections to be bonded(threads, stub axle splines) to ensure proper adher-ence.

Protect the accessories and timing belts, the electricalaccessories (starter, blanking cover, electric power as-sisted steering pump) and the mating face to preventdiesel fuel spilling onto the clutch friction plate.

ELECTRIC VEHICLE

IMPORTANT

Any work performed on the vehicle's high voltagenetwork entails a risk of death by electrocution. Anoperator is authorized by the company thatemploys him/her, subject to certain mandatorytraining and skills.

ELECTRIC VEHICLE

IMPORTANT

Risks of serious burns or electric shock that mayprove fatal.

It is strictly prohibited to repair orange high-voltagecables and connectors.

WARNING

To prevent disconnected connectors and socketsfrom all contamination, hermetically seal the con-nectors and sockets using a plastic bag (ref: 82 01274 401) and a clamping collar.

DIESEL VEHICLE PETROL VEHICLE FLEXFUELVEHICLE

01D-10


The design quality of our vehicles demands that noth-ing is left to chance in making a good repair, and it isessential to refit parts or components exactly as theywere originally (for instance: heat shields, wiring rout-ing, pipe routing, particularly in the area of the orangehigh-voltage wirings).

Do not blow away dust (brakes, etc.), vacuum them upor clean the component with a cleaning agent (such asa brake cleaning product).

Use professional products and apply them with care,for example do not apply too much sealing paste to thesealing surface.

Exhaust gases (petrol and diesel) are pollutants. Op-erate engines or self-contained heaters with care andalways use exhaust gas extractors.

Ensure that there is no risk of a short circuit occurringwhen the electrical connections are reconnected (e.g.charger, converter, traction battery and 12V battery,etc.). Some points need greasing, others do not, there-fore particular attention should be paid during refittingoperations to ensure that they work properly under allconditions.

2 - Special tooling - ease of use

The repair procedures have been designed using spe-cial tools; they must therefore be carried out usingthese tools to ensure a high degree of working safetyand quality of repair.

The equipment we have approved has undergonecareful research and testing, and must be used andmaintained with care.

3 - Reliability - updating

New repair procedures are constantly being developedin the interests of repair quality, either with new prod-ucts (emission control, injection, electronics, etc.), or infault finding. Be sure to consult the Workshop RepairManuals or Technical Notes or fault finding summariesbefore any servicing operation.

Since vehicle specifications are subject to change dur-ing their commercial life, it is essential to check wheth-er there are any updated Technical Notes whenseeking information.

4 - Safety

Operations on certain equipment and certain parts (forinstance: spring-shock absorber assembly, electrictraction reduction gearing, brake system, ABS, airbag,etc.) require particular attention to be paid to safety,cleanliness and care.

The safety symbol used in this manual indicates thatspecial attention must be paid to the procedure or thetightening torque values.

Working safely:

- use suitable tools which are in good condition (use of« multi-purpose » tools, such as adjustable pliers,etc., should be avoided wherever possible),

- use supports and adopt a correct posture when per-forming heavy work or raising loads,

- make sure that the procedure used is not dangerous,

- do not wear any jewellery or other small objects dur-ing an operation,

- use personal protection (gloves, safety glasses, workshoes, masks, skin barrier creams, etc.),

- always follow the safety instructions associated withthe operation to be performed,

- do not smoke when working on vehicles,

- use smoke extractors (welding, exhaust gases, etc.),

- do not use harmful products in unventilated rooms,

- do not overstrain yourself or attempt inappropriatework operations,

- use axle stands when working under a vehicle raisedon a jack,

- do not ingest any chemicals (brake fluid, coolant,etc.),

- do not open the cooling circuit when it is hot andpressurised,

- take care with components that are liable to start upsuddenly (engine cooling fan, etc.).

Respecting the environment:

- do not allow waste refrigerants to escape into the at-mosphere,

- do not dispose of waste vehicle fluids (oil, brake fluid,etc.) in drains,

- do not burn discarded products (tyres, etc.).

5 - Conclusion

The procedures contained in this document merit yourattention. Please read them carefully in order to re-duce the risk of injury, and avoid using incorrect pro-cedures that could damage the vehicle or make itdangerous in use.

Following the recommended procedures will help youto provide a quality of service which will ensure the ve-hicles achieve the highest levels of performance andreliability.

01D-11


Maintenance and repair operations must be carried outunder the proper conditions to ensure that our vehiclesrun safely and reliably.

01D-12

MECHANICAL INTRODUCTIONTightening torques: General information 01D

I - TABLE OF STANDARD TORQUES

Special notes on electrical earths

The property class is indicated on the bolt (1) or (2) .

II - FUNCTION OF A BOLTED ASSEMBLY

The bolting system connects parts of an assembly toprevent their separation or sliding when submitted toexterior forces.

Exterior forces

The assembly is submitted to forces that are:

- static and / or dynamic,

- simple (e.g. simple traction),

- multiple (traction + flexion + torsion).

Fastenings Standardtighteningtorque(N.m)

Diameter Propertyclass

M6 8.8 10

M8 8.8 25

M10 8.8 50

M10 10.9 62

M12 10.9 105

M14 10.9 180

M16 10.9 280

M18 10.9 400

Fastenings Standardtighteningtorque(N.m)

Diameter

M6 8

M8 21

M10 44

120736

120737

01D-13


Creating tension (or preload) F0

The assembly is held together by the tension createdin the bolt when it is tightened.

A reliable assembly is only possible if the correct ten-sion is used:

- insufficient tension: risk of loosening,

- too much tension: risk of deformation of the parts tobe assembled, or shearing of the bolt.

Customer complaints resulting from incorrect tighten-ing may be, following assembly, a safety issue (fire,loss of control of the vehicle etc.), an immobilising faultor a noise.

III - TIGHTENING PROCEDURES

The two controlled tightening procedures adapted toautomotive repairs because of their low cost and sim-ple operation are torque tightening and angle tighten-ing (also called torque and angle).

1 - Torque tightening

This is the most commonly used procedure. Is consistsof tightening until a given resisting torque is reached,known as tightening torque.

The tightening torque is distributed in a large part asfriction torque (under the head and in the thread) andin a small part as useful torque (to create the tension).

This practise spreads the tension significantly due tothe variation in the friction coefficients from one as-sembly to another and the uncertainty of the tighteningprocedures and methods.

2 - Angle tightening

The principle consists of putting the parts of the as-sembly in contact using a mating torque (approximate-ly 25 to 30% of the final torque) then to tighten to adetermined angle.

This method, which is not dependent on the friction ofthe tightened assembly, gives more precise resultsthan torque tightening.

IV - OBSERVING THE TIGHTENING TORQUES ANDANGLES

Bolted assemblies whose tightening torques and an-gles are explicitly specified in the removal / refittingprocedures must be observed using the appropriatetools (torque wrench, angle measuring disc). Failure toobserve this can lead to safety risks, immobilisingfaults or unwanted noises.

For other bolted assemblies, non-measured tightening(using standard spanners) is acceptable. Neverthe-less, the corresponding tightening torque is indicatedin the table of standard tightening torques.

V - RECOMMENDED TIGHTENING TOOLS

For measured tightening, the repairer must have avail-able torque wrenches to tighten from 4 to 400 N.m aswell as an angle measuring disc.

The torque wrenches used may be click type or elec-tronic.

120738

120739

(3) Bolt

(4) Assembled components

(5) Extension of the bolt

(6) Non-tightened assembly

(7) Tightened assembly

(X1) Compression of the assembly

(Fo) Sensor

(C) Tightening torque

01D-14


For example:

- 1 torque wrench 4 - 40 N.m,



- 1 angle measurement disc.

The torque wrenches used must comply with the ISO6789 standard. They must be calibrated regularly fol-lowing the supplier's recommendations using the ap-propriate procedures.

VI - PRECAUTIONS WHEN USING A CLICK TYPETORQUE WRENCH

A click type torque wrench is a manual tightening tool.The trigger mechanism causes a break or disengage-ment of the wrench past a force threshold.

This threshold depends on the setting of the wrenchbut also depends on the way the wrench is handled.

When used following best practises, the accuracy ofthe tightness when using a click type torque wrench is± 15%.

The instructions to be observed are:

- Place the hand in the centre of the handle. An incor-rectly positioned hand on the handle will alter the trig-ger threshold.

- Pull the wrench gently and steadily, without applyingany torsion. Excessive tightening speed as well asjerkiness are major causes of overtightening. Any tor-sion applied to the wrench will alter the trigger thresh-old.

- Hold the wrench on the bolt using a minimum of ef-fort. Any effort applied to the wrench head will alter thetrigger threshold.

- Apply the tightening effort perpendicular to themounting observing a tolerance of ± 15˚ relative to theperpendicularity. If the wrench is not perpendicular tothe mounting axis, this will result in insufficient tighten-ing.

- Stop tightening as soon as the wrench is triggered.Continued tightening after the wrench is triggered willlead to overtightening.

120740

(6) lever arm

120741

120742

01D-15


If the length of the wrench is modified (extending thehandle, adapting an end piece) it is essential to recal-ibrate the wrench to its new configuration.

Modifying the length of the wrench will modify its trig-ger threshold.

Use the formula: C1 = CO x L2 / (L1+L2)

- CO: torque to apply,

- C1: adjustment torque to be displayed on the wrench,

- L1: length of the extension,

- L2: length of the wrench.

Unless there are special instructions in the repairmethod, a universal joint (CARDAN joint type) shouldbe used for measured tightening. Using a universaljoint will result in a difference between the set torqueof the wrench and the actual torque applied.

Before storing the wrench, loosen the adjustmentspring completely. A wrench stored with a spring undertension will lose its tightening accuracy.

VII - PRECAUTIONS WHEN USING ELECTRONICTORQUE WRENCHES

An electronic torque wrench is a manual tighteningtool. The tightening torque and, depending on themodel, the angle is read directly.

When used following best practises, the accuracy ofthe tightness when using an electronic torque wrenchis ± 5%.

Electronic torque wrenches are not affected by the po-sition of the operator's hand.

It is advisable to handle the wrench with care and tostop tightening when the required value is displayedon the wrench.

120743

01D-16

MECHANICAL INTRODUCTIONIllustration key: Description 01D

Legend for icons

The following icons represent the adjustment possibil-ities for the bodywork components:

- the black dot in the centre represents the body of thebolt,

- the grey section represents the component to be ad-justed,

- the white section represents the adjustment area.

142945

a No.

b Part number

c A tightening order must be respected

D Non-standard tightening torque / angle

f [Initial torque] tightening torque / tighteningangle +/- tightening angle tolerance

g Part always to be replaced

h Product / Consumable

i Special tooling / Equipment required

j Safety precaution

k Front of the vehicle

l Tightening units

m Special tooling / Equipment required to useon all of the assembled parts

n Tightening order to be respected

o No adjustment possible

p Adjustment possible along all axis

q Adjustment possibly only along vertical axis

r Adjustment possibly only along horizontalaxis

s Adjustment possible along all axis

01D-17

MECHANICAL INTRODUCTIONVehicle: Lockout - Removal of lockout 01D

ELECTRIC VEHICLE

I - 12V SUPPLY CIRCUIT: CONNECTION -DISCONNECTION

a

1 - 12V supply circuit: disconnection

a - Identification of the vehicle

a Check the vehicle’s identification (registration, VIN)based on the repair order.

a Remove all personal metal objects (jewellery,chains, wedding ring, watch, etc.).

a Put the vehicle in neutral position.

a Open the driver's window.

a Switch on the vehicle and energize the electric en-gine (position "GO").

a Check the correct operation of the panel instrumentdisplay at vehicle start.

Special tooling required

Ele. 1967 Safety lockout plug of thetraction battery

Ele. 1980 Safety lockout plug padlockof the traction battery

Ele. 1993 Voltage detector

Equipment required

Class 00 or 0 electrical insulating gloves

Face shield

Bump cap

Electrical class 00 or 0 safety footwear

Protective overalls (Mainly coton)

Demarcation kit (posts, red and white chains, A4mounting)

Diagnostic tool

Tightening torquesm

nuts of the 12 V batteryearth terminal

8 N.m

nuts of the 12 V batteryearth terminal

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair:

- (see Battery: Precautions for the repair) ,

- (see Wiring: Precautions for the repair) ,

- (see 01D, Mechanical introduction, Vehicle:Precautions for the repair, page 01D-10) .

IMPORTANT

DANGER : Risk of serious injury due to short-circuiting or untimely triggering of an electricalsystem (pyrotechnic components, windscreenwiper motor, fan assembly etc.) following possi-ble re-supply of the 12-volt supply circuit by thevoltage converter.

Please follow the instructions regarding dis-conection of the 12-volt supply circuit.

If the procedure fails, do not continue with yourtask and ask an employee who is qualified andauthorised to work on a high-voltage onboardnetwork to perform fault finding (see 01D,Mechanical introduction, Vehicle: Precau-tions for the repair, page 01D-10) .

IMPORTANT

It is prohibited to work alone in the workshop.There must always be someone else in thevicinity to help the person in danger in the eventof a problem.

Note:

If the instrument panel does not work, do notcontinue with your task and ask an employeewho is qualified and authorised to work on ahigh-voltage onboard network to perform faultfinding.

01D-18

MECHANICAL INTRODUCTIONVehicle: Lockout - Removal of lockout

ELECTRIC VEHICLE

01D
a Check that no traction chain or traction battery fault
is indicated on the panel instrument display.

a Switch off the vehicle.

a Switch off all energy consumption devices (exteriorlights, air conditioning, heating, etc)

a Put on the handbrake.

a Check the operation of the hazard warning lights.

a Remove the vehicle keys or card.

a Place the vehicle keys or card outside the vehicle.

a Open the bonnet.

b - Separation of the power sources

a Disconnect external voltage sources (charging ca-ble, external electrical tool).

a Lock the doors:

- doors closed with central looking using the key orcard,

- with the doors open: hold down the « central dou-ble locking » button.

a With the doors locked, wait for the computers to goto sleep for 2 mins. (this normally happens if thereare no problems with the DC/DC converter stoppingand the battery switches opening). Check that thecentral door locking LED has gone out. Check thatthe instrument panel has turned off.

a Remove the earth terminal from the 12V battery.

c - Locking of power sources

a Insulate the 12V battery earth terminal.

d - Checking absence of voltage

a Check that the hazard warning lights do not workand are therefore no longer powered by the DC/DCconverter:

- if the hazard warning lights do not work, the 12 Vsupply has been cut. Check by putting the vehiclein after ignition to confirm.

- if the hazard warning lights still work, the 12 Velectrical circuits are re-supplied by the tractionbattery. An electrical vehicle specialist must per-form electrical fault finding before carrying out anyother procedures.

2 - 12V supply circuit: connection

a



a Check that the work requiring the disconnection hasbeen completed and that electrical and other riskshave been evaluated.

a Remove all personal metal objects (jewellery,chains, wedding ring, watch, etc.).


a Open the bonnet.


Note:

if there is a defect, do not continue with yourtask and ask an employee who is qualified andauthorised to work on a high-voltage onboardnetwork to perform fault finding.

IMPORTANT

DANGER: Risk of serious injury due to short-circuiting or untimely triggering of an electricalsystem (pyrotechnic components, windscreenwiper motor, fan assembly etc.) following possi-ble re-supply of the 12-volt supply circuit by thevoltage converter.

Please follow the instructions regarding discon-nection of the 12 V supply circuit.

If the procedure fails, do not continue with yourtask and ask an employee who is qualified andauthorised to work on a high-voltage onboardnetwork to perform fault finding (see 01D,Mechanical introduction, Vehicle: Precau-tions for the repair, page 01D-10) .

IMPORTANT


01D-19


ELECTRIC VEHICLE

01D

b - Check the vehicle and ensure its conformity

a Check the conformity of the vehicle after reassem-bly, visual inspection of connectors.

c - Unlocking of power sources

a Remove the insulation of the battery earth terminal.

d - Restore the power sources

a Refit the 12V battery earth terminal.

a Torque tighten the nuts of the 12 V battery earthterminal (8 N.m).

II - VEHICLE: LOCKOUT - REMOVAL OF LOCKOUT

a

WARNING

Incorrect tightening could cause heating of con-tacts, starting or charging faults, sparking, orcould cause the battery to explode (see Battery:Precautions for the repair) .

IMPORTANT

The procedures described below must be per-formed by a qualified employee authorised towork on a high-voltage onboard network.

Any work performed on the vehicle's high-volt-age network poses a risk of death by electrocu-tion. The company that employs the operator isresponsible for granting authorisation, subject tocertain conditions regarding mandatory skillsand training.

IMPORTANT

DANGER: HIGH VOLTAGE VEHICLE.

Risks of serious burns or electric shocks thatmay prove fatal.

Before carrying out any work on the vehicle, it isessential that you follow the instructions regard-ing vehicle lockout. This work must be carriedout by an employee who is qualified and autho-rised to work on a high-voltage onboard network(see 01D, Mechanical introduction, Vehicle:Precautions for the repair, page 01D-10) .

Note:

Remove all personal metal objects (jewels,watch,...).

01D-20


ELECTRIC VEHICLE

01D
a Required equipment:
- Class 00 or 0 electrical insulating gloves,

- Face shield,

- Bump cap,

- Electrical class 00 or 0 safety footwear,

- Protective overalls (Mainly coton),

- (Ele. 1967),

- (Ele. 1980),

- (Ele. 1993),

- Demarcation kit (posts, red and white chains,A4 mounting),

- Protection for traction battery connector sockets,

- « Disconnection/Connection » sheet,

- « Disconnection/Connection » instructions.

1 - Vehicle: lockout



a Remove all personal metal objects (jewellery, chain,wedding ring, watch, etc.).

a Position the vehicle on a two-post lift, if necessary,depending on the operation to be carried out subse-quently (see Vehicle: Towing and lifting) .



a Check the correct operation of the panel instrumentdisplay at vehicle start.

a Check that no traction chain or traction battery faultis indicated on the panel instrument display.




a Open the bonnet.


a Mark out the work area using a specified Demarca-tion kit (posts, red and white chains, A4 mount-ing).

a Make sure that no work is in progress.

a Ensure the work area is evacuated.

a Wear personal protective equipment:




- Face shield,

- Bump cap.

b - Separation of power sources

a Disconnect external voltage sources (charging ca-ble, external electrical tool).

IMPORTANT


Note:

If the instrument panel does not work, do notcontinue with your task and ask an employeewho is qualified and authorised to work on ahigh-voltage onboard network to perform faultfinding.

Note:

if there is a defect, do not continue with yourtask and ask an employee who is qualified andauthorised to work on a high-voltage onboardnetwork to perform fault finding.

Note:

Check that the gloves are not damaged.

WARNING

Before disconnecting the 12-volts battery:

- wait for the motor-driven fan assembly to stop,

- wait for the computers to complete saving (2minutes).

01D-21


ELECTRIC VEHICLE

01D

a Remove the protection cover (1) that is preventingaccess to the traction battery safety circuit breaker(2) .

a Remove the traction battery safety device switch (3).

a Place the traction battery safety device switch onthe dashboard or a lockout panel.

a Remove the earth terminal (4) from the 12V battery.

151541

151400

152064

152500

01D-22


ELECTRIC VEHICLE

01D
c - Locking of power sources
a Fit:

- Position the (Ele. 1967) (5) on the base of thetraction battery safety circuit breaker,

- Position the (Ele. 1980) (6) on the (Ele. 1967).

a Insulate the 12V battery earth terminal.

d - Checking absence of voltage

a Wait 5 mins after the disconnection of the tractionbattery safety circuit breaker.

a Remove:

- the fuse flap bolts (7) ,

- the fuse flap.

a Before taking any measurements, make sure thatthe (Ele. 1993) is working correctly.

151401

152499

IMPORTANT

Never use a voltage detector if its self-test isincorrect as it could provide erroneous data thatcould put you in danger.

01D-23


ELECTRIC VEHICLE

01D

a Check that there is no voltage using the (Ele. 1993)via the flaps used to check for the absence of volta-ge on both sides of the two fuses:

- between the phases (2 measurements),

- between the phases and the earth (4 measure-ments).

a Make sure that the (Ele. 1993) is working correctlyafter taking the measurements.

a Refit the fuse flap without tighten to torque the bolts.

a Tighten to contact the access flap of the electrictraction power electronics fuses to prevent exteriorpollution (definitive refitting with replacement of fuseflap seal and tightening to torque will be carried outduring the removal of lockout).

a Remove the personal protective equipment.

e - « VEHICLE IN ELECTRICAL SAFETY MODE »sign

a Place « WARNING DANGER » and « VEHICLESAFETY ZONE » at the front and rear of the vehi-cle.

a Complete and place the « Lockout / Removal ofLockout » sheet at the front of the vehicle.

2 - Vehicle: removal of lockout

a



a Check that the work requiring the lockout has beencompleted and that electrical and other risks havebeen evaluated.

a Remove all personal metal objects (jewellery, chain,wedding ring, watch, etc.).






a Open the bonnet.


a Mark out the work area using Demarcation kit(posts, red and white chains, A4 mounting).

a Make sure that no work is in progress.

a Ensure the work area is evacuated.

a Wear personal protective equipment:




- Face shield,

- Bump cap.

b - Check the vehicle and ensure its conformity

a Check the conformity of the vehicle after reassem-bly, visual inspection of connectors.

a parts always to be replaced: Seal of the flap ofthe electric traction power electronics fuses.

152678

IMPORTANT

An electrical hazard occurs if the voltage is not0V. Carry out a diagnosis and only proceed tothe next step once the problem has been recti-fied.

IMPORTANT


Note:

Check that the gloves are not damaged.

01D-24


ELECTRIC VEHICLE

01D
a Refit the fuse flap with a new fuse flap seal.
a Torque tighten the fuse flap bolts (see Electric ve-hicle charger assembly: Exploded view) .

c - Unlocking of power sources

a Remove:

- the (Ele. 1980) from the (Ele. 1967),

- the (Ele. 1967).

d - Restore the power supply

a Remove the insulation of the battery earth terminal.

a Refit the 12V battery earth terminal.

a Torque tighten the nuts of the 12 V battery earthterminal (8 N.m).

a Refit:

- the traction battery safety circuit breaker,

- the protective cover that prevents access to thetraction battery safety circuit breaker.

a Remove personal protective equipment:




- Face shield,

- Bump cap.

a Insert the vehicle keys or card.

a Switch on the vehicle (APC).

a Check:

- that no faults are indicated on the instrument pan-el,

- that there are no faults with Diagnostic tool,

- that it is possible to start the vehicle without fault.

e - Remove the « VEHICLE IN ELECTRICALSAFETY MODE » sign

a Remove the « Lockout / Removal of Lockout »sheet from the front of the vehicle.

a Complete the « LOCKOUT / REMOVAL OFLOCKOUT » sheet.

a Remove:

- the lockout signs from the front and rear of the ve-hicle,

- the Demarcation kit (posts, red and whitechains, A4 mounting) equipment

WARNING

Incorrect tightening could cause heating of con-tacts, starting or charging faults, sparking, orcould cause the battery to explode (see Battery:Precautions for the repair) .

01D-25

MECHANICAL INTRODUCTIONDiagnostic tool : Use 01D

ELECTRIC VEHICLE

BEFORE / AFTER REPAIR PROCEDURE

a Switch on the ignition.

a Connect the Diagnostic tool.

a Select the concerned computer.

a Go to repair mode.

a Display the "Before / After repair procedure" for thecomputer selected.

a If necessary, select the concerned component in the"List of components stored in the computer" section.

a Carry out the operations described in the "Before re-pair procedure" section or in the "After repair proce-dure" section, according to the case.

a Switch off the ignition.

Equipment required

Diagnostic tool

01D-26

MECHANICAL INTRODUCTIONTraction battery check-list : Description 01D

ELECTRIC VEHICLE

This check list must be filled in:

- by the after sales workshop operator who removedthe traction battery,

- before sending the traction battery to be repaired,

- to inform the battery repairing operator on the condi-tion of the traction battery.

This check list must be slid into a plastic cover and putinside the traction battery after sales packaging. Acopy of this check list must be archived with vehicle re-pair order.

Traction battery BIN(17 characters)

2. 9. 5. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

Vehicle VIN (17 char-acters)

V F 1 . . . . . . . . . . . . . .

Name and accountnumber of the aftersales workshop thatmade the traction bat-tery removal

Date (dd/mm/yyyy)

Delete what is inappropriate

1 Has the traction battery been removed from a damaged vehicle? YES NO

2 Is the traction battery lower case distorted/broken/scratched? YES NO

3 Is the traction battery upper case distorted/broken/scratched? YES NO

4 Are the traction battery connectors damaged? YES NO

5 Is there any electric insulation failure on the traction battery? YES NO

Other comments:

01D-27

Fault finding andrepair proceduresdepartment

Documents

KANGOO II 01D