installation manual renault kangoo swb wav-conversion petrol · version 1.9 renault kangoo 33 now...

Installation manual Renault Kangoo

SWB WAV-Conversion PetrolVersion 1.9

Version 1.9 Renault Kangoo

2

What is new in version 1.96.8 Ramp Page 85-86 Added a bolt and a washer to the ramp assembly

7.7 Hydraulic kneeling system Page 131-145 Updated pictures and information on lowering system Added the 2/2 Solenoid Valve

9.1 Contact PersonsPage 149 Updated the contact information


3

General guidelines

Read the instructions carefully, before starting to convert the vehicle.

Never throw the dismounted parts away, unless mentioned otherwise. •Keep all the parts stored together.•Be sure that you have enough working space in- and outside the vehicle.•Before you start, you need to disconnect the connections to the battery.•The vehicle must not move during the conversion, to assure a good •geometry of it.Neverremovethesteelbumperbeforetheloweredfloorisfixatedinthe•vehicle.

General guidelines:

IMPORTANT: When the car is brand new, direct from the factory, the electrical system of the car needs to be reset. The Renault dealer can do this.

IMPORTANT:Holes(max.20mm)maybedrilledinthehatchedpartsofthedrawingbelow.Alwaysuseametallic spacer!


4

Youneedanextrapairofhands.

Part can be thrown away. No need for it anymore.

Noopenfireorsmoking.

Wear protection for eyes and ears.


5

1. Table of contents 52. Tools list 6

2.1 Common tools 62.2 Electrical/compressed air tools 72.3 Special tools 7

3. Survey of the conversion kit 84. Dismounting 9

4.1 Dismounting the interior 94.2 Dismounting the exterior 15

5. 5. Preparations 235.1 Protection of the vehicle 235.2 Sawing out the floor 23

6. Installing the conversion kit 286.1 Bonding the lowered floor 286.2 Fuel tank 366.3 Exhaust system 496.4 Fuel tank protection plate 546.5 Electrical installation for 4-point belt fixation 556.6 Mounting the rear and rear bumper 596.7 Remounting the interior 706.8 Mounting the 1/3 part of the backseat on the right side 756.9 Ramp 816.10 4-Point belt fixation 90

7. Options 947.1 Mounting the folding seat (left side) 947.2 Mounting the stainless steel (INOX) protection plates 997.3 Connecting the moved parking sensors 1007.4 Emergency exit 1027.5 Taxi Hinges 1037.6 Installing the air suspension system 1047.7 Installation of the hydraulic kneeling system 131

8. 8. Notes 1469. Contact 148

9.1 Contact persons 1499.2 Other email addresses 149

10.Recommendationform 150


6

Tools list2. Common tools2.1

4 columns bridge • 1

Sealant gun • 2

Calibrated torque spanner • 3

Pop Riveter • 4

1.

3.4. 2.


7

Electrical/compressed air tools2.2

Floormould(onsaleatBierman,partnumberN200014003)• 11

Bumpermould(onsaleatBierman,partnumberN200014004)• 12

Wooden beam • 13

Special tools2.3

Abrasivemachine(electrical/compressedair)• 5

Circularsaw(electrical)formetal(forexample:MilwaukeeMCS65)• 6

Saw(compressedair)• 7

Impactnutsetter(compressedair)• 8

Popriveter(compressedair)• 9

Drillingmachine(electrical/compressedair)• 10

5.

6.

7.8.9.10.

11.

12.13.


8

Survey of the conversion kit3.

In the picture below you see the most important parts of the conversion kit.


9

Dismounting4. Dismounting the interior4.1

Remove the rubber of the rear and both side doors.Remove the rear shelf.

Remove the covers from the wheel arches, disconnect the connector plug.


10

Remove the cover of the door latch.

Remove the lock of the rear hatch.Remove the cover of the rear hatch.

Remove the door latch and all attachement eyes.


11

Unscrew the bolts that are indicated in the picture.

Remove the cover of the back seat.

Bend the bracket indicated in the left picture away, as indicated in the right picture.


12

Remove the back seat out of the vehicle.

Remove the bolts that are indicated in the picture.


13

Removethefloorcovering.

Remove the brackets that are indicated in the picture.


14

Unscrew the bolts of the belts, top and bottom, from the back seat.

Finally remove the caps over the windows and the ceiling.


15

Dismounting the exterior4.2

Remove the frame of the spare wheel.Remove the spare wheel by unscrewing the bolt.

Removing the tail lights (both sides):Unscrew the bolts.1. Disconnect the connector plug.2.


16

Removing the rear bumper:Unscrewtheboltsandremovethecap(bothsides).

Unscrew the bolts at the top of the bumper.

!!Connector plug!!


17

Removetheinnerbumperpartbyunscrewingthebolts(4bolts).!!Leave the steel bumper part on the vehicle!!

Disconnecttheconnectorplug(leftside)andremove the plastic bumper.

Unscrew the bolts underneath the bumper.

Unscrew the bolts in both wheel arches.


18

Dismounting the exhaust:Unscrew the mounting bracket at the rear.

Placeasupportunderneaththeexhaust.Unscrew the mounting bracket at the middle.

Sawthroughtheoriginalexhaustatapointwhich is good measured. To make sure you don’t maketheexhaustpipetoshortyoucantakealookatthenewexhaust.Lateryouhavetosawtheexhaustpipetotherightsize.

IMPORTANT: When the center heat shield is not standard on the car, you need to order it at your lo-cal Renault dealer!!Part number:8200521320


19

Remove the heat shield.

!!Keep these parts and matching bolts!!

Ontheleftsideoftherearaxle,youhavetoremoveasmallbracket. Saw it away and treat the sawing edge against corrosion.


20

IMPORTANT: Make sure that the fuel tank is empty before removing!!

Dismounting the fuel tank:Place a support underneath the fuel tank.

Unhook both pipes indicated in the picture.


21

Disconnecttheconnectorplugfromthefloatelementandbothfuelpipes(onetothefloatele-mentandonetothecarboncanister).

Unscrewtheboltsofthefueltank(5bolts).


22

The other parts you can throw away, no need for it anymore.

1.

3. 2.

Removethefueltankandkeepthefollowingparts:Float element • 1Attaching nipple • 2Carbon canister + attaching nipple • 3

IMPORTANT: Make sure that you keep all at-taching nipples!!


23

5. Preparations5. Protection of the vehicle5.1

Protect the interior of the vehicle.

Sawing out the floor5.2

IMPORTANT: Make sure that the vehicle is dry when sawing out the floor!!

Place the mould into the vehicle (fasten it with origi-nalbolts),markthelines(outersidesofthemould).Remove the mould from the vehicle.

IMPORTANT: During the sawing you must al-ways wear protection glasses and protection for your ears!!

IMPORTANT: Be sure that all hydraulic pipes and electrical pipes are bent downwards, before sawing out the floor!!


24

First saw through the lines in the longitudinal direc-tion of the vehicle, using the circular saw (minimal sawdepth50mmandmaximumsawdepth65mm).The front side and the parts underneath the car need to be done with the air saw.


25

Levelthesurfacewheretheloweredflooriscoming. Remove the obstacles.

Remove a part of the edge at both sides of the vehicle, as was indicated by the mould.

Remove any access kit on the right and left wheel arches.


26

Makesurethattheloweredfloorfitsperfectinthevehicle.Markthesawinglinesfortheholes,fortheelectricalfrontbelts(seebelow).

IMPORTANT: Before you glue the lowered floor in the vehicle you need to try it in the vehicle!!

Remove the sharp edges of the saw cuts.Do this by using an abrasive machine.

Saw the holes for the electrical front belts, marked earlier(leftpicture).On both sides you have to saw away the rectangle of the part below the carpet, which you see in the picture above.Put the brown electrical wire of the 4-point belt fixation underneath the floor covering before you glue the lowered floor into the vehicle.


27

Before you place the lowered floor into the vehicle, make sure that the connector plug of the brown electrical wire is going to the left wheel arch.

IMPORTANT: Always treat the sawing edges against corrosion!!

To treat the sawing edges against corrosion, use the primer that is included in the kit.

IMPORTANT: You always have to treat the saw-ing edges to prevent corrosion!!Your company is liable for the warranty!!


28

Installing the conversion kit6. Bonding the lowered floor6.1

IMPORTANT: Make sure that the vehicle is dry before preparing the vehicle.

IMPORTANT: Make sure that the parts which will be glued are prepared with Cleaner I and Prep M.

IMPORTANT: Be sure that the saw cuts are treated against corrosion before bonding the lowered floor into the vehicle.


29

Preparations:Preparethepartsoftheloweredfloorwithsand-•paper(P60).Clean the indicated parts with • Cleaner I.Wait 5 minutes.•

Tie plates


30

Preparations:Treat the parts with • PrepM(onlymetalparts).Wait 5 minutes.•

Tie plates

IMPORTANT: Put the glue on the vehicle in such a way that the triangle stands up and according the described pattern.

IMPORTANT: Keep 10 mm distance between the sawing edges and the glue.

IMPORTANT: To glue the different parts you need to use the triangular nozzle (included in the kit).


31

Apply the glue onto the vehicle in closed shapes.

Apply the glue in the front in a closed rectan-gle.


32

Nowcarefullylowerthefloorinthevehicleand press it downwards.

IMPORTANT: Put grease on the bolts, to isolate it from the glue.

Put4M8*40boltswithwashers(includedinthekit)andtheorigi-nal attachment eyes in the pre-drilledholesoftheloweredfloor.Place a protection cap on each bolt (includedinthekit).


33

Now apply the glue in three stripes on the tie plates and place them at each inner side of the vehicle on the earlier placed bolts. Finally put two nuts with washers on the ends of the bolts(includedinthekit),M68NmandM821 Nm.

Oneachsideputtwobolts,oneM6*30withwasherandoneM8*30withwasher(includedinthekit),intheholes.

Tighten the two front bolts with 21 Nm. The two rear bolts you need to tighten until both edges are aligned with each other.

21NmCHECK

21NmCHECK

8NmCHECK

IMPORTANT: Now you can remove the steel bumper (keep the dismounted parts).


34

Finallyyouneedtofilltheopenplacesupwithglue,around the tie plates and underneath the car (the sides and front.

At the front you need to place a wooden beam withprotectionforthefloor,topresstheloweredfloordownwards.

!

! !

!


35

IMPORTANT: After bonding the lowered floor into the vehicle you must wait 48 hours before using the car. This way, you will get the maximum strength of the glue!!

Usegluetofilluptheopenspace.Whentheglueisdry you can remove the tape.

Theopeningbetweentheloweredfloorandthebodyofthevehiclemustbefilledupwithglue(bothsides).Place tape over the edge.

Fill the open place at the back of the vehicle up with glue(bothsides).


36

Extending the electrical line of the float element:Extendtheelectricallineofthefloatelement(partisinthekit),connecttheconnectorplugs.

Fuel tank6.2 Important: When you place the new fuel hoses, make sure that the hoses not fold or have any contact with sharp edges.


37

Cutting the fuel pipes:Cut the fuel pipes on the places that are indicated in the pictures and put an brass tube shell in both pipes (keep the attaching nipples, see pictures below, and mark the pipes so you can see where the nipples are coming from in a later stadium of the conversion).


38

Replacing the float arm:Carefullyremovetheoriginalfloatarmandreplaceitbythenewone(includedinthekit).


39

Attachthe2550mmØ6mmhoseonthenippleofthesealcap,usinganearclamp(allpartsareincludedinthekit).Place the original carbon canister on the new fuel tank.Attach the original yellow attaching nipple of the carbon canister on the2550mmØ6mmhose,byusinganearclamp(allpartsareinclu-dedinthekit).Attach the connector to the top connection of the carbon canister.Place the hoses as indicated in the picture above.


40

Important: The float element must be placed in the right way. The fuel level gauge will now give a correct reading.

Placethefloatelementinthefueltankasin-dicatedinthepicture(DIESELandPETROLarethesame).IfthecarisaDIESELversionyouneedtoremove the seal cap with nipple and replace itbythesealcap(includedinthekit)byus-ing lock compound.

!!Petrol!! !!Diesel!!Seal cap with nipple Seal cap

Important: When replacing the float element you must use the new ring (included in the kit). Make sure the new ring is mounted on the right way!!

Place a rubber tule and two washers (includ-edinthekit)ineachholeofthefueltank,asindicated in the picture above.


41

Mounting the fuel tank:Place the tank on a support.

Attachtheoriginalgreenattachingnippleonthe870mmØ8mmhosebyusinganearclamp(includedinthekit).Attachthesideofthenippletothefloatelement(con-nectionwithgreendot).Attachtheothersidetothefuelpipewherethegreencon-nectoriscomingfrom,byusinganearclamp(includedinthekit).

Connect the connector plug, of the earlier extendedelectricalcable,tothefloatelement.


42

Attach the original attaching nipple of the fuel tank to the hose you see in the picture, by using the small hose clamp (includedinthekit).

Attach the side with the nipple tothetopconnectionnexttotheloweredfloor.

Important: For mounting the hoses use the hose clamps with elastic reserves, original Renault parts (large one: 7703083431/small one: 7703083427!!


43

Connect the hose that you see in the picture, by using a large hose clamp (included in the kit),tothefilleropeningofthevehicle.



44

Important: When mounting the fuel tank make sure you put loctite and use a lock ring on the four bolts!!

21NmCHECK

Now it is time to fasten the fuel tank under the vehicle. Use four bolts with the parts that are indicated in the pictureattheright(includedinthekit).At the side of the float element you need to place a heat shield to protect the cable of the hand brake (see picture’s).Makesurethatnoelectricalorfuellineisstuckbe-tweentheloweredfloorandthefueltank.

BoltM8*35

BoltM8*40

BoltM8*40withheatshield(seepicture’s)


45

ConnecttheØ40mmhose,byusing a large hose clamp (in-cludedinthekit),tothelargeopening on the fuel tank.

ConnecttheØ16mmhose,by using a small hose clamp (in-cludedinthekit),tothesmallopening on the fuel tank.



46

Attachtheoriginalblackattachingnippleonthe340mmØ8mmhose(includedinthekit)byusinganearclamp(includedinthekit).Attachthesideofthenippleto the lower connection on the carbon canister. Attach the other side to the fuel pipe where the black connector is coming from, by using an ear clamp (included in the kit).

Fasten the carbon canister by using ancabletie(includedinthekit).


47

Dismount the left wheel arch.

Attachbothearlierplacedhosestothefillerpipe,usingcableties(includedinthekit).

Place the air relieve valve (see picture,includedinthekit)onthe place that is indicated in the picture.Attach the hose that comes from the fuel tank to the bot-tom, using an ear clamp (in-cludedinthekit).Attach the hose from the car-bon canister to the top, using an earclamp(includedinthekit).

Mount the left wheel arch.


48

Important: The new fuel tank is full when the fuel gauge on the dashboard stands on 3/4, as indicated in the picture!! From this point the fuel gauge will give the correct fuel level of the fuel tank!!

Capacity of the new fuel tank: 45 litre.

Fuel indicator Kangoo

0

10

20

30

40

50

60

70

-0,5 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5

Meter dashboard

Litr

es

original float / 60L. fueltanknew float / 45L. fueltank


49

Diesel

PeTROl

Exhaust system6.3


50

First remount the original mounting brackets (with originalbolts)fortheexhaust,withtwobolts.Makesureyouplacethetwobracketsascloseaspossible to the heat shield.

21NmCHECK


51

Nowyoucanfitthenewexhaustsilencertoseewhereyouneedtosawthroughtheexhaustpipe.Sawthroughtheexhaustpipeandplacetheexhaustsilencerononesideontheoriginalexhaust(withanclamp)andontheotherside on the mounting bracket.

Putatoothedlockwasheroneachaxle(includedinthekit).

IMPORTANT: When the center heat shield is not standard on the car, you need to order it at your local Renault dealer!!Part number:8200521320

Important: Make sure that the clearance between the exhaust silencer and the heat shield is at least 20 mm!! 20mm

CHECK


52

Drill a hole of 8 mm for the other mounting bracket, treattheholeagainstcorrosion(includedinthekit).

FUELTANK

MountthebracketbyusinganM8jamnut,included in the kit.


53

Mounttheendpartoftheex-haust on the silencer (with an clamp)andmountthebracketontheendpartbyusinganM8jamnut, included in the kit.

Drillthreeholes(5mm)throughthe heat shield for the blind rivets.

Fasten the heat shield with three blind rivets.


54

Fuel tank protection plate6.4

Mounttheprotectionplateusingtwooriginalboltswithwashersandjamnuts. Usetwootherbolts(M8*40),with washers and metallic spacers (all included in the kit),tomounttheprotectionplate(makesureyouputloctiteonthebolts).

21NmCHECK

Important: When mounting the fuel tank protec-tion plate make sure you put loctite on the bolts!!


55

Electrical installation for 4-point belt fixation6.5

Connect the connector plug of the earlier placed brown wire with the one of the purple wire.

Placetheotherwire(purplewithswitch)ontopof the wheel arch.

Important: The green wire in the following pic-ture’s is the red wire in your set. Green is more obvious in the picture’s then another red wire!!


56

The ground switch need to come on the place thatisindicatedinthepicture(above).Drillahole(10mm)wherethegroundiscom-ing, treat the hole against corrosion (included in thekit).Mountthegroundswitchwiththescrewthat is included in the kit.

25 mm


57

The red wire is going to thefuseboxthatislocatedinside the vehicle under the steering wheel. Attach both wires to the original cable tree.

Leadtheredwiretothefuseboxinsidethevehicle.


58

PlacethesplitterinthefuseboxinfuseID9(seepicture).If present: you need to replace the old fuse in the splitter.


59

Mounting the rear and rear bumper6.6

Replacing the original gas spring:Remove the safety pins, at the bottom and top, dismount the gas spring.

Important: When you need to replace the parking sensors, make sure that you place the elctrical line (of these sensors) before mounting the new bumperpart!!

Mount the new gas springs:Placethenewgasspringsontheballjoints.Mountthesafetypins.

Place the rubber hose over one gas spring (includedinthekit).

Important: Make sure that you place the gas spring with the rubber hose on the side of the ground switch (placed earlier with the electrical installation for 4-point belt fixation!!


60

Preparing the rear hatch:Drill the original holes of the rear door to 9 mm, use a drillstop! Remove the drilling swarf and treat the holes against corrosion.

Attach the blind rivet nuts in the holes.

Then place the original door latchontheloweredfloor(with a black plate under the door latch, included in the kit).FastenthedoorlatchwithtwoboltsM8*20(inclu-dedinthekit).

21NmCHECK


61

We need the original lock for this part.

Connect the connector plug to the lock and mount the lock onto the bumperpart with two M6*20boltsandwashers(includedinthekit).

You have to change the position of the electric wire indicated in the pictures above. Otherwise there is the possibility that this wire gets stuck between the rear hatch and the bumper part.

ORIGINAL POSITION NEW POSITION


62

Attach the connector plug of the rear hatch to the connector plug of the bumperpart.Bolt the bumperpart onto the rear hatch. Use for each bolt one white and one normal washer, finnishitwithacap(allincludedinthekit).

BoltM6*90

BoltM6*80

BoltM6*70

BoltM6*40

Important: Before you fixate the bumper part on the rear hatch check if the locks are unlocking correctly!!


63

Markthesawinglinesasindicatedinthepictureaboveandsawthroughthe bumperpart. There are different versions of this bumperpart!!

Now mark the sawing lines on the steel bumper by using the earlier sawn bumperpart. And saw through the steel bumper. Remove the sawing dust and treat the edges against corro-sion.


64

Unscrew both bolts of the tie plates at each side and place the two parts of the steel bumper on the car by using the earlier used and original bolts. Now you can mount the plastic parts on the steel parts.

Original bolts

BoltM8*30andnutwithwasher

21NmCHECK

8NmCHECK

BoltM6*30andnutwithwasher


65

Placethebumpermouldonthebumperandmarkthesawinglines(bothsidesandonlythetop).Saw through the bumper according to the sawing lines at the bottom you only have to remove thepartsindicatedinthepictureabove(right).!!Keep all three parts!!

Remount the both side parts back on the car by using the original bolts.

Important: Before placing the mould make sure that bumper and mould are clean. No dust, dirt or sand!


66

Remount both parts of the bumper (by using theoriginalbolts)indicatedinthepictures.

Remounting the tail lights (both sides):Connect the connector plug.1. Mountthetaillightsbyusingtheoriginalbolts.2.


67

First glue the middle part of the bumper and the matching bumpercaps on the bumperpart. Use tape to keep them in place.

Drill a hole of 3 mm and fasten the bumper with a screw (4,2*19,includedinthekit)

Important: Use the same glue as you used for bonding the lowered floor.

If there are parkingsensors present in the rear bumper, connect them now and test it for proper functioning.


68

Drilltwoholes(3mm)oneachside(topandbottom),andfastenthecapbyusingtwoscrewswithspeednuts(4,2*19,allincludedinthekit).

Place the other bumpercaps over the original bumper (bothsides).

Important: Use the same glue as you used for bonding the lowered floor.


69

Important: Use the same glue as you used for bon-ding the lowered floor.

On the point that is indicated in the picture you need to use glue to give it a nice rounding, so the rear hatch closesbetter(useawetfinger).


70

Remounting the interior6.7

You need to enlarge the hole (12mm)whichyouseeinthepicture.Treat the hole against corrosion.

Mounting the bracket for the three point belt:Marktheholeyouneedtodrillanddrillthehole. Fasten the bracket with the bolt of the three point belt, now you can fasten the bracket with the blind rivet. Remove the bolt.


71

Nowremounttheceilingexceptforthecaponthe hole of the 3 point belt.

Remount the covers over the windows and fastenthetopbeltfixationbolts(bothsides),with 37 Nm.

37NmCHECK


72

Now remount the covers over the wheel arches. You need to remove the edge at the bottom, cut or saw this off. Fasten the covers with a screw in the bottom(includedinthekit).

In the left cover you need to make a hole for theswitchofthe4-pointbeltfixation.Markthelinesofthehole,maketheholeand place the switch.!!Don’t forget to reconnect the connector plugs of the light and the switch!!


73

Important: Only if required by customer.

Remounting the original belts of the back seat (both sides):Placeaspacer(includedinthekit)inbothholesandfastenthebeltswithanM10*50(10,9,includedinthekit)bolt,tightentheboltwith62Nm.

62NmCHECK

Remount the rubber of both side doors.


74

Remount the rubber of the rear door.Beginwiththeoriginalrubberatthetopsoyoucanfillupthespace at the bottom with the rubber that is included in the kit.


75

Mounting the 1/3 part of the backseat on the right side6.8

Dismount the 1/3 part of the back seat.

Unscrew both bolts and keep the bolts and the spacers.

Dismount the lock mechanism. And cut it off.


76

The rest of the back seat you can throw away, no need for it anymore.

Preparing the 1/3 part:Saw away both ‘legs‘ of the 1/3 part, protect the seat and treat the edges against corrosion.

Important: When you have ordered the optional folding chair make sure that you keep the head rest of the original back seat, this head rest is used for this chair!!


77

Place the two rectangular caps in the openings on the seat cusion (includedinthekit).

Place two caps over the openings of the back rest (includedinthekit).


78

Nowmountthisbracketonthe1/3part,usingtwoM6*20bolts,twoM6jamnutsandfourwashers(includedinthekit).Tightentheboltswith8Nm.

8NmCHECK


79

Mounting the seat:Place two of the original spacers on each side of the bracket.

Placethebracketonthepositionthatisindicatedinthepicture.Markthefourholesandremovethebracket.DrillthefourholesandapplyM8threadineachhole.Mountthebracketontheloweredfloor,usingfourbolts(M8*3010,9,includedinthekit).

31NmCHECK


80

Mounttheseatwiththetwooriginal bolts.

Placetheseatbeltsticknexttotheseat.


81

Ramp6.9

Remove the spring and the hinges from the assembly, asindicatedinthepicturebelow(bothsides).


82

Before you glue the mounting plates onto the lowered flooryouhavetomakesurethatthepart with the magnet is mounted as far as possible from the hole (bothsides).Youcanadjustthepositionofthispartbylooseningtheboltsandtoshuffletheparttothecorrectposition,indicated in the picture above.


83

Clean the indicated parts with Cleaner I.

IMPORTANT: Make sure that the parts which will be glued are prepared with Cleaner I and Prep M.


84

Treat the indicated part with Prep M.


85

Applytheglueontothemountingplateandplaceitontheloweredfloorasindica-tedinthepictureabove.Bolttheplateontothefloorasindicatedbelow.

IMPORTANT: After bonding the mounting plates onto the sides of the lowered floor you must wait 48 hours before using the ramp. This way, you will get the maximum strength of the glue!!

IMPORTANT: Make sure that you use the same glue as you have done for bonding the lowered floor into the vehicle.


86

When the mounting plates are fastened you can remount the hinges and the spring, as indicated in the picturesabove(bothsides).

IMPORTANT: When you are converting a car with air suspen-sion you have to mount the plate indicated in the left picture on the right side (the side where the compressorismounted).


87

Mounttherampontothehinges,whicharealreadyinstalled,byusingtwobolts(bothsides).

The double folding ramp is for the basic-version.

The single ramp is for the comfort- and the air-version.


88

Nowtherampisinstalledyoucanadjusttheposition(inthevehicle)ofit.Just loosen the indicated bolts on the mounting plates (bothsides)andpositionthepartwiththemagnetinthe position you prefer.When the ramp is in the correct position you have to fastentheboltsagain(bothsides).


89

Mounttheprotectioncoversbyusingdouble sided tape on the inner top side and two screws at the bottom.

The protection cover for the right side of an air-version is different but they are mounted in the same way as the normal protection covers.

Basic- and Comfort-version Air-version


90

4-Point belt fixation6.10

Dismount the plate and connect the connector plug and check if the belts are working before you remount the plate. Tighten the bolts with 31 Nm. 31Nm

CHECK


91

Place the rear retractors on the slide ‘n‘ click pots.


92

Mountthetopofthebeltwiththeboltandputtheprotection cap over it. 37Nm

CHECK

Drillaholeintotheloweredfloorforthe3-point belt. Place the retractor on the loweredfloor,in-linewiththeinnercatchplate bolt.

98NmCHECK


93


94

Marktheholethatyouneedtodrill,byusingthedrillingmould(nextpage)asindicatedinthepicture.Firstyoudrilltheholewith a 8 mm drill and after that you drill the hole up to 22 mm, make sure you do not damage the thread off the original bolt hole.

Options7. Mounting the folding seat (left side)7.1


95

Important: When you copy or print the drilling mould, make sure you check the dimensions before using the mould.


96

Markthefourholesthatyouneedtodrillasindicatedinthepictures.

These three holes you need to drill with a 6,5 mm drill. After youdrilledtheholesyouneedtoapplythreadforaM8boltinall three holes.This hole you need to drill with a 8 mm hole through the loweredfloorandthebodyofthevehicle,makesureyoutreatthe hole against corrosion.

Fasten the seat with the bolt that is indicated in the picture. Makesuretheseatstandsrightinthevehicle. 62Nm

CHECK


97

FastentheseatwiththreeM8*30mmboltsontheplacesindica-ted in the pictures. Tighten the bolts with 31 Nm.FastentheseatwithaM8*40boltandanutwithwasherunder-neath the car. Tighten the bolt with 31 Nm.

31NmCHECK


98

We now have mounted the seat on the left side in the vehicle. When you have to mount the seat on the right side you can do this in the same way, with a few adaptions.

Now you can place the seatbelt stalk. If your seat is installed on the left side you have to convert the seatbelt stalk so you can use him for the left side.

LEFT RIGHT


99

Mounting the stainless steel (INOX) protection plates7.2

Glue the protection plates on both sides of the loweredfloor(asindicatedinthepictures),usethesameglueasyouusedfortheloweredfloor.


100

Connecting the moved parking sensors7.3

3 of the 4 parking sensors cables need to be lengthened. Cut the wires of the two middle parking sensors.ManouvrethewireofthesetthroughtheD-styleofthecarintotherearhatch.Belowisanexampleofhowthewirescanbeconnected.

Use the provided cable connectors to connect the wires.


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Leadthewirethroughhere.


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Emergency exit7.4

Option1:Connect1wireontotheyellowwire(3)oftheRenaultplug and the other wire onto the ground of the vehicle as indicated in the picture. The button can be mounted into the left wheel arch.

Option2:Connect one wire onto the yellow wire of the Renault hatch opener and one onto the black wire. The button can be mounted into the bumper part.


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Taxi Hinges7.5 Inordertousethetaxihinges,allthesteps are the same as the installation of the ramp.

Placetheflangedbearing(2)asindicatedintothehole.Usethebolt(1)totightentherampontothehingeandusethenut(3)tosecureit.


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Installing the air suspension system7.6

INSTALLATION INSTRUCTIONS

Driverite Ltd. Unit 626 Kilshane Avenue North West Business Park

Ballycoolin, Dublin 15, Ireland Tel: +353 1 8612632 Fax: +353 1 8612647

Email: [email protected]

RENAULT KANGOO

ECAS AIR SUSPENSION

W21 - 760 - 3167

REV-04


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2

Thank you for purchasing a Driverite-Firestone Air Suspension System.

All work should be carried out in a properly equipped workshop with due regard to Health and Safety Regulations. No further reference to Health and Safety Regulations will be made, but they must be considered at all times.

The kit should be opened and the contents checked against the kit contents provided. Identify the various components and familiarise yourself with them using pictures and information provided.

WARNING

Do not inflate this assembly when it is unrestricted.

IMPORTANT This kit is not designed to increase the GVW of your vehicle. For your safety and to prevent possible damage to your vehicle, do not exceed the maximum load recommended by the vehicle manufacturer.

When fitting the wiring harness of the Driverite Air Suspension system it is advised to disconnect the battery terminals on the vehicle. Please check your vehicle workshop manual if this conflicts with any electronic vehicle management equipment. Make sure that the new wiring does not conflict with the original vehicle wiring and electronics.


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3

Pre-Assembly Information

The fitting of the Driverite Air Suspension System must be carried out by Driverite trained personnel in an authorized workshop, equipped with appropriate equipment and tools.

When routing the tubing and harness avoid sharp bends as these can lead to airline blockages or wire breakages in the long term. All tubing must be cut at right angles with a sharp blade. Do not use a pliers to cut the tubing as this will lead to deforming the tubing and can cause air leaks. Secure the tubing and harness to the vehicle where necessary and ensure they are not fas-tened to brake lines.

If it is necessary to route the tubing or harness through sheet metal then you must protect the tubing or harness from abrasion against the metal edges using rubber grommets or conduit.

The fitting instructions state where to attached the –Ve, +12V, ignition and handbrake wire. It is pro-hibited to attach these wires in a location which is not stated in this fitting instructions.

If the paintwork or corrosion protection layer is damaged it must be re-coated immediately. This can be done using corrosion prevention paint. Ensure only the metal work is coated and protect all other items within close proximity from any paint spray.

Any OEM parts that have been removed in order to fit the air suspension must be replaced back in their original position and condition. If there are any parts that require a torque setting (such as the shock absorbers) then the vehicle manual must be referred to in order to establish the correct torque setting.

Only tighten and torque the shock absorber bolts when the vehicle is at ride height. If the torque set-ting in this fitting instructions differs from the torque setting stated by the vehicle manufacturer always use the one recommended by the vehicle manufacturer.

Ensure that surrounding components on the vehicle can still be maintained and the air suspension components cannot inhibit servicing these components.


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5

Kit Contents

1. Right hand airpring assembly (x1) 2. Left hand airspring assembly (x1) 3. Bottom spacer (x2) 4. Compressor assembly (x1) 5. Air filter assembly (x1) 6. Shock absorbers (x2) 7. 6mm Tubing (x5M) 8. 6mm Tee pieces (x2) 9. Inflation Valves (x2) 10. Harness (x1)

For clarity purposes only the main items have been listed above

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6

Preparation

Start by removing the spare wheel.

Loosen the securing bolt at the rear door that clamps the spare wheel bracket in place.

Once the bolt is loosened sufficiently the spare wheel bracket can be removed from the its clamp and the wheel can be removed.

The spare wheel bracket is fixed to the body of the vehicle with a torx bolt (Circled in Red). Remove this bolt and re-move the spare wheel bracket from the vehicle.


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7

The next step is to remove the original shock absorbers. To do this you need to remove the original bolts that are on the vehicle. (Circled in red on the picture on the right) This should be carried out when the vehicle is at ride height.

Please note - do not discard these bolts as they are to be re-used.

NOTE: To avoid damage or injury always secure the rear axle to prevent tension in the parts. The rear wheels can be removed to create more working room but this kit can be fitted with the rear wheels in place.

With the shock absorbers removed it is possible to further lower the rear axle. Lower the axle until the coil spring becomes loose. Ensure the brake lines are not stressed during this procedure. It is now possible to remove the coil.

Remove the rubber bump stop (1)and lower spring seat (2).

(1)

(2)

The photo on the right shows the removed items including the coil spring (3).

(1)

(3)

(2)


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8

Before installing the adjustable shock absorber you should check that it is adjusted correctly.

Turn the wheel (or flat head screw) anticlockwise until it can-not turn any further.

The shock absorber is now set at its softest stiffness. Turn the wheel (or flat head screw) 10 clicks clockwise. This stiffness is the most suitable stiffness for this vehicle

If the shock absorber supplied is not adjustable (does not have the adjusting wheel) then you can disregard this step.

CHECK

Ensure that the bushings are correctly located in position on the shock absorbers.

Ensure that:

The top bushes should have a width of 50mm.

CHECK

The bottom bushes should have a width of 45mm.

CHECK

NOTE:

The black cover on the shock absorber body is at the top.

Locate the new shock absorbers that were supplied with the kit.

NOTE: The newly supplied shock absorbers come complete with an internal Bump Stop to replace the bump stop which was removed from the original suspension.

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45

Fitting the New Shock Absorbers


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9

Attach the top of the shock absorber to the vehicle top mount using the original nut and bolt.

NOTE: Do not tighten up at this stage. The vehicle needs to be at ride height to tighten these bolts

For ease of installation the lower end of the new shock absorbers are not bolted until the air spring assembly is attached in place .


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10

The air spring assembly then needs to be fitted to the top spring seat. For ease of installation any excess filler should be pared back.

CHECK

NOTE: When paring the filler ensure that the paintwork is not penetrated or damaged.

Identify the left air spring assembly and the right air spring assembly.

NOTE: There should be a sticker on each assembly to tell you which side is left and which side is right. Right

Left

Fitting the Air Spring Assembly


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11

Looking at the “Top Plate” of the air spring assembly - the two round spacers need to face outboard.

Ensure that inner spacer of the “Top Plate” sits in the recess of the top spring seat.

CHECK

Clamp the outboard side using the “Top bracket outboard clamp” and M8 x 30 bolts, flat washers and nyloc nuts.

Torque: 30 NM

CHECK

Top bracket outboard clamp

Leftsidefacingout

Right sidefacingout


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12

It is now necessary to clamp the inboard side of the assembly. The picture on the right shows the inboard front side being clamped.

It is fixed in place using two M8 x 30 Bolts, flat washers and nyloc nuts.

Clamp the inboard side of the assembly to the top spring seat using the “Front upper clamp” and the M8 x 30 bolts, flat washers and nyloc nuts.

Torque: 30 NM

CHECK

The rear inboard side is clamped in place using the “Rear upper clamp” which has been preassembled to contain the height sensor.

Torque: 30 NM

CHECK

NOTE: Do not mix the height sensors assemblies. Install one side first before starting on the opposite side to avoid getting the assemblies mixed up.

Front upper clamp

Front of vehicle

The height sensor linkage have been set by Driverite. Confirm this setting by ensuring that the height sensor link-age length is 130mm as per the picture on the right.

CHECK

NOTE: This measurement is taken from the bottom of the metal ball joints.


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13

The lower shock absorber bolt can now be re-inserted. The small flange on the “Height sensor lower bracket” should be facing outboard and be facing up as shown in the picture on the right.

CHECK

NOTE: Do not torque the shock absorber bolts at this point

Place the “Bottom spacer” over the raised area on the lower spring seat and bolt the airsping in place using the 3/8” UNC x 3/4” flange bolt.


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14

The compressor assembly unit is pre-assembled. For ease of installation the ECU bracket should be removed. The unit is installed on the right side of the vehicle. There are 2 x M10 holes in the chassis. These are utilised together with the M10 bolts and spring washers to fix the compressor assembly to the chassis.

Torque: 60 NM

CHECK NOTE: The compressor bracket is adjustable. Ensure there is 15mm clearance from the front of the compressor bracket to the airspring.

Remove the Torx screw holding the plastic mud guard in place. This will create more access when fixing the ECU bracket back in its original position.

Fitting The Compressor Assembly

Bolt the ECU bracket back in place using the M6 bolts, flat washers and nyloc nuts.

NOTE: The ECU bracket is adjustable. Ensure the ECU is not showing below the rear bumper at eye level.


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15

Connect an airline from the left air spring to the port on the valve block marked LR (Left Rear). Connect an airline from the right air spring to the port on the valve block marked RR (Right Rear). Check that there is an airline connecting the air drier on the compressor to the port marked COM (Compressor) on the valve block.

CHECK

Locate the air filter in a clean, dry location. Run an air line from the compressor intake to the air filter.

LR RR COM

Decide on a convenient location for the emergency inflation valves. Cut the airline that runs from the left airspring to the valve block. Insert the 6mm tee piece and run a short length of tubing from the tee to the chosen position for the inflation valve.Repeat on the opposite side. Use the inflation valves to bring the vehicle to ride height. The recommended ride height is 430mm from the wheel arch to the centre of the wheel for this vehicle. The shock absorber bolts can now be tightened and torque.

Torque: 175 NM

CHECK

NOTE: Ensure the “Height sensor lower bracket” does not move when torquing the shock absorber lower bolts. The top of the Driverite bracket should be parallel with the out-ward flange on the vehicles lower bracket for the shock ab-sorber

Connecting The Air Lines/Emergency Valves


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16

Height Sensor Template

This template is to scale and can be cut out of the manual and placed over the height sensors as out-lined above to establish if the height sensors are working within their toler-ances.

The height sensor arrangement has already been tested for this kit to ensure it is working within its tolerance. When the axle is hanging (max rebound) the height sensor arm must not enter the lower red section on the template. When the suspension is compressed onto the bump stops in the shock absorbers (max jounce) the height sensor arm must not enter the upper red section on the template.

This template slides on over the height sensor arm and lays flush with the height sensor. Once you are finished using the template you can either remove or leave it on.


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17

Harness Layout

1. ECU Connection 2. Compressor Connections 3. Valve Block Connection 4. Compressor Relay 5. Right Height Sensor Connection 6. Left Height Sensor Connection 7. User Interface 8. Programme Box 9. Handbrake Wire (Brown) 10. Speed Signal Wire (Black/Red) 11. Ground Wire (Black) 12. Ignition Wire (Purple) 13. Constant Live Wire (Red)

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Connecting/Routing the Harness

Connect the valve block to the harness as shown.

CHECK

Connect the ECU to the harness as shown. Secure any excess harness to the chassis using cable ties.

CHECK

NOTE: Ensure the harness is not exposed to any sharp objects or close to the exhaust. Do not attach the harness to the brake lines.

The harness is routed starting from the compressor. Connect the grey connection on the compressor to the grey connector on the harness. Connect the black connection on the compressor to the black connector on the harness.

CHECK


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Connect the right height sensor connection to the right height sensor. Repeat for opposite side.

CHECK NOTE:That there are 3 wires in each height sensor connection on the harness. 2 of these are common—black/blue and red/blue. The remaining third wire can be used to identify the left from the right height sensor. The connection with the green wire goes to the right height sensor while the connection with the brown/white wire goes to the left height sensor.

Left Height Sensor

Connection

Right Height Sensor

Connection

Open the rear door and remove the plastic panel on the right.

Temporarily remove the rear lights on the right hand side as shown.

Disconnect the User interface and the Programme box.

Route the disconnected end of the harness up into the cabin at the rear through the space in the bottom near the bumper. There is a 15mm grommet located behind the rear light. This grommet is used as an access point to get the harness into the vehicle. Once the harness has been routed into the vehicle the rear light can be put back in its original position.


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19

Mount the Programme box on the rear wall as shown.

Make a square cut-out in the square panel and mount the user interface as shown.

Note: Ensure the orientation is correct; the pink wire at the base of the switch should be on the top.

Write the location of the programme box in the back page of the user operating manual.

The remainder of the harness is routed up to the engine compartment with the exception of the brown and purple wires (Handbrake and Ignition wires respectively). There is a recess in the centre of the vehicle. This can be used to route the harness. Secure the harness in place using cable ties.

NOTE: DO NOT ATTACH THE HARNESS TO ANY BRAKE LINES, MOVING PARTS OR NEAR THE EXHAUST.

Temporarily remove the centre arm rest/storage compart-ment to reveal the OEM handbrake wire. This is the wire that sends a signal to the dash panel to illuminate the red handbrake light when the handbrake is activated.

Route the handbrake and ignition wires (brown and purple) into the cabin through the grommet in the centre of the vehi-cle.


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20

The handbrake wire (brown) is cut to length and the piggy back connector is crimped onto the cut end. Remove the original handbrake wire and insert it into the male connector on the piggy back connector.

Insert the female connector into the original male spade on the handbrake. (i.e. The spade that the original handbrake wire was removed from).

Remove the plastic cover under the steering wheel to ex-pose the fuse compartment. Feed the purple ignition wire into this fuse compartment and secure it using cable ties where necessary.

Temporarily remove the indicated red 10A Mini fuse from the fuse box. This is an ignition controlled fuse. It is located 4 rows up from the bottom and it is the second column from the left as shown in the picture on the right.

Connecting The Handbrake Wire

Connecting The Ignition Wire

At the end of the ignition (Purple) wire on the harness there is a dual housing mini fuse holder. There should be a 5A fuse inserted into the end furthest from the male spades on the housing. Place the removed 10A fuse in the remaining slot as shown.

Insert the 2 exposed spades on the housing into the slot on the fuse box that was previously used to hold the 10A fuse. Replace the plastic cover over the fuse box.


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21

The ground (black) and constant live wires (red) now needs to be routed to the fuse box in the engine compartment.

The black wire is connected to the ground (-ve terminal) on the battery as shown.

Connecting The Ground Wire

Remove the red cover that protects the positive terminal on the battery.

This will reveal a strip fuse busbar.

Use an empty slot to fix the 40A and strip fuse in place. Replace the protective cover.

Check all connections. Ensure all bolts are securely fastened Follow the setting instructions on the following pages to pro-gramme and calibrate the heights. NOTE:There is a time delay in the system.

Connecting The Constant Live Wire

Place the sticker that states “This vehicle is fitted with DriveRite air suspension” on a visible location on the vehicle.


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22

Step 1: Programming Setup

NOTE: PLEASE ENSURE ALL MEASUREMENTS ARE ACURATELY TAKEN

• Chock the front wheels to stop the vehicle from moving during the programming process.

• Leave the handbrake off until you are finished programming the suspension system.

• Turn the IntelliRide system off using the service switch. When the system is off the side of the switch will be red.

• Locate the push button program switch in the harness. This is in the programme box at the rear of the vehicle together with the service switch and the diagnostic connector.

• Turn on the vehicle’s ignition and leave it on until the entire programming of the vehicle’s heights is completed.

• There should be no lights on the height selection switch at this time.

• Push the program switch three times within six seconds.

• The lower light on the height selection switch should start blinking. This will be indicating that lowered height needs to be programmed into the ECU.

Programming The System (Program Switch)


125

Important: When you are going to program the different heights of the system it saves you a lot of time when you are using a relative simple tool. You can make some wooden blocks for each side of the vehicle, when you place these blocks in front of the rear wheels you get the three different heights programming heights. In this way you have a simple tool which you can use for each vehicle and you do not have to mea-surethedifferentheightsanymore.Anexampleofthewoodenblocksisindicatedinthepicturebelow.Theheight of the standard block is 175 mm, the height of block 1 is 15 mm, the height of block 2 is 75 mm and theheightofblockthreeis50mm.Forthefirstprogrammingheightitisbettertouse360mminsteadofthe350mmthatDrive-Riteprescribes.

1. 2.

3.


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Step 2: Programming the Lowest Vehicle Height

• Set the lowest height of your vehicle’s suspension by either using inflation valves at each cor-ner or jack stands.

Note: The lowest height cannot be fully deflated. The lowered position should be a minimum of 5mm from where the jounce bumper stops. This small gap is required to allow for a tolerance as the suspension height is controlled by the ECU. Without this small tolerance, the ECU will not achieve the lowered height if the suspension is stopped before the ECU believes the low-est vehicle height is reached.

The recommended lowered height is 350mm from the wheel arch to the centre of the wheel.

• When both rear corners of the vehicle are at the lowered height that you determine, hold the program switch in for eight seconds.

• The top light on the height selection switch should start blinking indicating that the ride height needs to be programmed into the ECU.

Step 3: Programming the Vehicle Design (Ride) Height

• Set the ride height of your vehicle’s suspension by either using inflation valves at each corner or jack stands. When the vehicle is at the ride height that you determine, hold the program switch for eight seconds.

The recommended ride height is 430mm from the wheel arch to the centre of the wheel.

• Both lights on the height selection switch should start blinking back and forth. This will indicate that the calibration height needs to be programmed into the ECU.


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Step 4: Programming Calibration Height

• This calibration step teaches the relative suspension reaction to the IntelliRide system. Spe-cifically this sets the internal tolerance bands and provides a relationship between the voltage that the ECU reads and the suspension height.

• Lower the height of each corner by 25mm by either using inflation valves at each corner or jack stands.

• When the vehicle is at the calibration height, hold the program switch for eight seconds, and then release.

• Both lights in the height selection switch should be on at the completion of programming.

• Turn off the vehicle’s ignition, and switch the service switch off so that it is all black and not showing red. After the vehicle’s ignition is turned back on, the system will put the vehicle at standard ride height.

Additional Note – 3rd Height Function:

INTELLIRIDE offers a very versatile and flexible computer system that allows you to regulate the height and lowering of the vehicle.

Typically 2 heights are provided :

1) Ride Height 2) Access lowered height.

We can also provide an IntelliRide ECU that gives a 3rd height option for extra height typically used for off-road or multiple height settings if required. In this case the speed signal wire must be connected.


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Ride Height at 430mm

Access Height at 350mm

Height Settings Visual


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Checklist

General Checklist CHECK

1. Ride height and access height has been set at the correct measurement

2. Shock absorbers have been adjusted to the correct setting

3. Shock absorbers have been torqued at ride height and to the correct torque setting

4. All other buts and bolts are secure and torque where stated

5. Harness, air-line and connectors are secure

6. The system was checked for air leaks

7. There is 15mm clearance around the airsprings

8. The ECU, compressor and valve block have been connected to the harness. An audi-

ble click is head when the connection is sealed.

9. Height sensors connection are in their correct side and have been connected to the

harness. An audible click is head when the connection is sealed.

10. Air Suspension Stickers have been applied

11. The back page titled “Service Information” on the User Operation Manual (which will be

kept in the vehicles glove box) has been completed

12. User Operation Manual has been placed in the glove box

Height Sensor Checklist CHECK

1. Height sensor orientation is correct

2. Is the threaded bar set to the correct length (130mm)?

For troubleshooting please refer to the “User Operation Manual” supplied with this kit.

Note:

The “User Operation Manual” should be stored in the vehicle that has been installed with the air suspension. This can be referred to by the end user for reference.


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Important: ThewarrantyspecificationsofDrive-RitefortheairsuspensionkitaredifferentthentheBier-manwarrantyspecifications.YouwillfindthewarrantyspecificationsofDrive-Ritebelow.

Driverite and Firestone Industrial Products Company warrants that its Air Suspension Products will be free fromdefectsinworkmanshipormaterialsforaperiodof24monthsor40,000km(whichevercomesfirst)from the date of installation.

TheDriveriteLtd.guaranteedoesnotapplyto:

CostsofmaintenanceasrecommendedbyDriveriteLtd.•Replacementofpartssubjecttonormalwearandtearconsideringtheusageandmileageofthevehicle.•Indirectconsequencesofadefect(recoverycosts,lossofuse,etc.)•


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Hydraulic kneeling system7.7


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Parts of the lowering system

Warning:Thehydrauliccylindersincombinationwiththepumphaveamaximumforceof7000Npercylinder.Makesurethepumpisdisconnectedwhenworkingonthe hydraulic system.

Item Title Qty Art.nr.1 Pumpbracket 1 N100005006 2 Cilinderbracketleft 1 N100005014 3 Cilinderbracketright 1 N100005015 4 Axlebracketleft 1 N100005016 5 Axlebracketright 1 N100005017 6 2-2Valveset 1 N150005007 7 Electrics 1 N150011011 8 Diodekabel 1 N150011015 9 SmallMaterial 1 N150013030 10 Hook 2 N703605004 11 Pump with presureguard 1 HE1-AP-SETA 12 Hydraulicpipeset 1 N756705001 13 Pullcylinder 2 N726605001 14 Hydraulicfluid 1 VB030051D0

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13

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4 3

9

7

1

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Removal of partsRemove the interior wheel arch cover on the left hand side. Both rear wheels can be unbolted for easier access, however this is not necessary. Removeanymaterial(grease,kitetcetera)thatpreventsthebracketstobemountedsnugontothebeamsofthe vehicle.

Mounting the lowering system

Mountthelongesthosesontherightcylinderandtheshortesthosesonthelefttcylinder.Thetop(A)willlateronbefittedontherightsideofthepump;thepipeswiththepressureswitch.

Bolt each special lowering cylinder on the cylinder brackets withtwoM10x60Bolts(1)andtwoM10lockwashers(2).The cylinders are identical and can therefore be mounted left or right.


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The brackets with the cylinders can now be mounted under the vehicle. Thebracketsshouldfitflatonthebeamsofthevehicle.Tomountthefrontofthebracket,puttheplatewiththeinnerthread(1)intothebeamandmountthebracketwiththethread(2),nut(6)andwashers(9&10).TheboltM8x30goesintheotherhole.ThetwoM10x30bolts,twowashersandtwospringwashersshouldbe bolted into the original threads on the back of the longitudinal beams.


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Thehydraulicpipesshouldbescrewedintoplaceontherearbeamwith4ofthetubeclamps(3)andtheincludedselftappingscrews(5).

Important: Do not screw the tube clampsintheloweredfloor!


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Theaxlebracketscanbemountedontherearaxleasindicatedintheimages.Usetheoriginalboltoftheshock absorber.

Important:Ifthewheelsareremovedtherearaxleisnotsup-ported when the shock absorbers are removed simultaneously. Supporttherearaxlewithajackorsimilardevice.

Important: Do not place the hooks on the brackets yet! Wait until the lowering system is fully in place and the vehicle is standing on its’s wheels.

Drill a hole trough the bracket and the spring seat andplacetheincludedM6boltwithwasher.


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Drill the three holes in the body of the Kangoo behind theleftwheelarchcovertoØ9mmtoplacetheblindrivet nuts.

The pump bracket can now be mounted intothevehicle,usingtheM6x20bolts,theM6springwashersandtheDIN9021washers.


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AttachthiscabletothebatteryONLYiftheconnections of the battery are disconnected!

Route the cable through the car as depicted in the drawing. The side with the attached eye should go on the battery.

Tape the red wire to the original cable tree under the bonnet, from the battery to the point where it goes into the interiour.


139

Connectthewiresontothesixlocationsofthe pump and the relays as indicated in the picture.

Theconnectorforthe10mm²cableispreassembled onto the pump relays. Connect it to the cable in similar to the one that is already attached to the cable.

6

32

1

4

5

The pump can now be placed on the pump bracket in the vehicle, usingthetwoM10x25bolts,theM10springwashersandtheM10DIN125washers.

Drilltwoholes(Ø24mm)inthesteelwheelarchforthethroughputofthehydraulicpipes.Youcanuseeither the included rubber grommets or seal the hole with the same kit you use to bond the composite loweredfloorinthecar.


140

Attach the purple wire with the diode to the ground switchofthe4pointfixation.

Remove the two relays from their socket and screw the socket under the wheel arch cover. Place the relays back in their sockets.

Connect the yellow cable from the pump and the brown wires to the ground on the car.


141

Attach the hydraulic pipes as indicated belowandfillthepumpwiththehydraulicfluid.Thelevelshouldbejustunderthefillopening.

ABC

A

C

B

The valve can be mounted where there is room available (the position the valve is in, is unimportant


142

Cutahole(22mmx45mm)indeleftwheelarchcoverasindicatedinthepicture,nexttotheswitchofthe4pointfixationswitch. Place the switch of the kneeling system in the hole.!!Don’t forget to connect the connector plugs of the light and the switch!!

Testifthecylindersoperateasexpected!


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Important: When the weight has been lifted from the suspension it takes some time to get back into it’s original position. Best is to make a quick drive beforeassemblingthehooksontotheaxlebrackets.

Toplacethehooks: Rotatethecylindersjustuntilthegrabbersarepointingforward. Thehooksshouldfitontheaxlebracketsasbelow.MarktheholesoftheaxlebracketonthehookanddrillthroughthehookØ9mm.EachhookcannowbeassembledwiththetwoM8bolts,4 rivets and 2 lock nuts.

Checkallhydraulicconnections(pump,cylindersandTeefittings)foranyleakage.Test if the system is working appropriately.Ifthesystemisnotworkingasitshould,checkthefuses,themass(doorswitch)andthebatteryconnection.


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8. Notes8.


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Contact9.

Bierman BVP.O.Box99,2150ABNieuw-VennepPesetaweg 16, 2153 PJ Nieuw-Vennep

The Netherlands

Tel.:+31252210611Fax:+31252232985

Email:[email protected]:[email protected]

www.bierman.eu


149

Stefan Bostelaar (NL-UK)email: [email protected]: + 31 252 629172

Technical advise/helpdesk•Training•Installation manual•Warranty•

Erik Henneken (NL-UK-D-F)email: [email protected]: +31 252 210611

General Manager•

Nicolette van Berkel (NL-UK-D)email: [email protected]: +31 252 629150

Booking trainings, travel + hotel•Dealercontracts•Database of s/n’s, orders, customers, •VIN’sOrder intake + invoicing•

Contact persons9.1

Alex Vieveen (NL-UK)email: [email protected]: [email protected]: +31 252 629157

Parts•Distribution•

Other email addresses9.2

Sales: [email protected]: [email protected]


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Recommendation form10.

YOUR REMARKS:

Dear installer,

Biermanstrivestoexcelindeliveringthehighestqualitywheelchairconversionkitsforvehicles.However this is an ongoing process. Therefore we are interested in your opinion! So if you have any com-ments, improvements or recommendations, please tell us. After all, with your input we are able to improve theconversionkit(andmanual).Thisisnotonlyinourfavour,butalsoyouandyourcompanywillbenefitfrom this!

[email protected],orsendthisfeedback-formtofaxnr.+31252232985.

Company:

Your name:

Date:

Vehicle:

Engine type:

Conversion:

Manual version:


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installation manual renault kangoo swb wav-conversion petrol · version 1.9 renault kangoo 33 now...

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