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SPECIAL FEATURES OF THE ESPACE
FITTED WITH THE G9T ENGINE
77 11 297 642
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed."
TECHNICAL NOTE 3426A
JE0 K - JE0 S
Basic manual:
Workshop Repair Manual 315
JUNE 2000
All copyrights reserved by Renault.
Reproduction or translation, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.
© RENAULT 2000
EDITION ANGLAISE

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   Summary of Contents for RENAULT 2000 Espace

  • Page 1

    Reproduction or translation, in part or in full, of this document or use of the service part The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault. in the production of the various component units and accessories from which his vehicles are constructed."...

  • Page 2: Table Of Contents

    Contents Page Page VALUES AND SETTINGS COOLING SYSTEM Capacities - Grades 07-1 Filling - bleeding 19-1 Tightening the cylinder head 07-2 Diagram 19-2 Coolant pump 19-3 Suspended mountings 19-4 Cooling system 19-5 ENGINE AND PERIPHERALS Identification 10-1 MANUAL GEARBOX Oil pressure 10-2 Engine and transmission assembly 10-3...

  • Page 3: Values And Settings

    VALUES AND SETTINGS VALUES AND SETTINGS Capacities - Grades Capacities - Grades Capacity in Components litres Grade (approx.)* Diesel engine For oil European Union countries (oil) changes 8.3 (1) Other countries Adjust using the dipstick (1) After replacing the oil filter Capacity in Components Grade...

  • Page 4: Tightening The Cylinder Head

    VALUES AND SETTINGS Tightening the cylinder head Tightening the cylinder head METHOD FOR TIGHTENING THE CYLINDER HEAD You must remove the engine and transmission assembly to remove the cylinder head Consult manual Mot. G9 for the details of this operation. 07-2...

  • Page 5: Engine And Peripherals

    ENGINE AND PERIPHERALS ENGINE AND PERIPHERALS Identification Identification Capacity Bore Stroke Compression Vehicle type Engine Gearbox (mm) (mm) ratio JE0 K 2188 18/1 JE0 S Manual to consult: Mot. G9 10-1...

  • Page 6: Oil Pressure

    ENGINE AND PERIPHERALS Oil pressure Oil pressure SPECIAL TOOLING REQUIRED Mot. 836-05 Boxed kit for measuring oil pressure ESSENTIAL SPECIAL TOOLING 22 mm long socket CHECKING The oil pressure should be checked when the engine is warm (approximately 80°C). Connect the pressure gauge in place of the oil pressure switch.

  • Page 7: Engine And Transmission Assembly

    ENGINE AND PERIPHERALS Engine and transmission assembly Engine and transmission assembly SPECIAL TOOLING REQUIRED Mot. 1390 Universal mounting Mot. 1410 Tool for unlocking the snap couplings in the refrigerant circuit Dir. 1282 -01 Spanner for undoing the steering rack union Dir.

  • Page 8

    ENGINE AND PERIPHERALS Engine and transmission assembly Place the vehicle on a two-post lift (fit the safety belts). Drain the cooling circuit through the lower radiator hose. Disconnect and remove the battery. Drain the refrigerant circuit (if fitted) using the filling station.

  • Page 9

    ENGINE AND PERIPHERALS Engine and transmission assembly Disconnect the air conditioning compressor pipe Remove: connections. – the exhaust pre catalytic converter, – the engine tie-bar. Remove the complete heater exhaust line (if fitted). Disconnect the olives on the gearbox control cable. 10442M 10-5...

  • Page 10

    ENGINE AND PERIPHERALS Engine and transmission assembly – the left hand headlight. Separate the electrical wiring from its clip beneath the computer. Remove: – the radiator grille rack, – the radiator grille (bolts (C) and (D)), 10-6...

  • Page 11

    ENGINE AND PERIPHERALS Engine and transmission assembly Disconnect the lead from the engine compartment Disconnect: connection unit; be sure to mark the location of the various connections correctly. Left side: – the clutch slave cylinder high pressure union and Separate: release the pipe from its clips, –...

  • Page 12

    ENGINE AND PERIPHERALS Engine and transmission assembly Prepare the universal mounting tool Mot. 1390 and Remove: position it beneath the engine and transmission – the right-hand suspended mounting cover, assembly (two people). – the travel limiter linkage located just behind this cover, –...

  • Page 13

    ENGINE AND PERIPHERALS Engine and transmission assembly REFITTING - Special points – bleed the hydraulic clutch circuit. Pre-position the gearbox control cables. IT IS ESSENTIAL THAT YOU FOLLOW THE BLEEDING METHOD GIVEN BELOW Position the engine/gearbox assembly in its compartment. Check the rear of the gearbox in relation to the sub-frame.

  • Page 14

    ENGINE AND PERIPHERALS Engine and transmission assembly BLEEDING METHOD TO BE USED: (for two people). 1) Filling the circuit: Check that the clutch pedal is in the top position; put it in this position and hold it by hand if necessary. Fill the hydraulic circuit by connecting a filling system and applying pressure to the tank, open the bleed screw (A) (always compensate for the force using a...

  • Page 15: Top And Front Of Engine

    TOP AND FRONT OF ENGINE TOP AND FRONT OF ENGINE Accessories belt Accessories belt TIGHTENING TORQUES (in daN.m) Wheel bolts REMOVAL Put the vehicle on a two post lift. Disconnect the battery. Remove: – the front right wheel, – the front right wheel arch, –...

  • Page 16: Timing Belt

    TOP AND FRONT OF ENGINE Timing belt Timing belt SPECIAL TOOLING REQUIRED Mot. 1390 Engine and transmission assembly mounting tool Mot. 1536 TDC setting pin Mot. 1534 Inlet camshaft timing/locking tool Mot. 1537 Exhaust camshaft timing/ locking tool Adjust the engine cylinder n˚ 1 to top dead centre TIGHTENING TORQUES (in daN.m) (marking (1) on the crankshaft pulley) and pin the crankshaft after removing the cap (A).

  • Page 17

    TOP AND FRONT OF ENGINE Timing belt Insert the mounting tool Mot. 1390 under the engine Remove the timing belt cover and the lower plastic and transmission assembly, positioning the right-hand cover. pads only underneath the engine. Lower the two unused left-hand pads.

  • Page 18

    TOP AND FRONT OF ENGINE Timing belt Fit the camshaft locking tools and tighten them Remove: carefully to the cylinder head. – the exhaust camshaft sprocket by undoing the three mounting bolts on the sprocket on the hub), – the timing belt. 15850M1 Remove tool Mot.

  • Page 19

    TOP AND FRONT OF ENGINE Timing belt – the pulley; remove the nut and take the pulley out without removing the stud. 17551M Adjust the position of the tension wheel (by pivoting 16026M the tension wheel eccentric anticlockwise) plus approximately 5˚ by aligning sections (5) and (6). REFITTING Fit: –...

  • Page 20

    TOP AND FRONT OF ENGINE Timing belt Tighten: Checking the timing and the tension – the tension wheel bolt (8), – the camshaft timing sprocket bolts (9) to a torque of Undo the tension wheel bolt (8) while holding the 1 daN.m.

  • Page 21

    TOP AND FRONT OF ENGINE Timing belt Tighten: Remove the camshaft timing tools Mot. 1534 and – bolt (8) of the tension wheel to a torque of 2.5 daN.m, Mot. 1537 and the TDC pin Mot. 1536. – the camshaft timing sprocket bolts (9) to a torque of 1 daN.m.

  • Page 22: Cylinder Head Gasket

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

  • Page 23: Turbocharger

    TURBOCHARGING TURBOCHARGING Turbocharger Turbocharger TIGHTENING TORQUES (in daN.m) Turbocharger mounting nuts Oil inlet union bolt Oil return union bolt Turbo mounting nut on the intermediate exhaust downpipe THE TURBOCHARGING PRESSUREON THE TURBOCHARGER FITTED ON THE G9T 710 ENGINE IS NOT ADJUSTABLE. In operation, the pressure should stabilise at 210 ±...

  • Page 24

    TURBOCHARGING Turbocharger IMPORTANT: Never attempt to remove the Run the engine at idling speed and check that there turbocharger with the engine in place; you will not be are no leaks at the oil connections. able to follow the recommendations for refitting the oil supply pipe (1) and the constraints created by blind Using the fault finding tool, erase the fault as a result tightening the connection (3) will lead to the pipe (1)

  • Page 25: Air Inlet

    FUEL MIXTURE FUEL MIXTURE Air intake Air intake AIR INTAKE CIRCUIT DIAGRAM Air-air exchanger Air filter Damper unit Inlet manifold Turbocharger Air inlet 12-3...

  • Page 26

    FUEL MIXTURE Air intake TIGHTENING TORQUES (in daN.m) Clip nuts DAMPER UNIT This unit, controlled by 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 recirculation solenoid valve.

  • Page 27

    FUEL MIXTURE Air intake REMOVAL Remove: – the turbocharger/exchanger air pipe mounting bolts Put the vehicle on a two post lift. from the cylinder head, Disconnect the battery. Remove: – the lower engine cover, – the air exchanger/damper unit pipe after disconnecting the electrics.

  • Page 28

    FUEL MIXTURE Air intake Remove: Remove the connection pipe (5) between the throttle – the mounting bolt from the low pressure air body and the inlet manifold, conditioning pipe bracket (3), – the mounting bolts (4) from the throttle body on the engine housing.

  • Page 29: Exhaust Manifold

    FUEL MIXTURE Exhaust manifold Exhaust manifold TIGHTENING TORQUES (in daN.m) Manifold mounting nut 0.8±0.2 Manifold mounting nut 2.7±0.4 EGR valve mounting bolt Turbocharger clamp mounting bolt REMOVAL Removal of the exhaust manifold requires removal of the engine and transmission assembly (see section 10 "Removing/refitting engine and transmission assembly"), and the removal of the turbocharger (see section 12 "Removing/refitting turbocharger").

  • Page 30: Inlet Manifold

    FUEL MIXTURE Inlet manifold Inlet manifold SPECIAL TOOLING REQUIRED Mot. 1390 Engine and transmission assembly mounting tool TIGHTENING TORQUES (in daN.m) Heater plugs Manifold mounting stud "Common-Rail" high pressure unions REMOVAL Remove the right-hand suspended engine mounting cover. The removal of the inlet manifold/cylinder head cover requires the removal of the injectors and injection harnesses.

  • Page 31

    FUEL MIXTURE Inlet manifold Remove the manifold mounting bolts and then remove the manifold. REFITTING IMPORTANT: note the rubber seal on the inlet tubes; if necessary, seal this in its casing 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.

  • Page 32: Starting - Charging

    STARTING - CHARGING STARTING - CHARGING Alternator Alternator IDENTIFICATION Type Engine Alternator Current JE0 K VALEO SG 12 125 A JE0 S CHECKING After 15 minutes warming up at a voltage of 13.5 volts. Amps 1500 26 A 4000 94 A 6000 105 A 16-1...

  • Page 33: Alternator

    STARTING - CHARGING Alternator REMOVAL – the accessories belt (see method on page 11-1), – the accessories belt pulley. Put the vehicle on a 2 post lift. Disconnect the battery and the electrical connections on the alternator and the air conditioning compressor. Remove: –...

  • Page 34

    STARTING - CHARGING Alternator Undo the four air conditioning compressor mounting On the right-hand side below, remove the vertical bolts and allow this to hang by its pipes. engine tie-bar mounting bolt. Undo without removing the pre-catalytic converter mountings on the exhaust pipe. Remove the upper mounting bolt on the alternator by manually lifting the engine and transmission assembly forwards;...

  • Page 35: Starter

    STARTING - CHARGING Starter Starter IDENTIFICATION Type Engine Starter motor JE0 K VALEO D7RP158 JE0 S 16-4...

  • Page 36

    STARTING - CHARGING Starter REMOVAL – the oil filter unit bracket. Put the vehicle on a 2 post lift. Release the filter bracket to the side, without disconnecting it. Disconnect the battery. Remove: – the lower engine cover, – the air exchanger/throttle body unit pipe after disconnecting it, 16028M Disconnect the starter electrical connections.

  • Page 37: Cooling System

    COOLING SYSTEM COOLING SYSTEM Filling and bleeding Filling and bleeding There is continuous circulation in the heater matrices. FILLING It is essential to open the two bleed screws at the top of the radiator and the cylinder head coolant pipe housing outlet. Fill the circuit through the expansion bottle opening.

  • Page 38: Diagram

    COOLING SYSTEM Diagram Diagram SPECIFIC COOLANT CIRCUIT 1 Engine 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 + "eco"...

  • Page 39: Coolant Pump

    COOLING SYSTEM Coolant pump Coolant pump ESSENTIAL SPECIAL TOOLING FACOM U 14 L sprocket extractor REMOVAL Put the vehicle on a 2 post lift. Disconnect the battery. Bleed the engine cooling circuit and engine oil; do not refit the oil drain plug. Remove: –...

  • Page 40: Suspended Mountings

    COOLING SYSTEM Suspended mountings Suspended mountings Offer up the engine and tighten the cover mounting The right-hand suspended mounting is fitted with a rear travel limiter linkage. bolts (D) on the engine to 6.2 daN.m. When removing the cover, linkage or cast iron Tighten the cover mounting bolt (E) on the rubber pad mounting attached to the cage, respect the tightening (3) to 6.2 daN.m and the linkage connecting bolts (F)

  • Page 41: Cooling System

    COOLING SYSTEM COOLING SYSTEM Cooling system Cooling system Bleed the cooling circuit, the air conditioning circuit Set the radiator cross member on a table with shims (see special manual for air conditioning) and release the mountings. Open the relay unit at the top left of the ring and disconnect the electric wiring harness from the cooling system at the radiator.

  • Page 42: Manual Gearbox

    MANUAL GEARBOX MANUAL GEARBOX Identification Identification 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 D: the factory of manufacture At E: the fabrication number 21-1...

  • Page 43

    MANUAL GEARBOX Ratios Ratios Final drive Index Type Reverse gear ratio JE0 K JE0 S 21-2...

  • Page 44: Lubricants

    MANUAL GEARBOX Lubricants Lubricants OIL CAPACITY : – Maximum: 2.8 l – Minimum: 2.3 l OIL LEVEL The oil level is adjusted using a locally manufactured dipstick, inserting into the oil filler hole (2) (see Technical Note 2579A). To check the level it is necessary to remove the left hand front wheel and the left hand wheel arch cover.

  • Page 45

    MANUAL GEARBOX Removal - refitting 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.

  • Page 46: Heating

    HEATING HEATING Additional heating Additional heating OPERATING PRINCIPLE The vehicle with a G9T engine is fitted with an additional heating system as an option in some countries (Germany, Nordic countries...). This comprises an engine coolant heater, mainly for starting when cold. The heater is switched on if the following three conditions are met: –...

  • Page 47

    HEATING Additional heating DIAGRAM OF THE D3WZ HEATER Air blower turbine 13 Fuel filter Electric motor 14 Main fuse Heat exchanger 15 Interface Combustion chamber Spark plug Combustion air inlet Flame detector Exhaust gas outlet Temperature sensor Vehicle fuel circuit Overheating switch Coolant inlet (thermoplunger outlet) Control unit...

  • Page 48

    HEATING Additional heating TECHNICAL SPECIFICATIONS SAFETY SYSTEMS The heater is fitted with an igniter appropriate for the The system is fitted with several safety features; it cuts vehicle fuel. out: – if the difference in coolant temperature read by the It operates in two power levels: two internal heater sensors reaches 15 ˚C, –...

  • Page 49

    HEATING Additional heating 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 61-4...

  • Page 50

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

  • Page 51

    HEATING Additional heating MAINTENANCE COMBUSTION CHAMBER (4) AND EXCHANGER (3) The principal maintenance operations on this Remove: assembly are: – the flame detector and spark plug, – replacing the ignition spark plug (5), – the wiring harness fitted on the overheating –...

  • Page 52: Air Conditioning

    AIR CONDITIONING AIR CONDITIONING Air conditioning compressor Air conditioning compressor The G9T engine vehicle is fitted with a variable Unscrew the two mounting clamps on the compressor geometry air conditioning compressor; that is, the refrigerant pipes and carefully plug the openings. compressor adapts the flow of refrigerant fluid according to a difference in pressure between the compressor inlet and outlet, and not according to the...

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