Kangoo Compact (aka Racevan3)

[Brigsy]

The two valves are mad, i thought it had been a f**k up when making the wheels initially, googled it to check it out and seems to be a rally thing.

Another pic from the side Ive come to the conclusion with a good bit of power itll be for go and not for show :LOL:

Seen quite a few modded Kangoo2 on instagram when having a sniff round. Most are stanced shite and on air or ridiculously static low.

Seen this though and looks great, i dont think i want to go as low purely for handling purposes, but will see. Facelift looks good too:unsure:

 

[Brigsy]

Small job done tonight after gym. The meg 250 inlet has a breather solenoid fitted which i dont have and is about a ton new. I wont be needing it as basically emissions crap as far as i can tell and i will be running a catch tank setup from the breather plate.

Anyway tried sniffing out a 2nd hand valve to blank the hole but no joy, was considering sending it to the local fabricators to get it gone permanently but have not had time to drop it off.

Browsing ebay and seen some bmw swirl flap alloy bungs with o ring, same diameter as the hole. Bought one for pennies and it fitted the hole but was a tiny bit slack, so fitted a small o ring under the original to nip it up, which has made it a really tight fit. Had to chop it about a little to get it on but looks alright.

 

[Brigsy]

Started off with setting cam timing and torquing the pulleys/tensioners up. Tippex method :LOL:

Cambelt cover on, aux pulley torqued, top cover mocked up as still need the spacers for the studs. Inlet mocked up, need to drill and tap the end for the extra bolt.

Fitted 250 dmf and clutch and rebuilt pk cup gearbox with lsd

Starter motor and 19t dropped in place. Turbo needs a rebuild, have made enquiries about that so that's away this week hopefully.

Megane engine mount should go straight in, same on gearbox side.

Getting closer to dropping it in the engine bay to see whats what, i reckon it should be in very soon:whistle:

 

[Brigsy]

Home made 20mm throttle body adaptor to fit 225 throttle on 250 inlet. Bit pikey but should work ok

Drilled and tapped throttle body to get rid of the crap push fit pipe

Sealed with loctite on the threads and copper washer

Give it a quick tart up, gasket cut and fitted

Inlet fitted, breather plate sealed and fitted, new plugs in, m6 thread bar to make studs for coil packs instead of bolts.

Next job was to pull diesel engine bay loom out, looks a bit better without the rats nest

Dci engine loom top, r26 bottom

R26 loom should bolt into underbonnet fusebox easy enough, both kangoo and r26 upc look very similar, kangoo one below. A few less fuses than meg but not worried about that as i will add my own wiring for fuel pumps.

Tried the r26 s3000 ecu and the plug that joins the dbw throttle plugs straight in. I have compared wiring for both on Visu and the Kangoo pins are identical, my kangoo might not have cruise wiring thats the only difference.

In theory, immob virginilize on r26 ecu and it might sync up to the kangoo setup fingers crossed. Its all very meglio like to do.

Turbo is on its way, so trial fit very soon.

 

[Brigsy]

Quick photoshop one of the lads done me on Cliosport, looks epic

 

[Brigsy]

Done a little bit more today. Engine dynamics stg 2 turbo purchased this week (think its based on 20t) supposed to be good for 360hp.

Fitted. Lifting eyes on, engine crane collected.

Lockdown? Its engine fitting time.

 

[Brigsy]

Foggy on Sat which was not motivating me to do any outside work. So dtuck all the ancillaries back on the engine, mocked up wiring (ignore the incorrectly plugged in wiring as couldnt be arsed popping the bonnet on the 225 to find out what goes where :LOL: )

Filled it up with oil and primed the oil circuit up, cranked engine over for a few seconds on the starter to prime it up and check prv was not stuck on the pump, all good.

Planned on fitting engine Sunday but was pissing down all morning. Eventually stopped so turned it round and stuck it nose first in the garage, front end off.

Engine and box on the crane, rolled it over to the kangoo and it just fell into place, straight in on the meg engine mounts. Thats one milestone achieved i guess !

Plenty of room for 3" decat. The whole setup fits a lot better than expected, proves that its megane or clio 197 based engine bay.

Sits a lot better with engine and box in, rear rideheight still offensive though so got that to sort.

F4r looks right at home.

 

[Brigsy]

Done a bit more at the weekend. Mostly mocking up what will fit and finding out what needs modification.

Tried a few combinations of gear cables that i have in stock, no joy as all around 75-100mm too short. Custom length bowden push pull cables are not too expensive so should be easy to sort. Kangoo clutch pipe fitted but knacker tight and the damper looked quite rotten, so ordered a 250 damper delete braided hose to get round that.

Cables everywhere.

Offered up megane rad and boost hoses, fits great just needs some brackets making up, tons of room for a large intercooler.

For mock up purposes i had used the meg 175dci gearbox mount that bolts to the gearbox combined with the original Kangoo dci alloy cradle on the inner wing. Everything bolted up ok but from some angles the engine looked a little bit on the piss.

The main issues were gearbox close to the subframe, and inner cv close to subframe, and dogbone was a little tiny bit off. It would have worked as is, and nothing hit when rocking engine with no dogbone mount on but was keen to get it fitted better.

Anyway done some digging and the 175 dci cradle that bolts to the inner wing was slightly higher than the kangoo one and more biased towards the front of the car. Ordered one from Latvia and turned up fast, its shared with some grand espace diesel, not that common.

Kangoo one in this pic

Megane 175 dci in pic below

Has sorted all the issues out. Its raised the box up by around 15mm giving more clearance to cv, and pulled box forward by 25mm or so. Ample clearance all round and engine is sat better.

Offered up the dci 175 driveshafts and they look like they will go no issues. Had to order a pk intermediate bearing carrier to suit as ndo one wont fit.

Ran out of jobs to do so done a bit of wiring. Its all plugged in, i reckon with immobiliser sorted and a fuel pump & pipe fitted, this will be up and running.

 

[Brigsy]

Kangoo clutch pipe was knacker tight so ordered a hel 250 dampener delete pipe. Had to modify the kangoo bulkhead joiner to fit the 250 pipe. Filled reservior up and stuck a pipe/syringe on the bleed point on clutch slave, pulled a vac and it bled up straight away, so hydraulic clutch is sorted.

Rebuilt dci 175 shafts with better condition outer cvs (messy horrible job)

Test fitted using the 250 PK intermediate bearing hanger and seem to fit ok, not much plunge on the passenger shaft only 8mm or so, should be able to move the engine over a few mm to drivers side if needs be so not too worried. So thats the drivetrain almost complete.

Looked at the brakes next. It had an issue with the pedal being stiff/sticking down when i first got it. As not used it not looked at it until today. Check out the rust on the clevis pin that joins the bar setup to the servo/master! Looks like its been in the sea, no leaks inside dry as a bone :unsure:

Tried to remove the pin and its solid. I lubed it up and it seems to have freed off, but ill revisit this soon and strip it down proper when i bleed the brakes.

My eeprom reader has turned up so had a crack at fitting the ecu and powering it up to test wiring. Cracked ignition on and the results are promising, all warning lights working as oem, oil leve correct pops up

Stuck clip on and the first screen pulls the megane vin number up :LOL: as clocks and ecu are matched seems to override the Kangoo uch which cant be entered as the vin is not matched.

Can access s3000 ecu ok, live parameters see coolant temp etc, but as ecu is immobilised cant clear any faults. Throttle body is powered up and moves when throttle is pressed. Promising stuff

After that small win i pulled out the eeprom reader and read the 95160 data, virgined the file and wrote it back to the ecu. Plugged in the ecu and scanned with clip to see if successful, Kangoo vin came up, ecu was powered up again but not available on clip. It seems like the vin needs inputting, but will prob need to do it with an open source diagnostic like pyren or ddt4all.

Ive done tons of research on the s3000 this week and i really need to get it more complete/near ready to fire so i can check more stuff before i really attack this.

Theres a few options but if all else fails ill bang a julie immob emulator on and its got no option to start.

 

[Brigsy]

Currently working on immobiliser issues but should be able to get over it.

Up to now i have successfully wired in the Sagem s3000 ecu in place of delphi dcm 1.2 / fitted cluster to suit & both talking to the Kangoo Uch. Not attempted a start yet, just testing the wiring, as fuel system is not complete.

Ecu is powered up and throttle responds etc. I plugged it in and scanned with clip which showed me the ecu and cluster, and the megane vin number to match but immob active. Can scan both s3000 ecu (immobilised/fault present as expected) and cluster but bcm and other modules not available (vin not matching causing issues i assume)

Took eeprom 95160 immob data from original delphi dcm1.2 and written onto sagem s3000 95160 to test if it would work - no joy ecu not available on clip - did not think it would but worth a try.

Used original 95160 immob data off sagem s3000 to make virgin ecu file wth ecuvonix - Scanned with clip and Kangoo vin comes up, cannot connect to ecu/cluster, checked vin and no vin data in s3000 ecu.

Scanned with ddt4all and all modules accessible, i dont think engine ecu immob is active but i believe uch is active.

Am i right in saying that i will need to virgin the uch, reprogram keys and that will let me sync the virgin s3000 ecu immob and vin will be added to s3000 ecu?

if not is immob emulator only option, which should work ok providing i write the original 95160 data onto the s3000 and possibly change wiring for starter solenoid.

Any help appreciated.

 

[andybond]

Great update. The van appears to have crazy proportions but strangely looks correct when next to a clio ..

 

[Adey]

Epic update, love the Renault parts bin builds and how everything over all the generations is so interchangeable.

Do you have both UCH's from the donor and original? I have gotten around the immo issue before by removing the immo chip from one to another on the 172/182 before.

Not been into the ecu side of things for donkeys so not sure where the 95160 is, isnt that on the ECU itself?

 

[Sparkysparks]

How did I miss this. Its mental. And really is a bit of a chode. Will it not be a bit back end jumpy being so short. Tall. And powerful? Will be hilarious embarrassing expensive cars

 

[DaveL485]

Like this, but OE!

 

[Turbell]

Absolutely amazing work!
Love how you spend in just the right places, no feckin about.
ECU stuff is way over my head, I'm too simple .....I bought can clip and had a mate sort it out onto an old laptop and plugged it in once whilst he was there....never touched it since....thought , Nah....leave that alone looks like an accident waiting to happen with my fingers and analogue brain.
This age of car is ripe for parts bin fun.

 

[Brigsy]

Cheers all, its coming together steady.

@Adey the 95160 is the small 8 leg chip for the immobiliser, one is on the back of the ecu & another somewhere in the uch. I think its the same one as 172/182. I have the gear to program it, i flashed the diesel immobiliser as it shares same chip & onto the s3000 ecu. Did not like it as i gather vin number was in a different place when reading the hex file.

I do indeed have the matched uch, i guess chip swap might work between uch’s but id still have to reprogram the keys as meg is card compared to normal key, might prove tricky if any differences in the bin data. Im thinking just rip the isk and pin code off current uch and virgin the lot and reprogram keys.

Should sync up as Kangoo2 petrol runs an s3000 ecu? Only one way to find out, i have the 3rd party software to do it (albeit in french)

@Sparkysparks its clio2/3 length so handling shouldnt be an issue especially rocking the meg bits up front. Just looks odd/short for a van id say they are rare but ive seen a couple of merc citan compact this week. As far as i know Kangoo2 compact was only sold for a year or two in the uk. Be comedy with a load of power hopefully!

@Turbell i think most of the work on this has been hours researching what will fit and what wont but have been quite savvy and bits seem to be falling together. On most parts you seem to have an option of using megane2, clio3 or meg 250 parts depending what is available, its crazy the platforms are all quite similar yet slightly different.

The ecu immobiliser stuff is a totall ballache agreed. Deep down i can just bang a standalone ecu on and it will do all i need but it will be nice to get it going on the original stuff if poss.

 

[davemaygtt]

What a read, great stuff brigsy.
Your engine work is always great but love the seats and fitment of them to!

 

[Big Steve - Raider]

The making of another devastatingly quick but equally great looking racevan @Brigsy!!

Great work sir and look forwards to seeing how this one comes together!!

I love the look of the facelift you posted earlier, looks a lot meaner than the sweet & innocent face the van has at the moment..!

 

[binge]

if not is immob emulator only option, which should work ok providing i write the original 95160 data onto the s3000 and possibly change wiring for starter solenoid.

Any help appreciated.

I can't help with programming of keys etc.
But I can tell you when the Immo is deactivated your fuel pump will prime on ignition pos2 and you'll get 12v at the coils. So even if you're not in a position to start the van, if the coils get 12v you know it'll start.

Id have loved to run something more OE / permamant than the carlabimmo hardware but the MK1 Mégane gubbins are all just too old.

I know the Meglio conversions are fairly straight forward though as the Immo is transferred into the Clio key. I can't see it being much different for the Kangoo?

 

[DaveL485]

I know the Meglio conversions are fairly straight forward though as the Immo is transferred into the Clio key

You reprogram the Megane ECU to work with the original Clio key & Imob.