Cylinder head gasket (Renault Kangoo 1)

Special tool and equipment required

• Mot. 251-01 Bracket for indicator.
• Mot. 252-01 Stand for measuring piston protrusion.
• Mot. 591-02 Magnetic support indicator for angular tightening of bolts.
• Mot. 591-04 Angled tightening key.
• Mot. 1054 TDC locking device.
• Mot. 1159 Device for supporting the engine on the subframe.
• Mot. 1202 Pliers for elastic clamps.
• Mot. 1273 Belt tension gauge.
• Mot. 1311-06 Fuel line removal tool.
• Device for supporting the engine.
• Torx bit 55.

Tightening torques, Nm

• Tension roller mounting nut: 50.
• Crankshaft pulley bolt: 20 + 115° ±15°.
• Engine pendulum mount upper bracket bolt: 62.
• Engine pendulum mount upper bracket nut: 44.
• Wheel mounting bolts: 90.

Removal

1. Place the vehicle on a two-post lift.

2. Disconnect the battery.

3. Remove:

• engine hood;
• timing belt for the gas distribution mechanism.

4. Drain the cooling system by disconnecting the drain hose on the radiator.

5. Install tool Mot. 1159 between the subframe and the cylinder block



6. Fit the Mot. 1159 tool bracket to the coolant hose mounting on the cylinder block, then remove the engine support tool.





7. Remove:

• exhaust pipe;
• hoses and sensor connectors on the thermostat housing;
• nipple 1 using tool Mot. 1311-06.

8. Remove:

• air filter, while disconnecting the connectors of the electromagnetic valve of exhaust gas recirculation and the air temperature sensor (disconnect the fuel lines from the air filter housing.
• fuel control cable;
• glow plug power wires;
• connectors of the 3rd cylinder injector with a built-in needle connector sensor, as well as a connector for the idle acceleration electromagnetic valve 5;
• gas and fuel return line fittings in A and B.

9. Disconnect connector 6 for the diesel fuel filter, disconnect the filter from the bracket, and move the pipelines with the filter aside.





10. Disconnect the quick-release couplings (figure 4.33).



11. Remove the fuel line holder bracket 7.



12. Loosen the bolts securing the lower timing cover.



13. Remove:

• auxiliary drive belt tensioner mechanism;
• cylinder head mounting bolts.

14. Separate the cylinder head by moving the lower part of the upper timing cover to the side; perform this operation without turning the cylinder head around the vertical axis, as it is centered by two bushings C.



15. Using a syringe, remove any remaining oil from the cylinder head bolt holes. This is necessary to ensure proper tightening of the bolts.

16. Take measures to prevent foreign particles from entering the cylinder head oil supply channel.

Caution: Failure to comply with this requirement may result in blockage of the oil supply channels and cause rapid wear of the camshaft.

Cleaning and checking

Caution! Do not clean the mating surfaces of aluminum parts with a tool with a sharp edge. Use Decapjoint to dissolve adhering gasket residues.

1. Apply the composition to the surface to be cleaned. Wait about ten minutes, then remove the stuck remains of the gasket with a wooden spatula. It is recommended to perform this operation with gloves.

Caution: This operation must be carried out carefully to avoid foreign particles from entering the pressurized oil supply system to the camshaft (the channels are located in the cylinder block and cylinder head). Failure to comply with this requirement may result in clogging of the rocker arm jets and cause rapid wear of the cams and rocker arm bearing surfaces.

2. Check the deformation of the mating surface. The maximum permissible non-flatness is 0.05 mm.

Caution! Grinding of the mating surfaces of the cylinder head is not permitted.

3. Check the cylinder head for cracks.

Determining the thickness of the gasket

1. Remove carbon deposits from the piston bottoms.

2. Turn the crankshaft in the direction of rotation by one revolution so that the piston of cylinder No.1 is near TDC.

3. Install the support Mot. 252-01 on the piston

Install bracket Mot. 25101 with indicator on stand Mot. 252-01. Bring the indicator leg into contact with the piston bottom and determine the piston TDC.

Attention! All measurements must be taken along the longitudinal axis of the engine to eliminate errors associated with piston tilt.

4. Measure the piston protrusion.

Attention! When choosing the thickness of the gasket, you should be guided by the greatest value of the piston protrusion.

5. If the maximum value of the engine piston protrusion:

• less than 0.858 mm, then a gasket with a tongue with two holes should be used;
• from 0.858 mm to 1 mm, use a gasket with a single-hole tab;
• more than 1 mm, use a gasket with a three-hole tab.

Installation

1. Place the pre-selected cylinder head gasket. The cylinder head is centered using two bushings C.



2. Position the pistons approximately halfway through their stroke so that they contact the valves when tightening the cylinder head bolts.

3. Center the cylinder head on the bushings.

4. Lubricate the underside of the heads and threads of the bolts with oil.

5. Tighten the cylinder head mounting bolts (see chapter "Maintenance").

6. Install in the reverse order of removal.

7. Install the timing belt.

8. Fill with coolant and bleed the cooling system (see chapter "Maintenance").