Renault Kangoo Repair Service Manual 1997-2012
Complete service repair manual with Electrical Wiring Diagrams for 1997-2012 Renault Kangoo, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Renault Kangoo workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Renault
MODEL: Kangoo I/II (X61, X76)
YEAR: 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
LANGUAGE: EN/FR/DE
PRODUCT DETAILS:
Total Pages: 11,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
MR-325-KANGOO 1 BIS-1....3
13-LUCAS DIESEL INJECTION....7
Fault finding - Introduction....7
Fault finding - XR25 fiche....8
Fault finding - Interpretation of XR25 bargraphs....11
Fault finding - Aid....37
Fault finding - Checking conformity....38
Fault finding - Customer complaints....43
Fault finding - Fault charts....44
17-INJECTION....51
Fault finding- Introduction....51
Fault finding - XR25 fiche....56
Fault finding - Interpretation of XR25 bargraphs....59
Fault finding - Status and parameter checks....80
Fault finding - Status and parameter interpretation....86
Fault finding - Customer complaints....106
Fault finding - Fault charts....107
Fault finding -Aid....112
Fault finding - Checking conformity....113
Fault finding- Introduction....122
Fault finding - XR25 fiche....127
Fault finding - Interpretation of XR25 bargraphs....130
Fault finding - Status and parameter checks....150
Fault finding - Status and parameter interpretation....156
Fault finding - Customer complaints....175
Fault finding - Fault charts....176
Fault finding -Aid....181
Fault finding - Checking conformity....182
Fault finding- Introduction....192
Fault finding - XR25 fiche....197
Fault finding - Interpretation of XR25 bargraphs....200
Fault finding - Status and parameter checks....220
Fault finding - Status and parameter interpretation....226
Fault finding - Customer complaints....246
Fault finding - Fault charts....247
Fault finding - Checking conformity....253
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS....264
Fault finding - Introduction....264
Fault finding - XR25 fiche....265
Fault finding- Fiche XR25....266
Fault finding - Interpretation of XR25 bargraphs....267
Fault finding - Conformity Check....281
Fault finding - Aid....282
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM....283
Fault finding - Customer Complaints....283
Fault finding - Fault chart....284
82-IMMOBILISER....300
Fault finding - Introduction....300
Fault finding- XR25 Fiche....301
Fault finding- Interpretation of XR25 Bargraphs....303
Fault finding - Customer complaints (petrol version)....313
Fault finding - Fault Chart (petrol version)....314
Fault finding - Customer complaints(diesel version)....324
Fault finding - Fault Chart (diesel version)....325
Fault finding - Checking conformity....333
Fault finding - Aid....338
88-AIRBAG - SEAT BELT PRETENSIONERS....342
Fault finding -Introduction....342
Fault finding -Wiring....343
Fault finding - XR25 Fiche....346
Fault finding - Interpretation of XR25 bargraphs....348
Fault finding - Checking conformity....363
Fault finding - Pretensioner Check....364
Fault finding - Aid....365
MR-325-KANGOO-0....366
01-SPECIFICATIONS....370
Engine- Clutch - Gearbox....370
Vehicle identification....371
02-LIFTING....372
Trolley jack - Axle stands....372
Underbody lifts....373
03-TOWING....374
All types....374
04-LUBRICANTS CONSUMABLES....375
Packaging....375
05-DRAINING - FILLING....378
Engine....378
Gearbox....380
Power assisted steering....381
07-VALUES AND SETTINGS....382
Dimensions....382
Capacity - Grades....383
Belt tension....386
Accessories belt tension....388
Timing belt tension....392
Tightening the cylinder head....393
Tyres and wheels....395
Brakes....396
Brake limiter....397
Underbody heights....398
Values for checking the front axle geometry....401
Values for checking the rear axle geometry....402
MR-325-KANGOO-1....403
10-ENGINE AND ENGINE PERIPHERALS....407
Consumables....407
Oil consumption....408
Oil pressure....409
Engine - Gearbox....410
Engine and transmission assembly....415
Sump....431
Crankshaft seal, timing end....435
Oil pump....436
11-TOP AND FRONT OF ENGINE....438
Timing belt....438
Cylinder head gasket....448
Replacement of valve adjusters....466
12-FUEL MIXTURE....468
Specifications....468
Throttle body....474
Inlet manifold....476
Exhaust manifold....479
Inlet/Exhaust manifolds....481
13-FUEL SUPPLY....483
Fuel cut off in case of an impact....483
Injector gallery....484
Fuel filter....488
Pump flow....489
Fuel pressure....490
Antipercolation device....494
13-DIESEL EQUIPMENT....495
General....495
Specifications....496
Location of components....498
Advance solenoid valve (1)....501
Advance solenoid valve....502
Altimetric corrector....504
Fast idle speed LDA....507
Coded solenoid valve....508
Load potentiometer....510
Computer configuration....511
Injector with sensor (needle lift)....513
Injection warning light....514
Pre-postheating control....515
Fast idle speed control....517
Injection/air conditioning programming....518
Computer....519
Defect modes....520
Pump....521
Pump - Timing....523
Adjusting idle speed....528
14-ANTIPOLLUTION....529
Test for the presence of lead....529
Fuel vapour rebreathing....530
Oil vapour rebreathing....535
Exhaust gas recirculation (EGR)....539
16-STARTING - CHARGING....542
Alternator....542
Starter motor....548
17-IGNITION....553
Semi-static ignition....553
Spark plugs....555
17-INJECTION....556
General....556
Location of components....560
Coolant temperature management....565
Injection fault warning light....566
Immobiliser function....567
Computer configuration depending on gearbox type....568
Injection/air conditioning programming....569
Idle speed correction....570
Adaptive idle speed correction....571
Richness regulation....572
Adaptive richness correction....574
19-COOLING....577
Specifications....577
Filling and bleeding....578
Testing....579
Diagram....580
Water pump....583
19-EXHAUST....588
General....588
Pipe assembly....591
19-FUEL TANK....593
Fuel tank....593
19-TANK....595
Fuel Tank....595
19-FUEL TANK....596
Fuel tank....596
Sender unit....605
Pump- sender unit....606
19-ENGINE MOUNTING....608
Suspended engine mountings....608
MR-325-KANGOO-2....611
20-CLUTCH....614
Mechanism - Disc....614
Flywheel....617
21-MANUAL GEARBOX....618
Identification....618
Ratios....619
Capacities - Lubricants....620
21-MECHANICAL GEARBOX....621
Consumables....621
21-MANUAL GEARBOX....622
Gearbox (removal - refitting)....622
29-DRIVESHAFTS....627
General....627
Front driveshafts....628
MR-325-KANGOO-3....633
30-GENERAL....637
General diagram of braking circuits....637
Tightening torques (in daN.m)....638
Dimensions of the main braking components....643
Front anti-roll bar specifications....644
Brake unions and pipes....645
31-FRONT AXLE....646
Lower wishbone....646
Lower wishbone rubber bushes....647
Lower wishbone ball joint....648
Brake pads....649
Front brake calipers....650
Brake discs....651
Stub axle carrier bearing....652
Spring and shock absorber assembly....654
Anti-roll bar....655
Engine sub-frame....657
33-REAR AXLE....659
Rear axle assembly....659
Brake drum....660
Brake cylinder....662
Brake linings (drum)....663
Bearing....665
Shock absorber....666
Anti-roll bar, tubular rear axle....667
Half suspension arms, tubular rear axle....668
Bushes, tubular rear axle....669
Suspension bars, tubular rear axle....673
Four bar rear axle....674
Suspension arm bearings....678
35-WHEELS AND TYRES....681
Specifications....681
Wheel balancing....684
36-STEERING ASSEMBLY....685
Axial ball joint....685
Manual steering rack....687
Power assisted steering rack....688
Gaiter....690
Steering pushrod....691
Manual steering assistance pump....692
Manual steering assistance pumpwithout AC....693
Steering column....696
37-MECHANICAL ELEMENT CONTROLS....701
Master cylinder....701
Brake servo....703
Air filter - Brake servo non-return valve....705
Vacuum pump....706
Handbrake control lever....707
Handbrake control....708
Brake pipes....710
Braking compensator....711
Clutch control cable....722
Clutch automatic wear take-up system....723
External gear control....724
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS....728
BOSCH ABS....728
MR-325-KANGOO-6....738
61-HEATING....741
Control panel....741
Control cables....742
Particle filter....743
Fan assembly (GMV)....744
Radiator....745
Air distribution unit....746
62-AIR CONDITIONING....749
General....749
Fault finding - Introduction....751
Fault finding - XR25 fiche....752
Fault finding - Interpretation of XR25 bargraphs....754
Fault finding - Customer complaints....766
Fault finding charts....767
62-CONDITIONING....786
Fault finding charts....786
62-AIR CONDITIONING....787
Fault finding charts....787
Fault finding - Associated checks....791
Wiring diagram....792
Evaporator....796
Air blower unit....798
Compressor....799
Condenser....802
Pressure relief valve....803
Dehydration canister....804
Connecting pipes....805
Electrical control....808
Computer....809
MR-325-KANGOO-8....811
80-BATTERY....814
Special notes....814
80-HEADLIGHTS....816
Lens units and indicators....816
Remote adjustment....817
81-REAR AND INTERIOR LIGHTS....818
Courtesy light....818
Fuses....819
82-IMMOBILISER....822
Coded key immobiliser system....822
83-INSTRUMENT PANEL....838
Dashboard....838
Instrument panel....843
Fuel level sensor....847
Oil level sensor....849
Coolant temperature sensor....850
84-CONTROLS - SIGNALS....851
Windscreen wiper stalk....851
Lights stalk....852
Stalk mounting....853
Rotary switch under steering wheel....854
Ignition switch....856
85-WIPERS....857
Front windscreen wiper....857
Rear screen wiper....859
Electric washer pump....860
87-ELECTRICAL ASSISTANCE EQUIPMENT....861
Relay plate....861
88-WIRING....866
Heated rear screen....866
Remote control for door locking....868
Airbags and seat belt pretensioners....873
MR325KANGOO0....894
01-SPECIFICATIONS....898
Engine- Clutch - Gearbox....898
Vehicle identification....899
02-LIFTING....900
Trolley jack - Axle stands....900
Underbody lifts....901
03-TOWING....902
All types....902
04-LUBRICANTS CONSUMABLES....903
Packaging....903
05-DRAINING - FILLING....906
Engine....906
Gearbox....908
Power assisted steering....909
07-VALUES AND SETTINGS....910
Dimensions....910
Capacity - Grades....911
Belt tension....914
Accessories belt tension....916
Timing belt tension....920
Tightening the cylinder head....921
Tyres and wheels....923
Brakes....924
Brake limiter....925
Underbody heights....926
Values for checking the front axle geometry....929
Values for checking the rear axle geometry....930
MR325KANGOO1....931
10-ENGINE AND ENGINE PERIPHERALS....935
Consumables....935
Oil consumption....936
Oil pressure....937
Engine - Gearbox....938
Engine and transmission assembly....943
Sump....959
Crankshaft seal, timing end....963
Oil pump....964
11-TOP AND FRONT OF ENGINE....966
Timing belt....966
Cylinder head gasket....976
Replacement of valve adjusters....994
12-FUEL MIXTURE....996
Specifications....996
Throttle body....1002
Inlet manifold....1004
Exhaust manifold....1007
Inlet/Exhaust manifolds....1009
13-FUEL SUPPLY....1011
Fuel cut off in case of an impact....1011
Injector gallery....1012
Fuel filter....1016
Pump flow....1017
Fuel pressure....1018
Antipercolation device....1022
13-DIESEL EQUIPMENT....1023
General....1023
Specifications....1024
Location of components....1026
Advance solenoid valve (1)....1029
Advance solenoid valve....1030
Altimetric corrector....1032
Fast idle speed LDA....1035
Coded solenoid valve....1036
Load potentiometer....1038
Computer configuration....1039
Injector with sensor (needle lift)....1041
Injection warning light....1042
Pre-postheating control....1043
Fast idle speed control....1045
Injection/air conditioning programming....1046
Computer....1047
Defect modes....1048
Pump....1049
Pump - Timing....1051
Adjusting idle speed....1056
14-ANTIPOLLUTION....1057
Test for the presence of lead....1057
Fuel vapour rebreathing....1058
Oil vapour rebreathing....1063
Exhaust gas recirculation (EGR)....1067
16-STARTING - CHARGING....1070
Alternator....1070
Starter motor....1076
17-IGNITION....1081
Semi-static ignition....1081
Spark plugs....1083
17-INJECTION....1084
General....1084
Location of components....1088
Coolant temperature management....1093
Injection fault warning light....1094
Immobiliser function....1095
Computer configuration depending on gearbox type....1096
Injection/air conditioning programming....1097
Idle speed correction....1098
Adaptive idle speed correction....1099
Richness regulation....1100
Adaptive richness correction....1102
19-COOLING....1105
Specifications....1105
Filling and bleeding....1106
Testing....1107
Diagram....1108
Water pump....1111
19-EXHAUST....1116
General....1116
Pipe assembly....1119
19-FUEL TANK....1121
Fuel tank....1121
19-TANK....1123
Fuel Tank....1123
19-FUEL TANK....1124
Fuel tank....1124
Sender unit....1133
Pump- sender unit....1134
19-ENGINE MOUNTING....1136
Suspended engine mountings....1136
MR325KANGOO1BIS....1139
13-LUCAS DIESEL INJECTION....1143
Fault finding - Introduction....1143
Fault finding - XR25 fiche....1144
Fault finding - Interpretation of XR25 bargraphs....1147
Fault finding - Aid....1173
Fault finding - Checking conformity....1174
Fault finding - Customer complaints....1179
Fault finding - Fault charts....1180
17-INJECTION....1187
Fault finding- Introduction....1187
Fault finding - XR25 fiche....1192
Fault finding - Interpretation of XR25 bargraphs....1195
Fault finding - Status and parameter checks....1216
Fault finding - Status and parameter interpretation....1222
Fault finding - Customer complaints....1242
Fault finding - Fault charts....1243
Fault finding -Aid....1248
Fault finding - Checking conformity....1249
Fault finding- Introduction....1258
Fault finding - XR25 fiche....1263
Fault finding - Interpretation of XR25 bargraphs....1266
Fault finding - Status and parameter checks....1286
Fault finding - Status and parameter interpretation....1292
Fault finding - Customer complaints....1311
Fault finding - Fault charts....1312
Fault finding -Aid....1317
Fault finding - Checking conformity....1318
Fault finding- Introduction....1328
Fault finding - XR25 fiche....1333
Fault finding - Interpretation of XR25 bargraphs....1336
Fault finding - Status and parameter checks....1356
Fault finding - Status and parameter interpretation....1362
Fault finding - Customer complaints....1382
Fault finding - Fault charts....1383
Fault finding - Checking conformity....1389
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS....1400
Fault finding - Introduction....1400
Fault finding - XR25 fiche....1401
Fault finding- Fiche XR25....1402
Fault finding - Interpretation of XR25 bargraphs....1403
Fault finding - Conformity Check....1417
Fault finding - Aid....1418
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM....1419
Fault finding - Customer Complaints....1419
Fault finding - Fault chart....1420
82-IMMOBILISER....1436
Fault finding - Introduction....1436
Fault finding- XR25 Fiche....1437
Fault finding- Interpretation of XR25 Bargraphs....1439
Fault finding - Customer complaints (petrol version)....1449
Fault finding - Fault Chart (petrol version)....1450
Fault finding - Customer complaints(diesel version)....1460
Fault finding - Fault Chart (diesel version)....1461
Fault finding - Checking conformity....1469
Fault finding - Aid....1474
88-AIRBAG - SEAT BELT PRETENSIONERS....1478
Fault finding -Introduction....1478
Fault finding -Wiring....1479
Fault finding - XR25 Fiche....1482
Fault finding - Interpretation of XR25 bargraphs....1484
Fault finding - Checking conformity....1499
Fault finding - Pretensioner Check....1500
Fault finding - Aid....1501
MR325KANGOO2....1502
20-CLUTCH....1505
Mechanism - Disc....1505
Flywheel....1508
21-MANUAL GEARBOX....1509
Identification....1509
Ratios....1510
Capacities - Lubricants....1511
21-MECHANICAL GEARBOX....1512
Consumables....1512
21-MANUAL GEARBOX....1513
Gearbox (removal - refitting)....1513
29-DRIVESHAFTS....1518
General....1518
Front driveshafts....1519
MR325KANGOO3....1524
30-GENERAL....1528
General diagram of braking circuits....1528
Tightening torques (in daN.m)....1529
Dimensions of the main braking components....1534
Front anti-roll bar specifications....1535
Brake unions and pipes....1536
31-FRONT AXLE....1537
Lower wishbone....1537
Lower wishbone rubber bushes....1538
Lower wishbone ball joint....1539
Brake pads....1540
Front brake calipers....1541
Brake discs....1542
Stub axle carrier bearing....1543
Spring and shock absorber assembly....1545
Anti-roll bar....1546
Engine sub-frame....1548
33-REAR AXLE....1550
Rear axle assembly....1550
Brake drum....1551
Brake cylinder....1553
Brake linings (drum)....1554
Bearing....1556
Shock absorber....1557
Anti-roll bar, tubular rear axle....1558
Half suspension arms, tubular rear axle....1559
Bushes, tubular rear axle....1560
Suspension bars, tubular rear axle....1564
Four bar rear axle....1565
Suspension arm bearings....1569
35-WHEELS AND TYRES....1572
Specifications....1572
Wheel balancing....1575
36-STEERING ASSEMBLY....1576
Axial ball joint....1576
Manual steering rack....1578
Power assisted steering rack....1579
Gaiter....1581
Steering pushrod....1582
Manual steering assistance pump....1583
Manual steering assistance pumpwithout AC....1584
Steering column....1587
37-MECHANICAL ELEMENT CONTROLS....1592
Master cylinder....1592
Brake servo....1594
Air filter - Brake servo non-return valve....1596
Vacuum pump....1597
Handbrake control lever....1598
Handbrake control....1599
Brake pipes....1601
Braking compensator....1602
Clutch control cable....1613
Clutch automatic wear take-up system....1614
External gear control....1615
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS....1619
BOSCH ABS....1619
MR325KANGOO6....1629
61-HEATING....1632
Control panel....1632
Control cables....1633
Particle filter....1634
Fan assembly (GMV)....1635
Radiator....1636
Air distribution unit....1637
62-AIR CONDITIONING....1640
General....1640
Fault finding - Introduction....1642
Fault finding - XR25 fiche....1643
Fault finding - Interpretation of XR25 bargraphs....1645
Fault finding - Customer complaints....1657
Fault finding charts....1658
62-CONDITIONING....1677
Fault finding charts....1677
62-AIR CONDITIONING....1678
Fault finding charts....1678
Fault finding - Associated checks....1682
Wiring diagram....1683
Evaporator....1687
Air blower unit....1689
Compressor....1690
Condenser....1693
Pressure relief valve....1694
Dehydration canister....1695
Connecting pipes....1696
Electrical control....1699
Computer....1700
MR325KANGOO8....1702
80-BATTERY....1705
Special notes....1705
80-HEADLIGHTS....1707
Lens units and indicators....1707
Remote adjustment....1708
81-REAR AND INTERIOR LIGHTS....1709
Courtesy light....1709
Fuses....1710
82-IMMOBILISER....1713
Coded key immobiliser system....1713
83-INSTRUMENT PANEL....1729
Dashboard....1729
Instrument panel....1734
Fuel level sensor....1738
Oil level sensor....1740
Coolant temperature sensor....1741
84-CONTROLS - SIGNALS....1742
Windscreen wiper stalk....1742
Lights stalk....1743
Stalk mounting....1744
Rotary switch under steering wheel....1745
Ignition switch....1747
85-WIPERS....1748
Front windscreen wiper....1748
Rear screen wiper....1750
Electric washer pump....1751
87-ELECTRICAL ASSISTANCE EQUIPMENT....1752
Relay plate....1752
88-WIRING....1757
Heated rear screen....1757
Remote control for door locking....1759
Airbags and seat belt pretensioners....1764
MR326....1785
MR-326-KANGOO GV-4....1786
EXPLODED VIEW....1787
Contents....1788
40-GENERAL INFORMATION....1789
Dimensions....1789
Engine and equipment....1790
Towing....1791
Key to Symbols....1792
Fitting extension elements....1793
Description of parts....1794
Sub-frame dimensions....1796
Repair Bench....1797
Tools and specific products....1800
41-LOWER STRUCTURE....1802
Semi-rear end cross member....1802
Rear floor extender....1809
44-UPPER REAR STRUCTURE....1812
Basic body rear wing panel....1812
Rear wing panel fitted....1814
Basic body side panel....1823
Added side panel....1825
Side panel extender....1835
Side inner panel extender....1839
Upper rear corner stiffener....1841
Lights mounting side panel rain channel....1844
45-TOP OF BODY....1846
Grand volume added roof....1846
Roof inner panel extender....1850
MR-326-KANGOO RX4-1....1852
Contents....1853
55-EXTERIOR PROTECTION....1854
Front bumper....1854
Side protective mouldings....1856
Front wing extenders....1858
Sill panel....1859
58-UPPER INTERIOR ACCESSORIES....1860
Storage compartment....1860
71-INTERIOR BODY LININGS....1861
Side trim panels....1861
MR-326-KANGOO-4....1862
40-GENERAL....1866
Dimensions....1866
Engine and equipment....1867
Identification....1869
Means of lifting....1871
Towing....1873
Using symbols....1874
Key to Symbols....1876
Description of parts (exploded view)....1877
Opening clearances....1880
Collision fault finding....1887
Sub-frame dimensions....1890
Repair Bench....1892
Special tooling....1903
41-LOWER STRUCTURE....1904
Front end lower cross member....1904
Front side member, front section....1908
Front side member closure panel....1913
Front half unit....1916
Front side cross member....1920
Front side member, rear section....1924
Front mounting of sub-frame....1929
Sill panel closure panel....1932
Cross member under front seat....1936
Side floor....1939
Tunnel....1942
Rear floor, front section....1944
Rear floor, rear section (part section)....1947
Rear floor front cross member, front section....1954
Rear floor stiffener....1956
Rear end cross member....1958
Rear shock absorber reinforcement....1961
Rear side member extension....1963
Rear side member, part section....1965
Complete rear side member....1966
Centre cross member of rear floor....1970
Seat anchoring reinforcement....1971
Rear floor unit....1974
42-UPPER FRONT STRUCTURE....1978
Front wing....1978
Headlight carrier panel....1979
Cowl side panel (pillar lining), part section....1982
Cowl side panel upper reinforcement....1985
Wheel arch, front section....1989
Wheel arch....1994
Plenum chamber....2001
Windscreen aperture lower cross member....2005
Steering column mounting....2009
Bulkhead....2011
43-UPPER SIDE STRUCTURE....2016
Front pillar....2016
Windscreen aperture pillar....2021
Front pillar lining / Cowl side panel....2024
Centre pillar / sill panel....2029
Centre pillar lower reinforcement / door pillar....2034
Sill panel reinforcement....2038
Left hand side sill panel....2040
44-UPPER REAR STRUCTURE....2043
Rear wing panel....2043
Side panel....2051
Side panel lining....2059
Roof stretcher lining....2068
Rear inner wheel arch....2072
Lights mounting side panel rain channel....2075
Rear wing panel extension....2080
Rear end panel....2083
45-TOP OF BODY....2086
Roof....2086
Roof front cross member....2092
Roof centre cross member....2093
Roof rear cross member....2094
47-SIDE OPENING ELEMENTS....2097
Front door....2097
Front door panel....2098
Front door stiffener....2102
Side door....2104
Side door panel....2107
Side door stiffener....2110
48-NON-SIDE OPENING ELEMENTS....2112
Bonnet....2112
Bonnet hinges....2113
Rear opening doors....2114
Tailgate....2115
Roof flap....2116
MR-326-KANGOO-5....2117
50-GENERAL....2120
Safety....2120
Tooling....2121
51-SIDE OPENING ELEMENT MECHANISMS....2123
Window winder handle on front door....2123
Door opening handle - interior, front door....2124
Door opening handle - exterior, front door....2125
Front door lock....2126
Front door window riser....2127
Door barrels....2128
Interior handle for opening the sliding door....2129
Exterior handle for sliding door....2130
Locking warning light and sliding door lock....2131
Sliding door runners....2132
Adjusting the sliding door....2134
52-NON-SIDE OPENING ELEMENT MECHANISMS....2136
Exterior handle for rear door....2136
Rear screen wiper motor....2137
Rear door lock....2138
Rear door latches....2139
Exterior handle for tailgate....2140
Hinged rear roof flap cross member....2141
54-WINDOWS....2142
Windscreen....2142
Front door window....2144
Tilting or fixed windows in sliding door....2145
Fixed or moving side window....2146
Window in rear door and window in tailgate....2147
Moving window/latch....2148
55-EXTERIOR PROTECTION....2150
Roof protection strip....2150
Bumpers....2152
Side protection strips....2153
Protective panel at rear....2154
56-EXTERIOR ACCESSORIES....2156
Exterior rear view mirror....2156
Rear view mirror....2157
Rear screen washer jet....2158
Number plate light....2159
57-LOWER INTERIOR ACCESSORIES....2160
Dashboard....2160
58-UPPER INTERIOR ACCESSORIES....2165
Upper storage compartment in cab....2165
59-INTERIOR SAFETY ACCESSORIES....2166
Front seat belts....2166
Rear seat belts....2167
MR-326-KANGOO-6....2168
64-BODY SEALING....2171
Seals for side opening elements....2171
Luggage compartment seal....2172
Interior finishing seal for sliding door and side opening....2173
MR-326-KANGOO-7....2174
71-INTERIOR BODY LININGS....2177
Door sill lining....2177
Side trim panels....2178
Upper central trim assembly....2179
Head lining....2181
Carpet....2183
72-SIDE OPENING ELEMENTS TRIM....2184
Front door trim....2184
Side door trim....2185
73-NON-SIDE OPENING ELEMENTS TRIM....2186
Lining for rear door or tailgate....2186
74-REAR PARCEL SHELF....2187
Rear side shelves....2187
75-FRONT SEAT FRAMES AND RUNNERS....2188
Complete front seat and runners....2188
76-REAR SEAT FRAMES AND RUNNERS....2189
Complete rear bench seat....2189
77-FRONT SEAT TRIM....2190
Seatback trim....2190
Folding seatback trim....2192
Seat squab trim....2193
78-REAR SEAT TRIM....2194
1/3 - 2/3 seatback trim....2194
1/3 - 2/3 seat squab trim....2197
79-SEAT ACCESSORIES....2198
Locking cable - 3rd seat belt retractor....2198
MR326KANGOO4....2199
40-GENERAL....2203
Dimensions....2203
Engine and equipment....2204
Identification....2206
Means of lifting....2208
Towing....2210
Using symbols....2211
Key to Symbols....2213
Description of parts (exploded view)....2214
Opening clearances....2217
Collision fault finding....2224
Sub-frame dimensions....2227
Repair Bench....2229
Special tooling....2240
41-LOWER STRUCTURE....2241
Front end lower cross member....2241
Front side member, front section....2245
Front side member closure panel....2250
Front half unit....2253
Front side cross member....2257
Front side member, rear section....2261
Front mounting of sub-frame....2266
Sill panel closure panel....2269
Cross member under front seat....2273
Side floor....2276
Tunnel....2279
Rear floor, front section....2281
Rear floor, rear section (part section)....2284
Rear floor front cross member, front section....2291
Rear floor stiffener....2293
Rear end cross member....2295
Rear shock absorber reinforcement....2298
Rear side member extension....2300
Rear side member, part section....2302
Complete rear side member....2303
Centre cross member of rear floor....2307
Seat anchoring reinforcement....2308
Rear floor unit....2311
42-UPPER FRONT STRUCTURE....2315
Front wing....2315
Headlight carrier panel....2316
Cowl side panel (pillar lining), part section....2319
Cowl side panel upper reinforcement....2322
Wheel arch, front section....2326
Wheel arch....2331
Plenum chamber....2338
Windscreen aperture lower cross member....2342
Steering column mounting....2346
Bulkhead....2348
43-UPPER SIDE STRUCTURE....2353
Front pillar....2353
Windscreen aperture pillar....2358
Front pillar lining / Cowl side panel....2361
Centre pillar / sill panel....2366
Centre pillar lower reinforcement / door pillar....2371
Sill panel reinforcement....2375
Left hand side sill panel....2377
44-UPPER REAR STRUCTURE....2380
Rear wing panel....2380
Side panel....2388
Side panel lining....2396
Roof stretcher lining....2405
Rear inner wheel arch....2409
Lights mounting side panel rain channel....2412
Rear wing panel extension....2417
Rear end panel....2420
45-TOP OF BODY....2423
Roof....2423
Roof front cross member....2429
Roof centre cross member....2430
Roof rear cross member....2431
47-SIDE OPENING ELEMENTS....2434
Front door....2434
Front door panel....2435
Front door stiffener....2439
Side door....2441
Side door panel....2444
Side door stiffener....2447
48-NON-SIDE OPENING ELEMENTS....2449
Bonnet....2449
Bonnet hinges....2450
Rear opening doors....2451
Tailgate....2452
Roof flap....2453
MR326KANGOO5....2454
50-GENERAL....2457
Safety....2457
Tooling....2458
51-SIDE OPENING ELEMENT MECHANISMS....2460
Window winder handle on front door....2460
Door opening handle - interior, front door....2461
Door opening handle - exterior, front door....2462
Front door lock....2463
Front door window riser....2464
Door barrels....2465
Interior handle for opening the sliding door....2466
Exterior handle for sliding door....2467
Locking warning light and sliding door lock....2468
Sliding door runners....2469
Adjusting the sliding door....2471
52-NON-SIDE OPENING ELEMENT MECHANISMS....2473
Exterior handle for rear door....2473
Rear screen wiper motor....2474
Rear door lock....2475
Rear door latches....2476
Exterior handle for tailgate....2477
Hinged rear roof flap cross member....2478
54-WINDOWS....2479
Windscreen....2479
Front door window....2481
Tilting or fixed windows in sliding door....2482
Fixed or moving side window....2483
Window in rear door and window in tailgate....2484
Moving window/latch....2485
55-EXTERIOR PROTECTION....2487
Roof protection strip....2487
Bumpers....2489
Side protection strips....2490
Protective panel at rear....2491
56-EXTERIOR ACCESSORIES....2493
Exterior rear view mirror....2493
Rear view mirror....2494
Rear screen washer jet....2495
Number plate light....2496
57-LOWER INTERIOR ACCESSORIES....2497
Dashboard....2497
58-UPPER INTERIOR ACCESSORIES....2502
Upper storage compartment in cab....2502
59-INTERIOR SAFETY ACCESSORIES....2503
Front seat belts....2503
Rear seat belts....2504
MR326KANGOO6....2505
64-BODY SEALING....2508
Seals for side opening elements....2508
Luggage compartment seal....2509
Interior finishing seal for sliding door and side opening....2510
MR326KANGOO7....2511
71-INTERIOR BODY LININGS....2514
Door sill lining....2514
Side trim panels....2515
Upper central trim assembly....2516
Head lining....2518
Carpet....2520
72-SIDE OPENING ELEMENTS TRIM....2521
Front door trim....2521
Side door trim....2522
73-NON-SIDE OPENING ELEMENTS TRIM....2523
Lining for rear door or tailgate....2523
74-REAR PARCEL SHELF....2524
Rear side shelves....2524
75-FRONT SEAT FRAMES AND RUNNERS....2525
Complete front seat and runners....2525
76-REAR SEAT FRAMES AND RUNNERS....2526
Complete rear bench seat....2526
77-FRONT SEAT TRIM....2527
Seatback trim....2527
Folding seatback trim....2529
Seat squab trim....2530
78-REAR SEAT TRIM....2531
1/3 - 2/3 seatback trim....2531
1/3 - 2/3 seat squab trim....2534
79-SEAT ACCESSORIES....2535
Locking cable - 3rd seat belt retractor....2535
MR326KANGOOGV4....2536
EXPLODED VIEW....2537
Contents....2538
40-GENERAL INFORMATION....2539
Dimensions....2539
Engine and equipment....2540
Towing....2541
Key to Symbols....2542
Fitting extension elements....2543
Description of parts....2544
Sub-frame dimensions....2546
Repair Bench....2547
Tools and specific products....2550
41-LOWER STRUCTURE....2552
Semi-rear end cross member....2552
Rear floor extender....2559
44-UPPER REAR STRUCTURE....2562
Basic body rear wing panel....2562
Rear wing panel fitted....2564
Basic body side panel....2573
Added side panel....2575
Side panel extender....2585
Side inner panel extender....2589
Upper rear corner stiffener....2591
Lights mounting side panel rain channel....2594
45-TOP OF BODY....2596
Grand volume added roof....2596
Roof inner panel extender....2600
MR326KANGOORX4....2602
Contents....2603
55-EXTERIOR PROTECTION....2604
Front bumper....2604
Side protective mouldings....2606
Front wing extenders....2608
Sill panel....2609
58-UPPER INTERIOR ACCESSORIES....2610
Storage compartment....2610
71-INTERIOR BODY LININGS....2611
Side trim panels....2611
MR376....2612
MR376X7613B000....2613
MR376X7617B000....2817
MR376X7617B050....2977
MR376X7636B000....3256
MR376X7638C000....3286
MR376X7680D000....3343
MR376X7682A000....3373
MR376X7682D000....3410
MR376X7683A000....3458
MR376X7685A000....3517
MR376X7687B000....3546
MR376X7688C000....3579
MR376X7688C050....3619
MR380....3674
MR380KANGOO0....3675
01A-VEHICLE MECHANICAL SPECIFICATIONS....3677
Dimensions....3677
Engines - Gearboxes....3678
01C-VEHICLE BODYWORK SPECIFICATIONS....3680
Vehicle identification....3680
01D-MECHANICAL INTRODUCTION....3681
Vehicle: Precautions for repair....3681
Tightening torques: General information....3683
02A-LIFTING EQUIPMENT....3687
Trolley jack - Axle stand....3687
Underbody lift....3688
04B-CONSUMABLES - PRODUCTS....3690
Vehicle: Parts and ingredients for the repairwork....3690
MR380KANGOO1....3698
10A-ENGINE AND CYLINDER BLOCK ASSEMBLY....3705
Engine/gearbox assembly: Removal - Refitting....3705
Engine oil: Draining - Refilling....3764
Oil consumption Check....3780
Sump: Removal - Refitting....3781
Conrod bearing shell: Removal - Refitting....3812
Oil pump: Removal - Refitting....3825
General information....3833
Flywheel: Removal - Refitting....3834
Drive plate: Removal - Refitting....3836
11A-TOP AND FRONT OF ENGINE....3837
Accessories belt: Removal - Refitting....3837
Timing belt: Removal - Refitting....3862
Rocker cover: Removal - Refitting....3953
Camshaft: Removal - Refitting....3957
Cylinder head gasket : Removal - Refitting....3960
Tightening the cylinder head....4040
12A-FUEL MIXTURE....4050
Air inlet....4050
Air filter: Replacement....4060
Air filter: Removal - Refitting....4067
Air filter unit: Removal - Refitting....4069
Throttle valve: Removal - Refitting....4076
Throttle valve: Cleaning....4084
Inlet manifold: Removal - Refitting....4086
Injector holder shim: Removal - Refitting....4106
Exhaust manifold - Intake distributor: Removal - Refitting....4108
Exhaust manifold: Removal - Refitting....4112
12B-TURBOCHARGING....4127
Turbocharging: Precautions for repair....4127
Turbocharger: Removal - Refitting....4130
Intercooler: Removal - Refitting....4141
13A-FUEL SUPPLY....4143
Petrol supply circuit....4143
Diesel fuel supply circuit....4145
Petrol filter: General information....4148
Petrol filter: Removal - Refitting....4149
Diesel filter: Removal - Refitting....4150
Fuel filter: Removal - Refitting....4154
Fuel circuit: Operating diagram....4156
Inertia switch operation....4157
Fuel pressure regulator:Checking....4158
Electric fuel: Checking....4162
13B-DIESEL INJECTION....4165
Diesel injection: Precautions for repair....4165
Location of components....4176
Diesel injection computer: Removal - Refitting....4190
High pressure pump: Removal - Refitting....4192
Injection pump: Removal - Refitting....4213
Fuel flow actuator: Removal - Refitting....4216
Fuel pressure regulator: Removal - Refitting....4219
Venturi: Removal - Refitting....4222
High pressure pipe: Replacement....4226
High-pressure pipe between the pump and rail: Removal - Refitting....4231
High-pressure pipe between the rail and injector: Removal - Refitting....4235
Injector rail: Removal - Refitting....4239
Rail pressure sensor: Removal - Refitting....4248
Fuel temperature sensor: Removal - Refitting....4252
Diesel injector: Removal - Refitting....4256
Accelerometer: Removal - Refitting....4269
Specifications....4273
Diesel injection: Specifications....4284
Description....4289
Operation....4291
Diesel injection computer specifications....4298
Injection warning light....4308
Injection / air conditioning programming....4311
Idling speed....4315
Accelerator pedal potentiometer: Removal - Refitting....4319
Specifications of the accelerator pedal sensor....4321
Injection pump: Adjusting....4323
Heating elements: Operation....4325
Reduced flow and electric stop solenoid valve: Removal - Refitting....4327
13C-PREHEATING....4329
Pre-postheating control....4329
Pre/postheating unit: Removal - Refitting....4333
Heater plugs Removal - Refitting....4334
14A-ANTIPOLLUTION....4335
Fuel vapour canister: Removal - Refitting....4335
Exhaust gas recirculation solenoid valve: Removal - Refitting....4337
Petrol vapour rebreathing: Operation....4339
Fuel vapour recirculation circuit: check....4340
Exhaust gas recirculation unit: Removal - Refitting....4342
Intercooler: Removal - Refitting....4351
Fuel vapour canister:Checking....4354
Oil vapour rebreathing....4355
Exhaust gas recirculation: Description....4365
16A-STARTING - CHARGING....4371
Alternator: Identification....4371
Alternator: Removal - Refitting....4374
Starter: Identification....4378
Starter: Removal - Refitting....4379
17A-IGNITION....4384
Coils Removal - Refitting....4384
Ignition function....4389
17B-PETROL INJECTION....4393
Fuel injection parts description....4393
Oxygen sensors: Removal - Refitting....4414
Petrol injection computer: Removal - Refitting....4418
Injector rail - Injectors: Removal - Refitting....4424
Accelerator pedal potentiometer: Removal - Refitting....4437
Specifications of the accelerator pedal potentiometer,....4438
Petrol injection computer: Connection....4440
Special notes....4455
Injection warning light....4461
Immobiliser function....4465
Injection - air conditioning programming....4466
Throttle valve: Operating....4471
Operating description of injection....4473
Special notes on the system (when driving)....4491
Conditions for carrying out fault finding (when driving)....4493
Combustion misfire fault finding....4496
Catalytic converter fault finding....4499
Oxygen sensor fault finding....4502
Fault finding warning light activation conditions (when driving)....4506
17D-NGV INJECTION....4507
Special features of CNG vehicles....4507
CNG safety advice....4508
Draining the CNG reservoir....4509
CNG tank: Removal - Refitting....4514
CNG multifunction valve: Removal - Refitting....4517
CNG filler neck: Removal - Refitting....4518
CNG tank pressure sensor: Removal - Refitting....4520
CNG injector rail: Removal - Refitting....4522
CNG vaporiser unit: Removal - Refitting....4527
CNG injector: Removal - Refitting....4531
CNG injection computer: Removal - Refitting....4534
19A-COOLING....4535
Engine cooling circuit: check....4535
Cooling circuit: Draining - Refilling....4539
Cooling radiator: Removal - Refitting....4543
Water pump: Removal - Refitting....4556
Thermostat: Removal - Refitting....4571
Thermoplunger unit: Removal - Refitting....4575
Specifications....4577
Diagram....4578
19B-EXHAUST....4588
Exhaust: Precautions for repair....4588
Catalytic converter: Removal - Refitting....4592
Expansion chamber: Removal - Refitting....4603
Silencer: Removal - Refitting....4605
General information....4606
19C-TANK....4609
Draining the fuel tank....4609
Fuel tank: Removal - Refitting....4612
Filler neck: Removal - Refitting....4620
Fuel pipes: Repair....4622
Fuel level sensor: Checking....4625
Pump-sender unit-filter: Removal - Refitting....4626
19D-ENGINE MOUNTING....4631
Suspended engine mounting....4631
MR380KANGOO2....4642
20A-CLUTCH....4645
Clutch: Precautions for repair....4645
Identification....4646
Mechanism / Disk: Removal - Refitting....4650
Clutch thrust bearing: Removal - Refitting....4652
21A-MANUAL GEARBOX....4655
Identification....4655
Gears....4656
Consumables....4658
Manual gearbox: Removal - Refitting....4659
Differential output seal: Removal - Refitting....4673
Input shaft lip seal: Replacement....4675
Differential cover seal: Removal - Refitting....4682
23A-AUTOMATIC GEARBOX....4684
Automatic gearbox: Precautions for repair....4684
Automatic gearbox: Identification....4685
Automatic gearbox: List and location of components....4686
Automatic gearbox: Removal - Refitting....4688
Automatic gearbox oil: Draining - Refilling....4693
Hydraulic distributor: Removal - Refitting....4697
Hydraulic distributor solenoid valves: Removal - Refitting....4701
Hydraulic distribution wiring: Removal - Refitting....4702
Flow regulation solenoid valve: Removal - Refitting....4704
Gearbox oil cooler: Removal - Refitting....4706
Differential output seal: Removal - Refitting....4708
Multifunction switch: Removal - Refitting....4710
Multifunction switch: Adjusting....4712
Speed sensor: Removal - Refitting....4713
Pressure sensor: Removal - Refitting....4715
Converter seal: Removal - Refitting....4717
Automatic transmission connector: Removal - Refitting....4718
Automatic transmission computer: Removal - Refitting....4720
26A-REAR AXLE....4721
Identification....4721
Rear axle assembly: Removing - Refitting....4722
Rear axle assembly: Draining - Refilling....4725
Longitudinal driveshaft input seal: Removal - Refitting....4726
Differential output seal: Removal - Refitting....4728
Rear final drive coupler: Removal - Refitting....4731
29A-DRIVESHAFTS....4733
Transmission....4733
Front left-hand wheel driveshaft: Removal - Refitting....4734
Front right-hand wheel driveshaft: Removal - Refitting....4736
Rear wheel driveshaft: Removal - Refitting....4739
Propshaft: Removal - Refitting....4741
Front right driveshaft gaiter on gearbox side....4743
Front left driveshaft gaiter on gearbox side....4744
MR380KANGOO3....4748
30A-GENERAL INFORMATION....4752
Brake circuit Operating diagram....4752
Brake circuit Precautions for repair....4753
Brake circuit Bleeding....4755
Brake circuit Tightening torque....4757
Brake fluid: Specifications....4759
Brake: Specifications....4760
Steering: Tightening torque....4761
Axle assemblies: Check....4762
Underbody height: Adjustment values....4763
Front axle: Tightening torque....4766
Front axle: Adjustment values....4771
Front axle: Adjusting....4773
Rear axle: Tightening torque....4774
Rear axle: Adjustment values....4777
31A-FRONT AXLE COMPONENTS....4779
Front brake pads: Removal - Refitting....4779
Front brake hose: Removal - Refitting....4780
Front brake calliper: Removal - Refitting....4782
Front brake disc: Removal - Refitting....4784
Front brake disc: Description....4785
Front driveshaft hub carrier: Removal - Refitting....4786
Front hub carrier bearing: Removal - Refitting....4790
Spring and front shock absorber: Removal - Refitting....4795
Front driveshaft lower arm: Removal - Refitting....4796
Lower arm rubber bush: Removal - Refitting....4802
Front driveshaft lower arm ball joint: Removal - Refitting....4803
Front driveshaft lower arm ball joint: Check....4804
Front axle sub-frame: Removal - Refitting....4806
Front anti-roll bar: Removal - Refitting....4812
33A-REAR AXLE COMPONENTS....4818
Rear brake pads: Removal - Refitting....4818
Rear brake caliper: Removal - Refitting....4819
Rear brake disc: Removal - Refitting....4820
Rear brake disc: Description....4821
Rear brake lining: Removal - Refitting....4822
Rear brake cylinder: Removal - Refitting....4824
Rear brake drum: Removal - Refitting....4825
Shock absorber: Removal - Refitting....4826
Rear suspension spring: Removal - Refitting....4827
Bearing: Removal - Refitting....4828
Tubular rear axle half suspension arm: Removal - Refitting....4829
Bush, tubular rear axle: Removal - Refitting....4830
Rear axle rubber bearing: Removal - Refitting....4835
Suspension bars: Removal - Refitting....4836
Rear axle mounting: Removal - Refitting....4839
Complete rear axle: Removal - Refitting....4840
Rear anti-roll bar: Removal - Refitting....4846
35A-WHEELS AND TYRES....4849
Wheel: Removal - Refitting....4849
Wheel: Balancing....4852
pneumatic: Precautions for repair....4855
Tyres: Identification....4856
Tyres: Removal - Refitting....4857
Tyres: Repair....4859
Tyre inflation pressure: Identification....4862
Wheel rim: Identification....4863
36A-STEERING ASSEMBLY....4864
Steering rack: Removal - Refitting....4864
Track rod: Removal - Refitting....4867
Axial ball joint linkage: Removal - Refitting....4868
Steering column: Removal - Refitting....4869
Steering rack gaiter: Removal - Refitting....4874
36B-POWER ASSISTED STEERING....4875
Power assisted steering pump: Removal - Refitting....4875
Power assisted steering pump pulley: Removal - Refitting....4882
Power assisted steering pump hub....4883
Power assisted steering pump assembly: Removal - Refitting....4884
37A-MECHANICAL COMPONENT CONTROLS....4886
Master cylinder: Removal - Refitting....4886
Brake servo non-return valve....4888
Brake servo: Removal - Refitting....4889
Vacuum pump: Removal - Refitting....4890
Accelerator pedal: Removal - Refitting....4891
Brake pedal switch: Removal - Refitting....4893
Brake compensator: Removal - Refitting....4895
Brake compensator: Check....4898
Parking brake lever: Check....4899
Parking brake lever: Removal - Refitting....4901
Parking brake lever: Adjusting....4905
Clutch control: List and location of components....4907
Clutch pedal: Removal - Refitting....4908
Clutch pedal position sensor: Removal - Refitting....4912
Clutch circuit: Bleeding....4914
Clutch master cylinder: Removal - Refitting....4920
Clutch circuit: Removal - Refitting....4925
Gear control unit: Removal - Refitting....4927
External gear control: Removal - Refitting....4930
Manual gear shift control: Adjusting....4932
Automatic transmission control unit: Removal - Refitting....4934
Automatic gear control cable: Removal - Refitting....4936
38C-ANTI-LOCK BRAKING SYSTEM....4939
Brake hydraulic assembly: Removal - Refitting....4939
Wheel speed sensor: Removal - Refitting....4943
Yaw speed and transversal acceleration sensor: Removal - Refitting....4946
MR380KANGOO6....4950
61A-HEATING....4952
Cabin filter: Removal - Refitting....4952
Air distribution cable: Removal - Refitting....4953
Air mixing cable: Removal - Refitting....4954
Air distribution unit: Removal - Refitting....4955
Heater matrix: Removal - Refitting....4957
Fan assembly: Removal - Refitting....4958
Passenger compartment fan assembly control unit: Removal - Refitting....4959
Control panel: Removal - Refitting....4960
62A-AIR CONDITIONING....4961
Air conditioning: Precautions for repair....4961
Air conditioning: Parts and consumables for the repair work....4962
Air conditioning: Check....4963
Coolant circuit check....4966
Coolant circuit Draining - Refilling....4967
Condenser: Removal - Refitting....4970
Dehydration canister: Removal - Refitting....4973
Compressor: Removal - Refitting....4975
Expansion valve: Removal - Refitting....4977
Evaporator: Removal - Refitting....4978
Pressure sensor: Removal - Refitting....4983
MR380KANGOO8....4985
80A-BATTERY....4990
Battery: Precautions for repair....4990
Battery : Removal - Refitting....4991
80B-HEADLIGHTS....4993
Halogen headlight: Removal - Refitting....4993
Halogen headlight: Adjustment....4994
Front fog light: Removal - Refitting....4995
Remote headlight adjustment control: Removal - Refitting....4996
Remote headlight adjustment motor: Removal - Refitting....4997
81A-REAR LIGHTING....4998
Rear light on wing: Removal - Refitting....4998
Third brake light: Removal - Refitting....4999
81B-INTERIOR LIGHTING....5000
Courtesy light....5000
81C-FUSES....5002
Consumer cut-out fuse: Identification....5002
Passenger compartment fuse and relay box: Identification....5003
Engine compartment fuse and relay box: Identification....5004
82A-ENGINE IMMOBILISER....5005
Decoder unit: Removal - Refitting....5005
Ignition switch: Removal - Refitting....5006
82B-HORN....5007
Horn: Removal - Refitting....5007
83A-INSTRUMENT PANEL....5008
Instrument panel: Removal - Refitting....5008
83C-ON-BOARD TELEMATICS SYSTEM....5010
Entry level navigation system: Removal - Refitting....5010
83D-CRUISE CONTROL....5011
Switch: Removal - Refitting....5011
84A-CONTROL - SIGNALS....5013
Rotary switch: Removal - Refitting....5013
Wiper switch: Removal - Refitting....5018
Indicator lighting switch: Removal - Refitting....5019
Hazard warning light switch: Removal - Refitting....5020
Heated rear screen switch: Removal - Refitting....5021
Central locking switch: Removal - Refitting....5022
Door mirror controls....5023
External temperature sensor: Removal - Refitting....5024
85A-WIPING - WASHING....5025
Windscreen wiper mechanism: Removal - Refitting....5025
Windscreen wiper motor: Removal - Refitting....5028
Rear screen wiper arm: Removal - Refitting....5030
Rear screen wiper motor: Removal - Refitting....5031
Windscreen washer pump: Removal - Refitting....5033
86A-RADIO....5034
Radio aerial: Removal - Refitting....5034
Offset multimedia socket: Removal - Refitting....5035
86B-CAR PHONE....5036
Pre-equipment: Description....5036
Computer: Removal - Refitting....5037
Hands-free microphone: Removal - Refitting....5040
Telephone control on steering wheel Removal - Refitting....5042
87B-PASSENGER COMPARTMENT CONNECTION UNIT....5046
UCH: Removal - Refitting....5046
87D-ELECTRIC WINDOWS - SUNROOF....5047
Front driver's door electric window switch....5047
Sunroof opening motor Removal - Refitting....5048
88C-AIR BAG AND PRETENSIONERS....5049
Airbag and Pretensioners: Precautions for repair....5049
Airbags and pretensioners: Recycling - Destruction....5050
Airbag computer locking procedure....5052
Computer....5053
Side impact sensor: Removal - Refitting....5055
Front buckle pretensioner: Removal - Refitting....5056
Driver's front airbag: Removal - Refitting....5058
Passenger front airbag: Removal - Refitting....5060
Front (chest) side airbag: Removal - Refitting....5062
Inhibitor switch: Removal - Refitting....5065
MR381....5066
MR381KANGOO0....5067
General Vehicle Information....5068
Contents....5068
01C-VEHICLE BODYWORK SPECIFICATIONS....5069
Opening clearances....5069
02B-BODYWORK INNOVATIONS....5071
Front end panel....5071
05B-BODYWORK EQUIPMENT AND TOOLS....5072
Special tools....5072
MR381KANGOO4....5073
40A-GENERAL INFORMATION....5075
Body: Transformation....5075
42A-UPPER FRONT STRUCTURE....5077
Front wing: Conversion....5077
Front panel side support: Description....5078
Front: Description....5081
44A-REAR UPPER STRUCTURE....5083
Quarter panel lining: Conversion....5083
47A-SIDE OPENING ELEMENTS....5086
Sliding side door: Conversion....5086
48A-NON-SIDE OPENING ELEMENTS....5087
Bonnet: Replacement....5087
MR381KANGOO5....5090
51A-SIDE OPENING ELEMENT MECHANISMS....5093
Front side door lock: Removal - Refitting....5093
Sliding side door lock: Removal - Refitting....5094
Front side door lock barrel: Removal - Refitting....5095
Interior door handle on front side door: Removal - Refitting....5096
Door exterior handle: Removal - Refitting....5097
Sliding side door opening controls: Removal - Refitting....5098
Front side door manual window winder: Removal - Refitting....5099
Front side door window winder handle: Removal - Refitting....5100
Sliding side door tracks: Removal - Refitting....5101
Sliding side door carriage: Adjusting....5103
52A-NON-SIDE OPENING ELEMENT MECHANISMS....5105
Loading door lock: Removal - Refitting....5105
Rear loading door exterior handle: Removal - Refitting....5106
Tailgate exterior opening control: Removal - Refitting....5107
Rear screen wiper motor: Removal - Refitting....5108
Roof flap cross member: Removal - Refitting....5110
Sunroof operating mechanism: Removal - Refitting....5111
Sunroof deflector: Removal - Refitting....5119
Sunroof lining: Removal - Refitting....5120
Sunroof opening motor Removal - Refitting....5121
54A-WINDOWS....5122
Windscreen: Removal - Refitting....5122
Sliding window in front side door: Removal - Refitting....5124
Sliding side door window: Removal - Refitting....5125
Side panel window: Removal - Refitting....5126
Fixed roof window: Removal - Refitting....5129
Rear screen glass: Removal - Refitting....5131
55A-EXTERIOR PROTECTION....5133
Front bumper: Removal - Refitting....5133
Front bumper: Stripping - Rebuilding....5134
Rear bumper: Removal - Refitting....5136
Side protective strip: Removal - Refitting....5137
Roof protective strip: Removal - Refitting....5140
Rear loading door strip: Removal - Refitting....5142
56A-EXTERIOR ACCESSORIES....5144
Radiator grille: Removal - Refitting....5144
Scuttle panel grille: Removal - Refitting....5145
Door mirror: Removal - Refitting....5146
Door mirror casing: Removal - Refitting....5147
Door mirror glass: Removal - Refitting....5148
Front wing extender: Removal - Refitting....5149
Sill panel protective strip: Removal - Refitting....5150
57A-INTERIOR ACCESSORIES....5151
Centre console: Removal - Refitting....5151
Dashboard: Removal - Refitting....5152
Dashboard: Conversion....5159
Rear side parcel shelf: Removal - Refitting....5160
Rear storage compartment: Removal - Refitting....5161
Separating components: Removal - Refitting....5162
59A-SAFETY ACCESSORIES....5175
Front seat belt: Removal - Refitting....5175
Rear seat belt: Removal - Refitting....5176
Rear centre seat belt: Removal - Refitting....5177
MR381KANGOO6....5178
65A-OPENING ELEMENT SEALING....5180
Side door double seal....5180
Tailgate seal....5181
66A-WINDOW SEALING....5182
Sliding side door tilting window seal....5182
MR381KANGOO7....5183
71A-BODY INTERIOR TRIM....5186
B-pillar trim: Removal - Refitting....5186
Front door sill lining: Removal - Refitting....5187
Front upperbody trim: Removal - Refitting....5188
Centre floor front carpet: Removal - Refitting....5190
Rear panel trim: Removal - Refitting....5191
Rear wheel arch lining: Removal - Refitting....5192
Headlining: Removal - Refitting....5193
72A-SIDE OPENING ELEMENT LINING....5195
Front side door trim: Removal - Refitting....5195
Sliding side door trim: Removal - Refitting....5196
73A-NON-SIDE OPENING ELEMENT LINING....5197
Left-hand rear loading door trim: Removal - Refitting....5197
Sunroof outer fabric: Removal - Refitting....5198
75A-FRONT SEAT FRAMES AND RUNNERS....5200
Complete front seat: Removal - Refitting....5200
Front seat runner: Removal - Refitting....5201
76A-REAR SEAT FRAMES AND RUNNERS....5202
Complete rear bench seat: Removal - Refitting....5202
77A-FRONT SEAT TRIM....5203
Front seat base trim: Removal - Refitting....5203
Front seatback trim: Removal - Refitting....5204
Front seat foldable seatback trim: Removal - Refitting....5206
Heated seat cover: Removal - Refitting....5207
78A-REAR SEAT LINING....5208
1/3 and 2/3 rear bench seat trim: Removal - Refitting....5208
1/3 and 2/3 rear bench seat seatback trim: Removal - Refitting....5209
79A-SEAT ACCESSORIES....5212
Seatback tray: Removal - Refitting....5212
Front armrest: Removal - Refitting....5213
MR417....5214
MR417KANGOO0....5215
01A-VEHICLE MECHANICAL SPECIFICATIONS....5217
Vehicle: Specifications....5217
01C-VEHICLE BODYWORK SPECIFICATIONS....5220
Vehicle: Identification....5220
Vehicle clearances: Adjustment values....5222
01D-MECHANICAL INTRODUCTION....5236
Vehicle: Precautions for repair....5236
Tightening torques: General information....5238
02A-LIFTING EQUIPMENT....5242
Vehicle: Towing and lifting....5242
03B-COLLISION....5246
Damaged vehicle: Collision fault finding....5246
Vehicle damaged at front: Description....5248
Vehicle damaged at side: Description....5250
Vehicle damaged at rear: Description....5254
04B-CONSUMABLES - PRODUCTS....5258
Vehicle: Parts and ingredients for the repairwork....5258
04E-PAINT....5266
Colour code: Specifications....5266
MR417KANGOO1....5267
10A-ENGINE AND CYLINDER BLOCK ASSEMBLY....5274
Crankshaft seal at timing end Removal - Refitting....5274
Crankshaft seal at gearbox end : Removal - Refitting....5279
Sump: Removal - Refitting....5284
Conrod bearing shell: Removal - Refitting....5303
Engine oil: Draining - Refilling....5311
Oil filter: Removal - Refitting....5318
Exchanger: Removal - Refitting....5324
Oil pressure sensor: Removal - Refitting....5327
Oil level sensor: Removal - Refitting....5330
Oil pump: Removal - Refitting....5332
Oil pressure: Check....5336
Multifunction support: Removal - Refitting....5342
Engine/gearbox assembly: Removal - Refitting....5351
Flywheel: Removal - Refitting....5376
Drive plate: Removal - Refitting....5384
11A-TOP AND FRONT OF ENGINE....5386
Final compression pressure: Check....5386
Accessories belt: Removal - Refitting....5392
Crankshaft accessories pulley: Removal - Refitting....5403
Dummy pulley for accessories: Removal - Refitting....5411
Timing belt: Removal - Refitting....5415
Rocker cover: Removal - Refitting....5450
Camshaft: Removal - Refitting....5468
Cylinder head: Removal - Refitting....5474
Camshaft seal at timing end: Removal - Refitting....5513
Oil decanter: Removal - Refitting....5523
12A-FUEL MIXTURE....5525
Air resonator: Removal - Refitting....5525
Air filter: Removal - Refitting....5526
Air filter unit: Removal - Refitting....5531
Air flowmeter: Removal - Refitting....5538
Air inlet flap: Removal - Refitting....5539
Throttle valve: Removal - Refitting....5541
Throttle valve: Cleaning....5544
Inlet manifold: Removal - Refitting....5546
Injector holder shim: Removal - Refitting....5555
Exhaust manifold: Removal - Refitting....5557
12B-TURBOCHARGING....5568
Turbocharging: Precautions for repair....5568
Turbocharger: Removal - Refitting....5571
Turbocharger oil pipe: Removal - Refitting....5579
Intercooler: Removal - Refitting....5580
Turbocharger outlet exhaust gas duct: Removal - Refitting....5583
13A-FUEL SUPPLY....5585
Fuel circuit: Operating diagram....5585
Manual priming pump: Removal - Refitting....5586
Fuel filter: Removal - Refitting....5588
Particle filter injector fuel filter: Removal - Refitting....5592
Injector rail - Injectors: Removal - Refitting....5594
Electric diesel fuel heater: Removal - Refitting....5601
Fuel pressure: check....5603
Fuel flow: check....5607
13B-DIESEL INJECTION....5613
Diesel injection: Precautions for repair....5613
Diesel injection: List and location of components....5620
Diesel injection computer: Removal - Refitting....5642
Camshaft position sensor: Removal - Refitting....5644
Crankshaft position sensor: Removal - Refitting....5651
Leak flow from high-pressure pump: Check....5652
High pressure pump: Removal - Refitting....5656
Fuel flow actuator: Removal - Refitting....5678
Venturi: Removal - Refitting....5683
Diesel injector fuel return rail: Removal - Refitting....5688
High pressure pipe: Checking....5693
High-pressure pipe between the pump and rail: Removal - Refitting....5698
High-pressure pipe between the rail and injector: Removal - Refitting....5712
Injector rail: Removal - Refitting....5730
Rail pressure sensor: Removal - Refitting....5745
Fuel temperature sensor: Removal - Refitting....5748
Leak flow from injectors: Check....5753
Diesel injector: Removal - Refitting....5766
Accelerometer: Removal - Refitting....5775
Flow regulation solenoid valve: Removal - Refitting....5781
Pressure regulation solenoid valve: Removal - Refitting....5782
13C-PREHEATING....5783
Pre/postheating unit: Removal - Refitting....5783
Heater plugs Removal - Refitting....5784
14A-ANTIPOLLUTION....5792
Oil vapour rebreathing system: Description....5792
Oil vapour rebreathing system: Operating diagram....5794
Fuel vapour recirculation circuit: Operating diagram....5795
Fuel vapour recirculation circuit: check....5796
Fuel vapour canister: Removal - Refitting....5797
Fuel vapour canister:Checking....5799
Exhaust gas recirculation solenoid valve: Removal - Refitting....5800
Intercooler: Removal - Refitting....5804
Exhaust gas recirculation mounting: Removal - Refitting....5811
Exhaust gas recirculation assembly: Removal - Refitting....5812
Exhaust gas recirculation rigid pipe: Removal - Refitting....5821
16A-STARTING - CHARGING....5825
Alternator: Removal - Refitting....5825
Starter: Removal - Refitting....5834
17A-IGNITION....5843
Ignition: Specifications....5843
Coils Removal - Refitting....5844
Spark plugs: Removal - Refitting....5848
17B-PETROL INJECTION....5851
Fuel injection: List and location of components....5851
Oxygen sensors: Removal - Refitting....5859
Petrol injection computer: Removal - Refitting....5863
Crankshaft position sensor: Removal - Refitting....5866
Pinking sensor: Removal - Refitting....5868
19A-COOLING....5869
Engine cooling circuit: Specifications....5869
Engine cooling circuit: check....5870
Engine cooling circuit: List and location of components....5872
Cooling circuit: Draining - Refilling....5874
Cooling radiator: Removal - Refitting....5882
Water pump: Removal - Refitting....5897
Thermostat: Removal - Refitting....5909
Plenum chamber: Removal - Refitting....5913
Engine cooling fan assembly: Removal - Refitting....5919
Thermoplunger unit: Removal - Refitting....5927
Water pump inlet pipe: Removal - Refitting....5929
Expansion bottle: Removal - Refitting....5933
Coolant temperature sensor: Removal - Refitting....5941
19B-EXHAUST....5946
Exhaust: List and location of components....5946
Exhaust: Precautions for repair....5958
Catalytic pre-converter: Removal - Refitting....5962
Catalytic converter: Removal - Refitting....5967
Expansion chamber: Removal - Refitting....5977
Connector pipe: Removal - Refitting....5979
Silencer: Removal - Refitting....5981
Particle filter: Parts description....5983
Particle filter: Removal - Refitting....5985
Particle filter: Cleaning....5992
Exhaust gas temperature sensor: Removal - Refitting....5994
Particle filter pressure sensor: Removal - Refitting....5998
Particle filter temperature sensors: Removal - Refitting....6003
Exhaust fuel injector: Removal - Refitting....6009
Exhaust fuel injector cooler: Removal - Refitting....6014
Connecting hose: Removal - Refitting....6018
19C-TANK....6022
Fuel tank: Draining....6022
Fuel tank: Removal - Refitting....6027
Filler neck: Removal - Refitting....6041
Fuel level sensor module: Removal - Refitting....6043
19D-ENGINE MOUNTING....6045
Left-hand suspended engine mounting: Removal - Refitting....6045
Right-hand suspended engine mounting: Removal - Refitting....6058
Lower engine tie-bar: Removal - Refitting....6069
MR417KANGOO2....6075
20A-CLUTCH....6078
Clutch: Precautions for repair....6078
Clutch: Specifications....6079
Mechanism / Disk: Removal - Refitting....6081
Clutch thrust bearing: Removal - Refitting....6089
21A-MANUAL GEARBOX....6094
Manual gearbox oil: Specifications....6094
Manual gearbox oil: Draining - Refilling....6095
Differential output seal: Removal - Refitting....6099
Manual gearbox: Removal - Refitting....6107
Reverse gear switch: Removal - Refitting....6124
23A-AUTOMATIC GEARBOX....6126
Automatic gearbox: Precautions for repair....6126
Automatic gearbox: Identification....6127
Automatic gearbox: Specifications....6128
Automatic gearbox: List and location of components....6129
Automatic gearbox: Removal - Refitting....6131
Automatic gearbox oil: Draining - Refilling....6138
Hydraulic distributor: Removal - Refitting....6142
Hydraulic distribution wiring: Removal - Refitting....6147
Flow regulation solenoid valve: Removal - Refitting....6150
Hydraulic distributor solenoid valves: Removal - Refitting....6152
Gearbox oil cooler: Removal - Refitting....6154
Differential output seal: Removal - Refitting....6156
Multifunction switch: Removal - Refitting....6158
Multifunction switch: Adjusting....6161
Speed sensor: Removal - Refitting....6162
Pressure sensor: Removal - Refitting....6165
Automatic gearbox converter: Removal - Refitting....6168
Converter seal: Removal - Refitting....6170
Automatic transmission connector: Removal - Refitting....6172
Automatic transmission computer: Removal - Refitting....6174
29A-DRIVESHAFTS....6175
Front left-hand wheel driveshaft: Removal - Refitting....6175
Front right-hand wheel driveshaft: Removal - Refitting....6178
Relay shaft bearing: Removal - Refitting....6181
Front driveshaft gaiter on wheel side: Removal - Refitting....6182
Front right-hand driveshaft gaiter on gearbox side: Removal - Refitting....6186
Front left-hand driveshaft gaiter on gearbox side: Removal - Refitting....6189
MR417KANGOO3....6192
30A-GENERAL INFORMATION....6196
Brake circuit Operating diagram....6196
Brake circuit Precautions for repair....6197
Brake circuit Bleeding....6199
Brake circuit Tightening torque....6201
Rigid brake pipe: Repair....6204
Brake fluid: Specifications....6209
Brake: Specifications....6210
Steering: Tightening torque....6211
Axle assemblies: Check....6213
Underbody height: Adjustment values....6214
Front axle: Tightening torque....6217
Front axle: Adjustment values....6220
Front axle: Adjusting....6222
Rear axle: Tightening torque....6223
Rear axle: Adjustment values....6224
31A-FRONT AXLE COMPONENTS....6226
Front axle assemblies: Precautions for repair....6226
Front brake pads: Removal - Refitting....6228
Front brake hose: Removal - Refitting....6230
Front brake calliper: Removal - Refitting....6232
Front brake calliper: Repair....6234
Front brake calliper support: Removal - Refitting....6236
Front brake disc shield: Removal - Refitting....6238
Front brake disc: Removal - Refitting....6241
Front brake disc: Description....6243
Front driveshaft hub carrier: Removal - Refitting....6244
Front hub carrier bearing: Removal - Refitting....6247
Spring and front shock absorber: Removal - Refitting....6251
Front driveshaft lower arm: Removal - Refitting....6256
Front driveshaft lower arm ball joint: Check....6257
Front axle sub-frame: Removal - Refitting....6258
Front anti-roll bar: Removal - Refitting....6262
33A-REAR AXLE COMPONENTS....6263
Rear axle assemblies: Precautions for repair....6263
Rear brake pads: Removal - Refitting....6265
Rear brake hose: Removal - Refitting....6268
Rear brake caliper: Removal - Refitting....6270
Brake calipers: Repair....6272
Rear brake calliper mounting: Removal - Refitting....6274
Rear brake disc shield: Removal - Refitting....6276
Rear brake disc: Removal - Refitting....6278
Rear brake disc: Description....6280
Rear brake lining: Removal - Refitting....6281
Rear brake cylinder: Removal - Refitting....6284
Rear brake drum: Removal - Refitting....6286
Rear brake drum: Description....6288
Shock absorber: Removal - Refitting....6289
Rear suspension spring: Removal - Refitting....6291
Rear drum bearing: Removal - Refitting....6293
Rear stub-axle carrier: Removal - Refitting....6295
Rear axle rubber bearing: Removal - Refitting....6297
Complete rear axle: Removal - Refitting....6301
35A-WHEELS AND TYRES....6305
Wheel: Removal - Refitting....6305
Wheel: Balancing....6308
pneumatic: Precautions for repair....6311
Tyres: Identification....6312
Tyres: Removal - Refitting....6313
Tyres: Repair....6315
Tyre inflation pressure: Identification....6318
Wheel rim: Identification....6319
Emergency spare wheel carrier: Removal - Refitting....6320
36A-STEERING ASSEMBLY....6322
Steering: List and location of components....6322
Steering: Precautions for repair....6323
Steering rack: Removal - Refitting....6325
Track rod: Removal - Refitting....6327
Axial ball joint linkage: Removal - Refitting....6329
Steering column: Removal - Refitting....6332
Steering rack gaiter: Removal - Refitting....6337
Steering wheel: Removal - Refitting....6339
37A-MECHANICAL COMPONENT CONTROLS....6341
Master cylinder: Removal - Refitting....6341
Brake servo non-return valve: Removal - Refitting....6344
Brake servo: Removal - Refitting....6346
Vacuum pump: Removal - Refitting....6350
Accelerator pedal: Removal - Refitting....6351
Brake pedal: Removal - Refitting....6352
Brake pedal switch: Removal - Refitting....6354
Brake compensator: Removal - Refitting....6356
Brake compensator: Check....6358
Brake compensator: Adjustment....6362
Parking brake lever: Removal - Refitting....6363
Parking brake lever: Adjusting....6364
Braking assistance circuit: Check....6365
Clutch pedal: Removal - Refitting....6368
Clutch pedal position sensor: Removal - Refitting....6369
Clutch circuit: Bleeding....6371
Clutch master cylinder: Removal - Refitting....6377
Clutch circuit: Removal - Refitting....6383
Manual gearbox selector cable: Removal - Refitting....6387
Automatic gear control cable: Removal - Refitting....6393
Automatic gear control cable: Adjusting....6395
Gear control unit: Removal - Refitting....6397
Gear control unit: Adjusting....6400
Parking brake cables: Removal - Refitting....6402
38C-ANTI-LOCK BRAKING SYSTEM....6403
ABS system: List and location of components....6403
ABS system: Precautions for repair....6406
Brake hydraulic assembly: Removal - Refitting....6407
Front wheel speed sensor: Removal - Refitting....6411
Rear wheel speed sensor: Removal - Refitting....6413
Yaw speed and transversal acceleration sensor: Removal - Refitting....6415
MR417KANGOO6....6417
61A-HEATING....6420
Heating: List and location of components....6420
Cabin filter: Removal - Refitting....6424
C-pillar intermediate air distribution duct: Removal - Refitting....6430
Rear air distribution duct: Removal - Refitting....6432
Front side air distribution duct: Removal - Refitting....6434
A-pillar air distribution duct: Removal - Refitting....6435
Recirculation control cable: Removal - Refitting....6437
Air distribution cable: Removal - Refitting....6440
Air mixing cable: Removal - Refitting....6442
Air distribution unit: Removal - Refitting....6444
Heater matrix: Removal - Refitting....6450
Fan assembly: Removal - Refitting....6457
Fan assembly: Cleaning....6460
Heating resistor unit: Removal - Refitting....6461
Passenger compartment fan assembly control unit: Removal - Refitting....6463
Control panel: Removal - Refitting....6466
Recirculation motor: Removal - Refitting....6468
Mixer motor: Removal - Refitting....6471
Distribution motor: Removal - Refitting....6474
Passenger compartment temperature sensor: Removal - Refitting....6477
External temperature sensor: Removal - Refitting....6479
Insolation sensor: Removal - Refitting....6480
62A-AIR CONDITIONING....6481
Air conditioning: Precautions for repair....6481
Air conditioning: Parts and consumables for the repair work....6482
Air conditioning: List and location of components....6483
Air conditioning: Check....6484
Coolant circuit check....6487
Coolant circuit Draining - Refilling....6488
Condenser: Removal - Refitting....6491
Dehydration canister: Removal - Refitting....6494
Compressor: Removal - Refitting....6496
Expansion valve: Removal - Refitting....6499
Evaporator: Removal - Refitting....6500
Evaporator: Cleaning....6502
Condenser - evaporator connecting pipe: Removal - Refitting....6503
Dehydration canister - evaporator connecting pipe: Removal - Refitting....6509
Dehydration canister - compressor connecting pipe: Removal - Refitting....6514
Condenser - compressor connecting pipe: Removal - Refitting....6517
MR417KANGOO8....6521
80A-BATTERY....6527
Battery: Precautions for repair....6527
Battery : Removal - Refitting....6528
Battery tray: Removal - Refitting....6531
80B-HEADLIGHTS....6532
Headlight: List and location of components....6532
Front headlight: Removal - Refitting....6534
Front headlight: Adjusting....6536
Halogen bulb: Removal - Refitting....6538
Remote headlight adjustment motor: Removal - Refitting....6542
Front fog light: Removal - Refitting....6544
Side indicator: Removal - Refitting....6545
81A-REAR LIGHTING....6546
Rear light on wing: Removal - Refitting....6546
Rear light bulb: Removal - Refitting....6548
3rd brake light: Removal - Refitting....6550
High level brake light bulb: Removal - Refitting....6552
Rear fog lights: Removal - Refitting....6554
Number plate light: Removal - Refitting....6555
81B-INTERIOR LIGHTING....6556
Interior lights: List and location of components....6556
Headlining light: Removal - Refitting....6558
Luggage compartment light: Removal - Refitting....6562
81C-FUSES....6566
Fuses: List and location of components....6566
82A-ENGINE IMMOBILISER....6568
Immobiliser system: List and location of components....6568
Ignition switch: Removal - Refitting....6569
Transponder ring: Removal - Refitting....6571
82B-HORN....6572
Horn: Removal - Refitting....6572
83A-INSTRUMENT PANEL....6573
Instrument panel: Removal - Refitting....6573
83C-ON-BOARD TELEMATICS SYSTEM....6574
Navigation: List and location of components....6574
Multimedia network interface unit: Removal - Refitting....6576
Navigation screen: Removal - Refitting....6578
83D-CRUISE CONTROL....6580
Cruise control / speed limiter: List and location of components....6580
Switch: Removal - Refitting....6581
Steering wheel switch: Removal - Refitting....6583
84A-CONTROL - SIGNALS....6584
Steering wheel controls assembly: Removal - Refitting....6584
Wiper switch: Removal - Refitting....6586
Indicator lighting switch: Removal - Refitting....6588
Hazard warning lights switch and central locking: Removal - Refitting....6590
ESP inhibitor switch: Removal - Refitting....6591
Remote headlight adjustment control: Removal - Refitting....6593
Door mirror control switch: Removal - Refitting....6595
85A-WIPING - WASHING....6596
Wipers and washer: List and location of components....6596
Windscreen wiper blade: Removal - Refitting....6599
Windscreen wiper arm: Removal - Refitting....6601
Windscreen wiper mechanism: Removal - Refitting....6603
Windscreen wiper motor: Removal - Refitting....6605
Rear screen wiper blade: Removal - Refitting....6609
Rear screen wiper arm: Removal - Refitting....6610
Rear screen wiper motor: Removal - Refitting....6614
Rain and light sensor: Removal - Refitting....6618
Windscreen washer pump: Removal - Refitting....6621
Windscreen washer bottle: Removal - Refitting....6622
Windscreen washer bottle funnel: Removal - Refitting....6623
86A-RADIO....6624
Audio equipment: List and location of components....6624
Car radio: Removal - Refitting....6628
Radio aerial: Removal - Refitting....6629
Tweeter: Removal - Refitting....6630
Front speakers: Removal - Refitting....6631
Rear speakers: Removal - Refitting....6632
Display: Removal - Refitting....6633
86B-CAR PHONE....6635
Mobile phone: List and location of components....6635
Computer: Removal - Refitting....6636
Hands-free microphone: Removal - Refitting....6637
87B-PASSENGER COMPARTMENT CONNECTION UNIT....6639
UCH: Removal - Refitting....6639
87C-OPENING ELEMENT MANAGEMENT....6641
Lock motor for the fuel filling compartment: Removal - Refitting....6641
87D-ELECTRIC WINDOWS - SUNROOF....6643
Electric window: List and location of components....6643
Front electric window switches on driver's door Removal - Refitting....6645
Front electric window switch on the passenger door: Removal - Refitting....6646
Rear electric window switch: Removal - Refitting....6647
87F-PARKING DISTANCE CONTROL....6648
Parking proximity sensor: List and location of components....6648
Parking proximity sensor switch: Removal - Refitting....6650
Parking proximity sensor buzzer: Removal - Refitting....6652
Proximity radar Removal - Refitting....6653
Parking proximity sensor computer: Removal - Refitting....6654
87G-ENGINE COMPARTMENT CONNECTION UNIT....6657
Protection and Switching Unit: Removal - Refitting....6657
88A-WIRING HARNESS....6661
Computers List and location of components....6661
Diagnostic socket: List and location of components....6662
Wiring: Precautions for repair....6663
Front bumper wiring: Connector opening....6664
Front bumper wiring: Removal - Refitting....6665
Engine harness: Removal - Refitting....6667
Dashboard wiring harness: Connector opening....6704
Dashboard wiring harness: Removal - Refitting....6713
Driver's front side door wiring: Removal - Refitting....6729
Passenger's front side door wiring: Removal - Refitting....6732
Rear right-hand side door wiring: Removal - Refitting....6735
Rear left-hand side door wiring: Removal - Refitting....6738
Rear wiring: Connector opening....6741
Rear wiring: Removal - Refitting....6754
Rear bumper wiring: Connector opening....6776
Rear bumper wiring: Removal - Refitting....6777
88C-AIR BAG AND PRETENSIONERS....6779
Airbag and Pretensioners: List and location of components....6779
Airbag and Pretensioners: Precautions for repair....6783
Airbags and pretensioners: Recycling - Destruction....6784
Airbag computer: Removal - Refitting....6786
Driver's front airbag: Removal - Refitting....6789
Passenger front airbag: Removal - Refitting....6791
Front (chest) side airbag: Removal - Refitting....6794
Side curtain airbag: Removal - Refitting....6796
Side impact sensor: Removal - Refitting....6800
Inhibitor switch: Removal - Refitting....6803
Front seat belt buckle: Removal - Refitting....6804
Rear seat belt buckle: Removal - Refitting....6807
Front side seat belt: Removal - Refitting....6810
Rear side seat belt: Removal - Refitting....6812
Rear centre seat belt: Removal - Refitting....6814
88D-DRIVER'S POSITION....6816
Electrical accessories socket: Removal - Refitting....6816
Cigarette lighter: Removal - Refitting....6817
MR418....6818
MR418KANGOO0....6819
01A-VEHICLE MECHANICAL SPECIFICATIONS....6821
Vehicle: Specifications....6821
01C-VEHICLE BODYWORK SPECIFICATIONS....6824
Vehicle: Identification....6824
Vehicle clearances: Adjustment values....6826
01D-MECHANICAL INTRODUCTION....6840
Vehicle: Precautions for repair....6840
Tightening torques: General information....6842
02A-LIFTING EQUIPMENT....6846
Vehicle: Towing and lifting....6846
03B-COLLISION....6850
Damaged vehicle: Collision fault finding....6850
Vehicle damaged at front: Description....6852
Vehicle damaged at side: Description....6854
Vehicle damaged at rear: Description....6858
04B-CONSUMABLES - PRODUCTS....6862
Vehicle: Parts and ingredients for the repairwork....6862
04E-PAINT....6870
Colour code: Specifications....6870
MR418KANGOO4....6871
40A-GENERAL INFORMATION....6876
Vehicle on repair bench: Description....6876
Sub-frame: Specifications....6879
Hollow body parts inserts: List and location of components....6884
Earths on the body: List and location of components....6887
Vehicle front section structure: Description....6890
Vehicle side section structure: Description....6892
Vehicle central section structure: Description....6894
Vehicle structure rear section: Description....6895
Vehicle removable section structure: Description....6897
Structure components to be positioned on body repair bench: Description....6899
41A-FRONT LOWER STRUCTURE....6904
Front impact cross member: General description....6904
Front impact cross member: Removal - Refitting....6905
Radiator support cross member: General description....6906
Radiator support cross member: Removal - Refitting....6907
Radiator cross member support: Description....6909
Front side member: General description....6911
Front side member: Description....6914
Front side member closure panel: General description....6918
Front side member closure panel: Description....6920
Battery tray support: General description....6923
Battery tray support: Description....6924
Front mounting of front sub-frame: General description....6926
Front mounting of front sub-frame: Description....6927
Sub-frame rear mounting: General description....6929
Sub-frame rear mounting: Description....6930
Engine mounting: General description....6932
Engine mounting: Description....6933
Front half unit: General description....6935
Front half unit: Description....6936
41B-CENTRE LOWER STRUCTURE....6939
Centre floor, side section: General description....6939
Central floor, side section: Description....6941
Centre floor reinforcement: Description....6944
Centre floor front lateral cross member: Description....6946
41C-SIDE LOWER STRUCTURE....6948
Sill panel: General description....6948
Sill panel: Description....6951
Sill panel closure panel: General description....6962
Sill panel closure panel, front section: Description....6963
Inner sill panel rear section: Description....6969
Sill panel reinforcement: Description....6971
Sill panel rear reinforcement: Description....6975
Sill pane stiffener: Description....6977
41D-REAR LOWER STRUCTURE....6979
Rear floor: General description....6979
Rear floor: Description....6980
Rear floor, front section: General description....6982
Rear floor, front section: Description....6984
Rear floor stiffener: Description....6986
Rear side member: General description....6988
Rear side member: Description....6991
Rear impact cross member mounting reinforcement: Description....6994
Rear floor centre cross member: Description....6995
Rear end lower cross member: Description....6996
Far rear lower cross member, side section: Description....6998
Front cross member under rear seat: Description....6999
Tank mounting support: Description....7000
Rear impact lower cross member: General description....7001
Rear impact lower cross member: Removal - Refitting....7002
42A-FRONT UPPER STRUCTURE....7003
Front wing: General description....7003
Front wing: Removal - Refitting....7005
Front wing: Adjusting....7007
Front: General description....7010
Front: Removal - Refitting....7011
Scuttle side panel: General description....7012
Cowl side panel: Description....7014
Scuttle side panel upper reinforcement: General description....7017
Scuttle side panel upper reinforcement: Description....7018
Front wheel arch: General description....7020
Front wheel arch: Description....7021
Windscreen aperture lower cross member: General description....7023
Windscreen aperture lower cross member: Description....7024
Dashboard cross member: Removal - Refitting....7025
43A-SIDE UPPER STRUCTURE....7028
A-pillar: Description....7028
A-pillar reinforcement: Description....7032
Windscreen pillar lining: Description....7034
A-pillar lining stiffener: Description....7035
B-pillar: Description....7036
B-pillar reinforcement: General description....7042
B-pillar reinforcement: Description....7043
Body side: General description....7047
Body side: Description....7049
44A-REAR UPPER STRUCTURE....7051
Rear side panel: General description....7051
Rear side panel: Description....7052
Rear section of rear side panel: Description....7078
Rear side panel rain channel: General description....7084
Rear side panel rain channel: Description....7085
Far rear pillar: General description....7088
Far rear pillar: Description....7089
Inner wheel arch: Description....7092
Body side rear lining: Description....7094
Rear end panel: Description....7112
45A-TOP OF BODY....7113
Roof: General description....7113
Roof: Description....7114
Roof front section: Description....7117
Roof rear section: Description....7118
Roof front cross member: Description....7119
Roof centre cross member: Description....7120
Roof panel arch: Description....7121
Roof rear cross member: Description....7122
47A-SIDE OPENING ELEMENTS....7124
Front side door: Removal - Refitting....7124
Front side door: Stripping - Restoring....7127
Front side door: Adjustment....7129
Rear side door: Removal - Refitting....7131
Rear side door: Stripping - Restoring....7135
Rear side door: Adjustment....7137
48A-NON-SIDE OPENING ELEMENTS....7140
Bonnet: Removal - Refitting....7140
Bonnet: Stripping - Rebuilding....7142
Bonnet: Adjustment....7143
Tailgate: Removal - Refitting....7146
Tailgate: Stripping-Rebuilding....7149
Tailgate: Adjusting....7150
Rear loading door: Removal - Refitting....7153
Rear loading door: Stripping - Rebuilding....7159
Rear loading door: Adjustment....7165
Upper rear opening element: Stripping - Rebuilding....7173
Upper rear opening element: Removal - Refitting....7175
MR418KANGOO5....7180
50A-GENERAL INFORMATION....7184
Pair of unclipping pliers: Use....7184
51A-SIDE OPENING ELEMENT MECHANISMS....7186
Front side door lock: Removal - Refitting....7186
Front side door lock barrel: Removal - Refitting....7188
Door exterior handle: Removal - Refitting....7189
Front side door electric window mechanism: Removal - Refitting....7191
Rear side door electric window mechanism: Removal - Refitting....7193
Front side door manual window winder mechanism: Removal - Refitting....7194
Sliding side door tracks: Removal - Refitting....7196
Sliding side door carriage: Removal - Refitting....7201
Sliding side door lock: Removal - Refitting....7204
Sliding side door opening controls: Removal - Refitting....7206
Fuel filling compartment mechanism: Removal - Refitting....7209
52A-NON-SIDE OPENING ELEMENT MECHANISMS....7211
Bonnet release handle: Removal - Refitting....7211
Bonnet latch: Removal - Refitting....7212
Loading door lock: Removal - Refitting....7213
Rear loading door exterior handle: Removal - Refitting....7218
Tailgate lock: Removal - Refitting....7220
Upper rear opening element lock: Removal - Refitting....7221
Upper rear opening element mechanism: Removal - Refitting....7223
Upper rear opening element rail: Removal - Refitting....7229
Tailgate balancer: Removal - Refitting....7231
Upper rear opening element strut: Removal - Refitting....7232
Rear opening element electric window mechanism: Removal - Refitting....7234
Tailgate exterior opening control: Removal - Refitting....7236
Sunroof opening control: Removal - Refitting....7237
Rear loading door stop: Removal - Refitting....7238
Sunroof operating mechanism: Removal - Refitting....7239
Sunroof moving panel: Removal - Refitting....7242
54A-WINDOWS....7243
Windscreen: Removal - Refitting....7243
Sliding window in front side door: Removal - Refitting....7245
Sliding window in rear side door: Removal - Refitting....7247
Quarter panel light....7248
Rear side door fixed window: Removal - Refitting....7249
Sliding side door window: Removal - Refitting....7251
Rear screen: Removal - Refitting....7252
Opening rear screen: Adjusting....7253
Rear loading door window: Removal - Refitting....7255
Fixed roof window: Removal - Refitting....7260
55A-EXTERIOR PROTECTION....7264
Front bumper: Removal - Refitting....7264
Front bumper: Stripping - Rebuilding....7266
Rear bumper: Removal - Refitting....7270
Rear bumper: Stripping-Rebuilding....7272
Front side door strip: Removal - Refitting....7275
Rear side door strip: Removal - Refitting....7277
Rear loading door strip: Removal - Refitting....7278
Front side door moulding: Removal - Refitting....7280
Rear wing protective strip: Removal - Refitting....7281
Front wheel arch liner: Removal - Refitting....7282
Rear side door moulding: Removal - Refitting....7283
Rear wheel arch liner: Removal - Refitting....7284
56A-EXTERIOR EQUIPMENT....7285
Scuttle panel grille: Removal - Refitting....7285
Scoop under scuttle panel grille: Removal - Refitting....7286
Door mirror: Removal - Refitting....7288
Door mirror casing: Removal - Refitting....7289
Door mirror glass: Removal - Refitting....7290
Rear badges: Removal - Refitting....7291
Roof rack bar: Removal - Refitting....7293
Upper rear opening element strip: Removal - Refitting....7295
57A-INTERIOR EQUIPMENT....7297
Dashboard: Removal - Refitting....7297
Lower section of dashboard trim: Removal - Refitting....7300
Dashboard air vent: Removal - Refitting....7302
Centre front panel: Removal - Refitting....7303
Glovebox: Removal - Refitting....7305
Dashboard glovebox: Removal - Refitting....7307
Centre console: Removal - Refitting....7309
Floor flap and storage: Removal - Refitting....7311
Interior rear-view mirror Removal - Refitting....7312
Sun visor: Removal - Refitting....7314
Grab handle: Removal - Refitting....7315
Front storage compartment under roof: Removal - Refitting....7316
Rear storage compartment: Removal - Refitting....7317
Separating components: Removal - Refitting....7318
59A-SAFETY ACCESSORIES....7323
Belt height adjustment system: Removal - Refitting....7323
MR418KANGOO6....7324
65A-OPENING ELEMENT SEALING....7326
Door sealing film: Removal - Refitting....7326
Sunroof seal: Removal - Refitting....7328
Tailgate seal: Removal - Refitting....7329
66A-WINDOW SEALING....7331
Front side door glass run channel: Removal - Refitting....7331
Front door side exterior weather strip: Removal - Refitting....7333
Rear side door exterior weather strip: Removal - Refitting....7334
Sliding side door window seal: Removal - Refitting....7335
68A-SOUNDPROOFING....7338
Bonnet soundproofing: Removal - Refitting....7338
MR418KANGOO7....7339
71A-BODY INTERNAL TRIM....7342
Floor carpet: Removal - Refitting....7342
Luggage compartment carpet: Removal - Refitting....7346
Headlining: Removal - Refitting....7348
Cab headlining: Removal - Refitting....7353
B-pillar lower trim: Removal - Refitting....7355
Rear wheel arch lining: Removal - Refitting....7356
A-pillar trim: Removal - Refitting....7359
B-pillar upper trim: Removal - Refitting....7360
Rear quarter panel trim: Removal - Refitting....7362
Rear panel trim: Removal - Refitting....7363
Rear side door sill: Removal - Refitting....7365
Loading door sill: Removal - Refitting....7366
72A-SIDE OPENING ELEMENT TRIM....7367
Front side door trim: Removal - Refitting....7367
Sliding side door trim: Removal - Refitting....7369
73A-NON-SIDE OPENING ELEMENTS TRIM....7371
Tailgate lining: Removal - Refitting....7371
Right-hand rear loading door trim: Removal - Refitting....7374
Left-hand rear loading door trim: Removal - Refitting....7375
75A-FRONT SEAT FRAMES AND MECHANISMS....7376
Front seat frame: Precautions for repair....7376
Front seat frame: Removal - Refitting....7377
Front seat base frame: Removal - Refitting....7380
Front seatback frame: Removal - Refitting....7382
Front seat runner: Removal - Refitting....7384
Rear seat access mechanisms: Removal - Refitting....7386
Complete front seat: Removal - Refitting....7388
76A-REAR SEAT FRAMES AND MECHANISMS....7394
Rear seat frame: Removal - Refitting....7394
Rear seat runner: Removal - Refitting....7395
Complete rear bench seat: Removal - Refitting....7397
Rear bench seatback frame 1/3 and 2/3: Removal - Refitting....7400
Rear bench seat base frame: Removal - Refitting....7401
Rear bench seat mechanism: Removal - Refitting....7403
77A-FRONT SEAT TRIM....7407
Front seat base trim: Removal - Refitting....7407
Front seatback trim: Removal - Refitting....7414
Front seat lower cover: Removal - Refitting....7422
78A-REAR SEAT TRIM....7426
Rear seat base trim: Removal - Refitting....7426
Rear seatback trim: Removal - Refitting....7429
1/3 and 2/3 rear bench seat trim: Removal - Refitting....7431
1/3 and 2/3 rear bench seat seatback trim: Removal - Refitting....7433
79A-SEAT COMPONENTS....7437
Front headrest: Removal - Refitting....7437
Front seat headrest guide: Removal - Refitting....7440
Rear headrest: Removal - Refitting....7442
Rear seat headrest guide: Removal - Refitting....7443
MR419....7444
MR419X6101E000....7446
01E-FAULT FINDING INTRODUCTION....7447
General method....7447
Fault finding – Tests....11772
BAC_V04_TEST1....11773
Fault finding – Customer complaints....11774
Fault finding – Fault finding chart....11775
BAC_V04_ALP01....11775
BAC_V04_ALP02....11776
MR419X6188A000....11777
88A-WIRING....11778
Fault finding – Customer complaints....11778
Fault finding – Fault finding chart....11779
MR419X6188B000....11799
88B-MULTIPLEXING....11800
Fault finding – Introduction....11800
Fault finding – List and location of components....11805
Fault finding – Function....11806
Fault finding – Defect and safe modes....11810
Fault finding – Configurations....11811
Fault finding – Interpretation of faults....11813
Fault finding – Customer complaints....11817
Fault finding – Fault Finding Chart....11818
Renault Kangoo Repair Service Manual 1997-2012
