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Renault 2000 Espace, Technical Note

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Renault 2000 Espace Technical Note Download Page 45

MANUAL GEARBOX

Removal - refitting

21

21-4

Removal - refitting

The method for removing/refitting the PK1 G9T 
gearbox is the same as for the G8T engine. 
See 

Workshop Repair Manual 315 section 21 

"Transmission: removing/refitting the  PK1 
gearbox".

Please observe the recommendations for bleeding the 
hydraulic clutch system given in 

Technical Note 

3345A

 when refitting.

IMPORTANT:

The TDC sensor (1) may be moved during the gearbox 
removal/refitting operation. 
If necessary, push this until it is in contact with the 
backing plate.

Too great a gap could cause a starting fault which is 
not visible on the fault finding tool.

16027M1

Summary of Contents for 2000 Espace

Page 1: ...en 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 constr...

Page 2: ...ylinder head gasket 11 8 TURBOCHARGING FUEL MIXTURE Turbocharger 12 1 Air inlet 12 3 Exhaust manifold 12 7 Inlet manifold 12 8 STARTING CHARGING Alternator 16 1 Starter 16 4 Page 19 21 61 62 COOLING S...

Page 3: ...Capacity in litres approx Grade Diesel engine oil G9T For oil changes 7 7 8 3 1 European Union countries Other countries Components Capacity in litres Grade Special notes Gearbox PK1 3 1 All countrie...

Page 4: ...the cylinder head 07 07 2 Tightening the cylinder head METHOD FOR TIGHTENING THE CYLINDER HEAD Consult manual Mot G9 for the details of this operation You must remove the engine and transmission assem...

Page 5: ...RIPHERALS Identification 10 110 ENGINE AND PERIPHERALS Identification Manual to consult Mot G9 Vehicle type Engine Gearbox Capacity cm3 Bore mm Stroke mm Compression ratio JE0 K JE0 S G9T PK1 2188 87...

Page 6: ...be checked when the engine is warm approximately 80 C USE Connect the pressure gauge in place of the oil pressure switch Oil pressure 1 000 rpm 1 2 bar 3 000 rpm 3 5 bars SPECIAL TOOLING REQUIRED Mot...

Page 7: ...ck union ESSENTIAL SPECIAL TOOLING Two post lift Safety pad or belts TIGHTENING TORQUES in daN m Shock absorber base mounting bolts M16 x 200 20 Driveshaft gaiter mounting bolt 2 5 Wheel bolts 10 Engi...

Page 8: ...the end of the wheel arches the wheel arch protectors the front bumper the side driveshafts see section 29 of Workshop Repair Manual 315 Remove and refit side driveshafts Open the degassing tank Drai...

Page 9: ...assembly 10 10 5 Disconnect the air conditioning compressor pipe connections Remove the complete heater exhaust line if fitted Remove the exhaust pre catalytic converter the engine tie bar Disconnect...

Page 10: ...PERIPHERALS Engine and transmission assembly 10 10 6 Remove the radiator grille rack the radiator grille bolts C and D the left hand headlight Separate the electrical wiring from its clip beneath the...

Page 11: ...e effort of loosening retightening the bleed screw A see Technical Note 3345A Disconnect Left side the clutch slave cylinder high pressure union and release the pipe from its clips the water hoses con...

Page 12: ...sembly two people Remove the right hand suspended mounting cover the travel limiter linkage located just behind this cover the left hand suspension axis mounting nut Gently raise the vehicle in relati...

Page 13: ...the components deprogrammed by disconnecting the battery Fill the refrigerant circuit using the filling station see section 62 Air conditioning Refrigerant fluid R134a 800 20 g Carry out filling and...

Page 14: ...s the bleed screw briefly A With the bleed screw closed again the operator inside the vehicle releases the clutch pedal and slowly lifts it to top position by hand It is normal that the pedal does not...

Page 15: ...front right wheel arch the lower engine cover Using a ring spanner turn the tensioner axle clockwise to release the belt and insert a tool e g Allen key to lock the tensioner in this position REFITTIN...

Page 16: ...st the engine cylinder n 1 to top dead centre marking 1 on the crankshaft pulley and pin the crankshaft after removing the cap A SPECIAL TOOLING REQUIRED Mot 1390 Engine and transmission assembly moun...

Page 17: ...on assembly positioning the right hand pads only underneath the engine Lower the two unused left hand pads Remove the right hand suspended engine mounting cover Remove the timing belt cover and the lo...

Page 18: ...efully to the cylinder head Release the tension in the timing belt by undoing the timing tension wheel bolt Remove the exhaust camshaft sprocket by undoing the three mounting bolts on the sprocket on...

Page 19: ...is at top dead centre Fit the timing belt at the same time as the exhaust camshaft sprocket and position the sprocket mounting bolts at the centre of the holes Operation of the exhaust camshaft timing...

Page 20: ...e the top dead centre mark on the crankshaft accessories pulley must be in the vertical axis of the engine Fit the camshaft timing tools Mot 1534 and Mot 1537 Check that the tab of Mot 1537 moves vert...

Page 21: ...of 1 daN m Remove the camshaft timing tools Mot 1534 and Mot 1537 and the TDC pin Mot 1536 Refit the cap in the TDC pin opening applying RHODORSEAL 5661 to the thread and by tightening to a torque of...

Page 22: ...ND FRONT OF ENGINE Cylinder head gasket 11 11 8 Cylinder head gasket Consult manual Mot G9 for the details of this operation You must remove the engine and transmission assembly to remove the cylinder...

Page 23: ...TABLE In operation the pressure should stabilise at 210 3 5 mbar REMOVAL Removal or refitting of the turbocharger requires the removal of the engine and transmission assembly TIGHTENING TORQUES in daN...

Page 24: ...gine disconnect the pressure rail sensor connector 5 Then run the starter motor until the oil pressure warning light goes out persist for a few seconds Reconnect the sensor preheat and start the engin...

Page 25: ...FUEL MIXTURE Air intake 12 12 3 FUEL MIXTURE Air intake AIR INTAKE CIRCUIT DIAGRAM 1 Air air exchanger 2 Air filter 3 Damper unit 4 Inlet manifold 5 Turbocharger 6 Air inlet...

Page 26: ...y the injection computer comprises a throttle placed in the air inlet flow which closes when the ignition is switched off to ensure that the engine stops cleanly It also includes the exhaust gas recir...

Page 27: ...t the pump Separate the power steering reservoir without disconnecting the pump and move it on the side member Remove the turbocharger exchanger air pipe mounting bolts from the cylinder head the stif...

Page 28: ...e bolts WARNING avoid loosening the four self tapping bolts A which attach the top to the unit body Remove the connection pipe 5 between the throttle body and the inlet manifold If necessary unclip th...

Page 29: ...fitting engine and transmission assembly and the removal of the turbocharger see section 12 Removing refitting turbocharger REFITTING Refit the manifold bolts in the order recommended above Refitting...

Page 30: ...he engine and transmission assembly positioning the right hand pads only beneath the engine Lower the two unused left hand pads Remove the right hand suspended engine mounting cover Undo the two clips...

Page 31: ...with some grease Bring all the cylinder head cover bolts into contact Tighten to 1 2 daN m observing the tightening order for the cylinder head cover bolts It is essential that you observe the order o...

Page 32: ...r 16 116 STARTING CHARGING Alternator IDENTIFICATION CHECKING After 15 minutes warming up at a voltage of 13 5 volts Type Engine Alternator Current JE0 K JE0 S G9T VALEO SG 12 125 A Rpm Amps 1500 26 A...

Page 33: ...nections on the alternator and the air conditioning compressor Remove the front right wheel the right hand wheel arch cover the lower engine cover the bumper the windscreen washer tank the air exchang...

Page 34: ...er bolt without removing it On the right hand side below remove the vertical engine tie bar mounting bolt Undo without removing the pre catalytic converter mountings on the exhaust pipe Remove the upp...

Page 35: ...STARTING CHARGING Starter 16 16 4 Starter IDENTIFICATION Type Engine Starter motor JE0 K JE0 S G9T VALEO D7RP158...

Page 36: ...hrottle body unit pipe after disconnecting it the dipstick the three starter mounting bolts the oil filter unit bracket Release the filter bracket to the side without disconnecting it Disconnect the s...

Page 37: ...ttle opening Close the bleed screws as soon as the liquid starts to flow in a continuous stream Start the engine 2 500 rpm Adjust the level by overflow for a period of about 4 minutes Close the bottle...

Page 38: ...2 Radiator 3 Hot tank with degassing after thermostat 4 Heater matrix 5 Thermostat mounting 6 Thermoplunger mounting 7 Coolant pump 8 Bleed screw 9 Temperature switch 10 Heater if fitted 11 Oil cooler...

Page 39: ...ock the crankshaft using a screwdriver in the starter crown Remove the 30 hub lock nut from the coolant pump Remove the coolant pump sprocket using the U 14 L FACOM hub extractor REFITTING Replace the...

Page 40: ...on the shock absorber cage and tighten the bolts A to 3 daN m the linkage 2 on the mounting 1 without tightening it the rubber pad 3 on the cage and tighten the bolts C by 5 to 6 5 daN m the suspended...

Page 41: ...nection and at the quick release union for the bottle bulkhead connection When removing refitting the cooling system it is recommended that you do not disconnect the connections between the high press...

Page 42: ...ation JE0 K JE0 S vehicles with G9T turbo engines are fitted with PK1 manual gearboxes A mark on the gearbox casing shows At A the gearbox type At B the homologation number At C the gearbox suffix At...

Page 43: ...MANUAL GEARBOX Ratios 21 21 2 Ratios PK1 Index Type Final drive ratio 1st 2nd 3rd 4th 5th Reverse gear 026 JE0 K JE0 S 21 74 11 43 19 40 31 43 41 40 41 31 11 40 29...

Page 44: ...Note 2579A To check the level it is necessary to remove the left hand front wheel and the left hand wheel arch cover The oil can also be changed and refilled with the recommended quantity 1 Drain plug...

Page 45: ...ing refitting the PK1 gearbox Please observe the recommendations for bleeding the hydraulic clutch system given in Technical Note 3345A when refitting IMPORTANT The TDC sensor 1 may be moved during th...

Page 46: ...re met starting the engine air intake temperature less than 5 C coolant temperature less than 75 C The heater is usually switched off when the engine is stopped or the coolant temperature reaches 85 C...

Page 47: ...ark plug 6 Flame detector 7 Temperature sensor 8 Overheating switch 9 Control unit 10 Combustion air intake tube 11 Burnt gas exhaust pipe 12 Dosing pump 13 Fuel filter 14 Main fuse 15 Interface A Com...

Page 48: ...pump if the battery voltage is greater than 16 volts or less than 10 volts Other safety devices when the heater does not light 90 seconds after the supply of fuel is started the starting procedure is...

Page 49: ...HEATING Additional heating 61 61 4 RIGID HEATER COOLANT PIPES These are fixed to the body by bolt A When refitting tighten this bolt last after refitting and tightening all the clips 15966M1...

Page 50: ...HEATING Additional heating 61 61 5 EXPLODED VIEW OF THE HEATER Marking as on page 61 2 16 Cap...

Page 51: ...perature sensor 7 the turbine support 1 Remove the combustion chamber 4 and the exchanger 3 if necessary FAULT FINDING In case of a fault check if there is fuel in the tank if the fuses are intact if...

Page 52: ...elief valve is still present but calibrated differently REMOVAL Put the vehicle on a 2 post lift Disconnect the battery Drain the refrigerant circuit see special AIR CONDITIONING manual Remove the fro...

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