Kangoo Sport DCI 85 / Daily Day Van

[Mcaff]

Done a refresh in silver on the Laguna wheels and changed the tyres for some 205/50/17 the Megane wheels where just too heavy and too much contact patch. I’m suspecting that the extra size and grip might have been too much for the box and it’s now whining at me. Also with a little bit of sympathetic driving I’m averaging 47 - 48 mpg where as I couldn’t break 43 with the Megane wheels. So I think that’s sealed their fate.

Last night lowered the front of it a bit more so it’s level, I’m pretty happy with how it sits now, was running a hubcentric spacer on the Megane wheels at the rear but they snapped on the hub so I might just find a 10mm spacer and that should be fine to bring the wheels out safely.

We had planned on giving the van the works detailing wise, but when coming up with a game plan and assessing the state of the paint it just wasn’t worth the time and effort. It really has been abused over the years like you would imagine a builders van would be. So just went for a hand polish and wax and didn’t bring out the polisher. Also used some trim restorer to bring the plastics back. The worst part that took most of the time was the roof. It was so dry it was just absorbing the product.

While my mate was setting about that I was painstakingly going around the van with a touch up pen to take your eye off the scratches. So she does look miles better in pictures but she’s good enough for the girls I go out with so I’m over the moon!

Both cars are pretty much ready to hit the road now. Clio needs a final clean and hoover and fuelled up. Past it’s MOT thankfully so I can have a couple of days rest before hitting the road!

 

[Brigsy]

Looks class. Mines the same paint work wise, good ten footer due to previous van use.

 

[Mcaff]

Looks class. Mines the same paint work wise, good ten footer due to previous van use.

Mine could do with having the sliding door and 2 rear doors replaced as they have all been nudged at some point. Then with the rest of the van the way it is the only solution would be throw some more paint at it. Once I’ve sorted more mechanical niggles that we spoke about I might not be opposed to a motorsport style paint job then at least it will be all one colour.

 

[Martin_172]

thats looking mega mate good work

 

[Djw John]

Good going to town rig that

 

[Crayola]

Looks spot on that, well worth the effort to polish it

 

[Danith]

Want one!! Off to ebay to look up kangoo sports

 

[Mcaff]

Want one!! Off to ebay to look up kangoo sports

Best of luck finding one! Might have better luck finding a facelifted version. I think there is something like 200 of them left of this style on the road. I’m always seeing if I can find a cleaner one as mine is quite tatty up close. Mine has a load of miles and a worn out engine/turbo/gearbox 😂

 

[Danith]

Best of luck finding one! Might have better luck finding a facelifted version. I think there is something like 200 of them left of this style on the road. I’m always seeing if I can find a cleaner one as mine is quite tatty up close. Mine has a load of miles and a worn out engine/turbo/gearbox 😂

I'd have to get rid of a car to make space. I think I'm getting my brother's Twingo RS back soon so that's going to be the view out of my bay window soon.

Do need a van though, so cool. When I was passing my test a Mk4 escort RS van was the dream car.

 

[Brigsy]

I'd have to get rid of a car to make space. I think I'm getting my brother's Twingo RS back soon so that's going to be the view out of my bay window soon.

Do need a van though, so cool. When I was passing my test a Mk4 escort RS van was the dream car.

I always wanted a mk4 escort van with rst conversion. Back in the day my mate had a diesel mk4 van and we used to all pile in the back and cruise about no f***s given Astramax with c20let was good to but they are extinct

 

[Danith]

I always wanted a mk4 escort van with rst conversion. Back in the day my mate had a diesel mk4 van and we used to all pile in the back and cruise about no f***s given Astramax with c20let was good to but they are extinct

ha same. he had a mk5 in imperial blue, 17 inch smith's revolutions and we chucked a couch in the back. that got written off then he bought a mk6, painted it mallard green, put 18s on (when 18s were MASSIVE) and chucked about £10k worth of Cerwin Vega ICE in it! Weighed a tonne and was slow as frig - but looked cool as.

White RST Mk4 van with morettes was the dream

 

[VenomUK]

What miles is yours on @Mcaff ?

 

[Twingo 1??]

I'd have to get rid of a car to make space. I think I'm getting my brother's Twingo RS back soon so that's going to be the view out of my bay window soon.

Do need a van though, so cool. When I was passing my test a Mk4 escort RS van was the dream car.

Pop some red vinyl over the rear window remove rear seats ply out the back and you have a Twingo 133 van HTH 👍🏻

 

[Mcaff]

What miles is yours on @Mcaff ?

A bit over 168k I think, it runs fairly sweet once it’s going but needs a bit of sniff to start. I plugged it in today and says fuel pressure regulator and another code for glow plugs module.

gearbox is whining now though so not sure how long that’s going to last. And loads of oil around the turbo intake and around that area. So needs some attention.

 

[VenomUK]

Is it the gearbox or a pulley? Mine is 180k starts sweet and runs sweet although sometimes hunts but suspect it needs a clean out. Thought my box was wining but it was one of the pulleys.

 

[Mcaff]

Is it the gearbox or a pulley? Mine is 180k starts sweet and runs sweet although sometimes hunts but suspect it needs a clean out. Thought my box was wining but it was one of the pulleys.

I’ve got a belt kit here with pulleys so at some point I will investigate. I ran the box quite low on oil when I first had it thinking it was a shifter cable then when I put Megane wheels on it it almost instantly started whining. It doesn’t whine stationary or when revved so I’m assuming it wouldn’t be a pulley. Only when moving and doesn’t change with speed or when turning so not a wheel bearing either.

 

[VenomUK]

Ha, we almost certainly look after our vans equally. Mine got low due to a drive shaft seal, which after 5 years I've still not had replaced till I get a new clutch. I thought mine was the box but can hear it when idle and rises and lowers with revs. I need to take the Aux belt off and see which pulley is making the noise, my suspicion is the alt wheel.

 

[Mcaff]

Ha, we almost certainly look after our vans equally. Mine got low due to a drive shaft seal, which after 5 years I've still not had replaced till I get a new clutch. I thought mine was the box but can hear it when idle and rises and lowers with revs. I need to take the Aux belt off and see which pulley is making the noise, my suspicion is the alt wheel.

That was another job that I ignored for as long as possible, had to change the alternator but went for as long as possible as there is just hardly any room in the bay to work. Also the reason I’ve put off doing the belts. I might pull the engine and replace the turbo and have the box all done at the one time as it would be much easier than doing bits and bobs.

 

[Mcaff]

The van did the trip too and from CSF22 effortlessly and managed 50mpg, we did cruise up and down in the heat at 60mph. Was honestly quite surprised at the lack of issues from both vehicles!

But now we are back in the land of the living the van decided last Monday it was going to get even more difficult to start than usual. I’d been starting it most mornings on the sniff but it decided that enough was enough and an injector finally let go.
A common theme here is putting jobs off on this because I’m proper lazy and tight so don’t want to spend the money taking it to a real mechanic 😂.
I knew pretty much from the get go that the starting issue was most likely an injector. But the fact I’ve not worked on diesels before and all the horror stories of snapped injectors and leak down tests honestly frightened me a bit so I ignored it as long as I could.

Anyway a few YouTube videos later and a leak down test…

Came to the conclusion that injector 4 was the bad one.
I couldn’t get the b*****d out but I had a bit of muscle in the form of @Stu. From “Renomotive” that ended up pulling it for me with little effort.

I looked at various options online at new and refurbished injectors. But did I mention I’m tight… ended up with one for £40 delivered from a breaker and just the hope it would work.

fired the new injector in, coded it in and it fired right up off the key. It’s never done that before as quick, had a bit of Ticking past the injector so replaced the washer and buttoned it up again.

For the time being jobs a goodun. Proper luxury now starting up without having to open the bonnet.

 

[Crayola]

Nowt worse than when it's lashing it down and you've got to get the can of "start ya b*****d" out 😂

 

[Mcaff]

Nowt worse than when it's lashing it down and you've got to get the can of "start ya b*****d" out 😂

The amount of times I’ve borrowed someone else’s car just because I couldn’t be bothered with the hassle of f**king about with it 😂

 

[VenomUK]

Tackling the EGR today but mine looks loads different to yours! Also struggling with removing the top hose, can’t see how the snap ring releases?

It looks quite oily too?



This clip here on this hose is doing my head in and can’t figure out how to remove and feel I may need to Jack the van up to remove the turbo inlet that runs along the back of the engine?

 

[Mcaff]

Tackling the EGR today but mine looks loads different to yours! Also struggling with removing the top hose, can’t see how the snap ring releases?
View attachment 1617987
It looks quite oily too?

View attachment 1617988
View attachment 1617989
This clip here on this hose is doing my head in and can’t figure out how to remove and feel I may need to Jack the van up to remove the turbo inlet that runs along the back of the engine?
View attachment 1617990

From memory yes yours looks slightly different from mine. Cross over pipe on mine is metal. But I’m imagining things aren’t too dissimilar. Snap ring should just pop out with a screw driver. There’s like a little hump on it you should be able to flick under and it will release.
Mine is absolutely caked in oil and has been since I’ve got it. Way worse than yours is. But doesn’t seem to use any oil.

Can’t really tell from the picture but mine looks like it attaches further down. What year and model is yours?

I’ve not had the bonnet of mine open in some time so memory is vague. Although I’ve just had delivered a clutch and fly wheel for it and will be getting the belts done at the same time.

 

[VenomUK]

I was having a go at the snap ring for ages, will revisit it tomorrow and have been told the valve is at the back of where I’m looking under the intake pipe. Mines a 2012 van, I could see alot if oil deposits and I’ve never cleaned it so thought it’s best to get it done

 

[Mcaff]

I was having a go at the snap ring for ages, will revisit it tomorrow and have been told the valve is at the back of where I’m looking under the intake pipe. Mines a 2012 van, I could see alot if oil deposits and I’ve never cleaned it so thought it’s best to get it done

Not the best photo but I’ve got nothing else to hand. That’s the EGR valve there. The full egr system and cooler is down the back next the the turbo. There are 3 different types for this engine I’m sure but all very similarly placed and shaped.

Figure 1 is the egr valve.

 

[Brigsy]

Whip wipers and scuttle panel off, takes 5 mins and loads of access to the rear engine area once removed.

 

[Mcaff]

Have done a couple trips in the van last year took it down to CSF22 to cart my tent and spares down and took it down to visit my mate in Campbeltown. Clutch started to slip under load and with the van approaching 170k I decided it was time to do the belts as I’ve no history of them being done. I love driving it it’s proper comfy good on a fuel and to me it looks the part from 20ft as well.

So vans been parked for a few months while I compiled some parts.
new bits that I planned to do:
-Belt kit
-clutch / flywheel
-2 front tyres went for Avon zv7
- Modified to fit Avo front coilovers
-new top mounts

So in recent times the past couple of weeks on my down time I’ve managed to get the engine and box out.

Pressure washed the bay:

So as per renault ownership, things have grown arms and legs and it’s become the parts cannon. “May as well just do that while the engine is out”

other parts on the way now:

- New Radiator
- Aircon condenser
- wishbones / ball joints
- adjustable drop links
- tie rods and ends
- brand new borg Warner turbo
- new coolant hoses
- sump plugs and washers
- dogbone mount
- split charging kit for leisure battery and inverter.

Set about taking the turbo off today, seals are gone on it was far cheaper to get a brand new unit than getting this re built.
As you’d imagine all the bolts were typically seized on so was a fun time smashing all the nuts off the cat.

That’s where I’m at just now, plan is to get the clutch and belts done and the engine back in, hopefully in the next couple weeks.

I’m planning on pissing off to Spain in it for a month and doing a bit of traveling about.(not exclusively staying in the van) so I’m trying to make it reliable and comfortable enough to sleep in if I have to and have the bare necessities if I have a stop over somewhere.

 

[Crayola]

Add decat to your list👀

 

[Djw John]

You silly man. I fully approve.

 

[Mcaff]

Add decat to your list👀

Like I’m gonna take any advice from the man with the broken Megane 😂

You silly man. I fully approve.

Parts cannon bros x

 

[unhleashd]

Amazing work! Thank you keeping others in touch.

 

[VenomUK]

Mine is due to have the belts done soon, I've seen vids on other 9K9 engines one being done on a Modus and I thought it can't be that bad in the Kangoo... I'm thinking that perhaps pulling the engine is the better option as the engine bay is so bloody tight!

 

[Mcaff]

Mine is due to have the belts done soon, I've seen vids on other 9K9 engines one being done on a Modus and I thought it can't be that bad in the Kangoo... I'm thinking that perhaps pulling the engine is the better option as the engine bay is so bloody tight!

I don’t think it’s the worst job in the world with the engine in place to be honest. If I didn’t need the clutch etc done on mine I’d have just paid someone to do just the belts I recon. If you’re well versed on pulling engines and the like then it should be no bother this way although there were a few jobs that required a bit of brute force and swearing. Also this way exploits any other issues hence why mine ended up needing far more than I originally thought.

 

[Crayola]

Belt is a piece of piss on the K9K

The hardest bit is getting to it without breaking any of the plastic in the way 😂

 

[VenomUK]

I don’t think it’s the worst job in the world with the engine in place to be honest. If I didn’t need the clutch etc done on mine I’d have just paid someone to do just the belts I recon. If you’re well versed on pulling engines and the like then it should be no bother this way although there were a few jobs that required a bit of brute force and swearing. Also this way exploits any other issues hence why mine ended up needing far more than I originally thought.

I may end up doing the same and pulling the engine and box and doing the clutch too. I'm not well versed I would say, I know my way around a tool box and I've pulled an Evo engine and box myself a few times before but not a Renault but then, can it be any harder than a late 90s jap car?

Belt is a piece of piss on the K9K

The hardest bit is getting to it without breaking any of the plastic in the way 😂

I can imagine they are the hardest part, once out and supporting the engine, it all looks pretty straight forwards tbf

 

[Mcaff]

I may end up doing the same and pulling the engine and box and doing the clutch too. I'm not well versed I would say, I know my way around a tool box and I've pulled an Evo engine and box myself a few times before but not a Renault but then, can it be any harder than a late 90s jap car?


I can imagine they are the hardest part, once out and supporting the engine, it all looks pretty straight forwards tbf

As engines go they are easy to come out. Trouble I had was splitting the balljoints they were absolutely solid. So just opted for new wishbones. Then there is the turbo, seals were gone in mine but zero play in the shaft, to be honest absolutely no chance of that coming out with the engine in the bay. The nuts on the cat all needed smashed off on mine. So it does become pricey. I’m at over a grand in bits I recon easily.

 

[VenomUK]

That's the nature of the beast isn't it. When the engine is out you start to think every job becomes x100 easier when it,s out, before you know it you've ordered a load of parts 😭

 

[Mcaff]

That's the nature of the beast isn't it. When the engine is out you start to think every job becomes x100 easier when it,s out, before you know it you've ordered a load of parts 😭

As vehicles go parts are cheap I guess. It’s just one of those things if you know you’re going to keep it you may as well just cry once and spend it.

 

[Crayola]

That's the nature of the beast isn't it. When the engine is out you start to think every job becomes x100 easier when it,s out, before you know it you've ordered a load of parts 😭

I felt that, right in my bones I felt that!!

 

[Mcaff]

Few bits done tonight to get this thing moving.
New turbo on, realised the oil feed line was a bit leaky so I’ve ordered a new one.

New rear main seal installed along with a valeo clutch and release bearing. Fired the box back on.

Will hopefully get a bit of time to do the belts and can sling the engine back into the van.

Need to run some wiring through the bulkhead while the engine is out for a leisure battery and inverter. Will also fire the new wishbones on too while the engine is out amongst other bits and bobs.

Good to get a bit of progress again. Not had much time to work on it lately.