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"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
Scénic II - Section 3
Contents
Page
3877
IMPORTANT
This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before
removing them.
30A-1
GENERAL INFORMATION
Brake circuit Bleeding 30A
Essential equipment
pedal press
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Brake circuit Precautions for repair) .
WARNING Note:
The level must be between the « MIN » and The new hydraulic unit is pre-filled.
« MAX » markings on the reservoir.
When working on one of the following compo-
nents, position a pedal press to limit the outflow
of brake fluid and prevent any air from entering
the master cylinder and the circuits downstream
of the master cylinder:
- hydraulic unit,
- pipes between the hydraulic unit and brake cal-
lipers,
- brake hoses,
- brake calliper.
Remove the pedal press before carrying out the
braking system bleeding procedure.
30A-2
GENERAL INFORMATION
Brake circuit Bleeding 30A
a Connect the brake circuit bleeding device (after a Remove the brake circuit bleeding device from
having received Renault approval) to the master cy- the master cylinder reservoir.
linder reservoir (see the instructions for the equip-
a Check pedal travel and resistance. If it is not correct,
ment).
finish bleeding the brake circuit with the help of a se-
a Pressurise the brake circuit. cond operator. Start the bleed operation by bleeding
the calliper that is the furthest away from the master
a Adjust the pressure to between 1.5 bar < P < 2 bar cylinder:
for 3 minutes to stabilise it in the braking circuit.
- hold down the brake pedal,
a Close the circuit between the bleed screw and brake
fluid reservoir without dumping the pressure. - open the circuit bleed screw to release the air from
the brake circuit,
- close the circuit bleed screw,
Note:
- release the brake pedal.
The circuit between the bleed screw and brake
fluid reservoir is closed in different ways depen- a Top up the brake fluid level in the reservoir, if neces-
ding on the type of equipment used: sary. Check the sealing of the front and rear bleed
screws and ensure that the sealing covers are in pla-
- valve, ce (see 30A, General information, Brake circuit
- switch. Tightening torque, page 30A-4) .
a During a road test, trigger braking regulation to con-
a Fit the bleed containers to the four bleed screws of
firm that the brake pedal travel is correct.
the callipers.
a Clean off any traces of brake fluid on the vehicle
a Undo the calliper bleed screws: using BRAKE CLEANING PRODUCT (see Vehi-
- front left-hand, cle: Parts and ingredients for the repairwork)
- front right-hand,
- rear left-hand,
- rear right-hand.
a Open the circuit between the bleed screw and brake
fluid reservoir and allow the liquid to run until all the
air bubbles have been released.
a Tighten the bleed screws in the following order:
- front left-hand,
- front right-hand,
- rear left-hand,
- rear right-hand.
a Undo the calliper bleed screw:
- front left-hand,
- allow the fluid to run until all the air bubbles have
been released,
- tighten the bleed screw on the calliper.
30A-3
GENERAL INFORMATION
Brake circuit Tightening torque 30A
I - FRONT AND REAR BRAKES
Description Tightening
torque
(N.m)
II - BRAKE CONTROL
Description Tightening
torque
(N.m)
30A-4
GENERAL INFORMATION
Brake fluid: Specifications 30A
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc bra-
kes (hollow pistons which conduct little heat, have a
low volume of fluid in the cylinder, sliding callipers avoi-
ding the need for a fluid reserve in the least cooled
area of the wheel), has allowed us to prevent the risk of
« vapour lock » as far as possible, even with heavy
braking (mountainous area). However, current brake
fluids are subject to minor deterioration during the first
months of use due to slight humidity intake. This is why
it is recommended that you change the brake fluid: see
maintenance booklet for the vehicle.
30A-5
GENERAL INFORMATION
Brake: Specifications 30A
Engine
Piston diameter 54 54
Disc thickness 24 24
Piston diameter 34
Disc thickness 10
Diameter 23.8
Stroke 36
(1) Scenic.
(2) Long Scenic.
(3) Brake discs cannot be reground. If they are too hea-
vily worn or scratched they must be replaced.
30A-6
GENERAL INFORMATION
Steering: Tightening torque 30A
I-
Description Tightening
torque
(Nm)
II -
Description Tightening
torque
(Nm)
30A-7
GENERAL INFORMATION
Axle assemblies: Check 30A
a Lock the slip plates of the lift.
- track rods,
- subframe,
- shock absorbers,
- tyres,
a Check:
- tank full,
a Consult:
30A-8
GENERAL INFORMATION
Underbody height: Adjustment values 30A
I - MEASURING POINTS
101937
Radius under load:
- (R1) : Distance between the ground and the front
wheel centre line
139129
- (R2) : Height between the ground and the rear wheel
centre line (W1) : Height between the ground and the rear cross
member bolt head.
1 - Front height (W1)
2 - Rear height (W2)
102312
102246
30A-9
GENERAL INFORMATION
Underbody height: Adjustment values 30A
1 - Plate higher than the lift:
126087
II - MEASURING METHODS
2 - Plate lower than the lift:
Note:
For measurements (W1) and (W2) , take into
account the height difference between the plates
and the lift.
126088
Note: Measure the heights (1) , (2) and (3) .
The value of Wx to be entered into the geometry Example: (1) = 8 cm, (2) = 10 cm, (3) = 4 cm
bench is the average of the W1 heights, right-hand
and left-hand and of the W2 heights, right-hand and Calculate the height Wx:
left-hand.
Wx = height (1) + height (2) + height (3)
Special cases: Wx = 22 cm
30A-10
GENERAL INFORMATION
Underbody height: Adjustment values 30A
Note:
The position of the vehicle varies according to:
- the weight of the engine,
- the springs and shock absorbers,
- the tyres,
- the amount of fuel in the tank.
30A-11
GENERAL INFORMATION
Front axle: Tightening torque 30A
101232
30A-12
GENERAL INFORMATION
Front axle: Tightening torque 30A
101231
30A-13
GENERAL INFORMATION
Front axle: Adjustment values 30A
I - CHECK
Check the settings of the axle assemblies (see 30A,
General information, Axle assemblies: Check, page
30A-8)
II - CASTOR ANGLE
Not adjustable.
93013
III - CAMBER
Not adjustable.
93014
30A-14
GENERAL INFORMATION
Front axle: Adjustment values 30A
Value Position of front
axle (mm)
V - WHEEL ALIGNMENT
WARNING
93011
30A-15
GENERAL INFORMATION
Front axle: Adjusting 30A
Essential equipment
Tightening torquesm
Note:
Throughout the axle assembly checking and
adjustment process:
- the Renault Card must remain in the reader,
- do not press the « START » button. 121364
a Loosen the wheel alignment adjustment lock nut (1)
a Check the geometry (see 30A, General informa-
tion, Axle assemblies: Check, page 30A-8) . .
a Turn the track rod sleeve (2) to the required value.
II - ADJUSTMENT OPERATION a After adjustment, torque tighten the wheel align-
ment adjustment lock nuts (53 N.m).
1 - Wheel alignment
2 - Castor angle
a Set the wheels straight ahead.
a Not adjustable.
a Lock the steering wheel using a steering wheel
lock.
3 - Camber
a Adjust the wheel alignment by rotating the track rod
sleeves. a Not adjustable.
4 - Pivot
a Not adjustable.
30A-16
GENERAL INFORMATION
Rear axle: Tightening torque 30A
101900
30A-17
GENERAL INFORMATION
Rear axle: Adjustment values 30A
I - CHECK
Check the settings of the axle assemblies (see 30A, Axle p a rt Value Position of
General information, Axle assemblies: Check, page number vehicle
30A-8)
77 01 475 149 Toe-in:
II - CAMBER 77 01 475 150 +0˚40’ ± 25’
WARNING
Meaning of symbols used in this document, Axle p a rt Value Position of
-: toe-out number vehicle
93011-1
30A-18
GENERAL INFORMATION
Rear axle: Adjustment values 30A
EQT LEVEL EA6
30A-19
GENERAL INFORMATION
Rear axle: Adjusting 30A
Essential equipment
safety strap(s)
Tightening torquesm
WARNING
Never use the rear axle as support for a lifting sys-
tem.
102521
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
Note:
- During this operation, strap the vehicle to the lift
using a safety strap(s), to avoid any imba-
lance.
- For the procedure to fit the safety strap(s)
(see Vehicle: Towing and lifting) (MR 370,
02A, Lifting equipment).
106178
a Adjust the height of the pads to obtain a centre-to-
centre distance between the shock absorber moun-
ting points (body mounting (1) , axle mounting (2) )
corresponding to a length of 402 mm.
a Torque tighten the mounting bolt joints (12.5
daNm).
30A-20
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting 31A
II - OPERATION FOR REMOVAL OF PART
Essential special tooling CONCERNED
Fre. 1190-01 Brake calliper piston return
tool.
Tightening torquesm
WARNING
127486
a Remove:
- the caps (2) from the guide pin bolts,
- the calliper guide pin bolts (2) ,
- the calliper (3) from its support.
a Attach the calliper (3) to the shock absorber spring.
a Remove the brake pads.
31A-1
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting 31A
REFITTING
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
31A-2
FRONT AXLE COMPONENTS
Front brake hose: Removal - Refitting 31A
Essential equipment
pedal press
Tightening torquesm
IMPORTANT
Be sure to follow the order of operations in the pro-
cedure described below.
101709
a Unscrew:
REFITTING
a
WARNING
Do not twist the brake pipe, and straighten the
wheels as steering lock makes it easier for the
101707 unit to become twisted.
Make sure that there is no contact between the
REMOVAL brake pipe and the surrounding components.
a
WARNING Note:
Drain the brake fluid to prevent damage to the
The pipe supplied as spare parts are encased in
mechanical parts and bodywork around the bra-
a spr ing to prevent them from being twisted
king system.
during fitting.
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid. a Refit the brake hose at the calliper end.
a Torque tighten:
a Make sure that the end piece engages freely into the
bracket splines.
31A-3
FRONT AXLE COMPONENTS
Front brake hose: Removal - Refitting 31A
a Fit:
- the spring,
- the rigid pipe on the brake hose, making sure that
the hose does not twist when screwing on the rigid
pipe.
a Bleed the brake circuit ( (see 30A, General infor-
mation) ).
a Torque tighten the bleed screw (0.65 daNm).
31A-4
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting 31A
Essential special tooling
Essential equipment
pedal press
Tightening torquesm
Note: 101214
a Torque tighten:
WARNING
- Refasten the brake hose and wheel speed sen-
sor wiring, if they have been unclipped.
- Do not twist the brake hose.
31A-5
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting 31A
a Refit the wheels.
a Torque tighten:
- the bleed screw (0.65 daNm),
- the wheel bolts (13 daNm).
a Bleed the brake circuit partially if the compensation
reservoir is not completely emptied during the proce-
dure. Otherwise, carry out a full bleed ( (see 30A,
General information) ).
a Check the brake fluid level.
31A-6
FRONT AXLE COMPONENTS
Front brake calliper: Repair 31A
II - REPAIR OPERATION FOR PART CONCERNED
Essential special tooling
Essential equipment
pedal press
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see Front axle assemblies: Precautions
for repair) .
81546
81545
WARNING
The whole calliper must systematically be repla-
ced if there are any scratches in the calliper bore.
31A-7
FRONT AXLE COMPONENTS
Front brake calliper: Repair 31A
REFITTING
II - FINAL OPERATION.
a Refit:
- the brake calliper (see 31A, Front axle compo-
nents, Front brake calliper: Removal - Refitting,
page 31A-5) ,
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Remove the pedal press.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
31A-8
FRONT AXLE COMPONENTS
Front brake calliper support: Removal - Refitting 31A
Essential special tooling
REFITTING
a Push the piston back using the (Fre. 1190-01) until it
Fre. 1190-01 Brake calliper piston return is at the end of its housing.
tool.
The calliper mounting bolts and the guide pin bolts
must be coated with FRENBLOC type product befo-
re being fitted.
Tightening torquesm
a Refit:
calliper mounting bolts 10.5 daNm - the calliper mounting,
guide pin bolts 3.2 daNm - the calliper mounting bolts.
a Torque tighten the calliper mounting bolts (10.5
a When replacing brake pads or a disc, it is essential
daNm).
to change the pads and disc on the opposite side.
a Fit the pads, starting from the inside.
REMOVAL a Refit:
IMPORTANT
Depress the brake pedal several times to bring
the pistons, brake pads and discs into contact.
101215
a Remove the guide pin bolts (1) .
a Hang the brake calliper from the suspension spring.
a Remove:
- the brake pads,
- the two calliper mounting bolts (2) ,
- the calliper mounting.
a Check the condition of the braking components (re-
place defective parts).
a Clean the calliper supports and callipers.
31A-9
FRONT AXLE COMPONENTS
Front brake disc: Description 31A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
Note:
Use a Palmer type tool to check the thickness of the
disc.
88310
Measure the thickness of the disc at 4 points in order
(90˚ apart).
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-6) .
31A-10
FRONT AXLE COMPONENTS
Front brake disc: Removal - Refitting 31A
Tightening torquesm
disc bolts 15 Nm
REMOVAL
a Brake discs cannot be reground. If there is excessi-
ve scoring or wear, they will need to be replaced.
a When replacing a brake disc, be sure to replace the
disc on the opposite side.
a Be sure to replace the brake pads if the brake discs
are being replaced.
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Unlock the steering wheel. 101212
a Remove the front wheels (see 35A, Wheels and ty- a Remove
res, Wheel: Removal - Refitting, page 35A-1) . - the calliper mounting,
- the two disc bolts (2) ,
- the disc.
REFITTING
a
WARNING
- Attach the wheel speed sensor wiring and hose
if they were detached.
- Do not twist the brake hose.
31A-11
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting 31A
Essential special tooling
Essential equipment
diagnostic tool
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery).
a Remove the front wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .
a Unclip:
- the wheel speed sensor from the hub carrier,
- the xenon bulb sensor (if fitted to the vehicle).
31A-12
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting 31A
101212 112078
a Hang the « front brake calliper - front brake calliper a Position the (Sus. 1731).
mounting » assembly on the suspension spring.
a Tighten the bolt (8) of the (Sus. 1731) to remove the
hub carrier from the front driveshaft while holding it.
WARNING
Note:
In order to prevent irreversible damage to the
front hub bearing: Take care not to drop the hub carrier.
- Do not loosen or tighten the driveshaft nut when a Check that section (9) of the (Sus. 1731) is pressed
the wheels are on the ground. firmly against the shock absorber base.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened
or removed.
REFITTING
a Proceed in the reverse order to removal.
a Remove:
- the front brake disc bolts (5) , Note:
- the nut (6) from the front wheel driveshaft using the The calliper mounting bolts must be coated with
(Rou. 604-01), a product such as HIGH RESISTANCE THREAD
- the front brake disc, LOCK before being refitted.
- the anti-roll bar tie rod upper nut (7) ,
- the anti-roll bar tie-rod.
a Extract the ball joints using the (Tav. 476).
a Remove the front wheel driveshaft from the front dri-
veshaft hub carrier, taking care not to extract the dri-
veshaft from the front wheel.
31A-13
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting 31A
a Torque tighten:
- the shock absorber lower bolt (105 Nm),
- the lower ball joint nut (62 Nm),
- the track rod end nut (37 Nm),
- the front brake disc bolts (15 Nm),
- the front wheel driveshaft nut (280 Nm),
- the front brake calliper mounting bolts (105
Nm),
- the wheel bolts (130 Nm).
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
31A-14
FRONT AXLE COMPONENTS
Front hub carrier bearing: Removal - Refitting 31A
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Remove the front driveshaft hub carrier (see 31A,
Front axle components, Front driveshaft hub
carrier: Removal - Refitting, page 31A-12) .
20787
REFITTING
a
20786
a Remove: WARNING
- the hub, with the press, applying pressure with a 41 To ensure that the wheel speed sensor works
mm diameter tube, properly, do not mark the sensor target on the
bearing.
- the circlip.
a It is essential to check the condition of the hub surfa-
ce and the hub carrier bore before refitting the bea-
ring.
a Clean:
WARNING
Do not press the bearing's internal bush so as to
avoid damaging the bearing (very high shrink-fit-
ting force).
31A-15
FRONT AXLE COMPONENTS
Front hub carrier bearing: Removal - Refitting 31A
101934 101933
a Refit the sensor holder. a Refit the circlip.
a Position the sensor holder at (x) = 35˚ ± 5˚ from ver- a Check that the circlips are correctly positioned by
tical. This position corresponds to the centre of the measuring the inner diameter (Z = 67.6 mm) for a
housing. bearing with an outer diameter of 77 mm.
20788
a Apply force to the external bearing bush using a pipe
with an outer diameter of 77 mm and bore diameter
of 70 mm.
31A-16
FRONT AXLE COMPONENTS
Front hub carrier bearing: Removal - Refitting 31A
20789
a
WARNING
a Refit:
- the hub,
- the front driveshaft hub carrier (see 31A, Front
axle components, Front driveshaft hub carrier:
Removal - Refitting, page 31A-12) .
31A-17
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting 31A
Essential special tooling
Essential equipment
spring compressor
Tightening torquesm
112078
a Position the (Sus. 1731).
a Tighten the bolt (3) of the (Sus. 1731) to separate
the shock absorber base from the hub carrier.
a Ensure that the section (4) of the (Sus. 1731) is
pressed firmly against the shock absorber base.
a Suspend the hub carrier
31A-18
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting 31A
REFITTING
a Fit the spring compressor in a vice.
104428
a Remove:
96049
31A-19
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting 31A
102201
a Position the spring in the cup groove, smooth sheath
above, and grooved sheath below.
31A-20
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting 31A
101939 104428
a Respect the order and direction of fitting for the
a Fit the index bolt (6) in its housing.
constituent parts.
a Proceed in the reverse order to removal.
Note:
a Torque tighten:
Make sure that the rotary stop is correctly orien-
ted to facilitate refitting above and below. - the shock absorber turret mounting bolts (17
Nm),
a Refit:
WARNING
Refasten the brake hose and wheel speed sen-
sor wiring if they have been unclipped.
96049 Do not twist the brake hose.
a The shock absorber rod nut must be replaced.
a Torque tighten the shock absorber rod nut (62 a Refit the front wheels (see 35A, Wheels and tyres,
Nm). Wheel: Removal - Refitting, page 35A-1) .
a Decompress the spring.
a Connect the battery (see Battery : Removal - Refit-
a Remove the spring compressor. ting) (MR 370, 80A, Battery).
31A-21
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting 31A
Essential equipment
component jack
Tightening torquesm
WARNING
Do not use the lower arm for support with a lifting
system.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Unlock the steering wheel.
a Strap the radiator to the radiator grille.
31A-22
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting 31A
- the lower ball joint,
- the height sensor ball joint (if fitted to the vehicle).
a Remove:
- the lower arm front and rear bolts (4) ,
- the lower arm.
REFITTING
a Be sure to replace the sub-frame and arm moun-
tings.
a Proceed in the reverse order to removal.
101212
101213
a Remove:
- the front wheel concerned (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
- the wheel arch protectors,
- the engine undertray,
- the side stiffener lower bolts (1) ,
- the radiator cross member rear nuts,
- the radiator cross member front bolts (2) ,
- the radiator cross member.
a Unpick the wheel speed sensor harness.
a Disconnect the wheel sensor connector in the wheel
arch.
a Remove the lower ball joint bolt (3) .
a Remove:
31A-23
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting 31A
a Refit the lower ball joint into the hub carrier.
WARNING
A 10mm shim must be placed between the radia-
tor cross member and the subframe to tighten
the radiator cross member mountings to torque.
WARNING
Refasten the brake hose and wheel speed sen-
sor wiring if they have been unclipped.
Do not twist the brake hose.
107304
a Place the component jack against the subframe
rear bolt head (5) .
WARNING
When refitting, position the lower arm below the
subframe rear bolt head (H) = 10 mm to tighten
the rubber bushes freely.
31A-24
FRONT AXLE COMPONENTS
Front driveshaft lower arm ball joint: Check 31A
CHECKING 3 - Checking the play of the lower arm ball joint
101213
a Check:
- the "front driveshaft lower arm ball joint - front dri-
veshaft lower arm bolt" assembly is correctly posi-
tioned,
- the tightening torque of the stud (1) on the front dri-
veshaft lower arm ball joint (see 31A, Front axle
components, Front driveshaft lower arm: Re-
moval - Refitting, page 31A-22) .
31A-25
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
a Set the wheels straight ahead.
Essential equipment a Centre the steering wheel.
steering wheel lock a Lift the floor carpet to access the universal joint.
component jack
Tightening torquesm
front mountings of the 105 Nm a Discard the cover (do not keep it).
radiator cross member a Remove:
lower ball joint bolts 60 Nm - the universal joint bolt (do not keep),
- the universal joint cam nut (do not keep).
engine tie-bar bolts on 105 Nm
the subframe a Position the steering wheel lock.
anti-roll bar tie rod ball 44 Nm a Strap the radiator to the radiator grille.
joint nuts
WARNING
Do not use the lower arm for support with a lifting
system.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
31A-26
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
- the lower ball joint bolts (12) ,
- the anti-roll bar tie-rod upper ball joint nuts (13) .
a Remove:
- the track rod ends,
- the anti-roll bar tie-rod upper ball joints.
101212
101208
a Remove the engine tie-bar bolt (14) on the engine.
101213
a Remove:
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the wheel arch liners,
- the engine undertray,
- the side stiffener lower bolts (8) ,
- the radiator cross member front bolt (9) ,
- the radiator cross member rear nuts,
- the radiator cross member.
a Unpick the wheel speed sensor harness.
a Disconnect the wheel speed sensor connector from
the wheel arch.
a Remove:
- the track rod end nuts (11) ,
31A-27
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
a Fit the component jack underneath the sub-frame.
102313
a Remove the engine tie-bar bolt (15) on the engine.
M9R
114650
31A-28
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
101209
REFITTING WARNING
A shim of 10 mm in thickness must be placed
a Be sure to replace the sub-frame and arm moun-
between the radiator cross member and the sub-
tings.
frame. Centre the radiator cross member pin in
a Degrease the surfaces on the body that make con- the subframe hole at the level of the lower arm
tact with the subframe and cross member using front mounting, to torque tighten the radiator
some SURFACE CLEANER. cross member mountings.
- the sub-frame linkage bolt (105 Nm), - the radiator cross member rear bolts (21 Nm),
- the rear cross member bolts on the subframe - the front mountings of the radiator cross mem-
(62 Nm), ber (105 Nm).
- the bolts to the sub-frame tie-rod (105 Nm). - the lower ball joint bolts (60 Nm),
a Torque tighten the lower arm bolts (see 31A, Front - the track rod end nuts (37 Nm),
axle components, Front driveshaft lower arm:
Removal - Refitting, page 31A-22) . - the side stiffener bolts (21 Nm).
31A-29
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
101354
a Observe the direction of fitting for the universal joint
cam nut and bolt.
a Refit the universal joint.
a Refit the universal joint cam nut and bolt.
116021
a Position the universal joint cam nut and bolt.
a Lock the cam nut in its housing (on the universal
joint).
a Pretighten the universal joint cam nut and bolt.
116022
a Torque tighten:
WARNING
Refasten the brake hose and wheel speed sen-
sor wiring if they have been unclipped.
Do not twist the brake hose.
31A-30
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
F4R or F9Q or M9R
a Torque tighten the engine tie-bar bolts on the F or
M engine support (180Nm).
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
31A-31
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
EQT LEVEL SPORT
a In the passenger compartment, remove the steering
Essential special tooling column universal joint bolt and nut.
Tav. 476 Ball joint extractor. a Strap the radiator to the radiator grille.
a Remove:
Essential equipment
- the front wheels (see 35A, Wheels and tyres,
steering wheel lock Wheel: Removal - Refitting, page 35A-1) ,
- the front wheel arch liners (see Front wheel arch
component jack
liner: Removal - Refitting) (55A, Exterior protec-
safety strap(s) tion),
- the engine undertray.
Tightening torquesm
pivot bolts 72 Nm
31A-32
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
EQT LEVEL SPORT
105891 106114
a Remove: a Compress the driveshaft by approximately 10 cm.
- the track rod end nuts (4) , a Remove the three bolts (7) from the pivot support.
- the upper ball joint nuts (5) from the anti-roll bar tie- a Relax the driveshaft by raising the lift by 50 cm.
rods.
106085
a Remove the sub-frame stiffener strut (8) .
105893
a Remove the lower tie-bar nuts (6) .
a Extract the ball joints using the (Tav. 476).
31A-33
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
EQT LEVEL SPORT
II - OPERATION FOR REMOVAL OF PART
CONCERNED:
107161
102313
a Remove the engine tie-bar (11) .
a Fit the component jack underneath the subframe.
a Strap the subframe to the component jack.
106245
106085
a Remove the pivots (9) from their support (10) using
a Remove:
a hammer.
- the bolts (12) from the subframe bracket,
- the bracket.
31A-34
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
EQT LEVEL SPORT
106086
a Remove:
- the subframe tie rod bolts (13) ,
- the sub-frame.
a Remove the subframe fittings.
REFITTING
102313
31A-35
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting 31A
EQT LEVEL SPORT
II - REFITTING OPERATION FOR PART - the front wheel arch liners (see Front wheel arch
CONCERNED liner: Removal - Refitting) (55A, Exterior protec-
tion),
a Refit the subframe equipment.
- the front wheels (see 35A, Wheels and tyres,
a Strap the sub-frame onto the component jack. Wheel: Removal - Refitting, page 35A-1) ,
a Refit: - the universal joint.
- the sub-frame, a Torque tighten the universal joint bolt (24 Nm).
- the bracket, a Remove the safety strap(s) from the radiator.
- the engine tie-bar . a Adjust the axle assemblies (see 30A, General infor-
a Tighten to torque: mation, Axle assemblies: Check, page 30A-8) .
31A-36
FRONT AXLE COMPONENTS
Front anti-roll bar: Removal - Refitting 31A
Tightening torquesm
REMOVAL
a Mount the vehicle on a two post lift.
a Remove:
- the front axle sub-frame (see 31A, Front axle
components, Front axle sub-frame: Removal -
Refitting, page 31A-26) ,
- the steering rack - sub-frame mounting bolts,
- the steering rack,
- the anti-roll bar - sub-frame mounting bolts,
- the anti-roll bar.
REFITTING
a Proceed in the reverse order to removal.
WARNING
Make sure the anti-roll bar mounting bracket lugs
are correctly positioned in the sub-frame apertu-
res.
a Torque tighten:
- the anti-roll bar - sub-frame mounting bolts (2.1
daNm),
- the steering rack - sub-frame mounting bolts
(10.5 daNm).
31A-37
REAR AXLE COMPONENTS
Rear brake pads: Removal - Refitting 33A
Essential special tooling
Tightening torquesm
WARNING
To avoid damaging the parking brake cable protec-
tors and causing premature wear of the system, do
not handle the cables with a tool.
101702
REMOVAL a Rotate the calliper upwards.
a Remove the brake pads.
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
REFITTING
a Release the parking brake.
I - REFITTING PREPARATION OPERATION
a Remove the rear wheels (see 35A, Wheels and ty-
a Measure the thickness of the brake pads and com-
res, Wheel: Removal - Refitting, page 35A-1) .
pare them with the minimum values (see 30A, Ge-
neral information, Brake: Specifications, page
II - OPERATION FOR REMOVAL OF PART 30A-6) .
CONCERNED
a Clean using a wire brush and BRAKE CLEANER
a Unclip the parking brake cable. (see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):
a Remove the calliper guide pin lower bolt (discard it).
- the calliper supports,
- the callipers.
a parts always to be replaced: Rear brake calliper
guide pin bolt (13,03,04,10).
33A-1
REAR AXLE COMPONENTS
Rear brake pads: Removal - Refitting 33A
a Refit the parking brake cable.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
18931
a Push the calliper piston back using the (Fre. 1190-
01) until it reaches the end of its bore.
127485
33A-2
REAR AXLE COMPONENTS
Rear brake caliper: Removal - Refitting 33A
Essential special tooling
Essential equipment
pedal press
Tightening torquesm
brake hose 17 Nm
Note:
The callipers supplied as spare parts are supplied
pre-filled.
117348
a Clean the calliper and calliper mounting using the
cleaning station.
WARNING
Prepare for brake fluid outflow, to prevent damage
to the mechanical parts and bodywork around the
braking system.
REMOVAL
a Position the vehicle on a two-post lift.
a Remove:
- the calliper,
33A-3
REAR AXLE COMPONENTS
Rear brake caliper: Removal - Refitting 33A
REFITTING
101306
18931 a Refit the parking brake cable.
a Push the calliper piston back using the (Fre. 1190- a Check that the parking brake cable stop is properly
01) until it reaches the end of its bore. engaged in its housing.
a Refit: a Bleed the brake circuit (see 30A, General informa-
- the brake pads, tion, Brake circuit Bleeding, page 30A-2) .
- the guide pin bolts. a Apply the parking brake control several times to ac-
tivate the locking - unlocking function and to activate
the calliper automatic play compensation.
Note:
a Refit the wheel (see 35A, Wheels and tyres,
Coat the guide pin bolts with HIGH RESIS- Wheel: Removal - Refitting, page 35A-1) .
TANCE THREAD LOCK product before fitting.
a Torque tighten:
- the guide pin bolts (36 Nm),
- the brake hose (17 Nm).
33A-4
REAR AXLE COMPONENTS
Rear brake calliper mounting: Removal - Refitting 33A
Essential special tooling
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift.
a Release the parking brake (see Parking brake) .
a Refit the rear wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Detach the parking brake cable. 117348
a Note the parking brake cable routing for refitting. a Clean the calliper and calliper mounting using the
a Remove: cleaning station.
33A-5
REAR AXLE COMPONENTS
Rear brake calliper mounting: Removal - Refitting 33A
18931 101301
a Push the calliper piston back using the (Fre. 1190- a Check that the parking brake cable stop is properly
01) until it reaches the end of its bore. engaged in its housing.
a Refit: a Apply the parking brake control several times to ac-
tivate the locking and unlocking function and to acti-
- the brake pads,
vate the calliper automatic play compensation.
- the calliper,
a Refit the wheel (see 35A, Wheels and tyres,
- the guide pin bolts. Wheel: Removal - Refitting, page 35A-1) .
a Torque tighten the guide pin bolts (36 Nm).
a Refit the parking brake cables.
33A-6
REAR AXLE COMPONENTS
Rear brake disc: Description 33A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
Remove the rear wheel concerned (see 35A, Wheels
and tyres, Wheel: Removal - Refitting, page 35A-1) .
Note:
Use a Palmer type tool to check the thickness of the
disc.
99582
Measure the thickness of the disc at 4 points in order
(90˚ apart).
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-6) .
33A-7
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting 33A
Essential special tooling
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Remove the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
101306
a Remove the brake calliper lower bolts (2) .
33A-8
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting 33A
101702 101306
a Turn the brake callipers upwards. a Remove the brake calliper upper bolts (3) .
a Suspend the brake callipers from the suspension
springs.
18931
a Push back the brake calliper pistons using (Fre.
1190-01) until they reach the end of their bore. 101306
a Remove:
- the brake pads,
- the calliper mounting bolts (4) ,
- the calliper mountings,
- the hub caps,
- the stub-axle nuts,
- the « disc - bearing » assemblies.
33A-9
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting 33A
a Check the condition of the braking components (re-
place the faulty parts), (see 30A, General informa-
tion, Brake: Specifications, page 30A-6) .
101306
a Refit the parking brake cables (5) .
117348 a Check that the parking brake cable stops are proper-
ly engaged in their housing.
a Clean the callipers and calliper mountings using the
cleaning station.
Note:
REFITTING Depress the brake pedal several times to bring
the pistons, brake pads and discs into contact.
a
Coat the calliper mounting and guide pin bolts a Apply the parking brake control several times to ac-
with HIGH RESISTANCE THREAD LOCK pro- tivate the locking and unlocking function and to acti-
duct before fitting them. vate the calliper automatic play compensation.
a Refit the wheels (see 35A, Wheels and tyres,
a Torque tighten: Wheel: Removal - Refitting, page 35A-1) .
- the stub-axle nuts (standard chassis) (220 Nm),
- the stub-axle nuts (long chassis) (280 Nm),
- the calliper mounting bolts (105 Nm),
- the guide pin bolts (36 Nm).
33A-10
REAR AXLE COMPONENTS
Brake pipe: Removal - Refitting 33A
II - REAR RIGHT-HAND RIGID BRAKE PIPE
Essential equipment
pedal press
Tightening torquesm
WARNING
Prepare for brake fluid outflow, to prevent damage
to the mechanical parts and bodywork around the
braking system.
104399
REMOVAL a Unscrew:
- the rigid brake pipe at the rear axle (3) ,
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02, Lifting equip- - the rigid pipe at the calliper (4) .
ment).
a Unclip the rear axle rigid brake pipe.
a Fit the pedal press to the brake pedal to limit the
a Remove the rigid brake pipe.
outflow of brake fluid.
a Raise the vehicle.
REFITTING
I - REAR LEFT-HAND BRAKE RIGID PIPE a
WARNING
Do not twist the brake pipe.
Make sure that there is no contact between the
brake pipe and the surrounding components.
104398
a Unscrew:
- the rigid brake pipe at the rear axle (1) ,
- the rigid pipe at the calliper (2) .
a Unclip the rear axle rigid brake pipe.
a Remove the rigid brake pipe.
33A-11
REAR AXLE COMPONENTS
Brake pipe: Removal - Refitting 33A
106768
a To refit, proceed in the reverse order of removal.
IMPORTANT
Make sure that the underbody brake pipes are
not under any strain at all the clips, and that they
are not crossed. If the brake pipes are crossed,
the ABS and ESP systems will not work properly.
a Torque tighten:
- the rigid brake pipe on the rear axle (1.4 daNm),
- the rigid brake pipe on the calliper (1.4 daNm).
a Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-2) .
33A-12
REAR AXLE COMPONENTS
Bearing: Removal - Refitting 33A
REMOVAL REFITTING
a Remove the brake disc (see 33A, Rear axle com- a
ponents, Rear brake disc: Removal - Refitting,
page 33A-8) . WARNING
Take care not to mark the wheel speed sensor
target on the bearing fitted with it when refitting.
WARNING
Clean:
- the internal and external surfaces of the new
bearing in contact with the hub carrier and the
stub-axle,
- the hub carrier surfaces in contact with the new
bearing,
- the stub-axle surfaces in contact with the new
bearing,
WARNING
Before refitting the bearing, the condition of the
stub-axle surface and the bore of the hub carrier
104528 must be checked. Replace the hub carrier if it is
a Remove the circlip (1) faulty.
WARNING
Do not apply pressure to the inner bearing bush,
to avoid damaging the bearing (significant force
is required for fitting).
104396
a Remove the bearing with a press, applying pressure
with a 49 mm diameter tube.
33A-13
REAR AXLE COMPONENTS
Bearing: Removal - Refitting 33A
104395
a Refit the bearing with a press, applying pressure
with a 49 mm diameter tube.
a Refit the circlip.
a To refit, proceed in the reverse order of removal.
33A-14
REAR AXLE COMPONENTS
Rear suspension spring: Removal - Refitting 33A
Essential equipment
1 - Left side
component jack
Tightening torquesm
WARNING
Never use the rear axle as support for a lifting sys-
tem.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle: 101304
Towing and lifting) (MR 370, 02A, Lifting equip- a Fit the component jack, with a shim, under the left
ment). spring cup.
a Remove: a Mark the position where the left spring is fitted.
- the rear wheels (see 35A, Wheels and tyres, a Remove the left-hand shock absorber lower
Wheel: Removal - Refitting, page 35A-1) , mounting (1) using a long socket.
- the clips from the rear axle protective fairing using a Release the left shock absorber lower mounting.
unclipping pliers,
a Remove the component jack.
- the rear axle protective cowling.
33A-15
REAR AXLE COMPONENTS
Rear suspension spring: Removal - Refitting 33A
101307 101304
a Remove the left spring with its lower support. a
WARNING
WARNING Make sure that the shock absorber lower moun-
If the upper support is unclipped, replace it with a ting is fitted the right way round.
new one.
a Refit the shock absorber lower mounting.
- the springs in their housing. a Repeat these operations on the right side of the ve-
hicle.
a Mount the bump stops on the axle assembly, with
the marking towards the rear and in the longitudinal a Refit the rear wheels (see 35A, Wheels and tyres,
axis of the vehicle. Wheel: Removal - Refitting, page 35A-1) .
a Insert the spring into its bump stops, starting at the a Raise the lift again.
top.
a Refit the rear axle aerodynamic fairing, replacing
a Compress the rear axle. any damaged plastic clips.
33A-16
REAR AXLE COMPONENTS
Shock absorber: Removal - Refitting 33A
- the shock absorber.
Tightening torquesm
REFITTING
shock absorber upper 6.2 daNm
mounting bolts a Refit:
- the shock absorber,
shock absorber lower 10.5 daNm
mounting bolts - the shock absorber lower mounting.
WARNING
- Never use the rear axle as support for a lifting sys-
tem.
- When replacing a shock absorber, the shock
absorber on the opposite side must be replaced.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Lift up the carpet in the boot.
101304
a
WARNING
Make sure that the shock absorber lower moun-
ting is fitted the right way round.
WARNING
The shock absorber mountings are only to be
tightened with the vehicle wheels on the ground.
33A-17
REAR AXLE COMPONENTS
Shock absorber: Removal - Refitting 33A
- the shock absorber lower mounting bolts (10.5
daNm) while holding the bolt heads.
a Refit the shock absorber lower mounting protective
fairing covers, replacing any damaged plastic clips.
33A-18
REAR AXLE COMPONENTS
Rear axle rubber bearing: Removal - Refitting 33A
Essential special tooling
Tightening torquesm
REMOVAL
122816
a Remove the rubber bushes by hitting them with a
hammer or the bush castor of the tool (Tar. 1838).
125483
a Remove:
- the bearings bolt (1) ,
- the bearings (2) .
33A-19
REAR AXLE COMPONENTS
Rear axle rubber bearing: Removal - Refitting 33A
REFITTING
122815
a Tighten the tool rod (Tar. 1838) until the cover co-
mes into contact with the rear axle.
a Check that the notch is always aligned with the
mark.
a Torque tighten the nut of the cover B (16 Nm).
a Remove the (Tar. 1838).
a Refit the bearings.
a Torque tighten the new bolts of the rubber bea-
rings (130 Nm).
- the threaded rod (C) of the tool (Tar. 1838), - the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
- the washer (D) of the tool (Tar. 1838),
a Adjust the rear axle (see 30A, General information,
- the nut (E) of the tool (Tar. 1838). Rear axle: Adjusting, page 30A-20) .
33A-20
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting 33A
Essential special tooling
Essential equipment
pedal press
component jack
Tightening torquesm
Note:
- During this operation, secure the vehicle to the
lift with a strap to prevent it from becoming
unbalanced.
- For the strap fitting procedure, (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equi-
pment).
33A-21
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting 33A
2 - Right-hand side
a Repeat these operations on the right side of the ve-
1 - Left side hicle.
101304
a Mark the position where the left spring is fitted. a Remove both mounting bolts (3) from the automatic
parking brake control unit support.
a Remove the left shock absorber lower mounting (2)
using a long socket. a Take out the automatic parking brake control unit
downwards.
a Put aside the left shock absorber lower mounting.
a Disconnect the automatic parking brake control unit
a Remove the component jack. wiring (4) .
a Hang the automatic parking brake control unit on the
rear axle.
101307
a Remove the left spring and its supports.
33A-22
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting 33A
101300 101303
a Fit the (Mot. 1390) on the rear axle jacking points. a Loosen the bearing bolts.
a Position the pads of the (Mot. 1390) in contact with
the rear axle.
a Strap the rear axle.
a Remove the bearing bolts.
a Raise the vehicle.
106178
a Adjust the height of the pads to obtain a centre-to-
centre distance between the shock absorber moun-
ting points (body mounting (5) , axle mounting (6) )
corresponding to a length of 402 mm.
33A-23
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting 33A
101305
a Remove the rear axle equipment.
REFITTING
a Refit the rear axle equipment.
a Strap the rear axle onto the (Mot. 1390).
a Position the axle under the vehicle.
33A-24
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting 33A
101300 101706
a Lower the lift. a Check that the parking brake cable stops are proper-
ly inserted in their housing.
a Position the bearing locators opposite the centring
holes. a Refit:
a Refit the mountings, starting with the left-hand bea- - the supports on the springs,
ring.
- the springs in their housing.
a Insert the brake pipes into their housing.
a Mount the bump stops on the axle assembly, with
a Remove the strap. the marking towards the rear and in the longitudinal
a Raise the lift. axis of the vehicle.
a Remove the (Mot. 1390).
a Torque tighten: J84, and AUTOMATIC PARKING BRAKE
- the bearing mounting bolts (6.2 daNm), a Reconnect the parking brake control unit wiring.
- the brake hose bolts (1.4 daNm). a Refit the parking brake control unit bracket mounting
bolts.
a Reconnect the ABS system connectors.
a Refit the parking brake cables.
1 - Left side
a Fit the component jack with a shim, under the
spring cup.
WARNING
The shock absorber mountings are only to be
tightened with the vehicle wheels on the ground.
33A-25
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting 33A
a Remove the component jack.
2 - Right-hand side
a Fit the component jack with a shim, under the
spring cup.
a Check the position of the bump stop on the axle as-
sembly.
a Compress the rear axle.
a Refit the shock absorber lower mounting.
a Remove the component jack.
a Lower the lift.
a Torque tighten the shock absorber lower moun-
tings (10.5 daNm).
a Raise the lift again.
a Refit the rear axle protective cowling, replacing the
damaged plastic clips.
a Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Torque tighten the wheel bolts (13 daNm).
33A-26
WHEELS AND TYRES
Wheel: Removal - Refitting 35A
Tightening torquesm
REMOVAL
Note:
Use sockets with protective sheaths in order to
avoid scratching the alloy wheel rims.
- the wheel.
35A-1
WHEELS AND TYRES
Wheel: Removal - Refitting 35A
If this procedure does not work:
124750
106089 a Coat the wheel-mating face (3) with COPPER ANTI-
a Strike the inner surface of the wheel (2) using a mal- SEIZE AGENT (see Vehicle: Parts and ingre-
let and a wooden block to detach it. dients for the repairwork) (04B, Consumables -
Products).
a Align the mark on the wheel with the mark made on
Note: the hub when it was removed.
Do not strike the surface of the wheel using a Fit the wheel to the vehicle, positioning the valve at
excessive force as this may damage it. the top.
- the wheel.
REFITTING
Note:
There are two types of wheel bolts for aluminium
and steel wheel rims; do not swap them.
35A-2
WHEELS AND TYRES
Wheel: Removal - Refitting 35A
M9R, and STANDARD CHASSIS F4R or F9Q or K4J or K4M or K9K, and STAN-
DARD CHASSIS
100682
a Tighten the wheel bolts to bring all the bolt heads 113180
into contact with the wheel. a Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.
35A-3
WHEELS AND TYRES
Wheel: Balancing 35A
I - PREREQUISITES FOR WHEEL BALANCING
a Wheel balancing is a measurement operation.
Several conditions must be met to achieve a reliable
result in a single operation.
The wheel balancer must be installed in accordance
with the manufacturer's instructions.
It is essential to calibrate the balancer according to
the frequency recommended by the manufacturer.
Do not grease the threaded shaft.
Check the condition of the supports, centring com-
ponents and mountings.
Replace any faulty parts (see manufacturer's ins-
tructions).
The wheel and the wheel balancer must be clean.
Driver's perception
a If the wheels are not correctly balanced this causes 105870
the steering wheel and/or the vehicle floor to vibrate. a
These vibrations appear between 54 mph (90 km/h)
Note:
and 90 mph (150 km/h).
The ring is available from the supplier of the
equipment used.
II - BALANCING PREPARATION OPERATION
a Adjust the tyre pressure (see 35A, Wheels and ty- To reproduce the exact vehicle wheel assembly, use
res, Tyre inflation pressure: Identification, page a ring (1) of diameter:
35A-10) . a 60 mm
a Always carry out a road test for a minimum distance a There are three types of weight:
of 1 mile (2 km) before balancing the wheels, in or-
der to remove any flat spots on the tread caused by
the vehicle being immobilised.
a Actions to be carried out immediately after the test
drive:
- Position the vehicle on a two-post vehicle lift (see
Vehicle: Towing and lifting) ,
- raise the vehicle,
- leave the four wheels hanging free,
- release the parking brake.
35A-4
WHEELS AND TYRES
Wheel: Balancing 35A
113742 105871
a The wheel is fitted on the wheel balancer as follows:
(2) Steel wheel with flange
- (5) ring,
(3) Alloy wheel with flange
(4) Alloy wheel without flange - (6) wheel balancer back-plate,
- (7) wheel tightening device (certain alloy wheels
a In some countries, the use of lead weights is forbid-
require a device 200 mm in diameter to ensure that
den; in this case it is recommended to use ZAMAK
the wheel has been correctly tightened),
weights instead.
- (8) outer wheel plane,
Only use weights provided by the Parts Department.
a Remove the wheels (see 35A, Wheels and tyres, - (9) wheel.
Wheel: Removal - Refitting, page 35A-1) .
a Always clean the wheel, disc, and hub bearing surfa-
ces.
100681
a Place the wheel on the wheel balancer, with the val-
ve at the top, then lock the wheel in place.
a Remove any stones trapped in the tyre tread.
35A-5
WHEELS AND TYRES
Wheel: Balancing 35A
a Enter the specific wheel parameters when starting
the wheel balancer.
a Start the wheel balancer and check the wheel balan-
ce, which should be 0 g on each plane of the wheel.
a If this is not the case, remove the old wheel balan-
cing weights and repeat the wheel balancing proce-
dure, checking that the wheel balance equals 0 on
each wheel plane.
WARNING
To avoid detachment of the balance weights, use
only weights which correspond to the vehicle
wheel rims.
IV - FINAL OPERATION
a Refit the wheel (see 3 5 A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
35A-6
WHEELS AND TYRES
Tyres: Identification 35A
Example of a tyre identification mark: 205/65 R 15 91 Speed code table:
V.
Code Maximum
speed in
mph (km/h)
R 170
S 180
T 190
U 200
H 210
V 240
ZR above 240
W 270
Y 300
101008
123448
65 Height/width ratio
R Radial structure
91 Load index
V Speed code
35A-7
WHEELS AND TYRES
Tyres: Removal - Refitting 35A
REMOVAL
a Remove:
REFITTING
a Detach:
II - REFITTING OPERATION FOR PART
- the bead from the outside of the tyre, starting with CONCERNED
the side opposite the valve,
a Engage the lower tyre bead approximately 15 cm af-
- the bead from the inside of the tyre. ter the valve.
35A-8
WHEELS AND TYRES
Tyres: Removal - Refitting 35A
a Finish fitting the tyre at the valve.
a Fit the exterior bead approximately 15 cm after the
valve using the tyre lever.
a Inflate the tyre to 3.5 bar to press the tyre beads
against the wheel rim.
Note:
It is not necessary to drive the vehicle before and
after a new wheel is balanced.
35A-9
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
I - INFLATION
STANDARD CHASSIS
Tyre pressure when cold (bar), for the tyre
pressure monitoring system (SSPP)
WARNING
If checking the tyre pressure when hot, increase the
tyre inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
35A-10
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
Tyre inflation pressure when cold (bar)
LONG CHASSIS
Engine Wheel rims Tyre Roads and motorways Roads and motorways Emer-
gency
Front Rear Front Rear spare
wheel
35A-11
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
Load condition 5 persons Load condition 5 to 7 persons
maximum
Engine Wheel rims Tyre Roads and motorways Roads and motorways Emer-
gency
Front Rear Front Rear spare
wheel
All types 6.5 J 16 175/70 R16M 2.5 2.5 2.5 2.5 2.5
WARNING
If the size of the tyres is changed, calibrate the
Electric Power-assisted Steering computer and the
tyre pressure monitoring system (see MR 372 Fault
finding, 36B, Electric power-assisted steering,
Configuration and programming).
35A-12
WHEELS AND TYRES
Wheel rim: Identification 35A
IDENTIFICATION 2 - Installation diameter for the wheel bolts
1 - Marking
The wheel bolts are positioned with a pitch circle dia-
There are two types of identification marking on the meter of:
wheel rims:
- 5 holes: 108 mm,
- engraved marking for steel wheel rims, - 4 holes: 100 mm.
- cast marking for alloy wheel rims.
The marking gives the main dimensional specifications 3 - Rim run-out
of the wheel rim. The maximum run-out is measured at the wheel rim
This marking may be: edge (7) .
- complete, for example 6 J 15 5 CH 36, Steel wheel rims: 0.8 mm
- simplified, for example 6 J 15. Alloy wheel rims: 0.3 mm
4 - Out-of-roundness
Wheel type 6 J 15
The maximum out-of-round value is measured on the
1 Width (in inches) 6 tyre bead bearing surface.
4 Number of holes 5
100988
There are 3 types of wheel rim edges (2) :
- those with two flat edges,
- those with two raised edges,
- those with one flat edge and one raised edge.
35A-13
WHEELS AND TYRES
Spare wheel winch: Removal - Refitting 35A
Tightening torquesm
WARNING
Take care not to insert the tool between the unloc-
king mechanism and the screw head.
This could lead to the destruction of the emergency
spare wheel winch mechanism.
REMOVAL
a Lower the luggage cover (if necessary).
a Remove the floor carpet.
a Tilt the rear right-hand seat to base position (if ne-
cessary). 111120
a Remove the blanking cover.
IMPORTANT
WARNING
To remove the emergency wheel: Do not use an air tool.
- do not work on an inspection pit,
a Loosen the bolt (1) .
- do not lift the vehicle.
a Press the emergency spare wheel lock.
a Rotate the emergency spare wheel lock a quarter of
a turn.
a Remove the emergency wheel.
a Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift).
35A-14
WHEELS AND TYRES
Spare wheel winch: Removal - Refitting 35A
111111
a Remove:
- the emergency spare wheel winch mounting nuts
(2) ,
- the emergency spare wheel winch.
REFITTING
a Proceed in the reverse order to removal.
a Tighten to torque the emergency spare wheel
winch bolts (21 Nm).
35A-15
WHEELS AND TYRES
Run flat tyres: Identification 35A
I - TYRE IDENTIFICATIONS The marking on these tyres differs from that on con-
ventional product ranges.
Example of marking read on sidewall: 195-620 R 420 A
90 H
21576
R Type of s t ructure
(R = radial)
A Asymmetric
Note:
The internal diameter (di) is always greater than the
external diameter (de) .
35A-16
WHEELS AND TYRES
Run flat tyres: Identification 35A
II - SUPPORT IDENTIFICATIONS Example of markings read: 195-440 (49)
21577
35A-17
WHEELS AND TYRES
Run flat wheel rim: Identification 35A
WHEEL RIM IDENTIFICATIONS Example of markings read: 185-420 A-4-43
21578
A Asymmetric
43 Offset in mm
35A-18
WHEELS AND TYRES
Run flat tyres: Repair 35A
REPAIR AFTER PUNCTURE OR FLAT RUNNING
a
WARNING
No repair can be carried out without removing
the tyre and support.
WARNING
Be sure to replace any components damaged in
any of the specified ways.
WARNING
Hot repair is strictly prohibited.
Note:
Always use a source of dry compressed air.
35A-19
WHEELS AND TYRES
Run flat tyres: Specifications 35A
WHEEL COMPOSITION
21575
- a support (B) ,
The tyre, the support and the wheel rim are asymme-
tric.
35A-20
WHEELS AND TYRES
Run flat tyres 35A
REMOVAL
a Remove:
- the valve cap;
- the valve insert.
a Empty the air from the tyre.
21581
a Push the bead slightly towards the outside of the
wheel rim with the roller to lubricate the outer edge
of the wheel rim and bead.
21579
a Push the bead slightly inside the wheel rim with the
roller to lubricate the inner edge of the wheel rim and
bead.
21582
a Rotate the assembly to insert the rule into the space
created by the roller between the tyre and the wheel
rim. Make sure the rule is fitted the right way round,
with the badge facing the tyre sidewall.
21580
a Gradually push the tyre bead towards the inside of
the tyre, the wheel rim groove using the roller and
turning the assembly.
35A-21
WHEELS AND TYRES
Run flat tyres 35A
21583 21585
a Insert the lever in the rule slot and remove the outer a Extract the support by hand or with a lever.
bead. Do not forget the rule in the tyre.
21584
a Pull off the tyre and support by pushing the roller and
rotating the assembly, without damaging the pressu-
re detector.
35A-22
WHEELS AND TYRES
Run flat tyres 35A
REFITTING
21585
21587 a Remove the size label from the support, if present.
a For a new tyre, empty out the dose of gel inside the Insert the support, clean and free of gel, into the tyre
tyre and spread with the scraper. Never apply the making sure to fit it the right way round.
dose of gel on the tyre beads.
a For a tyre previously removed for repair or checking,
remove the gel from the tyre.
a Empty out the corresponding quantity of recommen-
ded gel (consult the manuals or Technical Notes
in section 35 for details) inside the tyre and spread
with the scraper. Never apply the dose of gel on the
tyre beads.
21588
a Lubricate the wheel rim over its entire width.
21586
a Lubricate the tyre beads with a lubricant solution for
passenger car tyres.
35A-23
WHEELS AND TYRES
Run flat tyres 35A
21589 21592
a Mount the support up to the wheel stop by pushing a Position the roller to bear against the wheel rim.
the roller and rotating the assembly. Make sure the
a Mount the tyre's outer bead on the wheel rim seat.
support is properly positioned against the wheel
stop, without damaging the pressure detector.
21591
21590 a Fit the tyre's inner bead in the same way as before.
a Remove the tyre's inner bead from the wheel rim a Make sure that the tyre is correctly fitted when infla-
groove using the lever. ting, and then screw on the valve cap.
Note:
Always use a source of dry compressed air.
35A-24
TYRE PRESSURE MONITOR
SSPP: List and location of components 35B
102413
The system consists of:
- four pressure sensors (1) built into the valves (one per
wheel); the sensors transmit a radio signal,
- a computer (2) which collects, decodes and proces-
ses sensor signals, and then determines which mes-
sage to display,
- a display (3) integrated to the instrument panel.
Note:
Each sensor is identified by a coloured marking
around the valve:
- green = front left,
- yellow = front right,
- red = rear left-hand,
- black = rear right-hand.
35B-1
TYRE PRESSURE MONITOR
Pressure sensor: Removal - Refitting 35B
I - RIGID TYRE PRESSURE MONITOR VALVE
Essential equipment
diagnostic tool
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equip-
ment). 18887
112627
a Remove:
35B-2
TYRE PRESSURE MONITOR
Pressure sensor: Removal - Refitting 35B
II - HINGED TYRE PRESSURE MONITOR VALVE III - ALL TYPES
115168 102242
a The following parts must be replaced: a Make sure that the sensor is correctly positioned on
the wheel rim:
- the seal with the metal ring (8) ,
- figure 1 = fitted incorrectly,
- the mechanism (9) ,
- the retaining nut (10) , - figure 2 = fitted correctly.
- the cap (11) . a Position the sensor in the valve opening, checking
that the seal is attached all around the edge of the
a If necessary, replace: opening.
- the coloured marker (12) .
Note:
After using a tyre repair aerosol, remove the pro-
duct residue from the valve with a dry cloth or air
gun before refitting it on the wheel rim.
35B-3
TYRE PRESSURE MONITOR
Pressure sensor: Removal - Refitting 35B
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a If replacing a pressure sensor, carry out the neces-
sary operations using the diagnostic tool (see MR
372 Fault finding, 35B, Tyre pressure monitor,
Replacement of components).
35B-4
STEERING ASSEMBLY
Steering rack: Removal - Refitting 36A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Steering: Precautions for repair) .
REMOVAL
- the front axle subframe (see 31A, Front axle com- - the steering box (2) .
ponents, Front axle sub-frame: Removal - Refit-
ting, page 31A-26) . REFITTING
WARNING
- A 10 mm thick shim must be placed between
the radiator cross member and the sub-frame to
torque tighten the radiator cross member moun-
tings to the recommended torque.
- The wheels must be set straight ahead; centre
the steering wheel.
36A-1
STEERING ASSEMBLY
Steering rack: Removal - Refitting 36A
116021
116022
a Check that the universal joint is in the correct posi-
tion.
a Refit:
- the engine undertray,
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-8) .
a If necessary, adjust the geometry of the axle assem-
blies (see 30A, General information, Front axle:
Adjusting, page 30A-16) .
36A-2
STEERING ASSEMBLY
Track rod: Removal - Refitting 36A
Essential special tooling
Tightening torquesm
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see Steering: Precautions for repair) .
REMOVAL
122713
a Remove the front wheel (see 35A, Wheels and ty- a Remove the track rod.
res, Wheel: Removal - Refitting, page 35A-1) .
REFITTING
II - OPERATION FOR REMOVAL OF PART
CONCERNED
I - REFITTING OPERATION FOR PART
CONCERNED
a Tighten to torque:
II - FINAL OPERATION
36A-3
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EA6 or EQT LEVEL EAG
II - OPERATION FOR REMOVAL OF PART
Essential special tooling CONCERNED
Dir. 1306-04 Tool for locking steering rack.
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle: a Set up the (Dir. 1306-04) (1) on the steering rack, at
Towing and lifting) . the pinion end.
a Remove the front wheel (see 35A, Wheels and ty- a Unlock the axial ball joint using tool (Dir. 1305-01)
res, Wheel: Removal - Refitting, page 35A-1) . (2) .
a Remove the track rod (see 36A, Steering assem- a Remove the axial ball joint.
bly, Track rod: Removal - Refitting, page 36A-3) .
a Remove the steering rack gaiter (see 36A, Steering REFITTING
assembly, Steering rack gaiter: Removal - Refit-
ting, page 36A-15) .
I - REFITTING PREPARATION OPERATION
a Unlock the steering column.
a parts always to be replaced: Steering axial ball
joint washer (13,04,02,04)
Note:
During this operation, the steering rack must be
in place on the vehicle.
36A-4
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EA6 or EQT LEVEL EAG
II - REFITTING OPERATION FOR PART
CONCERNED
101355
a Refit:
- a new washer (3) ,
- the axial ball joint (4) .
a Torque tighten the axial ball joint (80 N.m) using
the tool (Dir. 1305-01).
a Coat with SILICONE GREASE (see Vehicle: Parts
and ingredients for the repairwork) :
- the steering rack,
- the axial ball joint.
36A-5
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
EQT LEVEL SPORT
a Remove:
Essential special tooling
- the ball joint housing,
Tav. 476 Ball joint extractor.
- the lock nut,
Dir. 1306-04 Tool for locking steering rack. - the gaiter retaining clips,
Tightening torquesm
102206
REMOVAL a Set up the (Dir. 1306-04) (1) on the steering rack, at
a Position the vehicle on a two-post lift. the pinion end.
a Unlock the steering column lock using the diagnos- a Unlock the axial ball joint using tool (Dir. 1305-01)
tic tool. (2) .
Note:
During this operation, the steering rack must be
in place on the vehicle.
36A-6
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
EQT LEVEL SPORT
WARNING
Program the torque and angle sensor using the
diagnostic tool.
Note:
It is essential to initialise the xenon bulb system
(see MR 364, Electrical equipment, 80C,
Xenon bulbs).
Adjust the headlights.
101355
a Always replace washer (3) with a new one.
a Refit:
- the stop (3) (13 mm thick),
- the axial ball joint (4) (specific length: 230 mm).
a Torque tighten the axial ball joint (80 N.m) using
the tool (Dir. 1305-01).
a Coat the following parts with lithium grease:
- the steering rack,
- the axial ball joint.
a Refit:
- the gaiter,
- the metal clip,
- the new plastic clip, the same as the original fitting,
- the lock nut,
- the ball joint housing.
a Retighten the track rod end housing by the number
of rotations noted during removal.
a Refit the track rod end.
a Tighten to torque:
- the wheel alignment adjusting lock nut (53
N.m),
- the track rod end nut (37 N.m),
- the wheel mounting bolts (130 N.m).
WARNING
Connect the battery, starting with the positive ter-
minal; carry out the necessary programming (see
80A, Battery, Battery: Removal - Refitting).
36A-7
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
TRW steering column
Tightening torquesm
IMPORTANT
Never handle the pyrotechnic systems (pretensio-
ners or airbags) near to a source of heat or naked
flame - they may be triggered.
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or preten-
sioners), lock the airbag computer using the dia-
gnostic tool.
When this function is activated, all the trigger lines
118660
are inhibited and the airbag warning light on the ins-
trument panel lights up continuously (ignition on).
(A) Black intermediate shaft
REMOVAL
36A-8
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
a Remove: 1 - TRW column
- the steering wheel (see 36A, Steering assembly,
Steering wheel: Removal - Refitting, page 36A-
21) ,
- the steering column switch assembly (see Stee-
ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals),
- the centre panel (see Centre front panel: Remo-
val - Refitting) (57A, Interior equipment),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front left-hand air distribution duct (see Front
air distribution duct: Removal - Refitting) (61A,
103585
Heating system).
a Unclip the dashboard upper trim.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Lift the floor carpet to access the universal joint.
103584
a Unclip the dashboard lower trim.
104020
a Discard the cover (1) (do not keep it).
a Remove:
- the universal joint bolt (do not keep),
- the universal joint cam nut (do not keep).
36A-9
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
104019
a Remove the steering column upper nut (4) .
a Disconnect:
- the electric power-assisted steering computer
power connector using a 4 mm wide and 0.5 mm
104016
thick screwdriver,
a
- the electric power-assisted steering computer si-
WARNING gnal connector using a 4 mm wide and 0.5 mm
The bolt for the electric steering column lock has thick screwdriver.
a left-hand thread. It unscrews in a clockwise
direction.
Note:
Do not remove any power-assisted steering
column component.
104018
a Remove:
- the steering column lower nuts (5) ,
- the steering column.
36A-10
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
2 - NSK column
115381
115386
a Rest the steering column on the shim.
a
WARNING
The bolt for the electric steering column lock has
a left-hand thread. It unscrews in a clockwise
direction.
Note:
Do not remove any power-assisted steering
column component.
a Remove: a Disconnect:
- the steering column nuts, - the connector (8) by pressing (1) while pulling (2) ,
- the steering column. - the connector (9) .
WARNING
To ensure the electronic systems work properly,
do not damage the locking system (10) of the
connector (8) .
36A-11
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
REFITTING
Note:
When replacing an NSK type steering column on
vehicles not equipped with ESP, do not remove
the steering wheel angle sensor located on the
new steering column.
115385
a When refitting, the steering column must stay in pla-
ce using the retainers (11) ,
a Push and pull on the electric power-assisted stee-
ring computer power and signal connectors to check
that they are properly secured (risk of loss of assis-
tance).
Note:
The steering wheel should enter the splines
freely (the splines have foolproofing devices).
Do not damage the foolproofing splines.
Note:
- Do not refit the housing.
- On a new steering column, the universal joint
cam nut is pre-fitted.
36A-12
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
II - REFITTING OPERATION FOR PART a Clip on:
CONCERNED
- the instrument panel lower trim piece,
- the instrument panel upper trim piece.
1 - NSK column
a
Note:
When replacing an NSK type steering column on
vehicles not equipped with ESP, do not remove
the steering wheel angle sensor located on the
new steering column.
a Refit:
- the steering column,
36A-13
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
III - FINAL OPERATION
a Refit:
- the front left-hand air distribution duct (see Front
air distribution duct: Removal - Refitting) (61A,
Heating system),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the steering column switch assembly (see Stee-
ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals),
116022
- the steering wheel (see 36A, Steering assembly,
Steering wheel: Removal - Refitting, page 36A-
21) .
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
a Unlock the airbag computer (see Fault finding - Re-
placement of components) (88C, Airbag and pre-
tensioners).
116021
a Check that the universal joint is in the correct posi-
tion.
a Torque tighten:
- the universal joint bolt (TRW column) (30 N.m),
- the universal joint bolt (NSK column) (44 N.m).
a Refit the floor carpet.
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
36A-14
STEERING ASSEMBLY
Steering rack gaiter: Removal - Refitting 36A
REMOVAL REFITTING
Note:
Be sure to centre the steering to ensure the air in
the gaiters is equalised.
Note:
Be careful not to damage the gaiters: risk of irre-
versible damage.
a Refit:
a Remove the gaiter retaining clip (1) - the track rod, (see 3 6 A, Steering assembly,
a Cut the gaiter retaining clip (2) . Track rod: Removal - Refitting, page 36A-3)
a Remove the gaiter (3) . - the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
36A-15
STEERING ASSEMBLY
Bulkhead seal: Removal - Refitting 36A
Essential equipment
diagnostic tool
REMOVAL
a Remove the front axle subframe (see 31A, Front
axle components, Front axle sub-frame: Remo-
val - Refitting, page 31A-26) .
101352
REFITTING
a To refit, proceed in the reverse order of removal.
Note:
- The universal joint cam bolt and nut must be
replaced.
WARNING
36A-16
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
Tightening torquesm
NSK column
103584
a Remove:
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front left-hand air distribution duct (see Front
air distribution duct: Removal - Refitting) (61A,
Heating system).
118660
REMOVAL
36A-17
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
118664
104020
36A-18
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
116021 118922
a Check that the intermediary shaft on the steering co-
lumn side is in the correct position.
a Fit the intermediary shaft bolt on the steering column
side without tightening it.
116022
a Check that the universal joint is in the correct posi-
tion on the steering rack attack pinion stem.
a Fit the intermediate shaft on the steering column
while taking care not to shift it more than one tooth in
relation to its initial position.
36A-19
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
a Refit the floor carpet.
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
103810
a Connect:
- the start button (3) .
- the RENAULT card reader (4) .
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
a Unlock the steering wheel.
a Tighten to torque:
- the steering column intermediate shaft bolt (30
Nm),
- the universal joint bolt (44 Nm).
36A-20
STEERING ASSEMBLY
Steering wheel: Removal - Refitting 36A
Essential equipment
diagnostic tool
Tightening torquesm
IMPORTANT
It is essential to lock the airbag computer using the
diagnostic tool before starting the removal. When
this function is activated, all the trigger lines are
inhibited and the airbag warning light on the instru-
ment panel is continuously lit (with the ignition on).
Locking the airbag computer also unlocks the elec-
tric steering column lock.
103799
36A-21
STEERING ASSEMBLY
Steering wheel: Removal - Refitting 36A
a If all is correct, unlock the airbag computer (see
Fault finding - Replacement of components) (MR
366, 88C, Airbags and seat belt pretensioners).
36A-22
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
Tightening torquesm
WARNING
Prepare for brake fluid outflow, to prevent damage
to the mechanical parts and bodywork around the
braking system.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
103617
Towing and lifting) (MR 370, 02A, Lifting equip-
ment). a Remove:
a Disconnect the battery (see Battery : Removal - - the air filter access panel mounting bolts (1) ,
Refitting) (MR 370, 80A, Battery).
- the air filter access panel,
a Remove:
- the battery (see Battery : Removal - Refitting)
- the wiper arms, (MR 370, 80A, Battery),
- the scuttle panel grille (see Scuttle panel grille: - the battery tray (see Battery tray: Removal - Re-
Removal - Refitting) (MR 371, 55A, Exterior pro- fitting)
tection).
37A-1
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
F9Q or M9R
104084
a Remove:
101889 - the air inlet sleeve (4) ,
a Remove the turbocharger regulation solenoid valve - the inlet trunking (5) ,
(2) .
- the inlet trunking downstream of the air unit (6) ,
- the air unit (7) (see Air filter unit: Removal - Re-
fitting) (particularly for M9R)).
F4R or K4M
F9Q or M9R
a Disconnect the air flowmeter connector (8) .
101955
a Remove:
- the front left-hand wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) ,
- the wheel arch liner,
- both air resonators (3) .
37A-2
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
REFITTING
104087
a Disconnect the electrical connector (9) on the mas- 101704
ter cylinder reservoir. a
a Drain the master cylinder reservoir with a syringe.
WARNING
a Remove: The master cylinder seals (14) must be replaced.
- the clutch master cylinder pipe (10) ,
a Clip the master cylinder reservoir onto the master
- the brake pipes (11) on the master cylinder, cylinder correctly.
- the master cylinder mounting nuts (12) on the bra- a Refit the master cylinder reservoir mounting bolt on
ke servo, the master cylinder.
- the « master cylinder/master cylinder reservoir » a Torque tighten the master cylinder reservoir
assembly, mounting bolt (8.5 Nm).
- the master cylinder reservoir mounting bolt (13) on
the master cylinder,
- the master cylinder reservoir.
37A-3
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
101711
a Line up the master cylinder with the brake servo so
that the pushrod goes into the master cylinder hou-
sing.
WARNING
When refitting the master cylinder, be sure that
the cup is centred in the brake servo.
37A-4
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
WARNING
Prepare for brake fluid outflow, to prevent damage
to the mechanical parts and bodywork around the
braking system. 115165
a Unclip the vacuum pipe (1) from the air inlet duct.
REMOVAL a Disconnect the oil vapour rebreathing pipe (2) .
a Position the vehicle on a two-post lift (see Vehicle: a Undo the clip (3) securing the air inlet duct on the
Towing and lifting) (MR 370, 02, Lifting equip- turbocharger.
ment).
a Remove:
a Remove:
- the air inlet duct,
- the engine cover,
- the clip (4) .
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 371, 56A, Exterior equi-
pment),
- the battery (see Battery : Removal - Refitting) a Remove the master cylinder (see 37A, Mechanical
(MR 370, 80A, Battery), component controls, Master cylinder: Removal -
Refitting, page 37A-1) .
- the air filter unit and the injection computer (see Air
filter unit: Removal - Refitting) (MR 370, 12A,
Fuel mixture).
37A-5
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
- the sleeve stop support (7) .
F4R or F9Q
104086
102245
104085
WARNING
Do not touch the gearbox control rack.
104086
a Remove:
a Remove:
- the gearbox control ball joints (6) ,
- the brake servo valve (8) ,
- the control cables from the sheath stops
- the brake servo mounting bolts (9) , on the engine
- the sheath stop support mounting bolts, compartment side.
37A-6
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
M9R
115163
a Position the servo support on the servo.
a Compress the servo pushrod using a screwdriver in
order to remove the pushrod from its opening.
a Remove:
115162 - the servo with its support,
a Move the servo forwards. - the servo support.
a Remove the nuts (10) from the servo support.
37A-7
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting 37A
F4R or F9Q or K4J or K4M or K9K or M9R
91101
a Check the following dimensions before refitting:
- for left-hand drive vehicles: (X1) = 163.7 mm,
- for right-hand drive vehicles: (X1) = 133.2 mm.
a Proceed in the reverse order to removal.
IMPORTANT
Check that the connecting shaft between the
brake servo pushrod and the brake pedal is loc-
ked in place.
a Torque tighten:
- the servo mounting nuts (21 Nm),
- the brake servo mounting bolts (21 Nm),
- the gear lever sheath mounting bolts (21 Nm).
a Refit:
- the master cylinder (see 37A, Mechanical compo-
nent controls, Master cylinder: Removal - Refit-
ting, page 37A-1) ,
- the air filter unit and the injection computer (see Air
filter unit: Removal - Refitting) (MR 370, 12A,
Fuel mixture),
- the battery (see 80A, Battery, Battery: Removal -
Refitting),
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 371, 56A, Exterior equi-
pment),
- the engine cover.
37A-8
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting 37A
M9R, and LEFT-HAND DRIVE
REMOVAL
a Remove:
- the wiper arms,
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 371, 55A, Exterior pro-
tection).
115383
a Unclip:
- the turbocharger regulation solenoid valve (3) ,
- the vacuum pipe (4) from the air inlet duct.
a Disconnect:
104343
- the air flow sensor connector (5) ,
- the oil vapour rebreathing pipe (6) .
104246
a Remove: 115382
- the air filter access panel mounting bolts (1) , a Undo the retaining clips (7) on the air inlet duct.
- the air filter access panel, a Remove the air inlet duct.
37A-9
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting 37A
M9R, and LEFT-HAND DRIVE
115384
REFITTING
74883
37A-10
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting 37A
F4R or K4J or K4M
REMOVAL
a Remove the engine covers.
104171
a Disconnect the vacuum pipe on the brake servo side
104172
(3) on the brake servo.
a Undo the air duct clips (1) . a Pull and turn the non-return valve to release it from
the rubber sealing washer.
a Remove the air duct (2) .
Note:
Do not damage the vacuum tube on the plenum
chamber. If it is damaged, the plenum chamber
will have to be replaced.
REFITTING
a Check the condition of the sealing washer and the
non-return valve.
a Replace any faulty parts.
a To refit, proceed in the reverse order of removal.
37A-11
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting 37A
F9Q
REMOVAL REFITTING
a Remove the engine covers. a Check the condition of the sealing washer and the
non-return valve.
a Replace any faulty parts.
a To refit, proceed in the reverse order of removal.
104089
104088
37A-12
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting 37A
K9K
REMOVAL
a Remove the engine covers.
104397
a Disconnect the vacuum pipe at the brake servo end
(1) .
a Pull and turn the non-return valve to release it from
the rubber sealing washer.
a Disconnect the vacuum pipe at the vacuum pump
end (2) .
REFITTING
a Check the condition of the sealing washer and the
non-return valve.
a Replace any faulty parts.
a To refit, proceed in the reverse order of removal.
37A-13
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting 37A
K9K
Tightening torquesm
REMOVAL
a Remove the engine covers.
103565
a Remove:
- the hose connected to the brake servo,
- the vacuum pump mounting bolts (1) ,
- the vacuum pump.
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the vacuum pump mounting bolts
(2.1 daNm).
37A-14
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting 37A
F9Q
Tightening torquesm
REMOVAL
a Remove the engine covers.
103566
a Remove:
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten:
37A-15
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting 37A
M9R
a Move the wiring harness to one side.
Tightening torquesm a Remove the battery tray with the injection computer
support.
vacuum pump bolts 21 Nm
REMOVAL
a Remove:
- the engine cover,
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery).
115167
a Disconnect:
- the vacuum pipe (5) ,
- the non-return valve (6) .
a Remove:
- the bolt (7) from the diesel pipe retaining bracket,
- the diesel pipe retaining bracket,
- the vacuum pump bolt (8) .
112659
a Disconnect:
- the computer connectors (1) ,
- the air flowmeter connector.
a Unclip:
- the wiring harness (2) from the computer connec-
tor,
- the wiring harness to the battery negative terminal,
- the air filter unit turbocharger regulation solenoid
valve,
- the wiring harness.
a Remove:
- the battery tray bolts (3) ,
- the nut (4) from the wiring harness.
37A-16
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting 37A
M9R
a Refit:
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery),
- the engine cover.
115166
a Unclip the harness at (9) .
a Remove:
- the vacuum pump bolts (10) ,
- the vacuum pump.
REFITTING
a Be sure to replace the vacuum pump seal.
a Proceed in the reverse order to removal.
a Torque tighten:
- the vacuum pump bolts (21 Nm),
- the diesel pipe retaining bracket bolt (14 Nm).
a Refit the battery tray with the injection computer sup-
port.
a Fit the wiring harness.
a Refit:
- the wiring harness nut,
- the battery tray bolts,
a Tighten to torque the battery tray bolts (21 Nm).
a Fit the wiring harness.
a Refit the turbocharger regulation solenoid valve on
the air filter unit.
a Fit:
- the wiring harness to the battery negative terminal,
- the wiring harness for the computer connector.
a Connect the injection computer connectors.
37A-17
MECHANICAL COMPONENT CONTROLS
Accelerator pedal: Removal - Refitting 37A
Tightening torquesm
REMOVAL
a Switch off the vehicle ignition.
116018
a Disconnect the accelerator pedal potentiometer con-
nector (1) .
a Remove:
- the accelerator pedal nuts (2) ,
- the accelerator pedal.
REFITTING
a Refit the accelerator pedal.
a Torque tighten the accelerator pedal nuts (8 Nm).
a Connect the accelerator pedal potentiometer con-
nector.
37A-18
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
Tightening torquesm
WARNING
When the brake pedal is replaced, the pedal is sup-
plied fitted with a pin. (Fre. 1752).
103598
When removing and refitting (without replacing the
brake pedal), always fit the pin (Fre. 1752) during
the removal - refitting procedure.
REMOVAL
a Disconnect the battery, starting with the negative
terminal.
103600
a Unclip the « knob - gear lever gaiter » assembly.
37A-19
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
103601 103604
a Unclip the upper trim from the gear lever. a Remove:
a Disconnect: - the gear lever lower trim,
- the hazard warning lights switch connector, - the radio using the (Ms. 1373) and the (Ms. 1639),
- the cigarette lighter connector, - the air conditioning control panel fascia.
- the voice synthesiser speaker connector.
103603
a Remove the gear lever lower trim mountings.
37A-20
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
103166
a Unclip:
- the glovebox (1) , 103847
- the headlight beam adjustment control (2) from the a Remove the automatic parking brake control lever
rear (see 80B, Headlights, Headlight beam ad- mounting bolts (3) .
justment and lighting dimmer control).
a Disconnect the automatic parking brake control le-
a Disconnect the remote adjustment control connec- ver connector.
tors.
a Remove the lever.
103850
37A-21
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
103848 103849
a Unclip the front left-hand side panel.
103853
a Remove:
- the dashboard lower section mounting bolts,
- the lower section of the dashboard,
37A-22
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
104102 104823
a Remove: a Cut pin (4) .
- the air duct, a Insert the pin (Fre. 1752) moving from left to right
(when not replacing the pedal).
- the « brake pedal - idler bar » assembly connecting
shaft.
a Disconnect the potentiometer from the accelerator
pedal.
a Disconnect the brake switch.
a Turn the brake pedal switch one quarter of turn in an
anti-clockwise direction.
37A-23
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
REFITTING
104824
a Remove: 104824
Note:
- Do not remove the pin before refitting and loc-
king the pedal assembly.
37A-24
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
104826
a Remove the pin from the pedal.
IMPORTANT
Check that the connecting shaft between the
brake servo pushrod and the brake pedal is loc-
ked in place.
104825
a Adjust the brake pedal position switch (see 37A, Me-
a Cut the pin along the dotted line.
chanical component controls, Brake light
a Proceed in the reverse order to removal. switch).
a Torque tighten the brake pedal yoke mounting a Connect the battery, starting with the positive termi-
nuts (21 Nm). nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting).
37A-25
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
RIGHT-HAND DRIVE
Essential equipment
diagnostic tool
Tightening torquesm
IMPORTANT
- Before carrying out any work on a safety system
component, lock the airbag computer using dia-
gnostic tool (see 88C, Airbags and pretensio-
ners, Airbag computer locking procedure).
104757
- When this function is activated, all the trigger lines a Disconnect the connector from the accelerator pedal
are inhibited and the airbag warning light on the position potentiometer.
instrument panel is continuously lit (with the igni-
tion on). a Remove:
- Handling pyrotechnic systems (airbags or preten- - the mounting bolts (1) from the accelerator pedal,
sioners) near to a source of heat or flame is forbid- - the accelerator pedal.
den: there is a risk of triggering the airbags or
pretensioners.
WARNING
When the brake pedal is replaced, the pedal is sup-
plied fitted with a pin. (Fre. 1752).
When removing and refitting (without replacing the
brake pedal), always fit the pin (Fre. 1752) during
removal.
REMOVAL
a Disconnect the battery, starting with the negative
terminal.
a Remove:
37A-26
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
RIGHT-HAND DRIVE
103829 104823
WARNING
Do not damage the clutch master cylinder pipes.
104755
37A-27
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
RIGHT-HAND DRIVE
REFITTING
104755
104754
a
WARNING
Before refitting the brake pedal, the fuse plate (7)
must be checked for deformation. If there is any
deformation to the fuse board, the brake pedal
must be replaced.
Note
- Do not remove the pin before refitting and loc-
king the pedal assembly.
104756
a Remove:
- the brake pedal mounting bolts (5) and (6) ,
- the brake pedal assembly by rotating it to release it
from the idler bar.
37A-28
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting 37A
RIGHT-HAND DRIVE
104823
a Cut the pin along the dotted line. (do not remove the
pin from the pedal).
a Proceed in the reverse order to removal.
a Torque tighten the brake pedal yoke mounting
nuts (21 Nm).
a Remove the pin from the pedal.
a Adjust the brake pedal position switch (see 37A, Me-
chanical component controls, Brake light
switch).
IMPORTANT
Unlock the computer using the diagnostic tool
(see 88C, Airbags and pretensioners, Airbag
computer locking procedure).
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting).
37A-29
MECHANICAL COMPONENT CONTROLS
Brake pedal bell crank rod: Removal - Refitting 37A
RIGHT-HAND DRIVE
When the brake pedal is replaced, the pedal is sup-
plied fitted with a pin.
REMOVAL
a Remove the brake pedal (see 37A, Mechanical
component controls, Brake pedal: Removal - Re-
fitting, page 37A-19) .
103828
a Remove:
- the two nuts (4) from the idler bar retaining ring,
WARNING
Do not damage the clutch master cylinder pipes.
REFITTING
a To refit, proceed in the reverse order of removal.
37A-30
MECHANICAL COMPONENT CONTROLS
Brake pedal switch: Removal - Refitting 37A
REFITTING
WARNING
The switch must be replaced if handling of the pis-
ton results in three adjustments being made.
REMOVAL
108436
WARNING
Handle the switch (3) with care.
Only operate the piston (4) to adjust the dimen-
sion (X) .
The switch must be replaced:
- if the piston (4) is separated from the switch (3)
,
- if more than three adjustments to dimension (X)
are necessary during the operation.
Note:
The brake pedal switch has an automatic adjust-
ment which adapts to the pedal position.
The automatic adjustment makes a clicking noise
when in operation.
37A-31
MECHANICAL COMPONENT CONTROLS
Brake pedal switch: Removal - Refitting 37A
a Check that the brake light switch is operating cor-
rectly:
- depress the brake pedal to switch on the lights,
- release the brake pedal to switch off the lights.
37A-32
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting 37A
WITHOUT AUTOMATIC PARKING BRAKE
Tightening torquesm
REMOVAL
a Put the vehicle on a two-post lift.
104534
a Remove:
104533
a Remove the centre console cover (1) .
104531
a Pull out the parking brake control cables (4) from the
control lever.
37A-33
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting 37A
WITHOUT AUTOMATIC PARKING BRAKE
REFITTING
a Follow the routing noted during removal.
a To refit, proceed in the reverse order of removal.
104530
a Pull the parking brake control cables out via the ve-
hicle underbody.
104529
37A-34
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting 37A
STANDARD CHASSIS, and AUTOMATIC PARKING BRAKE
Essential equipment
diagnostic tool
REMOVAL
a Release the parking brake using the handle. a Unclip the anchorage guard.
104406
REFITTING
37A-35
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting 37A
STANDARD CHASSIS, and AUTOMATIC PARKING BRAKE
a Position the brake cables in the position marked du-
ring removal.
II - FINAL OPERATION
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
a Switch on the + after ignition feed.
a Activate the handle several times to adjust the brake
cables.
a Clear the faults using the diagnostic tool.
37A-36
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting 37A
Tightening torquesm
REMOVAL
104534
a Remove:
- the centre console mountings (2) ,
- the centre console.
104533
a Remove the centre console carpet (1) .
104531
a Unscrew the adjusting nut (3) .
a Remove the parking brake control cables (4) .
37A-37
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting 37A
104532 104531
a Disconnect the parking brake control lever switch a Screw the adjusting nut to obtain a measurement (X)
connector (5) . of 17 mm.
a Remove: a Tighten the adjusting nut so that the brake pads are
rubbing lightly against the brake discs.
- the parking brake control lever mountings (6) ,
a Check the parking brake lever stroke.
- the parking brake lever.
a Refit:
- the parking brake lever mountings. a Torque tighten the centre console mountings (0.2
daNm).
a Torque tighten the parking brake control lever
mountings (0.8 daNm).
a Reconnect the parking brake lever switch connector.
37A-38
MECHANICAL COMPONENT CONTROLS
Clutch control: Description 37A
RIGHT-HAND DRIVE or LEFT-HAND DRIVE
LEFT-HAND DRIVE
102207
37A-39
MECHANICAL COMPONENT CONTROLS
Clutch control: Description 37A
RIGHT-HAND DRIVE or LEFT-HAND DRIVE
RIGHT-HAND DRIVE
37A-40
MECHANICAL COMPONENT CONTROLS
Clutch control: Description 37A
RIGHT-HAND DRIVE or LEFT-HAND DRIVE
37A-41
MECHANICAL COMPONENT CONTROLS
Clutch control: Description 37A
RIGHT-HAND DRIVE or LEFT-HAND DRIVE
102208
37A-42
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
Tightening torquesm
REMOVAL
104246
PK4 a Remove:
a Position the vehicle on a two-post lift (see Vehicle: - the scuttle panel partition mounting bolts (3) ,
Towing and lifting) (MR 370, 02A, Lifting equip- - the scuttle panel partition,
ment).
- the battery (see Battery : Removal - Refitting)
(MR 370, 80A, Battery),
- the battery tray with the injection computer,
a Disconnect the battery (see Battery : Removal - - the air filter box (see Air filter unit: Removal - Re-
Refitting) (MR 370, 80A, Battery). fitting) (MR 370, 12A, Fuel mixture).
a Remove:
a Drain the brake fluid reservoir using a syringe until
- the engine cover, the level is below the master cylinder supply orifice.
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 371, 55A, Exterior pro-
tection).
104343
a Remove:
37A-43
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
101701 102513
a Lift up clip (4) . a Apply pressure to the clip (5) manually, whilst pulling
on the pipe.
a Pull out the clutch control pipe one notch.
WARNING
Do not pull the clip. If it is incorrectly handled in
any way, the pipe will need to be replaced.
37A-44
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
PK4
101741
REFITTING
a Visually check the condition of the seals.
37A-45
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
a Proceed in the reverse order to removal.
WARNING
Do not use the take-off pipes as a support when
fitting.
37A-46
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and LEFT-HAND DRIVE
REMOVAL
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery).
a Remove:
- the engine cover,
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 371, 55A, Exterior pro- 104246
tection). a Remove:
- the scuttle panel partition mounting bolts (3) ,
- the scuttle panel partition,
- the battery (see Battery : Removal - Refitting)
(MR 370, 80A, Battery),
- the battery tray with the injection computer,
- the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 370, 12A, Fuel mixture).
104343
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the scuttle panel partition mounting bolt (2) .
37A-47
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and LEFT-HAND DRIVE
101701 102513
a Lift up clip (4) . a Apply pressure to the clip (5) manually, whilst pulling
on the pipe.
a Pull out the clutch control pipe one notch.
WARNING
Do not pull the clip. If it is incorrectly handled in
any way, the pipe will need to be replaced.
37A-48
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and LEFT-HAND DRIVE
PK4
101740
- the bleed plug (6) . a Place a cloth under the master cylinder.
a Turn the end (7) of the slave cylinder anticlockwise a Remove the union clip from the master cylinder (9) .
as far as it will go.
a Disconnect the pipes.
19399
37A-49
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and LEFT-HAND DRIVE
REFITTING
19148
a Check the condition of the seals.
a Proceed in the reverse order to removal.
Note:
- Lubricate both ends of the supply pipe with
brake fluid to facilitate fitting on the brake fluid
reservoir take-off pipe.
- The master cylinder has a foolproofing device, it
only fits in one position.
WARNING
Do not use the take-off pipes as a support when
fitting.
37A-50
MECHANICAL COMPONENT CONTROLS
Clutch pedal switch: Removal - Refitting 37A
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX
diagnostic tool
REMOVAL
LEFT-HAND DRIVE
101741
101899
37A-51
MECHANICAL COMPONENT CONTROLS
Clutch pedal switch: Removal - Refitting 37A
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX
LEFT-HAND DRIVE
101741
a Disconnect the connector from the start of travel a Turn the start of travel switch (2) one quarter of a
switch (2) . turn anticlockwise.
a Turn the start of travel switch (2) one quarter of a a Remove the clutch switch.
turn anticlockwise.
a Remove the clutch switch.
37A-52
MECHANICAL COMPONENT CONTROLS
Clutch pedal switch: Removal - Refitting 37A
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX
Note:
The clutch pedal switch has an automatic adjust-
ment feature, adapting to the pedal position.
- if the piston (4) is separated from the switch (3) a Position the end of travel switch on the pedal assem-
, bly.
- if more than three adjustments to the dimension a Lock the end of travel switch by turning it one quarter
(X) are necessary during the operation. of a turn clockwise.
a Measure dimension (X) of the piston (4) . If the di-
a Depress the clutch pedal by hand.
mension (X) is less than 17 mm, carefully pull on the
end of the piston (4) to adjust the dimension (X)
between the values 17 mm minimum and 18 mm
Note:
maximum.
The clutch pedal switch has an automatic adjust-
ment feature, adapting to the pedal position.
The automatic adjustment makes a clicking noise
when in operation.
37A-53
MECHANICAL COMPONENT CONTROLS
Manual gearbox selector cable: Removal - Refitting 37A
AJ0 or DP0 or JH3 or JR5 or ND0 or PK4 or TL4
I - REMOVAL II - REFITTING
a Precautions to be taken when removing and refitting
the gear cable end pieces to avoid tearing the plastic
guide tube and damaging the ball joints.
121257
a To remove the gear control cables from their ball
joints, use an open-ended spanner as shown above. 121258
This prevents the control cables from being dama-
ged.
121259
a To refit, use pliers to clip the gear control cables to
the ball joints.
a Perform rapid gearchanges for all gears for 20 se-
conds.
Check that the cables are not unclipped.
37A-54
MECHANICAL COMPONENT CONTROLS
Gear control unit: Removal - Refitting 37A
AJ0
Tightening torquesm
REMOVAL
Note:
It is essential that the passenger compartment 104343
gear lever and the multifunction switch lever on
the gearbox are in D.
37A-55
MECHANICAL COMPONENT CONTROLS
Gear control unit: Removal - Refitting 37A
AJ0
II - OPERATION FOR REMOVAL OF PART
CONCERNED
114991
a Remove the bolts (5) from the exhaust bracket.
105107
a Move the exhaust pipe to one side.
a Unclip the control cable on the gearbox at:
a Disconnect the oxygen sensor connector.
- the anchoring ball joint (6) using an open-jawed
a Remove the bolts from the heat shield. spanner,
a Move the heat shield towards the back of the vehi- - from the cable sleeve stop (7) .
cle.
37A-56
MECHANICAL COMPONENT CONTROLS
Gear control unit: Removal - Refitting 37A
AJ0
105108 104733
Note:
Do not open the automatic gearbox control unit, it
could cause damage (infrared system).
REFITTING
a Connect the automatic gearbox control unit connec- a Clip the automatic gearbox control cable anchoring
tor. ball joint on the automatic gearbox.
a Clip the control cable on the gearbox at the sleeve a Lock the adjustment mechanism while pushing back
stop level. the catch to its initial position.
37A-57
MECHANICAL COMPONENT CONTROLS
Gear control unit: Removal - Refitting 37A
AJ0
II - FINAL OPERATION.
a Refit the heat shield.
a Connect the oxygen sensor connector.
a Refit:
- the exhaust pipe,
- the air pipe at the air filter box outlet,
- the injection computer (see Diesel injection com-
puter: Removal - Refitting) (13B, Diesel injec-
tion),
- the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
- the battery (see Battery : Removal - Refitting)
(80A, Battery)
- the scuttle panel grille scoop,
- the air filter access panel,
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (55A, Exterior protection),
- the engine undertray,
- the engine cover,
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment).
a Check that the system and gear selection are wor-
king correctly.
37A-58
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
Tightening torquesm
REMOVAL
a Disconnect the battery, starting with the negative
terminal.
101899
REFITTING
a To refit, proceed in the reverse order of removal.
37A-59
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
102205
a Position the switches in their housing.
a Turn them one quarter turn clockwise.
a Reconnect the two clutch pedal switches.
WARNING
Connect the battery. carry out the necessary pro-
gramming (see (see 8, Electrical equipment) ).
37A-60
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting 37A
RIGHT-HAND DRIVE
Tightening torquesm
REMOVAL
a Disconnect the battery, starting with the negative
terminal.
Note:
The clutch master cylinder is mounted on the
clutch pedal assembly. Remove the « pedal -
104246
master cylinder » assembly to extract the pedal
or master cylinder. a Remove:
a Drain the brake fluid reservoir until the level is below - the radiator tank partition mounting bolts (3) ,
the master cylinder supply port. - the scuttle panel partition.
a Remove: a Remove:
- the engine covers, - the battery,
- the scuttle panel grill ( (see 8 5 A , Wiping - - the battery tray,
Washing) ).
- the computer with its mounting,
- the air filter outlet duct.
a Drain the brake fluid reservoir until the level is below
the master cylinder supply port.
104343
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the mounting bolt (2) from the scuttle panel parti-
tion.
37A-61
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting 37A
RIGHT-HAND DRIVE
101701 102513
a Lift up the clip (3) . a Apply pressure to the clip (5) manually, whilst pulling
on the pipe.
a Pull out the clutch control pipe by one notch.
a Place a cloth under the bleed port.
WARNING
a Operate the pedal by hand to empty the master cy-
Do not pull the clip. If it is incorrectly handled in
linder and the pipes.
any way, the pipe will need to be replaced.
a Lift up the clip (4) .
a Pull out the pipes on the clutch control by one posi-
a Disconnect the pipes from the slave cylinder. tion.
a Fit plugs into the openings. a Place a cloth under the bleed port.
a Operate the pedal by hand to empty the master cy-
linder and the pipes.
a Remove clip (5) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
37A-62
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting 37A
RIGHT-HAND DRIVE
In the passenger compartment REFITTING
a Check the condition of the seals.
a To refit, proceed in the reverse order of removal.
a Torque tighten the clutch pedal plate nuts (2.1
daNm).
a It is essential that the sensors are pulled to the end
stop to position them at the minimum.
The clutch pedal position sensors have an automatic
adjustment function which adjusts in accordance
with the position of the pedal.
101741
a Remove the grey start of travel switch (6) by turning
it a quarter of a turn.
a Disconnect the connector from the switch (6) .
a Remove the green end of travel switch (7) by turning
it a quarter of a turn.
a Disconnect the connector from the switch (7) .
a Place a cloth under the master cylinder.
a Remove the union clips on the master cylinder (8) .
a Disconnect the pipes. 102205
a Fit plugs into the openings. a Position the switches in their housing.
a Remove the clutch master cylinder ball joint from the a Turn them one quarter turn clockwise.
pedal.
a Reconnect the two clutch pedal switches.
a Disconnect the clutch pedal position sensor connec-
tor. a Bleed the clutch control (see 37A, Mechanical
component controls, Clutch circuit: Bleeding,
a Remove the clutch pedal position sensor. page 37A-73) .
a Remove the four clutch plate nuts.
a Extract the « pedal - master cylinder » assembly. WARNING
a Remove the master cylinder from the pedal assem- Connect the battery. carry out the necessary pro-
bly by turning it clockwise a quarter of a turn (bayo- gramming (see (see 8, Electrical equipment) ).
net type mounting).
37A-63
MECHANICAL COMPONENT CONTROLS
Clutch pedal position sensor: Removal - Refitting 37A
AUTOMATIC PARKING BRAKE, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX
Essential equipment
diagnostic tool
REMOVAL
21410
a Tilt the clutch pedal position sensor, taking care not
to damage the sensor lower mounting bracket.
REFITTING
II - FINAL OPERATION
100220
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
a Disconnect the position sensor connector (1) from
the clutch pedal. a Switch on the + after ignition feed.
37A-64
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and LEFT-HAND DRIVE
104343
a Remove:
- the two air filter access panel mounting bolts (1) , 101701
- the air filter access panel, a Lift up clip (6) .
- the scuttle panel partition mounting bolt (2) . a Pull out the master cylinder control pipe by one
notch.
a Place a cloth under the bleed hole.
a Operate the pedal by hand to empty the master cy-
linder and the pipe.
a Lift up clip (7) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
104246
a Remove:
- the scuttle panel partition mounting bolts (3) ,
- the scuttle panel partition,
37A-65
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and LEFT-HAND DRIVE
ND0 PK4
102513 115170
a Apply pressure to the clip (8) manually, whilst pulling a Remove:
on the pipe.
- the engine undertray,
- the bleed plug (9) .
WARNING
a Connect a transparent pipe to the bleed hole running
Do not pull the clip. If it is incorrectly handled in
to an empty container placed under the bleed hole.
any way, the pipe will need to be replaced.
a Turn the end (10) of the slave cylinder anticlockwise
a Pull out the master cylinder control pipe by one as far as it will go.
notch.
a Depress the pedal using your hand (to drain the
a Place a cloth under the bleed hole. master cylinder and the pipe).
a Depress the pedal using your hand (to drain the
master cylinder and the pipe).
a Press the clip (8) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
37A-66
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and LEFT-HAND DRIVE
REFITTING
PK4 a Check the condition of the seals.
a Proceed in the reverse order to removal.
a Bleed the clutch control (see 37A, Mechanical
component controls, Clutch circuit: Bleeding,
page 37A-73) .
a Check that the clutch system is operating correctly.
a Connect the battery (see Battery : Removal - Refit-
ting) (MR 370, 80A, Battery).
115169
a Lift up clip (11) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
a Unclip the pipe at (12) .
101739
a Place a cloth under the master cylinder.
a Remove the clip (13) from the union on the master
cylinder return.
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
a Withdraw the slave cylinder supply pipe.
37A-67
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery).
a Remove: 104246
- the engine cover, a Remove:
- the scuttle panel grille (see Scuttle panel grille: - the scuttle panel partition mounting bolts (2) ,
Removal - Refitting) (MR 371, 55A, Exterior pro-
- the scuttle panel partition,
tection).
- the battery (see Battery : Removal - Refitting)
(MR 370, 80A, Battery),
- the battery tray with the injection computer,
- the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 370, 12A, Fuel mixture).
a Drain the brake fluid reservoir using a syringe until
the level is below the master cylinder supply orifice.
104343
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the scuttle panel partition mounting bolt (2) .
37A-68
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
101701 102513
a Lift up clip (3) . a Apply pressure to the clip (5) manually, whilst pulling
on the pipe.
a Pull out the master cylinder control pipe by one
notch.
a Place a cloth under the bleed hole. WARNING
Do not pull the clip. If it is incorrectly handled in
a Operate the pedal by hand to empty the master cy-
any way, the pipe will need to be replaced.
linder and the pipe.
a Lift up clip (4) . a Pull out the master cylinder control pipe by one
notch.
a Disconnect the pipes from the slave cylinder.
a Place a cloth under the bleed hole.
a Fit plugs into the openings.
a Depress the pedal using your hand (to drain the
master cylinder and the pipe).
a Press the clip (5) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
37A-69
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
PK4 PK4
115169
a Pull out clip (8) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
115170 a Unclip the pipe at (9) .
a Remove:
- the engine undertray,
- the bleed plug (6) .
a Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
a Turn the end (7) of the slave cylinder anticlockwise
as far as it will go.
a Depress the pedal using your hand (to drain the
master cylinder and the pipe).
101739
a Place a cloth under the master cylinder.
a Remove the clip (10) from the union on the master
cylinder return.
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
a Take out the slave cylinder supply pipe.
37A-70
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
a Remove:
- the left-hand glove compartment,
- the left-hand air duct.
101741
a Place a cloth under the master cylinder.
a Remove the clip (13) from the master cylinder sup-
102212 ply union on the master cylinder return.
a Place a cloth under the pipe unions. a Disconnect the pipes.
a Remove the clip (11) from the master cylinder union a Fit plugs into the openings.
on the master cylinder return.
a Withdraw the master cylinder supply pipe from the
a Disconnect the pipes. left-hand side.
a Fit plugs into the openings. a Remove the clip (14) from the slave cylinder supply
union on the master cylinder return.
a Remove the clip (12) from the slave cylinder supply
union on the master cylinder return. a Disconnect the pipes.
a Disconnect the pipes. a Fit plugs into the openings.
a Fit plugs into the openings. a Withdraw the slave cylinder supply pipe from the
left-hand side.
37A-71
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting 37A
JH3 or JR5 or ND0 or PK4, and RIGHT-HAND DRIVE
101739
a Place a cloth under the hole (15) .
a Remove the brake fluid reservoir pipe.
a Fit plugs into the openings.
a Remove the master cylinder return (16) from the
bulkhead by turning it clockwise a quarter of a turn
(bayonet type mounting) using the (Emb. 1797).
REFITTING
a Check the condition of the seals.
a Proceed in the reverse order to removal.
a Bleed the clutch control (see 3 7 A, Mechanical
component controls, Clutch circuit: Bleeding,
page 37A-73) .
a Check that the clutch system is operating correctly.
a Connect the battery (see Battery : Removal - Refit-
ting) (MR 370, 80A, Battery).
37A-72
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding 37A
JH3 or JR5 or ND0 or PK4 or TL4
There are two types of equipment used to bleed the
clutch circuit:
Essential equipment
a ARC50 via the brake fluid reservoir.
brake circuit bleeding device
a Syringe via the bleed hole located on the clutch sla-
hydraulic circuit bleed syringe ve cylinder.
Bleed in the event of: There are two procedures used to bleed the clutch
- dead travel, circuit:
Risks relating to contamination. - Only carry out the bleed operation using a new sy-
ringe by injecting the brake fluid via the bleed hole
a The hydraulic clutch system is very sensitive to con- on the clutch slave cylinder.
tamination. The risks caused by contamination are:
- impossible to change gears, Note:
- damage to or destruction of the clutch system, - Even the tiniest air bubble in the circuit can
cause faulty operation (pedal failing to return
- leaks on the hydraulic circuit.
properly, crunching sound when changing gear,
All the operations on the hydraulic clutch circuit sys- etc.).
tem must be carried out under excellent cleanliness
- Incorrect bleeding can lead to incorrect detec-
conditions. This ensures that no impurities enter the
tion of faults and unnecessary part replace-
hydraulic circuit during the operation.
ments.
The cleanliness principles apply to all components
of the hydraulic clutch circuit.
Consumables required for the repair:
Items causing contamination are:
a Bleed the clutch circuit using approved (see Vehi-
- metal or plastic swarf, cle: Parts and ingredients for the repairwork)
brake fluid (04B, consumables - products).
- fibres:
• cardboard, II - PREPARATION STAGE
• brushes, a Position the vehicle on a two-post lift (see Vehicle:
• paper, Towing and lifting) (02A, Lifting equipment).
a Remove the engine undertray.
• clothing,
• cloth,
• dust and particles in the air,
• etc.
Cleaning cloths.
a Use lint-free cleaning cloths (see Recommended
products for repairwork) (04B, Consumables -
Products).
Each cloth must only be used once.
37A-73
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding 37A
JH3 or JR5 or ND0 or PK4 or TL4
There are several versions of bleed screw: Bleed screw with a clip.
112868
a To open the bleed screw, press and hold the clip (4)
113919 while pulling by one notch.
a To open the bleed screw, hold the plastic union (1)
using a ring spanner and undo the bleed screw (2) . Bleed screw with a clip.
107280
a To open the bleed screw, lift the clip (5) while pulling
114335 by one notch.
a To open the bleed screw, fully turn the bleed screw
(3) by hand.
37A-74
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding 37A
JH3 or JR5 or ND0 or PK4 or TL4
Bleed screw with two clips. a Connect the brake circuit bleeding device (after
having received Renault approval) to the master cy-
linder reservoir (see the instructions for the equip-
ment).
a Remove the bleed plug from the clutch slave cylin-
der.
a Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
a Open the bleed screw.
a Open the circuit between the bleeding device and
the brake fluid reservoir.
a Let the brake fluid run until all air bubbles have been
released.
a Stop the bleeding device to dump the pressure in the
clutch circuit.
a Close the bleed screw.
a Remove the transparent pipe from the bleed hole.
113732
a Refit the bleed plug.
a To open the bleed screw, lower the clip (6) and lift
the clip (7) while pulling by one notch. a Top up the brake fluid level in the master cylinder re-
servoir after disconnecting the bleed device.
III - BLEED PROCEDURE IF NO PARTS OF THE a Disengage and engage the clutch quickly around
HYDRAULIC CIRCUIT ARE REMOVED twenty times.
a Check that the clutch system is operating correctly.
1 - Bleed using the ARC50. a Repeat the bleed operation if necessary.
a Keep the clutch pedal in the upper position using a a Check the adjustment of the switch. (see 37A, Me-
strap attached to the steering wheel to ensure conti- chanical component controls, Clutch pedal
nuity of the hydraulic circuit during the bleed opera- switch: Removal - Refitting, page 37A-51) (37A,
tion. mechanical control elements).
Note:
Take care not to disrupt the adjustment of the
clutch start of travel switch.
37A-75
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding 37A
JH3 or JR5 or ND0 or PK4 or TL4
2 - Bleed using a new syringe. IV - BLEED PROCEDURE IF PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED.
a Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti- a
nuity of the hydraulic circuit during the bleed opera-
WARNING
tion.
The master cylinder pipe must be disconnected
from its take-off point on the brake fluid reservoir,
to avoid any foreign matter penetrating inside the
Note:
brake system hydraulic circuit.
Take care not to disrupt the adjustment of the
clutch start of travel switch.
WARNING
a Remove the bleed plug from the clutch slave cylin- Prepare for the flow of fluid and protect the sur-
der. rounding components.
Note:
The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.
37A-76
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding 37A
JH3 or JR5 or ND0 or PK4 or TL4
There are several versions of pipe with and without Filling position for pipe with filter.
a filter:
141810
141813
a Prefill the clutch pipe using the syringe.
a Plug the prefilled pipe on the master cylinder end to
141811 stop any brake fluid from escaping.
37A-77
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding 37A
JH3 or JR5 or ND0 or PK4 or TL4
V - BLEED PROCEDURE AFTER A REMOVING A
COMPONENT OF THE HYDRAULIC CIRCUIT.
Note:
Take care not to disrupt the adjustment of the
clutch start of travel switch.
Note:
The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.
37A-78
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding 37A
JH3 or JR5 or ND0 or PK4 or TL4
VI - FINAL OPERATION
a Refit the engine undertray.
a Remove the vehicle from the two-post lift (see Vehi-
cle: Towing and lifting) (02A, Lifting equipment).
37A-79
ELECTRONIC PARKING BRAKE
Emergency handle: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
diagnostic tool
Vehicles manufactured up to 28/05/07
REMOVAL
STANDARD CHASSIS
107507
a Remove the guard (1) .
104412
a Remove the guard (1) .
II - REMOVAL OPERATION FOR PART
CONCERNED
22274
a Pull out the emergency handle and the cable slight-
ly, by less than 2 cm.
a Remove the emergency handle.
37B-1
ELECTRONIC PARKING BRAKE
Emergency handle: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
REFITTING
STANDARD CHASSIS
a Always replace the guard.
37B-2
ELECTRONIC PARKING BRAKE
Control unit: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
diagnostic tool
STANDARD CHASSIS
107513
REMOVAL
37B-3
ELECTRONIC PARKING BRAKE
Control unit: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
II - REMOVAL OPERATION FOR PART
CONCERNED
STANDARD CHASSIS
a
Note:
the primary brake cable cannot be removed. It is
sold as part of the control unit.
104401
a Remove:
104407
37B-4
ELECTRONIC PARKING BRAKE
Control unit: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
104406
a Remove the primary cable from the rear axle ancho-
rage.
a Remove the « control unit - primary cable » assem-
bly.
107512
a Note the brake cable routing for refitting.
a Remove:
III - - the brake cables from the callipers,
- the cables from their guides.
LONG CHASSIS
a Let the parking brake cables hang freely.
107509
a Remove the luggage compartment trim (5) .
107515
a Pull out the emergency control cable via the vehicle
underbody.
37B-5
ELECTRONIC PARKING BRAKE
Control unit: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
107510
a Remove the bolts (6) from the control unit.
107513
a Remove:
- the control unit pre-retaining bolt (8) ,
- the control unit with its cables.
REFITTING
STANDARD CHASSIS
107514 a Refit the « control unit - primary cable » assembly.
a Disconnect the wiring (7) from the control unit. a Fit the primary cable to the rear axle anchorage.
a Refit the anchorage guard.
a Refit the anchorage on the rear axle.
a Position the brake cables in the position marked du-
ring removal.
a Connect the control unit wiring.
37B-6
ELECTRONIC PARKING BRAKE
Control unit: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
LONG CHASSIS
a Refit the control unit.
a Position the brake cables in the position marked du-
ring removal.
a Connect the control unit wiring.
a refit:
- the luggage compartment trim,
- the brake cables to the callipers.
II - FINAL OPERATION.
a If fitted to the vehicle, refit the emergency handle
(see 37B, Electronic parking brake, Emergency
handle: Removal - Refitting, page 37B-1) .
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
a Switch on the + after ignition feed.
a Activate the handle several times to adjust the brake
cables.
a Write the data saved before removal using the dia-
gnostic tool (see Fault finding - Replacement of
components) (37B, Electronic parking brake).
a Clear the faults using the diagnostic tool.
37B-7
ELECTRONIC PARKING BRAKE
Handle: Removal - Refitting 37B
AUTOMATIC PARKING BRAKE
Essential equipment
diagnostic tool
REMOVAL
REFITTING
II - FINAL OPERATION.
a Refit:
- the remote adjustment control mounting.
- the glove compartment, driver's side,
a Connect the battery (see Battery : Removal - Refit-
104411
ting) (80A, Battery).
a Remove the bolts (1) from the lever. a Switch on the + after ignition feed.
a Clear the faults using the diagnostic tool.
37B-8
ANTI-LOCK BRAKING SYSTEM
Introduction 38C
Where there is a difference between the desired trajec-
tory and the actual trajectory, the appropriate wheel is
Essential equipment
braked. In certain cases, the understeer monitoring
diagnostic tool brakes two wheels at the same time. The torque gene-
rated sets the vehicle on the desired trajectory.
The vehicle is fitted with a BOSCH 8.0. ABS system. In some cases, the anti-skid control modifies the engi-
ne torque.
Depending on the vehicle equipment, the BOSCH 8.0
system consists of the ABS system only or the Anti-
lock Braking System in conjunction with the Electronic III - ELECTRONIC STABILITY PROGRAM
Stability Program (ESP). OPERATION SPECIAL FEATURES
The ESP function can be disconnected via the switch
located on the dashboard.
IMPORTANT
This function can not be deactivated above a threshold
After any operation on the ESP system, it is essen- of approximately 50 km per hour.
tial to confirm the repair with a road test and a
check with the diagnostic tool (CLIP). This function is automatically reactivated when the ve-
hicle is switched on, or at speeds above approximately
50 km/h.
I - DESCRIPTION OF THE ABS SYSTEM WITH
ELECTRONIC STABILITY PROGRAM
• a hydraulic pump,
• a computer,
• a pressure sensor,
38C-1
ANTI-LOCK BRAKING SYSTEM
Hydraulic unit: Introduction 38C
102311
The anti-lock braking system pump assembly is equip-
ped with a 26-track computer.
102384
The ABS System and Electronic Stability Program
pump assembly is equipped with a 46-track computer.
Note:
The computer cannot be separated from the pump
assembly.
38C-2
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4J
Essential equipment
pedal press
diagnostic tool
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02, Lifting equip-
ment).
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery). 104246
a Fit the pedal press to the brake pedal to reduce the a Remove:
amount of brake fluid running out. - the engine covers,
104666
38C-3
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4J
101103 101100
a Remove: a Disconnect the air temperature sensor (6) .
- the air resonator mounting bolt (4) , a Unclip the engine wiring harness (7) .
- the air resonator unit (5) .
WARNING
Do not damage the vacuum outlet on the plenum
chamber. If it is damaged, the inlet manifold will
have to be replaced.
a Disconnect:
- the brake servo vacuum pipe inlet manifold end,
- the ignition coil connectors,
- the throttle valve connector.
101488
a Unclip the fuel vapour recirculation pipe (8) .
a Loosen the air filter box mountings without removing
it from the engine compartment.
38C-4
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4J
101104 101794
a Remove:
- the plenum chamber unit mounting bolts (12) ,
- the plenum chamber unit,
- the soundproofing screen mountings.
a Remove the soundproofing screen.
101800
a Remove: 104324
a Remove the lifting eye (13) .
- the filter element (9) ,
- the throttle valve mounting bolts (11) , AIR CONDITIONING or CLIMATE CONTROL
a Remove the air-conditioning hose between the bulk-
- the throttle valve (see Throttle valve: Removal - head bracket and the dehydrator reservoir (see De-
Refitting) (MR 370, 12A, Fuel mixture), hydration canister - evaporator connecting pipe:
Removal - Refitting) (MR 370, 62A, Air conditio-
- the air filter box (10) (see Air filter unit: Removal ning).
- Refitting) (MR 370, 12A, Fuel mixture).
38C-5
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4J
104341 106032
a Remove the ABS computer earth terminal mounting a
bolt.
WARNING
a Disconnect the computer connector.
Set up the ear th terminal wires facing
a Undo the pipes from the hydraulic unit. downwards, to optimise the hydraulic unit compu-
ter connector sealing.
a Unclip the pipes from the hydraulic unit.
a Remove:
- the mounting bolts (14) from the hydraulic unit sup-
port, AIR CONDITIONING or CLIMATE CONTROL
- the « hydraulic unit - support » assembly, a Refit the air-conditioning hose (see Dehydration
- the bolts securing the hydraulic unit on the support, canister - evaporator connecting pipe: Removal -
Refitting) (MR 370, 62A, Air conditioning).
- the hydraulic unit.
REFITTING
a Torque tighten:
a Proceed in the reverse order to removal.
- the hydraulic unit support mounting bolts (6.5
Nm),
- the bolts mounting the pipes on the hydraulic
unit (14 Nm),
- the air distributor mounting bolts (9 Nm),
- the bolts mounting the hydraulic unit on its
support (8 Nm).
Note:
- Replace the seal every time the throttle valve is
removed,
- The seals at the ends of the air conditioning
pipe must be replaced.
38C-6
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4J
a Bleed the brake circuit using the diagnostic tool
(see 3 0 A, General information, Brake circuit
Bleeding, page 30A-2) .
a Connect the battery (see Battery : Removal - Refit-
ting) (MR 370, 80A, Battery).
a Reinitialise the programming of the stops (see Fault
finding - Replacement of components) (MR 372,
17B, Petrol injection).
38C-7
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4M
Essential equipment
pedal press
diagnostic tool
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02, Lifting equip-
ment).
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery). 104246
a Fit the pedal press to the brake pedal to reduce the a Remove:
amount of brake fluid running out. - the engine covers,
104666
38C-8
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4M
- the throttle valve (see Throttle valve: Removal -
Refitting) (MR 370, 12A, Fuel mixture).
101807
Note:
Do not damage the vacuum outlet on the plenum 101795
chamber. If it is damaged, the inlet manifold will
a Unclip the fuel vapour recirculation pipe (8) .
have to be replaced.
a Disconnect the air temperature sensor.
a Disconnect:
a Remove the engine wiring harness (7) .
- the brake servo vacuum pipe inlet manifold end,
101813
a Remove:
38C-9
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4M
102304
a Remove:
- the air distribution unit mounting bolts (9) ,
- the air distribution unit (see Inlet manifold: Remo-
val - Refitting) (MR 370, 12A, Fuel mixture),
- the soundproofing screen mountings.
a Remove the soundproofing screen.
104341
a Remove:
104324 - the mounting bolts (11) from the hydraulic unit sup-
a Remove the lifting eye (10) . port,
REFITTING
a Proceed in the reverse order to removal.
38C-10
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
K4M
a Bleed the brake circuit using the diagnostic tool
(see 3 0 A , General information, Brake circuit
Bleeding, page 30A-2) .
a Connect the battery (see Battery : Removal - Refit-
ting) (MR 370, 80A, Battery).
a Reinitialise the programming of the stops (see Fault
finding - Replacement of components) (MR 372,
17B, Petrol injection).
106032
WARNING
Set up the earth terminal wires facing
downwards, to optimise the hydraulic unit compu-
ter connector sealing.
a Torque tighten:
Note:
- Replace the seal every time the throttle valve is
removed,
- The seals at the ends of the air conditioning
pipe must be replaced.
38C-11
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
F9Q or K9K
Essential equipment
pedal press
diagnostic tool
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02, Lifting equip-
ment).
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery).
a Fit the pedal press to the brake pedal to reduce the
amount of brake fluid running out. 104246
a Remove:
AIR CONDITIONING or CLIMATE CONTROL
- the engine covers,
a Drain the refrigerant circuit using the refrigerant
charging station. - the two air filter access panel mounting bolts (1) ,
104666
38C-12
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
F9Q or K9K
104324
a Remove:
- the lifting eye (4) ,
- the soundproofing screen mountings.
a Remove the soundproofing padding. 104341
a Remove the ABS computer earth terminal mounting
AIR CONDITIONING or CLIMATE CONTROL bolt.
a Remove the air-conditioning hose between the bulk- a Disconnect the computer connector.
head bracket and the dehydrator reservoir (see De- a Unscrew the six pipes on the hydraulic unit.
hydration canister - evaporator connecting pipe:
Removal - Refitting) (MR 370, 62A, Air conditio- a Unclip the six pipes on the hydraulic unit.
ning). a Remove:
- the mounting bolts (5) from the hydraulic unit sup-
port,
- the « hydraulic unit - support » assembly,
- the bolts securing the hydraulic unit on the support,
- the hydraulic unit.
REFITTING
a
WARNING
Ensure the hydraulic unit earth terminal wire is
facing downwards to optimise the computer con-
nector sealing.
38C-13
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
F9Q or K9K
a Bleed the brake circuit using the diagnostic tool
(see 30A, General information, Brake circuit
Bleeding, page 30A-2) .
106032
WARNING
Set up the earth terminal wires facing
downwards, to optimise the hydraulic unit compu-
ter connector sealing.
Note:
The seals at the ends of the air conditioning pipe
must be replaced.
a Torque tighten:
38C-14
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
F4R
Essential equipment
pedal press
diagnostic tool
Tightening torquesm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02, Lifting equip-
ment).
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery). 104246
a Fit the pedal press to the brake pedal to reduce the a Remove:
amount of brake fluid running out. - the engine covers,
104666
38C-15
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
F4R
101807
102725
Note: a Unclip the fuel vapour recirculation pipe on the sole-
Do not damage the vacuum outlet on the plenum noid valve side (8) .
chamber. If it is damaged, the inlet manifold will a Disconnect:
have to be replaced.
- the air pressure sensor (9) ,
- the air temperature sensor (10) .
a Remove the engine wiring harness (11) .
102735
a Disconnect:
- the brake servo vacuum pipe (6) from the air distri-
butor side,
38C-16
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
F4R
102726
a Remove:
- the air distribution unit mounting bolts (12) ,
- the air distribution unit (see Inlet manifold: Remo-
val - Refitting) (MR 370, 12A, Fuel mixture),
- the soundproofing screen mountings.
a Remove the soundproofing screen.
104341
a Remove:
104324 - the mounting bolts (14) from the hydraulic unit sup-
a Remove the lifting eye (13) . port,
REFITTING
a Proceed in the reverse order to removal.
38C-17
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
F4R
a Bleed the brake circuit using the diagnostic tool
(see 3 0 A , General information, Brake circuit
Bleeding, page 30A-2) .
a Connect the battery (see Battery : Removal - Refit-
ting) (MR 370, 80A, Battery).
a Reinitialise the programming of the stops (see Fault
finding - Replacement of components) (MR 372,
17B, Petrol injection).
106032
WARNING
Set up the earth terminal wires facing
downwards, to optimise the hydraulic unit compu-
ter connector sealing.
a Torque tighten:
Note:
- Replace the seal every time the throttle valve is
removed,
- The seals at the ends of the air conditioning
pipe must be replaced.
38C-18
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
M9R, and LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
WARNING
Drain the brake fluid to prevent damage to the
mechanical parts and bodywork around the bra-
king system.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02, Lifting equip-
ment).
104246
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery). a Remove:
a Fit the pedal press to the brake pedal to reduce the - the two air filter access panel mounting bolts (1) ,
amount of brake fluid running out.
- the air filter access panel,
a Remove the scuttle panel grille (see Scuttle panel
grille: Removal - Refitting) (MR 371, 56A, Exterior - the radiator tank partition mounting bolts (2) ,
equipment).
- the scuttle panel partition.
104666
38C-19
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
M9R, and LEFT-HAND DRIVE
a Remove:
- the engine cover,
- the catalytic converter (see Catalytic converter:
Removal - Refitting) (MR 370, 19B, Exhaust),
- the bulkhead heat shield clips,
- the bulkhead heat shield bolt,
- the lifting eye mounting bolts,
- the lifting eye.
a Remove the heat shield.
104341
106032
38C-20
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting 38C
M9R, and LEFT-HAND DRIVE
a Remove:
REFITTING
a Proceed in the reverse order to removal.
106032
WARNING
Set up the earth terminal with the wires facing
downwards to optimise the hydraulic unit compu-
ter connector sealing.
a Torque tighten:
38C-21
ANTI-LOCK BRAKING SYSTEM
ABS with ESP: Description 38C
Pump assembly
10 Multiplex network
11 Wire connection
12 Hydraulic connection
103798
No. Description
5 Diagnostic socket
Note:
Two types of pump assemblies are fitted, either
ABS or ABS - ESP. The ABS computer has 26
tracks. The ABS/ESP computer has 46 tracks.
38C-22
ANTI-LOCK BRAKING SYSTEM
Yaw speed and transversal acceleration sensor: Removal - Refitting 38C
Essential equipment
diagnostic tool
Tightening torquesm
REMOVAL
a Disconnect the battery (see Battery : Removal -
Refitting) (MR 370, 80A, Battery).
103597
a Remove the slide by pressing on the clip (1) with a
flat-blade screwdriver.
a Disconnect the yaw speed and transverse accelera-
tion sensor connector.
WARNING
Handle this sensor with care.
a Remove:
- the sensor mounting nuts,
- the sensor.
103596
a Unclip the drawer surround.
38C-23
ANTI-LOCK BRAKING SYSTEM
Yaw speed and transversal acceleration sensor: Removal - Refitting 38C
REFITTING
20912
Note:
Be sure to replace any sensor which has suffe-
red an impact.
38C-24
ANTI-LOCK BRAKING SYSTEM
Braking computer: Removal - Refitting 38C
a Always replace the computer mounting bolts.
Essential special tooling
a Refit the computer, holding it by its edge.
Mot. 1608 Torque screwdriver 1 to 6.6
N.m.
Note:
Essential equipment Do not try to force the computer into place when
refitting, it should fit in without any resistance.
diagnostic tool
Tightening torquesm
computer mounting 3 Nm
bolts
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 370, 02A, Lifting equip-
ment).
a Remove the entire hydraulic unit (see 38C, Anti- 19113
lock braking system, Brake hydraulic assembly: a The hydraulic pump (3) must be pressed against the
Removal - Refitting, page 38C-3) . pressure modulation unit (4) .
When a new computer is being fitted, remember to
attach the interconnection fork (5) between the pres-
sure modulation unit and the computer.
a Refit the bolts securing the computer on the pressu-
re modulation unit.
a Torque tighten the computer mounting bolts (3
Nm) using the (Mot. 1608).
a Refit the entire hydraulic unit (see 38C, Anti-lock
braking system, Brake hydraulic assembly: Re-
moval - Refitting, page 38C-3) .
a Configure the tachometric index using the diagnos-
tic tool (see Fault finding - Replacement of com-
ponents) (MR 372, 38C, Anti-lock braking system).
a Clear any faults that have been stored in the compu-
ter.
a Carry out a road test to confirm the repair.
115161
a Remove:
REFITTING
a Do not clean the pressure modulation unit (4) .
38C-25