VNX Su-R19 PDF

General
SPECIFICATIONS
LIFTING EQUIPMENT
TOWING
LUBRICANTS - CONSUMABLES
DRAINING - REFILLING
VALUES AND SETTINGS
77 11 190 814
OCTOBER 1996
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes by the manufacturer in the
production of the various component units and accessories from which his vehicles
are constructed".
Edition Anglaise
All copyrights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
Renault.
Rgie Nationale des Usines Renault S.A. 1996
http://vnx.su
EXPLODED VIEW
PRC0001
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General
Contents
Pages
Pages
01 SPECIFICATIONS
Engine - Clutch - Gearbox
Vehicle identification
05 DRAINING - REFILLING
01-1
01-2
02 LIFTING EQUIPMENT
02-1
03 TOWING
03-1
Dimensions
Capacities - Grades
Belt tension
Accessories belt tension
Timing belt tension
Cylinder head tightening
Main brake components and
dimensions
Front axle setting values
Front axle checking values
Rear axle checking values
Underbody heights
Brake compensator
04 LUBRICANTS - CONSUMABLES
Packaging
05-1
05-3
05-4
07 VALUES AND SETTINGS
Trolley jack - Axle stands
All types
Engine
Gearbox
Power assisted steering
04-1
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07-1
07-4
07-7
07-9
07-15
07-17
07-21
07-22
07-24
07-25
07-27
07-28
SPECIFICATIONS
01
Engine
Vehicle type
Type of manual and automatic

gearbox
Clutch type
Type
Cubic
capacity
(cm 3)
B530 - C530 - L530

S530
C1G
1237
180 CP 3300
JB0 - JB1 - JB4 - JB5
B531 - C531 - L531
C1J
1397
180 CP 3300
JB0 - JB1 - JB4 - JB5
C2J
1397
180 CP 3300
JB0 - JB1 - JB4 - JB5
B532 - C532 - L532
C3J
1390
180 CP 3300
JB0 - JB1
B53G - B537 - C537

L53G - L537 - S537
E6J
1390
180 CP 3300
JB0 - JB1 - MB1
B53A - C53A - L53A
E7J
1390
180 CP 3300
JB1 - MB1
B535 - C535 - L535
E7J
1390
180 CP 3300
JB1 - MB1
B53W - C53W - L53W
E7F
1171
180 CP 3300
JB0 - JB1 - JB3
B53E - B53M - B533

B536 - C53E - C53M
C533 - L533 - L536
F2N
1721
200 CP 4000
JB0 - JB1 - JB3 - AD4
B53B - B53C - B53F

C53B - C53C - C53F
D53C - L53B - L53C L53F
F3N
1721
200 CP 4000
AD4 - JB3 - MB3
B53V - B53Y - B538

C53V - C53Y - C538
D53V - D53Y - L53V
L53Y - L538 - 353A
353C - 353D - 353F
453A - 453C - 453D
453F - 453H - 553A
553C - 553D - 553F
553H - 853A - 853C
853F
F3P
1794
200 CP 4000
AD4 - JB3 - JC5
B53D - B539 - C53D

C539 - D53D - L53D
L539
F7P
1764
200 CP 4400
JB3 - JC5
B53I - B53J - B53K

B53T - B53Z - B534
C53I - C53J - C53K
C53T - C53Z - C534
L53I - L53J - L53K
L53T - L53Z - L534
S53I - S53J - S53K S534
F8Q
1870
B53H - B53P - C53P

L53H - L53P
200 CPV 4600

JB1 - JB3 - JC5
200 CPV 3500
01-1
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SPECIFICATIONS
01
IDENTIFICATION OF F3P ENGINES WITH REDUCED CUBIC CAPACITY
ENGINE
APPROVAL
LETTER
NUMBER
704
706
708
760
706
760
765
VEHICLE
TYPE
X53 Y
053 A
F3P
053 B - F - H
X53 V
053 C - D - H
A
682
X53 8
Definition of identification X and 0

X53 Y = B53 Y, C53 Y, L53 Y
Vehicle type code starting with a letter.
053A = 353 A, 453 A
Vehicle type code starting with a number.
The reduced cubic capacity can be identified using

the type approval letter (B) on the engine plate.
C D
A
B
C
D
E
F
000 0 000 /
0000000
F
:
:
:
:
:
:
the engine type

the vehicle type approval letter
the identity of RENAULT SA
the engine number
the engine manufacturing number
letter indicating the factory at which the engine was manufactured (e.g.: C for Clon)
E
90775
01-2
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SPECIFICATIONS
01
LOCATION OF THE VEHICLE IDENTIFICATION PLATE
Position n 1
Position n 3
95890-1R
Adhesive plate (D) is attached to the chassis on the

side of the right front door.
92025R
Plates (A) and (B) may be separate or on a single

plate (according to specification).
Position n 2
94946R
Plate (C) is located on the front panel.
01-3
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SPECIFICATIONS
01
METAL PLATE (Position n 1)
Rectangular plate
Oval plate
REGIE NATIONALE
DES USINES RENAULT
B2
X*0* 0000
B1
XX0000
00000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
0000
This consists of;
ding:
At B1 : the number of the country gran-
ting the EU approval

At B2 : the approval number for the ve-
At D
At E
At F
At G
At H
At J*
This consists of:

At 1 : the vehicle type
At 2 : special features of the vehicle*
At 3 : the basic equipment * (see table),
At 4 : options,
At 5 : the manufacturing number,
At 6 : the vehicle model year* or paint identification code*,
At 7 : the factory at which the vehicle was assembled:
A : Portugal
B : Batilly
C : Creil
D : Douai
E : Spain
F : Flins
G : Grand Couronne
H : Haren
J : Billancourt
K : Dieppe
N : Mexico
P : Mexico
Q : A.M.C.
S : Sandouville
T : Matra Romorantin
U : Maubeuge
W : Spain Valladolid
X : Heuliez
Y : Yugoslavia
Z : U.S.A.
At A : the manufacturers name,

At B : the EU official approval number, inclu-
At C
00000
00 000
000
X 0000000
0000
000
hicle type.
: the official type number preceded by the
manufacturers worldwide identification
code (for example VF1 is the code for
RENAULT France),
: the chassis number
: the gross vehicle weight,
: the gross train weight,
: the maximum permissible front axle
weight,
: the maximum permissible rear axle
weight,
: the vehicle model year or paint identification code.
* NOTE: some of these items of information are
not required for certain export markets. The

plates described above are shown in their most
complete form.
* DEPENDING ON COUNTRY OR SPECIFICATION
01-4
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SPECIFICATIONS
VEHICLE IDENTIFICATION
01
REGIE NATIONALE
0000
00 000 000
DES USINES RENAULT

B
AU 0000-00-00
VF1000000
00000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
1
3
4
00 000 000
0000000
6
8
5
2
This consists of:

: the manufacturers name,
: the EU official approval number
: the official type number preceded by the manufacturers worldwide identification code
(for example : VF1 for RENAULT France),
At D : the chassis number,
At E : the gross vehicle weight,
At F : the gross train weight,
At G : the maximum permissible front axle weight,
At H : the maximum permissible rear axle weight,
At A
At B
At C
At 1 : the vehicle type,

At 2 : the first number indicates the gearbox or the factory options
the second number indicates the level of equipment,
At 3 : the technical equipment number,
At 4 : the factory option additional equipment,
At 5 : the trim identification code,
At 6 : the paint identification code,
At 7 : the level of equipment,
At 8 : a letter indicating the factory of manufacture, followed by the manufacturing number.
WARNING: The 7 characters of the manufacturing number must not be separated. For vehicles manufactured
before that date, the manufacturing number is 7 numbers.

NOTE: some of these items of information are not required for certain export markets. The plates described
above are shown in their most complete form.
01-5
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SPECIFICATIONS
01
REGIE NATIONALE DES

A
B
USINES RENAULT S.A.

e000-00/00000-0000-00
VF0000000
00000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
8
9
0000
00 000 000
10
00 000 000
0000000
11
12
13
14
7
Renault
VF0000000
00000000
0000
00 000 000
10
14
00 000 000
11
13
0000000
01-6
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12
SPECIFICATIONS
01
This consists of:

At A : the manufacturers name,
At B : the EU official approval number
At 1 : the official type number preceded by the manufacturers worldwide identification code
(for example : VF1 for RENAULT France),
At 2 : the chassis number,
At 3 : the gross vehicle weight,
At 4 : the gross train weight,
At 5 : the maximum permissible front axle weight,
At 6 : the maximum permissible rear axle weight,
At 7 : the first number indicates the gearbox or the factory options
the second number indicates the level of equipment,
At 8 : the vehicle type
At 9 : the technical equipment number,
At 10 : the factory option additional equipment,
At 11 : the level of equipment,
At 12 : the paint identification code,
At 13 : a letter indicating the factory of manufacture, followed by the manufacturing number,
At 14 : the trim identification code.
NOTE: some of these items of information are not required for certain export markets. The plates described
above are shown in their most complete form.
ALLOCATION OF THE TECHNICAL EQUIPMENT CODES
The equipment code, three letters at (9), must be documented when vehicle identification is required (ordering of replacement parts, warranty form, etc).
01-7
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SPECIFICATIONS
01
Due to the European depollution standards, the "ABCD" coding of some vehicles has become saturated following the introduction of new engines (letter "D"), the body code "A" therefore becomes "A".
"ABCD"
3 door hatchback
C53A
353A
5 door hatchback
B53A
553A
4 door saloon
L53A
Utility
S53A
653A
Cabriolet
D53A
853A
Renault 19 all models
X53A
053A
The engine letter"D" at A in both cases corresponds:

to engine E7J 700 when the body type is B, C, D, L, and S
X covers B, C, D, L, and S
to motor F3P 706 when the body type is 3, 4, 5, 6 and 8
0 covers 3, 4, 5, 6 and 8.
Therefore
B53A :
553A :
C53A :
353A :
Renault 19 5 door hatchback with engine E7J 700

Renault 19 5 door hatchback with engine F3P 706
Renault 19 3 door hatchback with engine E7J 700
Renault 19 3 door hatchback with engine F3P 706
REMINDER:
"A" or "A"
"BC"
"D"
= body type
= N of project (example 53)
= Engine number
01-8
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"ABCD"
or
453A
LIFTING EQUIPMENT
02
Safety symbol (special precautions to be taken when carrying out work).
ESSENTIAL SPECIAL TOOLS
Cha.
Cha.
280 -02
408 -02
Trolley jack pad

Trolley jack socket
Suitable axle stands must be used when using a trolley jack.

It is forbidden to lift the vehicle by taking the load under the front suspension arms. Use whichever of the
sockets Cha. 408-02 that suits the trolley jack to fit pad Cha. 280-02.
LIFTING WITH THE TROLLEY JACK FROM THE

FRONT
LIFTING WITH THE TROLLEY JACK FROM THE

REAR
Apply the handbrake or place chocks under the

rear wheels.
It is FORBIDDEN to lift the rear of the vehicle

taking the load under the rear axle. Lift each
wheel separately taking the load under the
vehicle jacking points.
Use pad Cha. 280-02.

Take the load under the front sub-frame.
Avoid the pad touching the gearbox or the
exhaust down-pipe.
92556R
For some vehicles, make a notch in tool Cha. 28002 to prevent it touching the exhaust.
91936G2
02-1
http://vnx.su
85679-1G13
LIFTING EQUIPMENT
02
LIFTING WITH THE TROLLEY JACK FROM THE SIDE
AXLE STANDS
Use pad Cha. 280-02.
When taking the weight of the vehicle on the axle

stands ensure that the stands are under the
vehicle jacking points (1).
Take the load on the body sill, under the front

door.
Stands are to be placed under the rear end by

lifting the vehicle from the side.
Ensure that the body sill flange locates correctly in

the groove in the pad.
87709R
91936G3
02-2
http://vnx.su
85679-1G14
TOWING
All models
03
FOR TOWING, REFER TO THE LEGISLATION IN FORCE IN THE COUNTRY CONCERNED.

NEVER USE THE DRIVESHAFT TUBES AS ATTACHMENT POINTS.
The towing points are only to be used for towing the vehicle on the road. In no circumstances are they to be
used for pulling the vehicle out of a ditch, or for any other similar operation nor are they to be used for lifting
the vehicle either directly or indirectly.
FRONT
REAR
92020S
92019S
03-1
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Packaging
DESCRIPTION
PACK SIZE
04
PART NUMBER
GREASES
MOLYKOTE "BR2"
for bushing surfaces, thrust pad guide tube,
clutch fork pads, lower suspension arm bearings, torsion bar splines, steering box, driveshaft splines.
MOLYKOTE "33 Medium"
bushes on tubular rear axles
anti-roll bar bushes
ANTI-SEIZE
(high temperature grease) Turbo etc.
1 kg tin
77 01 421 145
100 g tube
77 01 028 179
80 ml tube
77 01 422 307
180 g sachet
77 01 366 100
Aerosol
77 01 422 308
"MOBIL CVJ" 825 Black star

or MOBIL EXF57C
for driveshaft seals

MULTIPURPOSE GREASE
wheel sensor
MECHANICAL SEALING COMPOUNDS

Perfect-seal "LOWAC"
liquid jointing compound
100 g tube
77 01 417 404
Mastic
for sealing exhaust pipe joints
1.5 kg tin
77 01 421 161
RHODORSEAL 5661
100 g tube
77 01 421 042
77 01 404 452
Kit
77 01 421 080
AUTO joint blue

jointing paste
100 g tube
45 g tube
77 01 396 227
77 01 397 027
AUTO joint or
sealing compound for the timing cover of V6
engines
100 g tube
77 01 422 751
HARDENER KIT (Rhodorseal 5661)

for sealing the sides of bearing caps
04-1
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Packaging
DESCRIPTION
PACK SIZE
04
PART NUMBER
MECHANICAL SEALING COMPOUNDS

AUTO joint grey
sealing compound
LOCTITE 518
for sealing gearbox housings
Leak detector
100 g tube
77 01 422 750
24 ml syringe
77 01 421 162
Aerosol
77 11 143 071
ADHESIVES
"LOCTITE - FRENETANCH"
to prevent bolts coming loose but still permit
their release
24 cc bottle
77 01 394 070
"LOCTITE - FRENBLOC"
for locking bolts
24 cc bottle
77 01 394 071
"LOCTITE SCELBLOC"
for bonding bearings
24 cc bottle
77 01 394 072
"LOCTITE AUTOFORM"
for bonding the flywheel to the crankshaft
50 cc bottle
77 01 400 309
CLEANERS - LUBRICANTS
"NETELEC"
release, lubricating agent
250 g aerosol
77 01 408 464
Cleaner NC1
electrical contact cleaner
Aerosol
77 01 422 379
250 ml can
300 ml aerosol
77 01 393 112
77 01 393 111
355 ml can
77 01 423 189
420 ml aerosol
77 01 407 689
Aerosol
77 01 405 952
Carburettor cleaner
Injector cleaner
Super concentrated release agent
"DECAPJOINT "
for cleaning aluminium cylinder head gasket
faces
04-2
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Packaging
DESCRIPTION
04
PACK SIZE
PART NUMBER
Bottle
77 01 421 135
Kit
77 01 422 752
VARNISH
"CIRCUIT PLUS"
Varnish for the repair of heated rear screens
"CONTACT PLUS"
Varnish for the repair of heated rear screen supply tabs
AIR CONDITIONING
Compressor oil ELF RIMA 100
250 ml (R12)
77 01 417 655
Fixed cubic capacity compressor oil SANDEN SP

20
250 ml (R134a)
77 11 143 700
Variable cubic capacity compressor oil SP10
250 ml (R134a)
77 01 419 313
04-3
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Engine
05
Engine drain plug spanner
DRAINING: plug (1)
REFILLING:
ENGINES C - F
plug (2)
dipstick (3)
ENGINES C1G - C1J - C2J - C3J
98486R
92179R
ENGINE E
ENGINES E6J - E7J - E7F
98701R
92178R
05-1
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Engine
REFILLING:
05
plug (2)
dipstick (3)
ENGINES F2N - F3P
ENGINE F7P
92035R
92715R
ENGINE F3N
ENGINE F8Q
95748R
95747R
05-2
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Gearbox
05
MANUAL
DRAINING: plug (1)
REFILLING: plug (2)
ENGINES C - E - F
98486R1
Plug (A) with no dipstick
Plug (A) with dipstick
92081R
DI0522
Fill to the level of the opening.
Wipe the dipstick section.

Refit the plug without tightening it, dipstick
downwards.
Remove the plug, the level should be on the boss
(2).
For automatic transmission, refer to the relevant section.
05-3
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CHECKING THE LEVEL
POWER ASSISTED STEERING PUMP LEVEL
Use ELF RENAULTMATIC D2 or MOBIL ATF 220 for

topping up or refilling.
The level is correct when the fluid is visible
between the MINIMUM and MAXIMUM levels on
the reservoir (1).
92030R
05-4
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05
VALUES AND SETTINGS

Dimensions
07
Phase 1
91936R1
Marks
Dimensions in metres
Marks
2.545
1.416 unladen
4.155
from 1.406 to 1.417
1.418
1.676 or 1.694
07-1
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VALUES AND SETTINGS

Dimensions
07
Phase 2
95890R
Marks
0.813
from 2.540 to 2.544 (1)
from 0.805 to 0.809 (1)
from 4.158 to 4.166 (1)
0.120 (2)
1.426
from 1.684 to 1.696 (1)
from 1.400 to 1.420 (1) - (3)
1.406 or 1.417 (1)
Turning circle (in metres)

Between kerbs : 10.4 (10.8 model with F7P engine)
Between walls : 11.0 (11,4 model with F7P) engine
(1) According to model with option
(2) Laden
(3) Unladen
07-2
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VALUES AND SETTINGS

Dimensions
07
Models D and L
95888R4
Marks
Marks
0.813
1.426
from 2.540 to 2.544
from 1.684 to (1.696 with moulding)
from 0.805 to 0.809
from 1.395 to 1.410
4.162
1.406 or 1.417
0.120 (*)
(*) Laden
07-3
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VALUES AND SETTINGS

Capacities - Grades
07
Units
Capacity
in litres
Grade
Petrol engine
(oil)
For oil
drain
EU countries
PETROL
- 15 C
- 30 C - 20 C
+ 25 C
- 10 C
0C + 10 C + 20 C + 30 C
CCMC-G4
ACEA A2-96/A3-96
3.5
F2N - F3N - F3P
4.8
F7P
15W40-15W50
15W40-15W50
CCMC-G5
ACEA A2-96/A3-96
10W30-10W40-10W50
10W30-10W40-10W50
CCMC-G5
ACEA A2-96/A3-96
5W30
5W30
CCMC-G5
ACEA A2-96/A3-96
5W40-5W50
5W40-5W50
Other countries
PETROL
- 15 C
- 30 C - 20 C
- 10 C
0C
+ 10 C + 20 C + 30 C
API SH 15W40
API SH 10W40
API SH 10W30
(plus 0.5 litre

for oil filter)
API SH 5W30
07-4
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VALUES AND SETTING

Capacities - Grades
07
Units
Capacity
in litres
Grade
Diesel engine
(oil)
For oil
drain
EU countries
DIESEL (All models)
- 15 C
- 30 C - 20 C
+ 25 C
- 10 C
0 C + 10 C
CCMC-PD2
ACEA B2-96/B3-96
F8Q
+ 20 C + 30 C
15W40
15W40
CCMC-PD2
ACEA B2-96/B3-96
10W40
10W40
CCMC-PD2
ACEA B2-96/B3-96
5W30
5W30
CCMC-PD2
ACEA B2-96/B3-96
5W40
5W40
5
Other countries
DIESEL
- 15 C
- 30 C - 20 C
+ 15
- 10 C
0 C
+ 10 C + 20 C + 30 C
API CF 15W40
API CF 10W40
API CF 10W30
(plus 0.5 litre

for oil filter)
07-5
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VALUES AND SETTINGS

Capacities - Grades
Units
Capacity
in litres
Manual
gearbox
JB0
JB1
JB3
JB4
JB5
JC5
Grade
07
Special points
All countries: TRANSELF TRX 75 W 80 W

(Standards API GL5 or MIL-L 2105 C or D)
3.25
3.40
3.40
2.80
2.90
3.10
Automatic
transmission
MB1
MB3
AD4
4.5
4.5
4.6
Final drive AD4
Braking system
Fuel
tank
or if not available use:
SAE J 1703
ABS : 1
and DOT 4
Separate
reservoir
1.1
MOBIL ATF 220 (D20104 or D21412)

TEXAMATIC 4011
Normal : 0.7
55
Power
assisted
steering
ELF RENAULT MATIC D2 (D20104)
The brake fluid must be of a type approved by our

Design office.
Unleaded
petrol/diesel
ELF RENAULT MATIC
D2 or
MOBIL ATF 220
Engine cooling
system
C1G - C1J - C2J
C3J
E6J
E7F - E7J
F2N - F3N
F3P
F7P
F8Q
5.4
6
5.2
5,2
6
6.1 or 6.5
7
6.8
07-6
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VALUES AND SETTINGS

Belt tension
07
Mot.
1273
Belt tension checking tool
96601R
A
B
C
D
:
:
:
:
Sensor
Display
Connecting lead
Calibration checking blade
Calibration of the equipment

The equipment is calibrated at the factory, however, this calibration must be checked every six
months.
Principle
Procedure
Via the pressure piece button (1), the pressure

piece (2) and the external pads (3), the sensor applies a constant slack to the belt.
Setting zero:
- switch on the equipment (button E) with the
pressure piece button (1) head down,
- if 0 is displayed, do not adjust anything,
- if there is no display, check the charge of the
equipments 9 volt battery,
- if a value other than 0 is displayed, operate
screw (F) until 0 is obtained .
The reactive force of the belt is measured using a

test unit (4) fitted with stress gauges.
The pulling of the gauges creates a variation in
their electrical resistances. Once converted by the
equipment, this variation is displayed in SEEM
units (US).
07-7
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VALUES AND SETTINGS

Belt tension
07
Checking the calibration

Switch on the equipment (button E).
Position the standard spring blade (Z) on the sensor as shown on the diagram (checking value etched towards
the top , (A) minimum value, (B) maximum value).
Tighten the pressure piece button (1) until it clicks (three "CLICKS").
Check that the display shows a value X between values (A and B) (A X B).
COMMENT: It may be necessary to carry out a few preliminary test in order to obtain the correct value.
If the values are incorrect after several tests, contact your local After Sales Head Office.
NOTE: Each apparatus has its own standard spring blade which is not interchangeable.
96602R
GENERAL RECOMMENDATIONS:
1 Knurled button (pressure piece)

A
Standard blade checking value
B
Z Standard blade
- Never refit a belt which has been removed, always fit a new one.
- Never retighten a belt the tension value of
which is between the fitting value and the minimum required for operation.
SEEM
Please contact your local After Sales Head Office

for details.
- When carrying out a check, if the tension is below the minimum operating tension, change
the belt.
07-8
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VALUES AND SETTINGS

07
RECOMMENDATIONS FOR FITTING BELTS:

V-BELT
Procedure for tensioning a new belt:

With the engine cold (ambient temperature).
Fit the new belt.
Fit the sensor of Mot. 1273.
Turn the sensor wheel until it clicks (three CLICKS").
Tension the belt until the recommended fitting value is displayed on Mot. 1273.
Lock the tensioner, carry out a check, adjust the value.
Turn the crankshaft through three revolutions.
Check that the tension is within the fitting tension tolerance, adjust it if it is not.
Procedure for tensioning a belt which has been operated:

Fit the belt.
Turn the sensor knob until it clicks (three CLICKS").
Tension the belt until 80% of the recommended fitting value is displayed on Mot. 1273.
Check that the tension is within the tolerance of 80% of the fitting tension. If it is not, adjust it to 80% of the
fitting value.
NOTE:
The V-belt is changed depending on its condition or the noise which it makes.
For the measuring point, fit the sensor of Mot. 1273 in place of El. 346-04.
07-9
http://vnx.su
VALUES AND SETTINGS

Toothed BELT
Tensioning procedure
Fit the new belt.
Turn the sensor wheel until it clicks (three "CLICKS").
Tension the belt until the recommended fitting value is displayed on Mot. 1273.
Check that the tension is within the fitting tension tolerance, adjust it if it is not.
NOTE :
Never refit a belt which has been removed.

Change the belt if the tension is below the minimum operating tension.
Small cuts or cracks are not criteria for changing the belt.
For the measuring point, fit the sensor of Mot. 1273 in place of El. 346-04.
07-10
http://vnx.su
07
VALUES AND SETTINGS

C
ENGINE
ALTERNATOR AND COOLANT PUMP
92648R1
A
B
C
Coolant pump
Crankshaft pump
Alternator pump
Tension checking point
Tension
(US=SEEM unit)
Coolant pump
Alternator
Belt
Air
conditioning
belt
Fitting
90 6
89 5 (*)
105 6 (*)
Minimum
operating
tension
64
68 (*)
75 (*)
(*) = C2J 776
07-11
http://vnx.su
07
E
ENGINE
VALUES AND SETTINGS

07
ALTERNATOR
92320R2
B Crankshaft pulley
C Alternator pulley
E6J engine
Alternator V-belt
Air conditioning
V-belt
Air conditioning
and power assisted
steering belt
(four teeth)
84 6
83 7
90
106
52
70
72
59
Tension
(US=SEEM unit)
Toothed alternator
belt
(three teeth)
Fitting
Minimum operating
tension
E7J engine
Tension
(US=SEEM unit)
Toothed
alternator belt
(three teeth)
Toothed power
assisted steering
belt (three teeth)
Alternator
V-belt
Air
conditioning
V-belt
Air
conditioning
and power
assisted
steering belt
(four teeth)
Fitting
84 6
84 5
83 7
90
106
Minimum operating
tension
52
46
70
72
59
07-12
http://vnx.su
VALUES AND SETTINGS

F
ENGINE
07
F2N, F3N engines
Tension
(US=SEEM unit)
Toothed belt
(six teeth)
Alternator
Air conditioning and
power assisted steering
Toothed belt
(six teeth)
Alternator
Toothed belt
(six dents teeth)
Alternator and
coolant pump
Fitting
106 6
98 6
83 6
Minimum operating
tension
71
73
57
F7P engine
Tension
(US=SEEM unit)
Toothed belt
(six teeth)
Alternator
Air
conditioning
Toothed belt
(six teeth)
Alternator
Power assisted
steering
Fitting
91 5
95 5
Minimum
operating
tension
58
57
F8Q engine
Tension
(US=SEEM unit)
Toothed belt
(six teeth)
Alternator
Air conditioning
and power assisted
steering
Toothed belt
(six dents teeth)
Alternator
Air conditioning
Toothed belt
(six teeth)
Alternator
Power assisted
steering
Toothed belt
(six teeth)
Alternator
Fitting
112 4
116 7*
101 5
99 5
97 3
67
68
67
Minimum operating
tension
*
67
only for belt Part number : 77 00 272 741
07-13
http://vnx.su
VALUES AND SETTINGS

F
ENGINE
07
ALTERNATOR AND COOLANT PUMP
87413R1
A
B
C
E
86979R1
Coolant pump
Crankshaft
Alternator
Air conditioning compressor
91136R3
92290R2
A
B
C
D
E
F
Coolant pump pulley

Crankshaft pulley
Alternator pulley
Assistance pump pulley
Compressor pulley
Tensioner roller
07-14
http://vnx.su
VALUES AND SETTINGS

Timing belt tension
Tensioning procedure
07
E engine

Fit the new belt
Turn the sensor knob until it clicks (three
"CLICKS").
Tension the belt until the recommended fitting

value is displayed on the Mot. 1273.
Lock the tensioner, carry out a check, adjust the
value.
Turn the crankshaft through a minimum of three
revolutions.
Check that the tension is within the fitting tension
tolerance ( 10%). If it is not, adjust it.
98708R
Belt tension (in SEEM units)

NOTE :
Fitting : 30 U.S.
Do not refit a belt which has been removed.
Minimum operating tension: 26 U.S.
Change the belt if the tension is below the minimum operating tension.
07-15
http://vnx.su
VALUES AND SETTINGS

Timing belt tension
F engine (petrol) except F7P
07
F8Q engine
96528R1
99175R
Fitting: 25 U.S.
Fitting: 38 U.S.
07-16
http://vnx.su
VALUES AND SETTINGS

07
E ENGINE
C ENGINE
CYLINDER HEAD TIGHTENING PROCEDURE
Grease the bolt threads and underneath the bolt

heads with engine oil.

REMINDER: In order to tighten the bolts correctly,

remove any oil from the cylinder head securing
holes using a syringe.

Tighten the cylinder head in the order shown below:
10
90775S
81528-1S
1st tightening to 2 daN.m.
1st tightening from 5.5 to 6.5 daN.m.
2nd tightening (angle) : 97 2.

Adjusting the clearance at the valves
Wait for at least three minutes.
Run the engine for 20 minutes.
Slacken bolts 1 and 2 then tighten to 2 daN.m.
After 2 hours 30 minutes with the engine stopped,
retighten the cylinder head:
- slacken bolt number 1 by 180 and retighten it
to the recommended torque,
- repeat for the other mounting bolts following
the tightening order.

Repeat the slackening and retightening operation
for bolts 3, 4, 5, 6 then 7, 8, 9, 10.
The cylinder head is not retightened.
Adjust the clearance at the valves.

07-17
http://vnx.su
VALUES AND SETTINGS

07
For engines F2N - F3N - F3P, refer to the "F ENGINE" section.
F ENGINE (petrol) ALL TYPES EXCEPT F7P
CYLINDER HEAD GASKET WITH ASBESTOS
CYLINDER HEAD GASKET WITH NO ASBESTOS

All of the bolts must be changed automatically after removal.


10
10
90775S

90775S
2nd tightening (angle) : 7 daN.m.
2nd tightening (angle) : 50 4 .
Slacken bolts 1 and 2 then tighten to 2 daN.m.
2nd assembly (angle) : 123 2.
Slacken bolt by bolt by 180, then tighten to

2.5 daN.m. :

for bolts 3, 4, 5, 6 then 7, 8, 9, 10.

for bolts 3, 4, 5, 6 then 7, 8, 9, 10.
07-18
http://vnx.su
VALUES AND SETTINGS

07
F7P ENGINE
CYLINDER HEAD GASKET WITH NO ASBESTOS
Grease the threads and underneath the heads of

the new bolts.
1) Pre-seating the gasket:

- tighten all of the bolts to 3 daN.m then carry
out an angular tightening of 51 3 in the
order recommended below.
Wait for at least 3 minutes to allow the gasket
to settle.
2) Cylinder head tightening:

- slacken bolt by bolt until they are completely free then tighten all of the bolts to 2.5
daN.m, then carry out an angular tightening
of 108 3 .
10
90775S
07-19
http://vnx.su
VALUES AND SETTINGS

07
F ENGINE (diesel)
CYLINDER HEAD GASKET WITH ASBESTOS
CYLINDER HEAD GASKET WITHOUT ASBESTOS
This operation is carried out when cold, when the

cylinder head is refitted, and there is no other reason for it to be carried out.
All of the bolts must be changed automatically after removal.




81528-1S
81528-1S
2nd tightening (angle) : 50 4 .
2nd tightening (angle) : 7 daN.m.
Slacken bolt by bolt until they are completely free,

then tighten to 2.5 daN,m.
Slacken bolt by bolt until they are completely free,

then tighten to 2 daN,m.
The cylinder head is not retightened except on

the F8Q Turbo.
- Special features of engines F8Q 610, 740, 744,
768.
- Following an increase in engine temperature
(operation of the fan).
- Wait until the engine returns to ambient temperature.
- In the recommended order, again tighten bolts
1-2, 3-4, 5-6, 7-8, 9-10, angle 120 7.
07-20
http://vnx.su
VALUES AND SETTINGS

Main brake components and dimensions
07
B/C/L/S
B/C/D/L/S
B/C/L/S
B/C/D/L
530, 531
532, 534
535, 537
53A, 53B
53G, 53H
53J, 53W
533, 536
538, 53C
53F, 53K
53T, 53V
53Y, 53Z
538, 53F
53K, 53T
539, 53D
X53 ABS*
3/4/5
53C, 53D
53H
3/4/5/8
53A, 53F
53H
FRONT BRAKE (dimensions in mm)
Diameter of slave cylinders
Diameter of discs
Thickness of discs
Minimum thickness of discs (1)
Thickness of linings (including mounting)
Minimum thickness of linings (including mounting)
Maximum run-out of discs
48
238
12
10.5
18
6
0.07
48
238
20
18.3
18
6
0.07
48
259
20.7
17.7
18
6
0.07
48
259
238
20.7
20
17.7
18
18
6
0.07
REAR BRAKE (dimensions in mm)

Diameter of slave cylinders
Diameter of drums
Maximum diameter of drums after grinding
Width of linings
Diameter of discs
Thickness of discs
Minimum thickness of discs (1)
Maximum run-out of discs
20.6 (2)
180.25
181.25
40
6.5
2.5
-
20.6 (2)
180.25
181.25
40
6.5
2.5
-
19
203.20
204.40
38
6.5
2.5
-
30
238
8
7
11
5
0.07
20.6
20.6
MASTER CYLINDER (dimensions in mm)
Diameter
20.6
20.6
(*) Except sport version

(1) The brake discs cannot be ground. The discs must be changed if they are excessively scratched or worn.
(2) Wheel cylinder with integral fixed compensator: in the event of a wheel cylinder or compensator
function fault: change the assembly, repair is forbidden.
07-21
http://vnx.su
VALUES AND SETTINGS

07
MANUAL STEERING
ALL TYPES EXCEPT B539 - C539 - L539 - B53D - C53D - D53D - L53D
ANGLES
POSITION OF
VALUES
ADJUSTMENT
FRONT AXLE
CASTOR
255
225
155
125
055
78423S3
H5-H2=
H5-H2=
H5-H2=
H5-H2=
H5-H2=
21 mm
40 mm
59 mm
78 mm
97 mm
NOT ADJUSTABLE
H1-H2=
H1-H2=
H1-H2=
H1-H2=
H1-H2=
22 mm
59 mm
86 mm
115 mm
149 mm
NOT ADJUSTABLE
H1-H2=
H1-H2=
H1-H2=
H1-H2=
H1-H2=
22 mm
59 mm
86 mm
115 mm
149 mm
NOT ADJUSTABLE
Maximum left/ right

difference= 1
CAMBER
135
030
05
030
045
30
Maximum left/right
difference = 1
78423S1
KING PIN INCLINATION
1045
125
1255
1340
1415
78423S2
30
Maximum left/right
difference = 1
PARALLELISM
(Toe-out)
For two wheels

010 10
(1 1 mm)
UNLADEN
Adjusted by
rotating track rod
sleeves
1 turn= 30
(3 mm)
78423S
POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN
81603S1
07-22
http://vnx.su
VALUES AND SETTINGS

07
POWER ASSISTED STEERING

ALL TYPES EXCEPT B539 - C539 - L539 - B53D - C53D - D53D - L53D
ANGLES
POSITION OF
VALUES
ADJUSTMENT
FRONT AXLE
CASTOR
5
430
4
330
3
78423S3
H5-H2=
H5-H2=
H5-H2=
H5-H2=
H5-H2=
21 mm
40 mm
59 mm
78 mm
97 mm
NOT ADJUSTABLE
H1-H2=
H1-H2=
H1-H2=
H1-H2=
H1-H2=
22 mm
59 mm
86 mm
115 mm
149 mm
NOT ADJUSTABLE
H1-H2=
H1-H2=
H1-H2=
H1-H2=
H1-H2=
22 mm
59 mm
86 mm
115 mm
149 mm
NOT ADJUSTABLE
Maximum left/right
difference= 1
CAMBER
135
030
05
030
045
30
Maximum left/right
difference= 1
78423S1
1045
125
1255
1340
1415
78423S2
30
Maximum left/right
difference= 1
PARALLELISM
(Toe-out)
For two wheels

010 10
(1 1 mm)
UNLADEN
UNLADEN
Adjusted by
rotating track rod
sleeves
1 turn= 30
(3 mm)
78423S
81603S1
07-23
http://vnx.su
VALUES AND SETTINGS

Front axle checking values
07
POWER ASSISTED STEERING

B/C/L 539 - B/C/D/L 53D
ANGLES
POSITION OF
VALUES
ADJUSTMENT
FRONT AXLE
CASTOR
530
5
430
4
330
93012-1S
H5-H2=
H5-H2=
H5-H2=
H5-H2=
H5-H2=
32 mm
51 mm
70 mm
89 mm
108 mm
NOT ADJUSTABLE
H1-H2=
H1-H2=
H1-H2=
H1-H2=
41 mm
120 mm
141 mm
185 mm
NOT ADJUSTABLE
H1-H2=
H1-H2=
H1-H2=
H1-H2=
41 mm
120 mm
141 mm
185 mm
NOT ADJUSTABLE
Maximum left/right
difference= 1
CAMBER
018
015
000
102
30
Maximum left/right
difference= 1
93013-1S
840
1040
1100
1106
93014-1S
30
Maximum left/right
difference= 1
PARALLELISM
(Toe-out)
Foe two wheels

010 10
(1 1 mm)
UNLADEN
Adjusted by
rotating track rod
sleeves
1 turn= 30
(3 mm)
93011-1S
UNLADEN
81603S1
07-24
http://vnx.su
VALUES AND SETTINGS

07
ALL TYPES EXCEPT B/C/L 539 - B/C/D/L 53D

POSITION OF THE
REAR AXLE
VALUES
ADJUSTMENT
ANGLES
Rear axle
Tubular
Rear axle
4 bars
Rear axle Rear axle

Tubular 4 bars
Rear axle Rear axle

Tubular 4 bars
UNLADEN
NOT ADJUSTABLE
UNLADEN
NOT ADJUSTABLE
UNLADEN
CAMBER
- 050 30
(negative)
78423S1
PARALLELISM
- 20 to 40
(Toe-in)
- 30 to - 50
(Toe-in)
or
or
- 3 to - 5 mm
- 2 to - 4
mm
78423S
POSITION FOR TIGHTENING

RUBBER BUSHES
81603S1
07-25
http://vnx.su
VALUES AND SETTINGS

07
B/C/L 539 - B/C/D/L 53D

ANGLES
VALUES
POSITION OF THE
ADJUSTMENT
REAR AXLE
CAMBER
- 050 30
(negative)
UNLADEN
NOT ADJUSTABLE
Per wheel
- 10 to 30
(Toe-in)
or
- 1 to - 3 mm
UNLADEN
NOT ADJUSTABLE
UNLADEN
93013-2S
PARALLELISM
93011-2S
81603S1
07-26
http://vnx.su
VALUES AND SETTINGS

Underbody heights
07
UNDERBODY HEIGHTS (1) (mm)
Type
B530
C530
L530
S530
B531
C531
L531
S531
B532
C532
L532
S532
B534
C534
L534
S534
B535
C535
L535
B537
C537
L537
S537
B53A
C53A
L53A
B53B
C53B
L53B
B53G
L53G
B53I
C53I
L53I
S53I
B53J
C53J
L53J
S53J
B53W
C53W
L53W
S53W
B533
C533
L533
B538
C538
L538
B53C
C53C
D53C
L53C
S53C
B53F
C53F
L53F
B53K
C53K
L53K
S53K
B53T
C53T
L53T
S53T
B53V
C53V
D53V
L53V
B53Y
C53Y
D53Y
L53Y
S53Y
B53Z
C53Z
L53Z
353A
453A
553A
853A
353B
353C
453C
553C
353D
453D
553D
353F
453F
553F
853F
453H
553H
At the front
H1 - H2 = ... mm
At the rear
H4 - H5 = ... mm
Dimension X (mm)
87
10
590
93
25
645
RH and LH
X53 ABS*
B536
L536
B53H
L53H
86
580
B539
C539
L539
B53D
C53D
D53D
L53D
120
54
580
Tolerances : 7.5 mm
The differences between the right hand side and the left hand side on the same axle must not exceed 5 mm,
with the drivers side always being the higher.
Any alteration to the underbody height must be followed by resetting of the headlight beams and the
braking compensator.
(1) If there is a minus sign in front of a value, this represents a floor position which is higher than that of the
wheel centreline in relation to the ground.
*
As an option.
07-27
http://vnx.su
VALUES AND SETTINGS

Brake compensator
Amount of fuel in tank

(driver on board)
Type
All types with fixed compensator
07
Checking pressure (Bar)
Front
Rear
60
34 +0
100
40
-4
incorporated in the wheel cylinder
B/C/L
533
53C
53Y
534
With ABS
(after 05/92)
53J
53K
B/C/L
53T
53V
With
ABS
53Z
90966S
3/4/5
53A
53B
With
ABS
53F
B/C/L/S
53F
538
53K
Without ABS
(before 11/94)
53T
53Z
3/4/5
53C
53D
Without ABS
(before 11/94)
53H
07-28
http://vnx.su
+0
-8
VALUES AND SETTINGS

Brake compensator

(driver on board)
Type
B/C/D/L
539
(before 05/92)
07
Front
Rear
100
47
100
52 -8
100
49
53D
B/C/L
+0
-8
53A
535
with ABS
53B
538
B/C/L
3/4/5
53F
with ABS
(after 05/92)
+0
53C
53D
with ABS
53H
90966S
D53D (after 05/92)

853C
B/C/L/S
53F
538
53K
53T
With ABS
(after 11/94)
53Z
3/4/5
53C
53D
Without ABS
(after 11/94)
53H
07-29
http://vnx.su
+0
-8
VALUES AND SETTINGS

Brake compensator

(driver on board)
Type
B/C/D/L/S
07
Front
Rear
100
43
+0
-8
100
52
+0
-8
533
53C
53F
534
With ABS
(before 05/92)
53J
53K
53Y
B/C
53M ABS
B/C/L
53D
(after 05/92)
90966S
53C
53Y
53V
53A
With ABS
(after 05/92)
With ABS
53F
07-30
http://vnx.su
GENERAL
Vehicle Dimensions
http://vnx.su
40
GENERAL
Descriptions of parts
http://vnx.su
40
GENERAL
Descriptions of parts
http://vnx.su
40
GENERAL
Main body dimensions
http://vnx.su
40
GENERAL
Door and lid clearances
http://vnx.su
40
GENERAL
http://vnx.su
40
GENERAL
http://vnx.su
40
GENERAL
http://vnx.su
40
GENERAL
Body jig bench
http://vnx.su
40
GENERAL
Special tool references
http://vnx.su
40
LOWER STRUCTURE
Side member lower section (A)
http://vnx.su
41
LOWER STRUCTURE
Side member lower section (A)
http://vnx.su
41
LOWER STRUCTURE
Lower side spacer (B)
http://vnx.su
41
LOWER STRUCTURE
Body sill cover stiffener (C)
http://vnx.su
41
LOWER STRUCTURE
Body sill cover stiffener (C)
http://vnx.su
41
LOWER STRUCTURE
Front door stiffener, lower section (D)
http://vnx.su
41
LOWER STRUCTURE
Floor and side member side stiffener (E)
http://vnx.su
41
LOWER STRUCTURE
Floor upper cross member (F)
http://vnx.su
41
UPPER FRONT STRUCTURE

Front wing (A)
http://vnx.su
42

Front door pillar upper stiffener (B)
http://vnx.su
42
UPPER SIDE STRUCTURE

Front door pillar assembly (A)
http://vnx.su
43

Front door pillar assembly (A)
http://vnx.su
43

Part of body sill (B)
http://vnx.su
43

Body sill assembly (C)
http://vnx.su
43

http://vnx.su
43

http://vnx.su
43

Body sill front stiffener (D)
http://vnx.su
43

Body sill front stiffener (D)
http://vnx.su
43

Body sill rear stiffener (E)
http://vnx.su
43

Centre door pillar (F)
http://vnx.su
43

Centre door pillar Lining (G)
http://vnx.su
43
UPPER REAR STRUCTURE

Rear wing panel (A)
http://vnx.su
44

Rear wing panel (A)
http://vnx.su
44

Rear wing panel (A)
http://vnx.su
44

Rear wing panel (A)
http://vnx.su
44

Rear wing panel (A)
http://vnx.su
44

Part of rear wing panel (B)
http://vnx.su
44

Wing panel assembly lining (C)
http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

Wing panel front lower lining (D)
http://vnx.su
44

Wing panel front upper lining (E)
http://vnx.su
44

Wing panel rear lining (F)
http://vnx.su
44

Outer wheel arch (G)
http://vnx.su
44

Outer wheel arch Stiffener (H)
http://vnx.su
44

Upper cross member between wheel arches (I)
http://vnx.su
44

Upper cross member between wheel arches (I)
http://vnx.su
44

Hood compartment floor (J)
http://vnx.su
44

Hood compartment floor (J)
http://vnx.su
44

Hood compartment rear cross member (K)
http://vnx.su
44

Boot lid channel (L)
http://vnx.su
44

Boot lid channel (L)
http://vnx.su
44

Rear light support panel (M)
http://vnx.su
44

Rear light support panel (M)
http://vnx.su
44
UPPER BODY
Windscreen frame (A)
http://vnx.su
45
UPPER BODY
Windscreen frame (A)
http://vnx.su
45
UPPER BODY
Windscreen pillar lining (B)
http://vnx.su
45
UPPER BODY
Windscreen upper cross member (C)
http://vnx.su
45
NON-SIDE DOORS AND LIDS

Boot lid
http://vnx.su
48

Sheet metal hood cover
http://vnx.su
48

Sheet metal hood cover
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48
SIDE DOOR AND LID MECHANISMS

Front window winder
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51

Front window winder
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51

Quarter window winder
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51
NON-SIDE DOOR AND LID MECHANISMS

Hood
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52

Hood
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52

Hood
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52

Hood
http://vnx.su
52

Hood
http://vnx.su
52

Hood
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52

Hood
http://vnx.su
52

Hood front latches
http://vnx.su
52

Hood rear latches
http://vnx.su
52

Hood cover latches
http://vnx.su
52

Adjusting the hood
http://vnx.su
52

Hood cover latch release
http://vnx.su
52

Hood cover latch release
http://vnx.su
52

Hood cover gas struts
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52
WINDOWS
Door windows
http://vnx.su
54
WINDOWS
Door windows
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54
WINDOWS
Windows quarter
http://vnx.su
54
EXTERNAL ACCESSORIES
Electric rear view mirror
http://vnx.su
56
Boot lid - Body styling transfer
http://vnx.su
56
Boot lid - Body styling transfer
http://vnx.su
56
INTERNAL SAFETY COMPONENTS

Front seat belts
http://vnx.su
59
INTERNAL SAFETY COMPONENTS

Rear seat belts
http://vnx.su
59
BODY SEALING
Windscreen pillar seal
http://vnx.su
64
WINDOW SEALS
Quarter window outer wiper strip
http://vnx.su
66
GENERAL
Tooling and consumables
http://vnx.su
70
BODY INTERIOR TRIM

Quarter panel trim
http://vnx.su
71
SIDE DOOR AND LID TRIM

Door trim
http://vnx.su
72
NON-SIDE DOOR AND LID TRIM

Hood outer cover
http://vnx.su
73

Hood outer cover
http://vnx.su
73

Hood outer cover
http://vnx.su
73

Hood outer cover
http://vnx.su
73

Hood outer cover
http://vnx.su
73

Padding
http://vnx.su
73

Padding
http://vnx.su
73

Hood inner lining
http://vnx.su
73

Hood inner lining
http://vnx.su
73

Hood inner lining
http://vnx.su
73

Hood inner lining
http://vnx.su
73
REAR SEAT TRIM

Seat cushion trim
http://vnx.su
78
REAR SEAT TRIM

Seat back trim
http://vnx.su
78
REAR SEAT TRIM

Seat back trim
http://vnx.su
78
SEAT ACCESSORIES
Headrest trim
http://vnx.su
79
SEAT ACCESSORIES
Ski compartment cover
http://vnx.su
79
GENERAL
Vehicle dimensions
http://vnx.su
40
EXTERNAL PROTECTION
Front bumpers
http://vnx.su
55
EXTERNAL PROTECTION
Front spoiler
http://vnx.su
55
EXTERNAL FITTINGS
Rear spoiler (B on C only)
http://vnx.su
56
EXTERNAL FITTINGS
Rear spoiler (L only)
http://vnx.su
56
EXTERNAL FITTINGS
Sill skirt
http://vnx.su
56
EXTERNAL FITTINGS
Sill skirt
http://vnx.su
56
EXTERNAL FITTINGS
Sill skirt
http://vnx.su
56
FRONT SEAT FRAMES AND SLIDES

Complete seat
http://vnx.su
75

Complete seat
http://vnx.su
75

Seat frame
http://vnx.su
75

Seat slides
http://vnx.su
75

Seat back frame
http://vnx.su
75
FRONT SEAT TRIM

Seat trim
http://vnx.su
77
FRONT SEAT TRIM

Seat trim
http://vnx.su
77
FRONT SEAT TRIM

Seat back trim
http://vnx.su
77
FRONT SEAT TRIM

Seat back trim
http://vnx.su
77
GENERAL
Vehicle dimensions
http://vnx.su
40
GENERAL
Description of parts (exploded view)
http://vnx.su
40
GENERAL
Description of parts (exploded view)
http://vnx.su
40
GENERAL
http://vnx.su
40
LOWER STRUCTURE
Rear end panel assembly (A)
http://vnx.su
41
LOWER STRUCTURE
http://vnx.su
41
LOWER STRUCTURE
http://vnx.su
41
LOWER STRUCTURE
Part of an extreme rear cross member (B)
http://vnx.su
41
LOWER STRUCTURE
Part of an extreme rear cross member (B)
http://vnx.su
41

Complete wing panel (A)
http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

Part of a wing panel (B)
http://vnx.su
44

Side channel (C)
http://vnx.su
44

Side channel (C)
http://vnx.su
44

Rear light support panel (D)
http://vnx.su
44

Part of a rear end panel cross member (E)
http://vnx.su
44

Part of a rear end panel cross member (E)
http://vnx.su
44

Rear end panel extension (F)
http://vnx.su
44

Rear end panel extension (F)
http://vnx.su
44

Quarter panel lining (G)
http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

http://vnx.su
44

Complete quarter vertical stretcher (H)
http://vnx.su
44

Complete quarter vertical stretcher (H)
http://vnx.su
44

Part of a quarter vertical stretcher (J)
http://vnx.su
44

Seat back fastening stiffener (K)
http://vnx.su
44

Jack support (on RH side) (L)
http://vnx.su
44

Centre cross panel (M)
http://vnx.su
44

Centre cross panel (M)
http://vnx.su
44

Half unit (N)
http://vnx.su
44

Half unit (N)
http://vnx.su
44

Half unit (N)
http://vnx.su
44

Half unit (N)
http://vnx.su
44

Half unit (N)
http://vnx.su
44

Half unit (N)
http://vnx.su
44
UPPER BODY
Roof panel (A)
http://vnx.su
45
UPPER BODY
Roof panel (A)
http://vnx.su
45
UPPER BODY
Roof rear cross member (B)
http://vnx.su
45

Boot lid
http://vnx.su
48

Broken gas strut ball joint
http://vnx.su
48
GENERAL
Special tools
http://vnx.su
50
GENERAL
Consumables
http://vnx.su
50

Boot lid lock and barrel
http://vnx.su
52

Boot lid gas strut
http://vnx.su
52
WINDOWS
Rear screen
http://vnx.su
54
WINDOWS
Rear screen
http://vnx.su
54
WINDOWS
Rear screen
http://vnx.su
54
EXTERNAL PROTECTION
Rear bumper
http://vnx.su
55
EXTERNAL PROTECTION
Rear bumper
http://vnx.su
55
BODY INTERIOR TRIM

Interior trim, rear section
http://vnx.su
71
PARCEL SHELVES AND REAR CROSS PANEL

Cross panel trim
http://vnx.su
74
Transmission
CLUTCH
MANUAL GEARBOXES
AUTOMATIC TRANSMISSION
DRIVESHAFTS
77 11 190 841
NOVEMBER 1996
are constructed".
Edition Anglaise

Renault.
Renault S.A. 1988
http://vnx.su
EXPLODED VIEW
PRD2013
http://vnx.su
Transmission
Contents
Pages
20 CLUTCH
Identification
Side views
Exploded view
Consumables
Mechanism - Clutch plate
Thrust pad - Fork
23 AUTOMATIC TRANSMISSION
20-1
20-4
20-4
20-5
20-6
20-10
21 MANUAL GEARBOXES
Identification
Gear ratios
Capacities - Lubricants
Special features
Consumables
Parts which must be changed
automatically
Gearbox (Removal - Refitting)
5th gear linkage in situ
Differential output seal
Speedometer drive
21-1
21-2
21-5
21-7
21-8
21-8
21-9
21-23
21-29
21-32
23 AUTOMATIC TRANSMISSION
MB automatic transmission
Exploded view
Use
Identification
Gear ratios
Gear change thresholds
Consumables
automatically
Oil
Draining - Filling - Levels
Checking and adjusting the
potentiometer
Oil pressure
Strainer
Automatic transmission (Removal Refitting)
Pages
23-1
23-2
23-3
23-4
23-5
23-6
23-6
23-7
23-8
23-11
23-13
AD4 automatic transmission

Exploded view
Use
Identification
Gear ratios
Consumables
automatically
Oil
Oil drain intervals
Oil draining
Filling - Levels
Oil pressure
Changing the strainer
Hydraulic distributor
Automatic transmission (Removal Refitting)
Full-load validation
Load potentiometer
Computer (119)
Line pressure sensor (8)
Multifunction switch (485)
Vehicle speed sensor (250)
Solenoid valve
Engine torque reduction
Special features
23-23
23-24
23-25
23-26
23-27
23-29
23-29
23-29
23-30
23-31
23-32
23-33
23-34
23-36
23-41
23-57
23-58
23-60
23-61
23-62
23-63
23-64
23-65
23-66
29 DRIVESHAFTS
Consumables
Driveshafts
Gaiter at wheel end
Gaiter at gearbox end
Gaiter - bearing assembly
23-15
http://vnx.su
29-1
29-2
29-9
29-19
29-26
CLUTCH
Identification
ENGINE
TYPE
Mechanism
20
Plate
C1G
C1J
C2J
C3J
85873S
90693R
76906R
E6J
26 splines
E = 7.7 mm
D = 181.5 mm
180 CP 3300
B = White
GB= Blue grey
V = Green
F2N
F3N
76907S
2000 CP 4000
90693R1
26 splines
M=
6 pale pink springs
E = 7.7 mm
D = 200 mm
20-1
http://vnx.su
76906R
CLUTCH
Identification
ENGINE
TYPE
MECHANISM
20
CLUTCH PLATE
F7P
76907S
93813R
26 splines
D = 200 mm
E = 7.7 mm
200 CP 4400
76906R
R = 4 red springs
J = 4 yellow springs
Special feature: 2 additional springs on the hub.
F8Q
76907S
200 CPV 3500
90693G1
26 splines
D = 200 mm
E = 7.7 mm
20-2
http://vnx.su
76906R
R = Red
J = Yellow
V = Green
CLUTCH
Identification
ENGINE
TYPE
MECHANISM
20
CLUTCH PLATE
Special feature: 2 additional springs on the hub.
F8Q
Turbo
76907S
200 CPV 4400
90693-2G2
26 splines
D = 200 mm
E = 7.7 mm
20-3
http://vnx.su
76906R
J = 4 yellow springs
G = 4 grey springs
CLUTCH
Side view
20
Single plate, dry, clutch, cable operated.

Diaphragm spring clutch plate.
Clutch plate with rubber hub.
Self-centring, guided, ball type thrust pad in
constant contact.
Automatic wear take-up mechanism.
DI2001
Exploded view
PRD2012
20-4
http://vnx.su
CLUTCH
Consumables
Type
Pack size
20
Unit
Right hand sunwheel splines
MOLYKOTE BR2
1 kg tin
RHODORSEAL 5661
100 g tube
LOCTITE 518
24 ml syringe
20-5
http://vnx.su
Shaft splines
Fork pivot
Release bearing guide
Fork pads
Clutch
Ends of driveshaft roll pins.

Housing assembly faces.
CLUTCH
Mechanism - Clutch plate
ALL TYPES
IMPORTANT PRECAUTIONS WHICH MUST BE
FOLLOWED WHEN REPAIRING THE CLUTCH
In order to improve the sliding of the clutch

plates, their hubs are nickel-plated.
Clean the clutch shaft splines and refit the assembly without any lubricant.
Special features of "diesel" clutch plates
These are fitted with a damping pre-hub which is
most efficient when its internal units are dry.
20-6
http://vnx.su
20
CLUTCH
Mechanism - clutch plate
20
CHANGING
This operation is carried out after the gearbox has been removed.
Mot.
582
Locking sector
Plus the tools required to remove the gearbox
REFITTING
TIGHTENING TORQUES (in daN.m)
7 mm diameter unit securing bolts

for 180 mm diameter clutch
8 mm diameter unit securing bolts
for 200 mm diameter clutch
Degrease the flywheel mounting face.

1.8
Use the plastic locating device supplied in the kit

to fit the plate.
2.5
REMOVAL
Fit locking sector Mot. 582.

Remove the mounting bolts from the mechanism
and remove the unit and the clutch plate.
Check and change the faulty parts.
94135S
92170R
20-7
http://vnx.su
CLUTCH
20
74413R
Gradually screw up then torque tighten the bolts

securing the mechanism.
Remove locking sector Mot. 582.
Coat the bore of the thrust pad, guide tube and
clutch shaft splines with grease MOLYKOTE BR2 .
20-8
http://vnx.su
CLUTCH
20
94235S
REMOVAL
F engines
Degrease the crankshaft bore which receives the centring bush.
Coat the external diameter of the bushing with Loctite FRENBLOC.
Using a tube with an external diameter of 38 mm, fit the bush fully into the crankshaft bore.
Observe the direction of fitting of the bush and check that it is fitted correctly.
C and E engines
The centring bush will not be used for these engines.
20-9
http://vnx.su
CLUTCH
Thrust pad - fork
20
CHANGING
Ensure that the assembly slides properly.
This operation is carried out when the gearbox

has been removed.
NOTE: when carrying out operations which do not
require removal of the gearbox or after fitting the

gearbox, DO NOT RAISE the fork as there is a risk
of it lifting out of catch (A) on the thrust pad.
REMOVAL
Remove:
- the thrust pad by tilting the fork,
- the rubber protector, and pull the fork towards the inside of the clutch casing.
Check the extent of fork travel.

It should be:
REFITTING
X = 17 to 18 mm
Coat the walls of the guide tube and the fork pads
with grease MOLYKOTE BR2.
Fit the fork and refit the rubber protector.
Fit the thrust pad on the guide tube, placing catch
(A) in the fork.
91830R1
90300G1
After refitting the gearbox, re-set the toothed

quadrant and check that the wear take-up mechanism operates correctly.
20-10
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MANUAL GEARBOXES
Identification
21
Gearbox type
Repair manual which deals

with the gearbox concerned
JB
B.V. JB
JC
B.V. JC
87227G
An identification plate on the clutch housing shows:

At A
At B
At C
At D
At E
:
:
:
:
:
the gearbox type

the gearbox suffix
the fabrication number
the production factory
a notch is used when the gearbox has been
assembled with a C or E type engine.
J B0 0 0 0
X 000000
B
C
E
90775
TWO-COLOUR MARKING
JB0 - JB1 - JB3 - JC5
Two-thirds of the surface are painted with a colour which is peculiar to each gearbox type, enabling the gearbox to be matched with the driveshaft.
The remaining one-third of the surface is painted with a specific colour according to the gearbox suffix.
JB4 - JB5
Two-colour marking (green and pink) in the form of two bands of equal width.
21-1
http://vnx.su
MANUAL GEARBOXES
Gear ratios
21
JB0
Index
Vehicle
Final drive
set
017
B531 - B532 - B537

C531 - C532
L531 - L532 - L537
16
57
019
B534
L53H
15
56
023
B530 - C530 - L530

S530
15
58
B53W - C53W
15
61
035
L53W
Speedo
drive set
1st
2nd
3rd
4th
Reverse
21
19
11
41
21
43
28
37
31
28
11
39
Speedo
drive set
1st
2nd
3rd
4th
Reverse
21
19
11
41
19
39
25
33
31
28
11
39
Speedo
drive set
1st
2nd
3rd
4th
5th
Reverse
21
19
11
43
21
43
28
37
30
29
39
31
11
39
26
21
19
11
41
21
43
28
37
30
29
39
31
11
39
26
21
19
11
45
21
43
28
37
30
29
39
31
11
39
26
26
JB4
Index
Vehicle
Final drive
set
000
B530 - C530 - L530

S530 - C531
15
58
006
B531 - L531
B53P - C53P - L53P
16
57
26
JB1
Index
023
025
Vehicle
Final drive
set
B532 - C532 - L532

B535 - C535 - L535
15
58
B530 - C530 - L530

S530 - B537 - C537
L537 - S537 - B53A
15
61
C53A - B53G
027
B53H
L53H
15
58
029
L53G
15
61
034
B531 - C531 - L531
16
57
047
B53W - C53W
L53W
14
63
B530 - C530 - L530

S530 - B535 - C535
L535 - S535 - B537
C537 - L537 - B53A
15
61
070
C53A - L53A
21-2
http://vnx.su
MANUAL GEARBOXES
Gear ratios
21
JB3
Index
059
027
Vehicle
Final drive
set
Speedo
drive set
1st
2nd
3rd
4th
5th
Reverse
15
61
21
19
11
34
22
41
28
37
30
29
41
31
11
39
26
14
59
21
19
11
34
22
41
28
37
30
29
41
31
11
39
26
15
61
21
19
11
34
22
41
28
37
34
35
34
28
11
39
26
21
19
11
41
22
43
28
37
30
29
39
31
11
39
26
21
19
11
41
21
43
28
37
30
29
39
31
11
39
26
B533 - C533 - L533

D53C
B533 - C533 - L533
B53C - C53C - L53C
D53C
B53M - C53M
062
094
353A - 453A - 553A

853A
B53C - D53C - L53C
B53Y - D53Y - L53Y
B538 - C538 - L538
B53F - C53F - L53F
S53C - S53D
095
353C - 453C - 553C

853C - 353D - 453D
553D - 453H - 553H
B538 - C538 - L538
S53C - S53D
037
B538 - C538 - L538

B53C - C53C - D53C
L53C - B53F - C53F
L53F - B53Y - L53Y
071
B53D - C53D - L53D
083
B53D - C53D - L53D
060
B533 - L533 - B53B

C53B - L53B - B53I C53I - L53I - B53J C53J - L53J - S53J
16
57
061
B533
15
58
067
353A - 453A - 553A

853A - B53Y - C53Y
D53Y - L53Y
047
B53B
B53Y - C53Y - L53Y
16
55
21-3
http://vnx.su
MANUAL GEARBOXES
Gear ratios
21
JB3
Vehicle
Final drive
set
Speedo
drive set
1st
2nd
3rd
4th
5th
Reverse
017
L532
051
B539 - C539 - B53D

C53D - D53D - L53D
15
61
21
19
11
34
19
35
25
33
30
29
33
25
11
39
26
Index
044
B539 - C539 - L539

B53D - C53D D53D - L53D
031
B533 - B536 - L536
15
58
21
19
11
34
21
43
28
37
30
29
39
31
11
39
26
053
B53D - C53D - L53D
15
61
21
19
11
34
22
41
28
37
34
35
34
28
11
39
26
16
57
21
19
11
41
21
43
28
37
30
29
39
31
11
39
26
028
B532 - B533 - L533

C534 - L534 - S534
B53B - C53B - L53B
B53C - L53C - B53E
C53E - B53I - C53I L53I - B53J - C53J L53J - S53J
JB5
Index
Vehicle
Final drive
set
Speedo
drive set
1st
2nd
3rd
4th
5th
Reverse
006
B531 - C531 - L531

B53P - C53P - L53P
16
57
21
19
11
41
19
39
25
33
30
29
34
27
11
39
26
000
B530 - C530 - L530

S530
15
61
21
19
11
41
19
39
25
33
30
29
34
27
11
39
26
JC5
Index
Vehicle
Final drive
set
Speedo
drive set
1st
2nd
3rd
4th
5th
Reverse
002
B532 - C532 - L532

B53K - L53K - S53K
B53T - C53T - L53T
B53Z
17
56
21
19
11
41
21
43
28
37
35
34
41
31
11
39
21-4
http://vnx.su
26
MANUAL GEARBOXES
Capacities - Lubricants
CAPACITY (in litres)
21
Plug (B) with dipstick
4-speed gearbox
5-speed gearbox
JB0
JB2
3.25
JB1
JB3
3.40
JB4
2.75
JB5
2.90
JC5
3.10
CHECKING THE LEVEL

DI2123
There are two ways of checking the level.
Wipe the dipstick section.
Plug (A) without dipstick
Refit the plug, without screwing it up, with the

dipstick pointing downwards.
Remove the plug, the level should be on the boss
(2).
OIL VISCOSITY GRADE
Tranself TRX 75/80 W
92081R
Fill to the level of the opening.
21-5
http://vnx.su
MANUAL GEARBOXES
Lubricants
21
Precautions (TRX and TRZ oils)

"TRANSELF TRX and TRZ" oils are high technology products and certain precautions must be taken in order
to prevent the entry of water which, even in very small quantities, will reduce the quality of the oil and result
in seizure of the gearbox or of the final drive.
STORAGE AND USE
Special care must be taken to ensure that open cans are sealed correctly in order to prevent the entry of materials or water.
In particular:
Storing oil cans
The cans must be stored:
- sheltered from bad weather (rain, snow, outside splashes),
- in a dry area (avoid storing in the vicinity of a washing area),
- tightly sealed.
Storing units (gearbox or final drive)
When storing a gearbox or final drive which has not been drained, close the air inlets.
Store the unit in a dry area.
Using the oil
The oil cans must be resealed each time they have been used.
In order to prevent a large surface area of the oil coming into contact with the air, do not transfer the oil into
a larger container.
When carrying out work which requires draining of the gearbox, the oil must be replaced with new oil.
The oil can must be shaken before refilling the gearbox, especially if the oil has been stored for a long time.
Washing under pressure (of the vehicle or of a unit)
Close the gearbox and final drive breather.
If the gearbox is removed, correctly close all of the openings to prevent the entry of water.
21-6
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MANUAL GEARBOXES
Special features
21
The gearboxes of the following types:

JB0
4 forward gears
JB4
1 reverse
JB2
JB1
JB3
JB5
JC5
5 forward gears
1 reverse
are fitted with BORG-WARNER synchronisers.
GEAR CHANGE PATTERN
R 1 3 5
2 4
To select reverse, raise ring (A) and move the lever.
DI2118
21-7
http://vnx.su
MANUAL GEARBOXES
Consumables
TYPE
PACK SIZE
21
UNIT
Clutch fork pivot

Thrust pad guide tube bore
Clutch shaft splines
Right hand sun wheel splines
MOLYKOTE BR2
1 kg sachet
Loctite 518
24 ml syringe
Housing joint faces
LOCTITE FRENBLOC
24 cc bottle
5th speed fixed gear

5th speed synchroniser hub
Primary shaft nut
Secondary shaft bolt
RHODORSEAL 5661
100 g tube
Ends of roll pins on driveshafts

Screw threads on switches
Parts which must be changed automatically
When they have been removed:

- the lip seals,
- the O-rings,
- the thrust pad guide tubes,
- the secondary shaft and differential nuts,
- the speedometer gear and its shaft,
- the speedometer crown wheel,
- the roll pins,
- the bushes under the gears.
21-8
http://vnx.su
MANUAL GEARBOXES
C
engines
21
B.Vi. 31-01
T.Av. 476
Set of pin punches

Ball joint extractor
MATERIALS
Loctite FRENBLOC
Brake caliper securing bolts

RHODORSEAL 5661
Ends of pins on driveshafts

MOLYKOTE "BR2"
Clutch shaft and sun wheel splines
85965R

Shock absorber lower securing bolts
Steering ball joint nut
Nut holding key on stub axle carrier
Mounting securing bolts
Wheel bolts
Left hand driveshaft gaiter securing bolt
10
11
3.5
5.5
4 to 5
8
2.5
- the three bolts holding the driveshaft gaiter,

- the two bolts securing the brake caliper and secure the caliper to the suspension spring so as
to avoid stretching the hose,
- the protective casing (side).
REMOVAL
The gearbox can be removed alone.

Place the vehicle on a two post lift.
Disconnect the battery.
Remove the front wheels.
On the left hand side of the vehicle

Remove:
- the steering tie rod ball joint using tool
T.Av. 476.
92122R2
21-9
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C
engines
MANUAL GEARBOXES
Remove:
- the two bolts (2) securing the base of the shock
absorber,
- the nut and key (1),
21
On the right hand side of the vehicle

Remove the driveshaft roll pins using tool
B.Vi. 31-01
90130R2
91755R
- the driveshaft - stub axle carrier assembly from

the lower ball joint,
Slacken lower bolt (3) on the base of the shock absorber and remove upper bolt (4).
90311S
91758R4
Tilt the stub axle carrier and uncouple the driveshaft.
Check that the driveshaft rollers do not come out

manually. If they do, on reassembly, check that
the needle bearings have not fallen into the gearbox.
21-10
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C
engines
MANUAL GEARBOXES
Under the vehicle, remove bolt (H) from the engine - gearbox tierod.
21
Disconnect:
- the starter leads,
- the connector on the reversing light switch.
On vehicles fitted with power assisted steering,
remove the two clamps securing the power
assisted steering pipes to the gearbox.
Remove:
- the air filter unit and its mounting,
92028R2
Slacken:
- the two mounting bolts on the engine,
- the clutch protection plate,
- the gear lever.
92031S
- the integral electronic ignition (A.E.I.) sensor,

- the bolts from around the gearbox and from
the starter.
85966R
21-11
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C
engines
MANUAL GEARBOXES
Disconnect:
- the clutch cable,
21
Lift the engine using a tool specific to this purpose

(example: desvil 300B).
89204S
92110S
- the speedometer pin and cable.
Petrol engines - all types

Remove:
- the front mounting,
- the earthing braid.
92108-1R1
92112R
21-12
http://vnx.su
C
engines
MANUAL GEARBOXES
21
Remove the three bolts securing the rear centre

mounting and move it back as far as possible.
92108R1
92903S
NOTE: to make it easier to remove the bolts, raise

the gearbox slightly with a component jack.
Uncouple the gearbox from the engine, sliding
the 5th speed housing between the vehicle sidemember and the engine cradle.
Raise the engine.
Turn the gearbox to the front slightly so as to free
the final drive section then remove the gearbox
from the vehicle.
After uncoupling the gearbox from the engine,
attach it to a workshop crane securing the eyes in
place of two bolts around the gearbox.
21-13
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E
engines
MANUAL GEARBOXES
21
Remove the idle speed regulation valve mounting.
REMOVAL
The gearbox is removed alone.

Disconnect the starter and oil pressure sensor
wires.
Remove the radiator after first draining the cooling system.

To detach the wiring, disconnect the connectors
on:
- the ignition power module,
- the throttle housing,
92904R
Disconnect the two side bolts which secure the engine - gearbox tierod, starter end torx bolt (T).
using a suitable spanner.
92817S
the idle speed regulation valve.
92904R1
92826S
21-14
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E
engines
MANUAL GEARBOXES
Disconnect the fan motor and thermal switch

connectors.
21

Unfasten the radiator mountings and move it to

the right hand side (without removing any of the
hoses or pipes), protecting the sides with cardboard.
Remove studs (A) and (B) using a nut and lock-nut,
using an angled spanner and a ball joint ratchet.
92903S
86308R1
21-15
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F
engines
MANUAL GEARBOXES
The gearbox cannot be removed alone. The engine - gearbox assembly must be removed first (refer to section 10) and then uncoupled.
21
Uncouple the gear lever at the gearbox outlet lever after detaching the protective gaiter.
Bolt which secures the pendulum

mounting system to the gearbox
Nuts and bolts which secure the clutch
housing to the engine
Bolt which secures the clutch
protector
Drain plug
Filler plug
Bolt which secures the left hand
driveshaft
3.5
5
2.5
1.8
0.15
2.5
Removal (Special points)
85966R
Speedometer cable mounting. Pinch the tabs (arrows) and remove the cable.
Remove the starter plate.
98865R2
93902S
21-16
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MANUAL GEARBOXES
F
engines
Disconnect the starter leads.
21

From the lower section, remove:

- nut (E) which secures the engine - gearbox,
85812-1R
the tierod - clutch protector assembly.

92903S1
Place the engine on a stand.

Remove the bolts from around the gearbox and
from the starter.
Vehicles fitted with power assisted steering, remove the two clamps (C) which secure the power
assisted steering pipe.
92028R3
21-17
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F
engines
MANUAL GEARBOXES
21
REFITTING
Ensure that the engine - gearbox locating rings

are present and correctly positioned:
- at A : gearbox assembled with a C or E type
engine,
- at B : gearbox assembled with an F type engine.
90300G1
86415R
Do not raise the fork since there is a risk of it lifting out of catch (A) on the thrust pad. To prevent
this, immobilise the thrust pad - fork assembly by
inserting a tube (example: tool El. 1382) between the fork and the sheath end on the housing
to prevent any movement of the thrust pad while
the gearbox is fitted.
Fit the thrust pad to the guide tube placing catch

(A) in the fork, ensure that it slides correctly.
Coat the walls of the guide tube and the fork pads
with MOLYKOTE BR2 grease .
21-18
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F
engines
MANUAL GEARBOXES
Fit the gearbox in place.
92903R1
Assemble the engine - gearbox.

Ensure that the locating rings are fitted correctly
in their locations.
Refit studs (A) and (B) in the same way as on removal. These studs and the bolts around the gearbox
are used for alignment and centring.
Fit the fork and refit the rubber protector.
21-19
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21
All types
MANUAL GEARBOXES
WARNING: fit bolt (V) and starter locating pin (D)
21
Reconnect the speedometer cable ensuring that

the pin is in the correct position (C and E type engines).
correctly.
C and E type engines
92108-1S
Speedometer cable mounting. Pinch the tabs (arrows) and remove the cable (F type engine).
86070R3
F type engine
93909S
86070-1R1
21-20
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All types
MANUAL GEARBOXES
21
Position the driveshaft in relation to the sun

wheel, pivot the stub axle carrier engaging the
driveshaft in the sun wheel using the angled drift
B. Vi. 31-01 to align the holes.
91830R1
Pull the cable at the clutch fork on the gearbox.

The cable should have at least 2 cm of slack.
74937-4S
There is an inlet chamfer on the sun wheel to

make it easier to fit new roll pins.
Seal the ends of the pins (RHODORSEAL 5661 ).
After refitting the engine - gearbox assembly to
the vehicle, check the extent of the fork travel.
It should be: X = 17 to 18 mm
89204S
These checks enable the correct operation of the

clutch automatic wear take-up system to be verified.
21-21
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F
engines
MANUAL GEARBOXES
Check the setting of the upper mountings (refer
to section 10).
Ensure that the engine movement limiter is fitted
the correct way: the nuts should be fitted at the
exhaust pipe end.
92661S
Fill the cooling system.

All types
Fit the brake caliper mounting bolts with Loctite
FRENBLOC and torque tighten them.
Press on the brake pedal several times to bring the
pistons into contact with the brake pads.
Tighten the bolts and nuts to the specified torque.

Fill the gearbox.
21-22
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21
MANUAL GEARBOXES
5th speed linkage in situ
21

B.Vi.
28-01
Extractor body
B.Vi.
31-01
1003
Drifts for fitting roll pins

5th speed hub extractor
B.Vi.
B.Vi.
B.Vi.
1007
1175
Jaws for B.Vi. 28-01, 02, 03

5th speed fixed gear mounting bolt
Primary shaft nut

Secondary shaft nut
13.5
7
MATERIALS
Loctite FRENBLOC :
Primary shaft nut

Secondary shaft bolt
5th speed fixed gear
5th speed hub
REMOVAL
Remove the front left hand wheel.
87180R
Remove the side housing.

Drain the gearbox.
The rear housing must be removed horizontally as
it has a lubricating duct (A) which goes into the
primary shaft.
21-23
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MANUAL GEARBOXES
21
Fit:
- a drainage tray under the rear housing and remove it,
- a wooden block between the 5th speed fork
and the leading gear to act as a counter-force;
then remove the fork roll pin using tool B.Vi.
31-01.
It is easier to remove the roll pin if the drift of tool
B.Vi 31-01 is bent slightly to avoid having to raise
the gearbox.
DI2122
Select 5th gear by sliding the fork on its shaft and

1st gear with the gear lever.
85979R
NOTE:
Do not pull the 5th speed fork shaft outwards as

there is a risk that the prohibiting lock may move
and prevent refitting of the shaft. As a safety
measure, engage a gear (3rd or 4th) when removing - refitting the roll pin.
85966R2
Slacken and remove the primary shaft nut and

secondary shaft bolt.
Return the gearbox to neutral.
21-24
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MANUAL GEARBOXES
21
Fit the rounded housing of the tool on the slide

gear, turn it as far as possible and then extract the
hub.
On the primary shaft:

Remove the 5th speed fork and the slide gear.
Extract the synchroniser hub using tool B.Vi. 1170.
93190R
93237R
Fit the slide gear of tool B.Vi. 1170 as for selecting

5th gear and turn it so as to position the splines of
the slide gear and the hub opposite each other.
Remove the 5th gear assembly.
86045R2
93189S
21-25
http://vnx.su
MANUAL GEARBOXES
On the secondary shaft:
REFITTING
Remove shouldered washer (64).
21
Put three drops of Loctite FRENBLOC on the fixed

gear splines.
Fit the fixed gear using tool B. Vi. 1175 and shouldered washer (64).
PRG21.1
Remove the fixed gear using tool B.Vi. 28-01-0203 fitted with its jaws B.Vi. 1007.
93462R
Remove tool B. Vi. 1175.
88575R
21-26
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MANUAL GEARBOXES
On the primary shaft:
Refit parts (21) (shoulder facing bearing (22), (23),

(24) and (8)) in order.
Fit shouldered washer (64).
21
Fit the fork on slide gear (26) fitted with part (25).
Put three drops of Loctite FRENBLOC on the hub
and refit the slide gear - hub assembly and fork.
Fit the bosses on the synchro ring in the notches
on the hub.
PRG21.1
Put three drops of Loctite FRENBLOC:

- on nut (27) of the primary shaft and torque
tighten it to 13.5 daN.m,
- on bolt (65) and torque tighten it to 7 daN.m .
86045R1
Select 1st gear at the gear lever and 5th gear at

the gearbox, sliding the 5th speed fork on its
shaft.
21-27
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MANUAL GEARBOXES
Place a wooden block between the 5th speed fork
and the primary gear as a counter-force and fit a
new roll pin in the 5th speed fork using tool B.Vi.
31-01 ensuring that it is fitted the correct way
round, with the slot in the centreline of the shafts.
21
Fit a new O-ring seal to ensure that the rear housing is leaktight.
Fit the rear housing engaging duct (A) in the primary shaft and the lubricating channel in oil inlet
rail (B) and torque tighten the bolts to 2.5 daN.m.
90498-1S
87180R6
Fill the gearbox with oil.
85979R1
Return the gearbox to neutral and check that all

of the gears can be selected.
If there are any difficulties, ensure that reverse
gear is not engaged.
21-28
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MANUAL GEARBOXES
21

B.Vi.
31-01
T.Av.
B.Vi.
476
945

Plug for fitting the differential seal
B.Vi.
1058
Plug for fitting the differential seal
10
Shock absorber lower securing bolts
11
Steering ball joint
3.5
Wheel bolts
MATERIALS
Loctite FRENBLOC :

RHODORSEAL 5661 :
Ends of driveshaft roll pins

MOLYKOTE BR2 :
Splines on right hand sun wheel
91755R
Remove:
- the steering ball joint (tool T.Av. 476),
REMOVAL
Remove the protective casing from under the engine.

Drain the gearbox.
Place the front of the vehicle on stands on the side
in question.
Remove the wheel.
Knock out the driveshaft roll pins using tool B.Vi.
31-01.
85965R
21-29
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MANUAL GEARBOXES
21
- the two bolts (A) securing the brake assembly.
86031S
REFITTING
Grease protector (A) of B. Vi. 945 and fit it on the

sun wheel. Position the greased seal using B. Vi.
1058.
90149R1
Fix the brake caliper to the suspension spring in

order to avoid stretching the hose.
Slacken lower bolt (3) on the shock absorber base
and remove upper bolt (4).
Tilt the stub axle carrier and uncouple the driveshaft (take care not to damage the gaiters during
this operation).
Remove the O-ring seal from the sun wheel.
Knock the base of the lip seal using a pin drift and
a small hammer so that it turns in its housing.
When the seal has been loosened, take it out
using a pair of pliers, taking care not to damage
the sun wheel splines.
92111R
21-30
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MANUAL GEARBOXES
21
Fit new roll pins and seal the ends (RHODORSEAL

5661).
Fit the O-ring seal on the sun wheel and coat the
splines with grease MOLYKOTE BR2.
wheel.
Turn the stub axle carrier engaging the driveshaft
in the sun wheel using drift B.Vi. 31-01 in order to
align the holes.
Tighten the bolts and nuts to the recommended

torque.
Fit the brake caliper in place and coat the bolts
with Loctite FRENBLOC.
Fill the gearbox.
74937-3S
21-31
http://vnx.su
MANUAL GEARBOXES
Speedometer drive
21
CHANGING
REFITTING
1st possibility:
Only the speedometer drive or shaft is damaged.
Refit the new speedometer drive using pliers with

a long, flat nose.
The drive gear and its shaft are refitted by hand.
The shaft must be positioned correctly in relation
to the locating notches on the drive gear, owing
to the elasticity of the shaft lips.
REMOVAL
It is not necessary to dismantle the entire gearbox.

Uncouple the left hand driveshaft.
Remove the spider sun wheel.
CORRECT
Turn the differential by hand so that the speedometer drive gear can be reached.
INCORRECT
Unclip the shaft, pulling it vertically using long nosed pliers.

Using the same pliers, remove the drive gear from
its location.
86053S
Ensure that it is properly clipped in place.

Refit the spider sun wheel.
2nd possibility:
The speedometer drive gear and crown wheel are
damaged.
88577S
The gearbox must be removed and the final drive

dismantled.
21-32
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MB AUTOMATIC TRANSMISSION
Exploded view
23
DI2325
23-1
http://vnx.su
Use
DRIVING
The automatic transmission is greased under pressure and therefore only while the engine is running.
Consequently, in order to avoid serious damage,
the following recommendations must be followed:
- never drive with the ignition switched off (on a
downwards slope, for example), the danger of
such a practice cannot be emphasised enough.
- never push the vehicle (for example: to reach a
petrol station), except in the situation where
the precautions stated in the section below on
"Towing" are observed.
Furthermore, the vehicle can only be driven if the
engine is running. It is therefore impossible to
start the engine of an automatic transmission vehicle by pushing it.
TOWING
The front of the vehicle should be lifted. However,

if this is not possible, the vehicle may, in exceptional circumstances, be towed with four wheels on
the ground under the following conditions:
1.
Add an additional two litres of automatic

transmission oil ELF RENAULTMATIC D2 or
MOBIL ATF 220.
2.
Only tow the vehicle at a speed of less than

20 mph (30 km/h) over a distance of less than
30 miles (50 km) (lever in"N")
DO NOT FORGET TO REMOVE THE EXCESS OIL

AFTER TOWING.
23-2
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23
Identification
23
ENGINE
STEP
DOWN
GEAR
RATIO
FINAL
DRIVE
RATIO
MB1
E7J
29/24
15/58
21/19
4.40.1
138
B537
C537
L537
MB1
E6J
29/24
15/58
21/19
4.40.1
138
B53B
C53B
L53B
MB3
F3N
29/24
16/57
21/19
4.40.1
132
VEHICLE
AUTO
TRANS
TYPE
B53A
C53A
L53A
SPEEDOMETER
DRIVE RATIO
(*) On the road, with the lever in 2nd at 50 mph (80 km/h).
Converter drive plate:
Maximum permissible run-out: 0.3 mm
Tightening torque:
- Bolt for securing to the crankshaft: 6.5 daN.m
- Bolt for securing to the converter: 2.5 daN.m
23-3
http://vnx.su
OIL
PRESSURE*
COMPUTER
Gear ratios
23
For vehicle types B53A - C53A - L53A - B537 - C537 - L537
Gear ratios
1st
2nd
3rd
Reverse
2.5
1.5
Gear reduction +step down
2.069
1.241
0.828
1.655
Gear reduction + stepdown + final drive
7.999
4.799
3.199
6.399
Speed in km/h for 1000 rpm *
12.937
21.562
32.343
16.171
Gear reduction
For vehicle types B53B - C53B - L53B
Gear ratios
1st
2nd
3rd
Reverse
2.5
1.5
Gear reduction + stepdown
2.069
1.241
0.828
1.655
Gear reduction + stepdown + final drive
7.370
4.422
2.948
5.896
Speed in km/h for 1000 rpm *
14.042
23.403
35.105
17.552
Gear reduction
* For vehicles fitted with 165/70 R13 tyres.
23-4
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23
Gear change thresholds in km/h for vehicle types B53B - C53B - L53B
1 2
2 3
3 2
2 1
No-load (PL)
23
40
27
15
Full-load (PF)
72
118
102
63
Kickdown
72
118
102
63
POSITION OF FOOT
Gear change thresholds in km/h for vehicle types B537 - C537 - L537 - B53A - C53A - L53A
1 2
2 3
3 2
2 1
No-load (PL)
23
46
26
13
Full-load (PF)
62
102
74
40
Kickdown
67
109
94
54
POSITION OF FOOT
No-load (PL) Foot off accelerator pedal

Full-load (PF) Accelerator pedal fully depressed
NOTE: The kickdown switch is incorporated in the computer via the load potentiometer. In the event of a
fault refer to workshop repair manual T.A. M.
23-5
http://vnx.su
Consumables
DESCRIPTION
23
COMPONENT CONCERNED
Sealing of the driveshaft roll pins
RHODORSEAL 5661
- Sun wheel splines

Grease MOLYKOTE BR2
- Converter locating device

Brake caliper securing bolt
Loctite FRENBLOC

Parts which must be changed once they have been
removed:
- the roll pins,
- the self-locking nuts,
- the copper seals.
Oil
The MB automatic transmission is a gearbox which has only one level and one grade of oil (converter, final
drive, mechanical section).
GRADE (for example) : ELF RENAULTMATIC D2.
If this is not available, use (example) :

- MOBIL ATF 220D
- TOTAL DEXRON
CAPACITY IN LITRES :
Theoretical total:
4.5 litres
After draining: 2 litres
23-6
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Draining - Filling - Levels
23
Start the engine and wait one or two minutes for

the converter and cooler to fill up.
DRAINING - FILLING
Draining must be carried out when cold, dipstick

and plug (A) removed.
The oil is at an ambient temperature of 20C.
Change the strainer.
Pull out the dipstick while the engine is running.

The level should not be below mark (1) MINIMUM
WHEN COLD (risk of damage) and should not exceed mark (2) MAXIMUM WHEN COLD (risk of damage).
Never exceed the "MAXIMUM WHEN COLD"
level.
WARNING
Too much oil results in:

- overheating of the oil,
- leaks.
Too little oil results in:
- damage to the mechanisms.
93609R
Refit the plug together with a new seal.

Fill with the recommended oil via the dipstick
tube.
Use a funnel fitted with a 15/100 filter in order to
prevent the entry of impurities.
Run the engine at idle speed.
Check the level and top up if necessary.
CHECKING THE OIL LEVEL WHEN COLD

85935R
With the vehicle empty, place it on a even, horizontal surface.

CHECK THE LEVEL WHEN COLD.
1. MINIMUM WHEN COLD
2. MAXIMUM WHEN COLD
Position the selector lever in "PARK" (P).
23-7
http://vnx.su
Checking and adjusting the potentiometer
23
1st METHOD
B.Vi. 958
Checking unit
ADVICE
With the vehicle stationary and the ignition off,

check that the accelerator cable is adjusted correctly.
Disconnect the 3-way connector (10) for the wiring which connects the computer to the potentiometer.
85651-1R
CHECKING
Press the accelerator pedal down

fully
Indicator
light 9
CORRECT
INCORRECT or maladjusted
93698R
Slightly slacken the two bolts (V) which secure the

potentiometer.
Connect the potentiometer connector (10) to the

B.Vi. 958 connector (16).
Keep the throttle fully open via the accelerator

pedal and slowly turn the potentiometer to illuminate indicator light (9) and retighten the two
bolts (V)
Supply the B.Vi. 958 from the battery.

Reversing switch "I2" on "Y".
If indicator light (9) cannot be illuminated by this

adjustment, check its wiring and if the potentiometer is faulty, change it.
Whenever the potentiometer is changed or removed, adjust it.
NOTE: if the carburettor is cleaned, dismantle
the load potentiometer or avoid splashing cleaning fluid on it.
23-8
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23
2nd METHOD
XR25
ADVICE
With the vehicle stationary and the ignition off,

check that the accelerator cable is adjusted correctly.
Disconnect the 3-way connector (10) of the wiring
which connects the computer to the potentiometer.
93607R
Connect:
- the round plugs to the battery (red on "+",
black on "-"),
- the three-way connector (16) to the
potentiometer connector (10).
93608R
Connect the XR25, the three-way extension lead

and the two round plugs.
23-9
http://vnx.su
93606S
On the XR25 keypad, press key "V" then "1";

Reading the numerical values on the display:
At full-load, the display should show a value between "0" and "3"; ignore any "-" signs which
may be displayed to the right of the value.
For the adjustment procedure, refer to workshop
repair manual MR T.A. M or the previous page.
23-10
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23
Oil pressure
23
B.Vi. 466-06
B.Vi. 466-07
Adaptor
Oil pressure gauge
CHECKING
ADJUSTING
Meauring conditions
Remove the stop (1) and turn the capsule. By screwing in the capsule, the pressure in increased and
vice versa.
Ensure:
- that the normal operating temperature is
80 C,
- that the accelerator cable is adjusted correctly.
Connect oil pressure gauge B.Vi. 466-07 to
adapter B.Vi. 466-06 at (A).
88967G
88990R
Measuring
Place the selector lever in 2nd.
Accelerate fully and apply the brake at the same
time to stabilise the speed at 50 mph (80 km/h).
The pressure should be 4.4 0.1 bars
85393S
NOTE: 2 notches = approximately 0.08 bar.
23-11
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Oil pressure
23
To make this operation easier, a tool can be made:

A = 8/30 mm diameter washer, thickness 1.5 mm
B = 6 mm round rod
88862R1
23-12
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Strainer
23
Lift the engine - gearbox assembly to a dimension

of approximately 135 mm.
The strainer should be changed every 36,000 or

40,000 miles (50,000 km) depending on servicing
programme applicable and when any significant
work is carried out on the mechanism.
CHANGING
Drain the automatic transmission.

Remove the gearbox silent block nut (A).
93605R
88170R
Place a lifting device under the gearbox at (B).
85546R
23-13
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Strainer
Remove the sump and the strainer fitted with its
seal.
Clean the sump and its magnets and refit them (so
that the grooved surface is fitted against the
panel).
93618S
Fit the new strainer fitted and its seal and torque
tighten to 0.9 daN.m.
Refit the sump and fill with oil.
23-14
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23
Automatic transmission (Removal - Refitting)
23
Removal of the MB type automatic transmission requires the removal of the engine - automatic transmission
assembly.
Mot. 453-01
Mot. 582
Mot. 878
Hose clamps
Converter locking sector
Engine lifting eyes and chain
B.Vi. 31-01
B.Vi. 465

Tool for replacing the torque
T.Av. 476
converter seal
Remove:
- the cooling system radiator and the expansion
bottle,

Shock absorber base securing bolts
Steering ball joint
Lower ball joint nut
Driveshaft gaiter securing bolts
Wheel bolts
Oil cooler bolts
Converter drive plate bolts
Bolts around the automatic
transmission mounting
10
11
3.5
6
2.5
8
4
2.5
Special point for the E engine

Remove :
- the integral electronic ignition (A.E.I.),
- hot air tube (A) then the air filter complete,
Depending on specification, remove the selfcontained air bag in order to eliminate any risk of
triggering it (refer to the first generation air bag
manual).
Removal of the assembly does present any special
points, however observe the points below:
REMOVAL

Drain:
- the cooling system (lower radiator flexible
hose),
- the automatic transmission oil.
DI2326
the bar between the shock absorber turrets,

the front wheels.
23-15
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-
Special point for the F3N engine
23
the power assisted steering hose securing

plate (1).
Remove:
- the ignition power module,
93601R
93603S
Fit clamps Mot. 453-01 to the steering pump reservoir hoses and then remove the steering pump
reservoir pipes and the front wheels.
the air filter complete,

the absolute pressure sensor and its mounting,
93602S
23-16
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Remove (all types) :
23
the steering ball joint using extractor tool

T.Av. 476,
On the left hand side of the vehicle

-
the brake caliper bolt (A) and attach it to the

body,
BENDIX series IV
85965-1R
the three driveshaft gaiter securing bolts,
90149R
GIRLING
85678R
91758R
23-17
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-
the lower ball joint and shock absorber base

bolts,
the transmission - stub axle carrier assembly,
taking care to protect the spider.
23
the upper bolt (1) and slacken the lower bolt

(2).
90311S
90259R
On the right hand side of the vehicle:
Tilt the stub axle carrier and uncouple the driveshaft.
It is not necessary to remove the brake caliper.
Disconnect the hoses for the heater matrix on the

coolant pump and the automatic transmission oil
cooler, the fuel circuit hoses and the brake servo
braking vacuum hoses.
Extract:
- the driveshaft roll pin using drift tool
B.Vi. 31-01,
93710R
23-18
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Remove (all types) :
- the electrical connectors,
23
the injection computer connector,
93598S
the oxygen sensor (1): this is located on the

exhaust manifold upstream of the clamp
which connects the primary down-pipe.
92056S
the earthing braids.
Special point for the F3N engine

Disconnect:
- the three hoses (A) (it is advisable to mark
them before disconnecting them),
89091R
93600R
23-19
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23
Figure 2
Remove:
- the earthing braids (engine and automatic
transmission),
- the following cables:
accelerator cable,
rev counter cable,
gear selection cable at attachment points
(A) and (B).
DI2327
the front and rear rubber mounting nuts (E).
93604R
Remove :
the computer retaining strap,
the exhaust clamp (for F3N engine figure 1)
the exhaust pipe (for E engine figure 2),
92108R
Figure 1
91128S
23-20
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Attach tool Mot. 878 to the engine lifting eyes.
23
Fit torque converter tool B.Vi. 465 and uncouple

the automatic transmission from the engine.
Lift the engine - automatic transmission assembly

and remove bolts (E).
Remove the engine - automatic transmission assembly from the engine compartment.
86724R
REFITTING (Special points)

93599S
Lower the engine - automatic transmission assembly, align it using the front rubber mountings and
secure the two bolts for the rear rubber mountings.
Remove:
- the starter motor,
- the converter protective plate.
Torque tighten the bolts and nuts.
Fit locking sector tool Mot. 852 and remove the

bolts for the drive plate on the converter.
Fit the brake caliper securing bolts with

adhesive (Loctite FRENBLOC) and torque
tighten them.
Press the brake pedal several times to bring the
pistons into contact with the brake pads.
Apply RHODORSEAL 5661 to the driveshaft roll
pin holes.
Adjust the accelerator and choke cables.
86511R
23-21
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23
Carry out the following:

- fill the automatic transmission,
- fill and bleed the cooling system (refer to subsection 19),
- fill and bleed the power-assisted steering
pump circuit,
- retighten the exhaust flange.
85915-1S
To ensure correct sealing, do not forget to fit the

O-ring seals (T) on each side of the oil cooler.
92323R
Gradually tighten the bolts to a torque of

4 daN.m.
NOTE: the exhaust down-pipe flanges are fitted
with spacers (1) which determine the tension of

the springs.
Tighten until the spacers are in contact.
Start the engine and check that the assembly is
perfectly sealed.
89010R
23-22
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AD4 AUTOMATIC TRANSMISSION

Exploded view
23
DI2302
23-23
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Operation
DRIVING
The automatic transmission is greased under pressure and therefore only while the engine is running.
Consequently, in order to avoid serious damage,
the following recommendations must be followed:
- never drive with the ignition switched off (on a
downwards slope, for example), the danger of
such a practice cannot be emphasised enough.
- never push the vehicle (for example: to reach a
petrol station), unless the precautions described in the "Towing" section below are taken.
Moreover, the vehicle canonly be driven if the engine is running. It is therefore impossible to start
the engine of an automatic transmission vehicle
by pushing it.
TOWING
It is always preferable to tow the vehicle on a flat

bed trailer or with the front wheels lifted.
However, if this is not possible, the vehicle may, in
exceptional circumstances, be towed under the
following conditions:
1-
rear wheels lifted by 15 cm or all four wheels

on the ground (without adding any oil to the
mechanism),
2.
Only tow the vehicle at a speed of less than

25 mph (40 km/h) over a distance of less than
15 miles (25 km) (lever in"N")
23-24
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23

Identification
23
VEHICLE
AUTO
TRANS
TYPE
ENGINE
CONVERTER
STEP
DOWN
RATIO
FINAL
DRIVE
RATIO
B533
C533
L533
AD4 001
F2N 721
F2N 727
227 D AA
69/77
17/64
18/16
100
B536
L536
AD4 001
F2N 725
227 D AA
69/77
17/64
18/16
103
B53C
C53C
D53C
L53C
AD4 004
F3N 743
227 D AA
69/77
17/64
18/16
101
353F
453F
553F
853F
B53V
C53V
D53V
L53V
AD4 014
F3P 765
227 D AA
69/77
17/64
18/16
108
B53Y
C53Y
D53Y
L53Y
AD4 004
F3P 705
F3P 707
227 D AA
69/77
17/64
18/16
103
D53Y
AD4 004
F3P 705
F3P 707
227 D AA
69/77
17/64
18/16
111
118
D53V
AD4 014
F3P 765
227 D AA
69/77
17/64
18/16
115
122
B53Y
AD4 014
F3P 705
227 D AA
77/71
17/64
18/16
103
111
118
B533
AD4 001
F3P 765
227 D AA
77/71
17/64
18/16
100
353H
453H
AD4 014
F3P 682
227 D AA
69/77
19/65
18/16
122
* For identification using the XR25 refer to the FAULT-FINDING section.
23-25
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SPEEDOMETER
RATIO
COMPUTER

Gear ratios
23
For vehicle types X533, X536, X53C, X53F, X53V, X53Y, 053H
Gear ratio
1st
2nd
3rd
4th
Reverse
Gear reduction
2.71
1.55
0.68
2.11
Overall reduction
11.40
6.51
4.20
2.85
8.86
Speed in km/h for 1000 rpm with

1.76 tyres
9.26
16.20
25.13
37.04
11.90
23-26
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VEHICLE
AUTO
TRANS
ACCELER-ATOR
X533
AD4 001
X536
AD4 001
2 2
AD4 004
AD4 004
No-load
17
20
35
40
60
70
46
51
Full-load
41
46
76
83
120
130
103
112
130
133
48
Kickdown
AD4 014
88
136
No-load
16
20
35
39
56
60
Full-load
41
44
68
79
100
120
81
103
126
135
117
130
48
2 2
86
17
20
35
40
60
70
47
50
Full-load
36
42
70
80
117
128
103
112
Kickdown
42
44
Full-load
80
18
40
131
40
47
75
50
87
130
62
65
50
55
122
140
108
120
90
144
31
46
68
26
30
41
45
30
10
43
28
78
83
38
30
68
78
81
32
70
41
10
52
135
B
10
85
48
No-load
Kickdown
X53F
X53H
X53V
3 3
No-load
X53Y
4 4
Kickdown
X53C
3 3
POSITION
TYPE
AD4 000
23
75
26
30
40
12
15
20
30
85
45
No-load
10
20
45
47
69
75
55
61
36
40
14
Full-load
45
51
85
95
138
152
114
132
68
79
21
36
Kickdown
53
98
23-27
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157
149
93
48

23
The figures shown in the table are average theoretical values of gear change speeds in km/h
tolerances = 10 %.
No-load (PL) :
Accelerator pedal released.
Full-load (PF) :
Accelerator pedal fully pressed.
Kickdown :
Kickdown (changing to a lower gear).
A : Lower gear change thresholds. The gears change to lower gear ratio. Switch (1) is not operated and the
EXC warning light is extinguished.
B : Higher gear change thresholds. The gears change to a higher gear ratio. Switch (1) is operated and the
EXC warning light is illuminated.
91115-1R
23-28
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Consumables
DESCRIPTION
COMPONENT CONCERNED
Sealing of the driveshaft roll pins
RHODORSEAL 5661
Sun wheel splines

Grease MOLYKOTE BR2
Converter locating device

Brake caliper securing bolt
Loctite FRENBLOC

Parts which must be changed once they have been
removed:
- the roll pins,
- the self-locking nuts,
- the copper seals.
Oil
The AD4 automatic transmission is a gearbox which has two grades of oil and two levels.
MECHANICAL SECTION : ELF RENAULTMATIC D2 (D20104).
If this is not available, use:

- MOBIL ATF 220 D (D 20104 or D 21412).
- TEXAMATIC 4011.
FINAL DRIVE: TRANSELF TRX 80W.
23-29
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23

Oil drain intervals
For draining of the mechanical section, refer to the warranty and servicing booklet for the vehicle.
The oil level must be checked every 10,000 miles (15,000 km) in case there is a slight oil leak.
The final drive is not drained; it is filled for life.
The level can be topped up if there is a slight leak.
Oil capacity
TOTAL volume
Volume after draining
MECHANICAL
SECTION
5.7 litres
3.5 litres
FINAL DRIVE
1 litre
NOTE : If the automatic transmission is changed, only carry out the level checking operation, as the
transmission is supplied filled by the Parts Department.
23-30
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23

Oil drain
23
Automatic transmission drain

plug spanner
XR25
B.Vi. 1213
M.S. 1019-10
DRAINING
Final drive:
Mechanical section :
The final drive is filled and topped up via plug (C)

by filling with oil until it overflows.
There are two plugs on the mechanical section

cover :
A : Oil level top-up plug.
B : Oil drain plug (triangular imprint on it).
The unit is drained by removing plug (B).
94882R
Reminder:
The final drive is not drained, it is filled for life.
94882R2
23-31
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Filling - Levels
23
1 - The vehicle must be on a four post lift and the

transmission at ambient temperature.
FILLING - LEVELS
Filling is via tube (D).
2 - Switch on the engine with the selector lever

in park.
3 - Connect the XR25 and enter:
D
then
4 - Lift the vehicle and run the engine until a temperature of 60 C is reached
5 - When the required temperature has been
reached, with the engine running, open the
oil top-up plug; allow the excess oil to flow
out for approximately 20 seconds (this excess
should exceed 0.1 litres). Refit the plug.
6 - If the volume of oil recovered is less than 0.1
litres, the level is not correct, repeat the operation.
In this case, add 1 litre of the recommended oil
and leave the automatic transmission to cool before carrying out the operations which follow.
94845R1
Use a funnel fitted with a 15/100 filter to prevent

the entry of impurities.
The level is MUST be checked in accordance with
the procedure described below:
Before carrying out this procedure:
- if the gearbox has been drained, fill it with
3.5 litres of oil,
- if the gearbox is simply to be checked, 0.5 litres
of the recommended oil must be added.
23-32
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Filling - Levels
23
ELECTRONIC FAULT WARNING LIGHT MESSAGE
Operation with no fault
Fault present
Oil temperature
<- 20C or >+140C
When the ignition is switched on, with the vehicle stationary and the engine
stopped, in position P or N, the warning light illuminates.
When the starter is operated, the warning light remains illuminated.
When the key is released, with the ignition on and the engine running, the
warning light extinguishes approximately 3 seconds after starting the engine.
When the vehicle is stationary with the engine running or when driving, the
warning light is permanently illuminated.
When the vehicle is moving the warning light illuminates and extinguishes
with no operation of the ignition key.
When the vehicle is moving, the warning light illuminates briefly.
When the vehicle is moving or stationary, the warning light flashes with a
frequency of approximately 1 flash per second. In this case, reduce the
performance requirement by reducing the acceleration.
Oil pressure
The transmission is fitted with an oil pressure
socket. Connect tool B.Vi. 1215 for checking the
automatic transmission pressure sensor only.
The oil pressure cannot be adjusted.
Its value is determined by the computer.
94845-1R
23-33
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This filters the oil and assures correct operation of
the automatic transmission.
23
For models with ABS

Remove:
- the nut (C) which secures the ABS electropump assembly to the silent block.
Strainer securing bolts

Casing securing bolts
Bolts securing the rubber
mounting to the sidemember
Rear mounting securing bolts
Wheel bolts
0.50 +0.1
0
1 0.1
2
6.5
9
REMOVAL
94933R
Place the vehicle on a two post lift and fit the tilting prevention claws to the pads (see Technical
Note 1168).
Drain the automatic transmission (mechanical section; triangular imprint on the drain plug).
Remove:
- the expansion bottle,
- the air filter,
- the two upper rubber mount bolts (A) and
slacken the other two (B), without removing
them.
the front left hand wheel and remove the plastic deflector in the wheel arch (to enable the
two automatic transmission sump rear securing bolts to be extracted later).
Using the component jack, lift the automatic

transmission.
94933-1R
94887S
23-34
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23
Remove
- the automatic transmission sump,
- the strainer and its seal (bolts 1).
94933-1S
On models with ABS

Refit the nut (C) which secures the ABS electropump assembly to the silent block.
92084R
Before refitting, clean the sump and its magnet.

Check the condition of the sump seal and the
drain and top-up plugs.
REFITTING
Fit the new strainer and its seal.

Torque tighten the bolts to 0.5
94933R
+0.1
0 daN.m.
Refit:
- the plastic deflector in the front left hand
wheel arch,
- the front left hand wheel,
- the air filter,
- the expansion bottle.
Fit the sump and torque tighten the bolts to

10.1 daN.m.
Lower the transmission and remove the component jack.
Refit the transmission rubber mounting bolts.
Fill with oil and check the level.
23-35
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-
Casing securing bolts
23
the selector lever (2) to enable the lever to travel beyond the "Park" position.
1 0.1
Strainer securing bolts
0.50
+0.1
0
Distributor securing bolts
0.50
+0.1
0
Removal
This operation is carried out with the selector lever in position "P" (Park).
Drain the transmission.
Remove:
- the sump (refer to the section on "Changing
the strainer"),
- the strainer (bolts 1),
94845-2R
This excess travel is necessary to release the drive

for the manual valve control sector.
94840R
the gear selector lever cable,
94841R
23-36
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Disconnect the sealed connector cable by pressing
on the locking ring.
23
the selector from the manual valve (4) by detaching first at (A) and then at (B).
Extract the hydraulic distributor manual valve.
94925S
Remove:
- the sealed connector after removing bolt (3),
94848R
Remove the 16 bolts which secure the hydraulic

distributor. Bolts (X) remain in place and secure
the closing plate to the distributor.
94848-1R
94841-1R
23-37
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Push the selector lever to the stop and disconnect
the hydraulic distributor by releasing the modulating solenoid valve from the casing.
23
REFITTING
Ensure that the F1 supply tube (8), the modulating

solenoid valve filter (7), and the system inserts (6)
are present.
91724R
94852R1
Ensure that the inserts (6) and the filter (7) remain
in place in the hydraulic circuit of the casing.
Engage the hydraulic distributor.
Push the gear selector lever to the stop taking
care to correctly engage the modulating solenoid
valve in the casing.
94852R2
23-38
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23
Fit the manual valve and the selector (4) by first

engaging section (A) and then section (B).
91724R
Fit the 16 bolts securing the distributor to the casing and torque tighten them to 0.5 daN.m in the
order shown.
91350R4
Refit the sealed connector with its O-ring seal and

bolt (3).
94841-1R1
94848-1R
23-39
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23
Fit a new strainer and a new seal.

Torque tighten to 0.5
+0.1
0 daN.m.
94845-2R
Refit the control cable.

Fill with oil and check the level.
94840R
NOTE:
Whenever the hydraulic distributor is changed or

removed, change the modulating solenoid valve
filter, the strainer and its seal.
Fit the sump (check that the seals are in good

condition and that the magnet is present).
Torque tighten bolts (1) to 1
+0.1
0 daN.m.
Refit the automatic transmission (refer to the

section on "Changing the strainer").
Reconnect the sealed connector.
Refit the gear selector lever (2).
23-40
http://vnx.su

Mot. 453-01 Hose clamps

Mot. 582
Locking sector
Mot. 1202
Hose clamp grips
Shock absorber securing bolts
11
Transmission securing bolts
3.5
Wheel bolts
Bolts securing the automatic

transmission to the engine
Bolt securing the rubber mounting to the

sidemember
Steering ball joint
3.5
Rear mounting securing bolts
6.5
Oil cooler bolts
2.5
1.5
IN ORDER TO REMOVE THE AUTOMATIC

TRANSMISSION, THE ENGINE - AUTOMATIC
TRANSMISSION ASSEMBLY MUST BE REMOVED.
Depending on equipment level, remove the selfcontained air bag in order to eliminate any risk of
triggering (refer to the first generation air bag
manual).
REMOVAL

Drain:
- the automatic transmission (only if it is to be
changed),
- the cooling system.
Remove:
- the bonnet,
- the air filter and its mounting,
- the antipercolation air duct.,
- the bar (if fitted).
23-41
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23

94948R
Disconnect the accelerator cable (2) from the carburettor after disconnecting the kickdown switch connector (1).
Carburation system
94932R
23-42
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23

23
Injection system
94927S
94930R
Disconnect:
- the choke cable (depending on type),
- the speedometer cable after unscrewing it
from the automatic transmission,
the earthing braids (engine and automatic

transmission),
the AEI (integral electronic ignition) or,
the MPA (ignition power module) and the
oxygen sensor connector (depending on vehicle type).
94834-1S
the engine wiring harness connectors in the

box on the left hand wheel arch and the automatic transmission computer connectors,
94929S
23-43
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Remove the following pipes:
fuel pipe,
vacuum pipe on the brake servo,
Remove:
- the 35-way injection computer connector (5),
- the purge canister solenoid valve supply
connector (6),
- the engine harness connection connector (7),
(Depending on vehicle type)

remove the pipes for the automatic
transmission accelerated idle solenoid valves
(2) and the power-assisted steering (3),
94931R
23
94928-1R
bleed canister (A),

bleed canister solenoid valve(B).
(all types)
-
the following hoses:

radiator,
heater,
power assisted steering pump reservoir after fitting tool Mot. 453-01.
94928R
23-44
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-
23
the oil cooler,
86511R
Remove:
- the starter motor heat shield,
94835S
the bolts securing the automatic transmission

to the engine.
Remove the transmission from the engine taking

care not to drop the converter.
REFITTING
Before refitting the automatic transmission to the

engine, check the presence of the centring pins on
the block.
Grease the device which locates the converter in
the crankshaft with Molykote "BR2" .
Fit the automatic transmission to the engine and
torque tighten the securing bolts to 4 daN.m .
Fit the nuts which secure the drive plate to the
converter using Loctite FRENBLOC and torque
tighten them to 1.5 daN.m.
94890S
Refit:
- the oil cooler and torque tighten the bolts to
2.5 daN.m,
- the starter motor and the heat shield,
Refit the engine - automatic transmission assembly in the engine compartment.
Refit in the reverse order to removal.
23-45
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23
1st type assembly: Hexagonal socket-type screws.

(For removal and refitting it is advisable to use, for
example, socket FACOM J 235 and the 6 mm hexagonal male adaptor).
Remove:
- the power assisted steering reservoir,
- the power assisted steering high pressure pipe
(detach it from the retaining plate underneath the vehicle),
2nd type assembly: 12-sided socket-type screws.

(For removal and refitting it is advisable to use, for
example, 12-sided male socket FACOM SV. 8L).
Right hand side
94949S
the gear selector lever,

the radiator,
the exhaust clamp
94838-2S
Left hand side
91128S
the front wheels,

the 6 bolts which secure the driveshafts to the
sun wheel outlet flanges.
94837S
23-46
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23
Remove :
- the driveshafts on the side,
- the engine - automatic transmission rubber
mountings.
On each side of the vehicle remove:

- the steering ball joint using extractor tool
T. Av. 476,
Fit the load positioner to the engine - automatic

transmission assembly.
Remove the assembly from the engine compartment.
85965-1R
the upper bolt (1) and slacken the lower bolt

(2) for the shock absorber base.
91131S
90259R
23-47
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Remove the converter protective plate.
23
REFITTING
Special points:
Before refitting the driveshafts, fill the sun wheel
outlet flanges with Molykote "BR2" grease .
94885S

three nuts which secure the drive plate to the
converter.
94890-2S
IMPORTANT:
When refitting the accelerator cable, adjust it correctly as this is important to ensure correct operation of the kickdown switch.
Carry out the following operations:
- fill and bleed the cooling system,
- top up the power assisted steering,
- top up the automatic transmission.
VERY IMPORTANT: DO NOT FORGET TO
VALIDATE THE FULL-LOAD POSITION in order to
reprogramme the computer with the load potentiometer travel.
23-48
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ABS version

23
On vehicles fitted with ABS, the automatic transmission is removed after removing the engine-gearbox
drive assembly.
Mot. 1040-01
Dummy engine cradle for

removing - refitting the enginegearbox drive assembly
Mot.
Hose clamps
453-01
REMOVAL
Front engine sub-frame mounting bolts
Rear engine sub-frame mounting bolts
8.5
Upper shock absorber mounting bolts
2.5
10
Steering universal joint securing bolt
Wheel bolts
Driveshaft mounting bolts
3.5
Shock absorber base mounting bolts
11
Steering ball joint
3.5
Remove the bumper at (A).
Bolts securing the automatic

transmission to the engine
Oil cooler bolts
2.5
15
92054R

Depending on equipment level, remove the selfcontained air bag in order to eliminate any risk of
triggering (refer to the 1st generation air bagmanual).
92058R
23-49
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ABS version

Remove:
- the interior wheel arch trim,
92057R
the air filter and its mounting.
Remove the separating bar and the antipercolation pipes (if fitted).
94948S
23-50
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23
ABS version

23
Disconnect:
- the accelerator cable from the carburettor after disconnecting connector (1) from the kickdown switch (2).
94927S
94932R
the choke cable (depending on type of carburation),

the speedometer cable after unscrewing it
the earthing braids (engine and automatic

transmission),
the integral electronic ignition (AEI) and remove it,
the following pipes :
fuel pipes,
vacuum pipes on the brake servo,
remove the pipes for the automatic transmission accelerated idle solenoid valves (2)
and the power-assisted steering (3),
94834-1S

94931R1
23-51
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radiator hoses,
heater pipes.
ABS version

Remove (depending on vehicle type) :

- the air filter and its mounting,
- the antipercolation air duct.
23

Disconnect:
- the accelerator cable from the throttle housing after disconnecting connector (1) for the
kickdown switch (2),
94927S
94930R
the speedometer cable after unscrewing it

the 35-way injection computer connector (5),

the bleed canister solenoid valve supply
connector (6),
the engine wiring harness connection connector (7).
94834-1S
94928-1R
23-52
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ABS version

23
Disconnect the oxygen sensor connector.

Remove:
- the earthing braids (motor and automatic
transmission),
- the ignition power module (MPA),
- the following pipes :
fuel pipes,
vacuum pipes on the brake servo,
bleed canister (A),
bleed canister solenoid valve (B).
92059S
Fit tool Mot. 1040-01.
94928R
radiator hoses,
heater pipes.
ALL TYPES
Unhook:
- the power assisted steering reservoir,
- the gear selector lever cable.
Refit:
- the radiator,
- the brake calipers and attach them to the vehicle body,
- the tie rods connecting the sub-frame to the
body,
- the primary exhaust down-pipe,
- the cam bolt for the universal joint.
92061S
Lower the vehicle to the ground.
23-53
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ABS version

Remove:
- the upper shock absorber bolts,
23
With the fan assembly removed.
92382S
92114R
Separate the engine - automatic transmission assembly from the engine sub-frame.
-
the bolt securing the rubber mounting to the

automatic transmission,
Remove the converter protective plate.
94933-2R
the four engine sub-frame mounting bolts.
Lift the body and remove the engine-gearbox

drive assembly.
94885S

three nuts which secure the drive plate to the
converter.
23-54
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ABS version

86511R
94835S
Remove:
- the starter motor heat shield,
23
the bolts securing the automatic transmission

to the engine.
Separate the transmission from the engine taking

care not to drop the converter.
REFITTING
Before refitting the automatic transmission to the

engine, check the presence of the locating pins on
the block.
Grease the device which locates the converter in
the crankshaft with Molykote "BR2" .
Fit the automatic transmission to the engine and
torque tighten the securing bolts to 4 daN.m .
Fit the nuts which secure the drive plate to the
converter using Loctite FRENBLOC and torque
tighten them to 1.5 daN.m.
Refit:
- the oil cooler and torque tighten the bolts to
2.5 daN.m,
- the starter motor and the heat shield,
94890S
the oil cooler,
Refit the engine - automatic transmission assembly to the engine sub-frame.

Refit in reverse order to removal.
23-55
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ABS version

23
Position the upper mountings in the appropriate

drilled hole.
A = Manual steering
B = Power assisted steering
Special points
Before refitting the driveshafts, fill the sun wheel
outlet flanges with Molykote "BR2" grease .
94890-2S
92114-1R
The alignment of the body with the engine subframe is made easier by using threaded rods
which are approximately 100 mm long.
IMPORTANT
When refitting the accelerator cable, adjust it correctly as this is important to ensure correct operation of the kickdown switch.
Carry out the following operations:
- fill and bleed the cooling system (refer to section 19),
- top up the power assisted steering,
- top up the automatic transmission.
VERY IMPORTANT: DO NOT FORGET TO
VALIDATE THE FULL-LOAD POSITION in order to
reprogramme the computer with the load potentiometer travel.
85742S
Tighten the brake caliper securing bolts to a torque of 10 daN.m.
23-56
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Full-load validation
Connect the XR25 to the vehicle diagnostic socket.
23
Switch on the ignition without starting the engine.

Enter the "A" transmission code on the keypad:
The diagnostic socket (1) is located in the passenger compartment, under the dashboard, in the relay and fuse compartment.
On the bargraph displays only bargraphs 1 - 3 - 4 5 - 6 - 11 remain illuminated either on the right or
on the left hand side.
Validate the full-load position by pressing the accelerator pedal for 5 seconds.
Bargraph 2 illuminates.
Bargraph 6 extinguishes.
When the accelerator pedal is released, only bargraphs 1 - 3 - 4- 5 - 11 should remain illuminated.
VERY IMPORTANT: switch off the ignition.
Switch the ignition on again and enter the "A"
transmission code to check whether the validation
has been carried out.
(Repeat the operation if necessary).
92827R
Switch off the ignition and disconnect the XR25.

WARNING: If the full-load is validated incorrectly,
this may cause:
- permanent illumination of the warning light,
- gear change difficulties,
- incorrect gear change thresholds,
- difficulties in the operation of the kickdown
function,
- uncomfortable driving conditions.
Place the selector in position S4.
92655R1
23-57
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Load potentiometer
Connect the XR25 to the vehicle diagnostic socket
(located under the dashboard, in the relay and
fuse compartment).
23
Slacken the idle screw fully until the flap is

completely closed.

Enter the "A" transmission code on the keypad:
D
The computer number is displayed.

Example :
Computer
identification
number
Enter on the keypad
4-speed
auto trans
90034
The potentiometer setting value in % appears on

the central display.
Slacken the potentiometer securing bolts (V).
Example :
ADJUSTMENT
According to type (carburation)

THE LOAD POTENTIOMETER IS SPECIFIC TO THIS
ENGINE AS IT HAS A LONGER TRACK.
THEREFORE IT IS NOT INTERCHANGEABLE WITH
ANOTHER TYPE OF POTENTIOMETER.
VERY IMPORTANT: Is is essential that the potentiometer adjustment procedure described below
is applied.
94922R
Rotate the potentiometer body until a value is obtained on the central display of between 89.7 and
92.1 %.
23-58
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Load potentiometer
Retighten securing bolts (1).
(If adjustment is not possible, check the feed).
Readjust the idle speed to 80050 rpm with the selector lever in neutral.
Then erase the memory and programme the
"Full-load" value.
Depending on vehicle type (Injection)
Slacken the potentiometer securing bolts (V).
94915R
With the accelerator cable at rest, rotate the potentiometer body until a value is obtained on the
central display of between 89.7 and 92.1 %.
Retighten the securing bolts (V).
(If adjustment is not possible, check the feed).
Then erase the memory and programme the
"Full-load" value.
23-59
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23

Computer (119)
94926R
When the computer is changed or the memory is

erased, do not forget to carry out a full-load validation.
23-60
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23

Line pressure sensor (8)
94884R
The sensor is secured to the automatic transmission casing by two bolts.

It is directly accessible from underneath the vehicle, after removing the protective sleeve.
After changing it, do not forget to erase the memory and carry out a full-load validation.
23-61
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23

Multifunction switch (485)
94837-1R
The switch is secured to the automatic transmission casing.

It is accessible from above or underneath the vehicle, after removing the securing plate and the
earth wire (A).
23-62
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23

Vehicle speed sensor (250)
94845-3R1
The speed sensor is secured to the top of the automatic transmission.

It is accessible after removing:
- the expansion bottle,
- the rubber mounting bracket.
23-63
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23

Solenoid valves
Solenoid valve securing bolts
0.9
0.1
Distributor plate securing bolts
0.5
0.1
Hydraulic distributor bolts
0.5
+0.1
0
The sequence and modulating solenoid valves and

the temperature sensor can only changed after removal of the hydraulic distributor.
Remove:
- bolts (A) which secure the distributor closing
plate(B),
- the bolts securing the sequence solenoid
valves (C) and modulating solenoid valve bolt
(D).
Remove the solenoid valve - sensor assembly from
the distributor.
91367R
Refitting the assembly does not present any particular difficulties. proceed in reverse order to removal.
Retighten the bolts to the recommended torque
(very important).
NOTE:
Each sequence solenoid valve is fitted to its own

mounting. Check to make sure that they are
fitted to the correct mounting.
23-64
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23

Engine torque reduction
23
The purpose of engine torque reduction during gear changes is:

1) to ensure smooth gear change,
2) to reduce the theoretical load of the hydraulic slave cylinders which are operated during gear changes,
3) to relieve the mechanical units.
The torque is reduced by action on the point of advance.
The torque reduction signal is supplied by the automatic transmission computer to the injection computer.
Throughout the duration of the gear change, the point of advance is moved back by 35.
CHECKING THE CONNECTION BETWEEN THE AUTOMATIC TRANSMISSION COMPUTER AND THE INJECTION
COMPUTER
Condition
Gear change pattern selector
in position "EXC".
Selection on the XR25

Enter D03 # 51
Automatic transmission in 3rd.

With the vehicle at
approximately 35 mph
(60km/h) in 2nd, change from
2nd 3rd under light
throttle.
23-65
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Display on
the XR25
Note
Brief change to zero on
the checking equipment
display.

Special features
23
KICKDOWN FUNCTION
ADJUSTING THE CABLE
In order to trigger the kickdown switch on the

AD4 automatic transmission, two pieces of information are required.
Connect the XR25 to the diagnostic socket on the

vehicle.
Place the selector in position S4.
1st piece of information

Accelerator pedal fully depressed to obtain load
potentiometer information (value less than 6%).
The value displayed on the XR25 at # 12 ).
2nd piece of information
The kickdown switch fitted to the accelerator cable detects excess accelerator pedal travel which,
when it compresses, creates an earth connection
to the automatic transmission computer.
92655R1

Enter the "A" transmission code D04 on the keypad and read # 22 .
94932S1
This methods enables the kickdown function to be

used at higher engine speeds.
In order for the accelerator cable over travel to be
fully effective, check to make sure that the accelerator cable is correctly adjusted.
23-66
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Special features
TEST CONDITIONS
DISPLAY ON THE XR25
23
NOTES
Accelerator pedal released

(No-load) (PL)
If value 1 is not displayed, check the electrical

connection on the kickdown switch.
Accelerator pedal pressed

(Full-load) (PF)
If value 0 is not displayed at Full-load, check the

adjustment of the accelerator cable.
23-67
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DRIVESHAFTS
Consumables
TYPE
29
QUANTITY
COMPONENT CONCERNED
Loctite SCELBLOC
Coating
Stub axle splines
RHODORSEAL 5661
Coating
Pins on driveshaft at gearbox end
MOLYKOTE BR2
Coating
Splines on coupling at gearbox end
FRENBLOC
Coating
Brake caliper bolt
MOBIL CVJ 825
320 g
Joint GE 86
Black Star
140 g
Joint AC 1700
or
160 g
Joint RC 490
MOBIL EXF 57C
130 g
Joint GI 62
Allocation of seals on the vehicle
JOINTS
Right hand
driveshaft
Left hand
driveshaft
Wheel end
GE 86
AC 1700
RC 490
GI 62
GI 69
29-1
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Gearbox
end
DRIVESHAFTS
Driveshafts
Rou. 604 -01

T.Av. 476
Hub locking tool

T.Av. 1050-02
B.Vi. 31-01
Hub extractor
Pin drift
On the left hand side
TIGHTENING TORQUES(en daN.m)
Driveshaft nut
Bolts securing gaiter to gearbox
Wheel bolts
Nuts securing bottom of shock absorber
Steering ball joint nuts
Drain the gearbox.
25
2.5
9
17
10
3.5
Remove the three bolts.
REMOVAL
Remove:
- the brake assembly (suspend it from the chassis so as not to damage the brake hose),
- the driveshaft nut using tool Rou. 604-01.
85678R
On the right hand side

Remove the rollpin using tool B.Vi. 31-01.
85876-1R
91755R
29-2
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29
DRIVESHAFTS
Driveshafts
29
Remove the lower bolt securing the bottom of the

shock absorber and take out the driveshaft.
On both sides:
Remove:
- the steering ball joint nut using tool T.Av. 476,
91691S
85965-1R
Take care not to damage the gaiters during this

operation.
the upper bolt securing the bottom of the

shock absorber.
These vehicles have bonded driveshafts which,

therefore, must be pushed back using tool T.Av.
1050-02.
REFITTING
NOTE: The Parts Department now supplies driveshafts equipped with protectors and supplied with
fitting instructions which MUST be followed to
ensure correct assembly with the highest degree
of QUALITY. The slightest knock on the gaiters
will damage them sooner or later and lead to destruction of the driveshaft.
91750R1
29-3
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DRIVESHAFTS
Driveshafts
29
ESSENTIAL FITTING INSTRUCTIONS
DI2905
29-4
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DRIVESHAFTS
Driveshafts
Never remove the cardboard protectors until the
very end of the refitting operation.
29

Remove the plastic protector from the gaiter and
engage the driveshaft keeping it as horizontal as
possible.
91630R
85677S
Never use a sharp instrument as this could damage the gaiters.
91629R
29-5
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DRIVESHAFTS
Driveshafts
On the right hand side
With the protector fitted, smear the driveshaft
splines at the gearbox end with MOLYKOTE BR2
grease.
29
On both sides
Coat the stub axle splines with Loctite SCELBLOC.

wheel and insert it.
Check its position using the angled drift from tool
B.Vi. 31-01.
Fit two new rollpins using tool B.Vi. 31-01. Seal
the pin holes using RHODOSEAL 5661.
NOTE: the inlet chamfers on the sun wheels make
it easier to fit new rollpins.
91749S
Engage the driveshaft stub axle in the hub.
91691R
74937-4S
29-6
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DRIVESHAFTS
Driveshafts
29

Clean the area where the gaiter bears against the
gearbox, re-fasten the gaiter and the plate.
Keep the gaiter as horizontal as possible and torque tighten the three bolts.
91691-1S
Re-secure:
- the two bolts for the bottom of the shock
absorber to the stub able carrier and torque
tighten them,
- the steering ball joint and torque tighten its
nut.
Torque tighten the driveshaft nut using tool Rou.
604-01.
85678R
85876-1R
29-7
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DRIVESHAFTS
Driveshafts
29
With the vehicle on its wheels, remove the cardboard protectors, tearing them as shown in the
diagram.
On both sides
Fit the brake calipers, coat the bolts with Loctite
FRENBLOC and torque tighten them.
Put the vehicle back on its wheels.
91693R
91633S
Never use a sharp instrument as this could damage the gaiter.
91631S
91632R
Press on the brake pedal several times so that the

piston makes contact with the shoes.
If the left hand driveshaft is being changed, top
up the oil in the gearbox.
29-8
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DRIVESHAFTS
Gaiter at wheel end
Joint GE 86
29
1
2
3
4
5
6
7
T. Av.
T. Av.
537 -02 GE 86 expander

1168
CAILLAU click collar tool
T. Av.
1256
OETIKER collar crimping tool
Bell-shaped stub axle

Retaining star plate
Spider
Shaft yoke
Retaining collar
Rubber gaiter
Retaining collar
DISMANTLING
Remove the existing collars taking care not to damage the grooves in the bell-shaped stub axle.
88578R
88638S
29-9
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Joint GE 86
DRIVESHAFTS
Gaiter at wheel end
29
Remove as much grease as possible.
REASSEMBLING
Free the bell-shaped stub axle from the driveshaft

by raising the star plate arms (2) one by one.
Expander tool TAv. 537-02 must be used when refitting the GE 86 gaiter.
74650R
DO NOT TWIST THE STAR PLATE ARMS.
78411R
Retain the thrust ball, spring and shim under the

ball joint (B).
Hold the driveshaft at a convenient angle in a vice

fitted with soft jaws.
NOTE: the thickness of the shim under the ball

joint is adapted to the original clearance.
Fit the expander on the end of the yoke (if it will

not fit, deburr the inside of the cylindrical section
of the tool with emery cloth).
This shim must be retained and reused on reassembly.
88579R
78408-1R
Remove all traces of grease.
29-10
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Joint GE 86
DRIVESHAFTS
Gaiter at wheel end
It is essential to make sure that there are no sharp

edges on yoke (A) (deburr lightly with emery cloth
if necessary).
29
Wrap a piece of clean rag round one hand and

grip the gaiter so that the first fold will stretch
when it is slid on.
Carefully and generously lubricate the following

with clean engine oil:
- the whole expander (stems and centre),
- inside the gaiter and in particular the neck.
Incorrect
Correct
Place a thumb over the bottom hole, pour some

oil into the gaiter and spread it round the inside.
80040
78409G
Lean against the edge of the vice.

Place one hand over the other and pull taking
care that the first fold does not double back.
80158S
Pull the gaiter as close as possible to the cylindrical

section of the expander and then let it return halfway.
Slip the gaiter over the end of the expander.
Repeat this operation several times (maximum 5

times ) to make the rubber of the gaiter more pliable (relubricate the stems during the operation if
necessary).
78410S
29-11
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Joint GE 86
DRIVESHAFTS
Gaiter at wheel end
When the gaiter slides more freely, with one

continuous pull, fit the gaiter on the cylindrical
section of the expander.
29
Insert the driveshaft yoke in the bell-shaped stub

axle.
Tilt the shaft to fit one arm of the retaining star
plate in a slot in the yoke and press in to locate it
correctly.
78412-2S
Fit the spring and thrust ball in the spider.
74653S
Move the roller cages towards the centre.

Position retaining star plate (2) so that each arm is
central between each spider trunnion.
74652R
29-12
http://vnx.su
Joint GE 86
DRIVESHAFTS
Gaiter at wheel end
29
The other two arms may be fitted easily by using,

for example, a screwdriver with the tip ground as
shown
A = 5 mm
B = 3 mm
Ensure that each arm of the retaining star plate is
located in its slot.
Tilt the shaft in the plane of one of the star plate
arms and the ball joint will be freed under the action of the spring.
88668S
74697R
Insert the shim under the top of the ball joint (the
shim should not project above the top of the ball
joint).
29-13
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Joint GE 86
DRIVESHAFTS
Gaiter at wheel end
29
Check the operation of the spider coupling by

hand.
No tight spots should be apparent.
Distribute the sachet of grease evenly between
the gaiter and the bell-shaped stub axle.
NOTE: make sure that you use the amount of
grease specified in the "Consumables" section.
Position the gaiter lips in their grooves in the stub
axle and driveshaft.
88601R
Correct
Incorrect
88578S
88639R
Insert a smooth round-edged piece of rod between the gaiter and the stub axle to restrict the
amount of air inside.
Fit the collars and tighten them using tool T. Av.
1034.
29-14
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DRIVESHAFTS
Gaiter at wheel end
Joint AC 1700
29
T. Av.
T. Av.
1168
1256

A driveshaft can be partially repaired at the wheel

end:
- a coupling change,
- a gaiter change.
6-BALL COUPLING AT THE WHEEL END
1
2
3
4
5
6
7
A
Bell-shaped stub axle

Balls
Ball cage
Retaining ring
Driveshaft
Gaiter
Ball hub
ABS crown wheel (option)
78616R
REASSEMBLING
Slide onto the shaft:

- the small collar,
- gaiter (3).
Slide the ball coupling (1) complete with retaining
ring (new) onto the shaft splines until the retaining ring locates in the shaft groove (B).
98824R
DISMANTLING
Cut the clip and gaiter all the way along.

Spread retaining ring (7) and tap the exposed
face of ball hub (5) at the same time.
78615R2
Separate the coupling from the shaft.
29-15
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DRIVESHAFTS
Gaiter at wheel end
Joint AC 1700
Spread the sachet of grease round inside the gaiter and the bell-shaped stub axle.
NOTE: it is essential to use the amount of grease
specified in the "Consumables" section.
Position the lips of the gaiter in the grooves in the
bell-shaped stub axle (1) and the driveshaft (2).
98824R
Fit the collars and tighten them using the tool

which corresponds to the type of collars supplied
in the kit (click CAILLAU or OETIKER).
29-16
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29
Joints AC 1700
and GE 86
DRIVESHAFTS
Gaiter at wheel end
OETIKER COLLAR
29
T.Av. 1256
96048S
POSITION 1 - Pre-crimping and positioning of the collar
DI2901
Fit connecting rod (A) in the lower notch and close the tool fully. The pre-crimped collar slides onto the gaiter
and can be positioned.
POSITION 2 - Crimping
DI2902
Fit connecting rod (A) in the upper notch and close the tool fully.
29-17
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Joints AC 1700
and GE 86
DRIVESHAFTS
Gaiter at wheel end
29
CAILLAU CLICK COLLAR
T.Av. 1168
DI2903
93039R
93040S
NOTE: CAILLAU click type collars cannot be re-used.
29-18
http://vnx.su
Joint RC 490
DRIVESHAFTS
29
T.Av. 1034
1
2
3
4
5
6
7
Driveshaft collar crimping

tool
Yoke
Spider
Metal cover
Rubber gaiter
Retaining collar
Driveshaft
Metal insert
Cut the retaining collar and gaiter along its entire

length.
92045S

92303R
Remove the metal cover.
DISMANTLING
Uncrimp the three points on the cover using

pliers.
92046S
92044S
29-19
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Joint RC 490
DRIVESHAFT
Remove the yoke.
29
Never use thinners to clean the component parts.

On the press, extract the spider, using a stripping
extractor for support.
89145S
NOTE: as the yoke is not fitted with an antiseparation pate, it can be removed without force.
Do not remove the roller cages from their respective trunnions since the cages and rollers are matched and must never be mixed.
90388S
Remove the circlips (depending on vehicle model).

REASSEMBLY
Grease the driveshaft and slide on:

- the new retaining collar,
- rubber gaiter (4) with metal insert (7) and metal cover (3).
90387S
92048-1R
29-20
http://vnx.su
Joint RC 490
DRIVESHAFTS
Fit the spider onto the splined shaft.
29
Spread the contents of the sachet of grease inside

the gaiter and the yoke.
Position:
- the gaiter and its metal insert in the metal cover,
- the metal cover, sliding it on until the guide
plate is flush with the yoke.
In this position, crimp three points in the locations
provided for this on the guide plate.
90389S
Refit the retaining circlips or make 3 crimping

points 120 apart, pushing back the metal on the
driveshaft splines.
92050S
Insert a smooth rod with a rounded end between

the gaiter and the shaft to restrict the amount of
air inside.
90391S
Grease the yoke and engage it on the spider assembly.
29-21
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Joint RC 490
DRIVESHAFTS
92051R
29
88601R
Lengthen or shorten the coupling until dimension

A = 156 1 mm is obtained (distance measured
between the end of the gaiter and the matched
face, with largest diameter, of the yoke).
In this position, remove the rod.
Fit the collar on the gaiter and tighten it using
tool T.Av. 1034.
92052R
29-22
http://vnx.su
Joint GI 62
1
2
3
4
5
6
7
DRIVESHAFTS
Yoke
Spider
Metal cover
Retaining spring
Rubber gaiter
Retaining collar
Driveshaft
29
Using a pair of pliers, raise each end of the antiseparation plate (C), then remove the yoke.
88648R
74655R
Do not remove the roller cages from their respective trunnions since the cages and rollers are matched and must never be mixed.
DISMANTLING
Cut the crimped collar and the gaiter along its entire length.
Never use thinners to clean the component parts.
Remove the circlips depending on the type of assembly.
75936-1S1
90387S
29-23
http://vnx.su
Joint GI 62
DRIVESHAFTS
gaiter at gearbox end
Extract the spider in a press, using a stripping extractor for support.
29
Refit the retaining circlips or make 3 crimping

points 120 apart, pushing back the metal on the
driveshaft splines.
90388S
REASSEMBLING
Lubricate the driveshaft and slide on the new retaining clip and gaiter.
90391S
Fit the spider onto the splined shaft.

Insert a 2.5 mm wedge (B), made as shown in the
sketch, between the anti-separation plate and
yoke.
90389S
75434-1R
29-24
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Joint GI 62
DRIVESHAFTS
Carefully tap the anti-separation plate into its original position with a bronze drift, then remove
wedge (B).
29
Insert a smooth round-ended piece of rod between the gaiter and yoke so as to restrict the
amount of air retained inside the coupling.
Lengthen or shorten the coupling to obtain dimension A = 153,5 1 mm (dimension measured
between the gaiter end face and the largest diameter machined face on the yoke).
74867R
Locate the gaiter lips in the groove on the driveshaft and on the metal cover.
90390R
In this position, remove the rod and fit the retaining collar.
Tighten it using tool T. Av. 1034.
75434-1S
88601R
29-25
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Joint GI 69
DRIVESHAFTS
29
T.Av. 944
Mandrel for fitting bearing to

shaft
REMOVAL
Never use thinners for cleaning component parts.

Remove the circlip depending on the type of assembly.
90388S
Remove the gaiter and bearing assembly in the

same way as the spider.
90387S
Remove the spider, on the press, using an extractor for support.
85933S
29-26
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Joint GI 69
DRIVESHAFTS
29
REFITTING
For it to be in its correct position on the shaft, the

bearing must be inserted until dimension
L = 148,5 mm is obtained between the front section of the bearing and the end of the shaft.
This dimension is obtained when the end of tool
T.Av. 944 is flush with the end of the shaft.
86197S
85884-1R1
The bearing is fitted with a lip seal. To avoid distortion and consequent leakage, it must never be
driven in with a hammer. Fit it on the press so as
to apply a gradual pressure.
29-27
http://vnx.su
Joint GI 69
DRIVESHAFTS
29
Furthermore, secure the driveshaft on the press

via its groove (G) using an extractor to avoid damaging the coupling at the wheel end.
86198R
Refit the spider on the splined shafts and refit the

retaining clrclips (depending on the type of assembly).
29-28
http://vnx.su
Chassis
GENERAL
FRONT AXLE
REAR AXLE
WHEELS AND TYRES
STEERING
MECHANICAL ELEMENT CONTROLS
ELECTRONICALLY CONTROLLED SYSTEMS
77 11 190 850
NOVEMBER 1996

Renault.
The methods may be modified as a result of changes introduced by the

manufacturer in the production of the various component units and accessories
from which his vehicles are constructed."
Edition Anglaise
Renault 1996
http://vnx.su
EXPLODED VIEW
PRG30.1
http://vnx.su
Chassis
Contents
Page
30 GENERAL
General braking system
circuit diagram
Tightening torques (in daN.m)
Measuring points
Underbody heights
Parts that must be systematically
replaced
Brake fluid
Front anti-roll bar
specifications
Rear anti-roll bar
specifications
Rear suspension bar
specifications
Rear torsion bar
identification marks
Brake unions and
pipes
The effect of geometry angles
Principles of checking geometry
Checking and adjusting front
axle geometry
Front axle fault finding
Braking system fault finding
Bleeding the braking system
33 REAR AXLE
30-1
30-2
30-6
30-8
30-9
30-9
30-10
30-11
30-11
30-12
30-13
30-13
30-14
30-15
30-16
30-17
30-20
31 FRONT AXLE
Subframe
Lower suspension arms
Lower suspension arm
rubber bushes
Lower suspension arm ball joint
Brake pads
Brake calipers
Brake disc
Stub axle carrier bearings
Stub axle carrier
Combined spring shock absorber
assembly
Spring and shock absorber assembly
Anti-roll bar
Page
Rear axle
Brake drums
Wheel cylinders
Brake calipers
Mechanical brake caliper
control
Brake shoes (drum)
Brake pads (disc)
Brake discs
Hub bearings
Shock absorbers
Anti-roll bars on tubular rear axle
Half suspension arms on tubular
rear axle
Bearings on tubular rear axle
Suspension bars tubular rear
axle
Underbody height tubular rear
axle
Torsion bars four bar rear
axle
Underbody height four bar
rear axle
Four bar type rear axle
Suspension arm bearings
33-1
33-2
33-4
33-5
33-7
33-9
33-23
33-25
33-26
33-30
33-31
33-32
33-33
33-27
33-39
33-40
33-42
33-43
33-46
35 WHEELS AND TYRES

31-1
31-4
Specifications
Wheel balancing
31-5
31-6
31-7
31-12
31-14
31-16
31-19
31-20
31-21
31-27
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35-1
35-3
Contents
Page
36 STEERING
38 ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEMS
Axial ball joints

Manual steering box
Anti-rattle bearing on
manual steering box
Power assisted steering box
Steering box plunger
Steering column
Retractable steering column shaft
36-1
36-3
36-5
36-11
36-12
36-19
37 MECHANICAL ELEMENT CONTROLS

Master cylinder
Brake servo
Brake servo air filter Non-return valve
Pedal assembly
Handbrake lever
Handbrake control
Brake hoses
Brake compensator
Testing - Adjustment
Clutch cable
Clutch automatic
wear take-up system
External gear control
Gear selection controls
37-1
37-2
37-4
37-5
37-6
37-7
37-10
37-11
37-13
37-15
37-16
37-19
37-25
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BENDIX ABS system
Location and composition

Electronic computer
Speed sensors and targets
Control relay of ABS
device
Operation
Regulation in defect mode
Pressure accumulator
Removal-refitting of
components
Fault finding with XR25
Checking level - Bleeding
Fault chart
38-1
38-6
38-6
38-7
38-10
38-13
38-14
38-16
38-32
38-65
38-70
BOSCH ABS system
Identification of the system

Location and composition
Operating principle
Summary of regulation principle
Self-testing
Fault finding with XR25
Checking the wiring
Wiring diagram
Connectors
Removal and refitting of
components
Bleeding
Additional tests
Brake compensator
adjustment check
Replacement of compensator
Fault chart
38-87
38-88
38-96
38-104
38-106
38-111
38-125
38-126
38-128
38-130
38-135
38-137
38-143
38-144
38-145
GENERAL
General braking system circuit diagram
30
NOTE: The following diagrams are general circuit diagrams and under no circumstances are they to be used
for determining the positions of connections or identifying the type of circuit used on a given vehicle. When
replacing any of the braking system component parts, always mark the pipes before disconnecting them so
that they can be reconnected in their original positions. This is essential.
"X" TYPE BRAKING SYSTEM
"X" TYPE BRAKING SYSTEM
with fixed compensator which

is integral with the wheel cylinder
with load sensitive compensator
91563S
91563-3S
30-1
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GENERAL
30
DIMENSIONS
TIGHTENING TORQUE
0.6 to 0.8
Hoses on front wheel cylinders
M 10 x 100
1.3
Hoses on rear suspension arms
M 10 x 100
1.3
Supply to rear wheel cylinders
M 10 x 100
or
M 12 x 100
1.3
Master cylinder outlets
M 10 x 100
or
M12 x 100
1.3
Compensator inlet
M 10 x 100
or
M12 x 100
1.3
Compensator outlet
M 10 x 100
or
M12 x 100
1.3
Bleed screws
30-2
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FRONT
AXLE
GENERAL
30
All types except B - C - L 539

B - C - D - L 53 D
DI3030
30-3
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FRONT AXLE
GENERAL
30
B - C - L 539
B - C - D - L 53 D
DI3031
30-4
http://vnx.su
TUBULAR TYPE
REAR AXLE
GENERAL
30
DI3032
30-5
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FOUR BAR TYPE

REAR AXLE
GENERAL
30
DI3033
30-6
http://vnx.su
FOUR BAR TYPE

REAR AXLE
GENERAL
30
91849R
30-7
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GENERAL
Underbody heights
The underbody heights are measured with the
vehicle unladen, on a flat horizontal surface
(preferably a lift):
- fuel tank full,
- tyre pressures correct.
H1 and H4 is the dimension between the centre of
the wheels and the ground.
H2 is the dimension between the front side
member and the ground in line with the wheel
centres.
H5 is the dimension between the centre of the
suspension arm and the ground.
Value in the section "Values and settings".
91936G1
92118
Measure dimensions :
H1 and H2 at the front,
H4 and H5 at the rear,
and find the difference.
30-8
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30
GENERAL
Parts to be systematically replaced
-
30
Axial ball joint locking washer.

Wheel balancing weight hooks.
Hub bearings.
Drive shaft bearing gaiter.
Girling caliper guide mounting bolts.
Stub axle lock nut.
Mounting bolts :
of the steering box,
of the front axle sub-frame,
rear axle.
Brake fluid
BRAKE FLUID CHANGE PERIODS
The design of our braking systems, in particular our disc brake units (hollow pistons that transmit very little
heat, a small amount of fluid in the caliper cylinder, sliding calipers to avoid the necessity for a reserve of fluid
in the hottest part of the wheel) avoids, as far as possible, risks of vapour lock, even when the brakes are
intensively used (under mountain driving conditions).
The brake fluids now used are subject to a slight deterioration, during their first few months of use, in that
they absorb a small amount of water (see warranty booklet - maintenance of the vehicle, for changing fluid).
Topping up the fluid level
The wear on the brake pads and linings causes the level of the brake fluid in the reservoir gradually to fall. It
is not necessary to top up this fall because the correct level is re-established when the pads are replaced.
Obviously, however, the level must not be allowed to fall below the minimum mark.
Officially approved brake fluids
If two non-compatible brake fluids are mixed together in the same system, there could be a serious risk of
leakage caused, in particular, by the deterioration of the seals and cup washers. To avoid such a risk, it is
essential to use only brake fluids that have been tested and officially approved by our laboratories and which
conform to Standard SAE J 1703 dot 3 or dot 4.
30-9
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GENERAL
Front anti-roll bar specifications
VEHICLE
TYPE
DIAMETER
B - C - L - S 530
531
532
53 W
53 H
30
B - C - D - L - S 53 ALL TYPES
except
B - C - L - S 530
531
532
53 W
53 H
23
30-10
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GENERAL
Rear anti-roll bar specifications
30
TUBULAR REAR AXLE
B- C - L - S
530 - 531 - 532
53 H - 53 W
VEHICLE
TYPE
4 BAR REAR AXLE
B- C - L - S
534, 536, 537, 53 A
53 B, 53 B, 53 G, 53 J,53 R,53 S
All types with ABS

option and
B, C, D, L, S
X 53
SPORTS
VERSION
533, 538, 53C, 53F

53K, 53T, 53V, 53Y
53Z, 535
353 A, F, H, C, D
453 A, F, C, D
553 A, F, H, C, D
853 A, 853 F
15 mm
17 mm
23.15 mm
24.75 mm
NUMBER OF SPLINES
AT BEARING END
31
31
NUMBER OF SPLINES AT
DOUBLE SHACKLE END
30
30
DIAMETER
Rear suspension bar specifications
TUBULAR REAR AXLE
VEHICLE
TYPE
DIAMETER
B- C - L - S
530, 531, 532, 534, 536, 537
53 A, 53 B, 53 G, 53 H, 53 J, 53 R
53 S, 53 U, 53 W
19.8 mm
4 BAR REAR AXLE
All types with ABS

option and
B, C, D, L, S
X 53
SPORTS
VERSION
533, 535, 538,

53C, 53F, 53K, 53T,
53V, 53Y
53Z,
533 A, F, H, C, D
453 A, F, C, D
553 A, F, H, C, D
853 A, 853 F
21.7 mm
23 mm
BEARING END
25
27
27
DOUBLE SHACKLE or ARM
24
26
26
END
30-11
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GENERAL
Rear torsion bar identification marks
30
As the direction of the torsion in the bars is different, when loaded, the RH and LH bars are identified by :
-
marks on their ends

or
letters stamped on their ends
LEFT HAND BAR
RIGHT HAND BAR
74384R
74385R
2 marks
3 marks
74384R1
74384R2
Letter G
Letter D
NOTE : the bars also have a drill end mark "1" which is used to position them in their bearings.
30-12
http://vnx.su
GENERAL
Brake unions and pipes
30
The pipes between the master cylinder, the front

calipers, the pressure limiting valve and the rear
wheel cylinders are connected by unions that have
METRIC THREADS.
Consequently, it is important only to use the parts

shown in the Parts catalogue for this vehicle.
Parts identification :
-
THE SHAPE of the ends of the steel or copper

PIPES (A),
THE SHAPE of the THREADED LOCATIONS in
the wheel cylinders (B),

-
the fact that the pipe UNIONS are GREEN or

BLACK in colour with an 11 mm or 12 mm
external hexagon (C).
78491R
The effect of the geometry angles
The effect of the different geometry angles on

the steering of the vehicle and on its tyre wear.
Differences in the variation of the parallelism

between the right and left hand wheels cause
(without any change in the position of the
steering wheel):
CAMBER
It is the comparison between the left hand and

right hand angles which is important. A
difference of more than one degree from one side
to the other causes the vehicle to pull to one side.
This has to be corrected at the steering wheel and
the result is abnormal tyre wear.
a pull to one side during acceleration,

a pull to the other side during deceleration,
changes in course holding when the vehicle is
driven over bumpy roads.
CASTOR
The steering must be in the straight ahead

position when this adjustment is carried out if a
detrimental effect on the road holding is to be
avoided.
PARALLELISM
Once again it is the comparison between the left

hand and right hand angles which is important. A
difference of more than one degree causes the
vehicle to pull to one side. This has to be
corrected at the steering wheel and the result is
abnormal tyre wear. Itcan be identified by a pull,
at constant speed towards the side on which the
angle is smallest.
It is to be noted :
STEERING BOX HEIGHT
This height affects the variation in the parallelism

that occurs as the suspension moves.
that too much toe-out causes symmetrical

excessive wear on the inside edge of both
tyres,
that too much toe-in causes symmetrical

excessive wear on the outside edge of both
tyres.
30-13
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GENERAL
Principles of checking the geometry
30
PRELIMINARY CHECKS
Before checking the axle geometry, check the

following points and, if necessary, rectify them :
- That the tyres on any given axle are the same
from the point of view of :
sizes,
pressures,
wear.
- At the hinge and pivot points :
the condition of the rubber bushes,
the play in the ball joints,
the bearing play.
82699R
In this position, fit the checking equipment, and

check the geometry.
- The wheel run-out: this should not exceed 1.2

mm (it will be compensated for by the
checking equipment).
When adjusting the parallelism, ensure that both

lengths x on the track rod end casings are the
same.
- That the underbody heights are the same on

both sides of the vehicle (the condition of the
suspension).
DETERMINING THE STEERING CENTRE POINT
Before checking and adjusting the front axle

geometry, the steering must be centralised to
avoid the vehicle pulling to one side.
Turn the steering to full lock in one direction.
Make a mark (A) at the top of the steering wheel
rim.
Move the steering to full lock in the other
direction whilst counting the number of turns and
fractions of a turn.
Return to half the number of turns (and fractions
of a turn) noted. The steering is then in the
"centre position".
83098R
30-14
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GENERAL
Checking and adjusting the front axle geometry
30
CHRONOLOGICAL ORDER OF OPERATIONS
Because of the design of the front axle, a change

in one of its angles (castor, camber, kingpin,
parallelism and variation) has repercussions, to a
greater or lesser extent, on the other angles. (The
castor angle is the one that has the most effect).
It is therefore essential to carry out the
operations in the following order
- mount the equipment on the vehicle by
following its manufacturers instructions,
- find the steering centre point (see previous
section) and lock the steering wheel,
- lift the vehicle, taking the weight under the
body,
- eliminate the wheel run-out,
- lower the vehicle on to the floating plates,
- fit the pedal press to the brake pedal,
- bounce the suspension to bring it to its
nominal height,
- check that the lengths X on the track rod end
casings are the same,
81940R
1
-
If both lengths X are the same :

dimension A should be the same on both
sides.
2
-
If the lengths X are not the same :

note dimensions A on the right and left hand
sides, subtract one from the other and equally
distribute, on each side, half of the result.
Example :
Reading on right hand side : 16
Reading on left hand side : 10
16 - 10 = 6
6 : 2 = 3
Turn the track rods to even-out the dimensions A
on both sides :
A = 13
83098R
note the readings A on the scales.
zero the floating plates in this position,

check, in the following order :
the castor,
the kingpin,
the camber,
the parallelism.
30-15
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GENERAL
Checking and adjusting the front axle geometry
30
ADJUSTING PARALLELISM
One of several cases may arise :

Parallelism
Distribution
Correction to be carried out
CORRECT
INCORRECT
Turn the adjusting sleeves (or end fittings) by the same

number of turns in opposite directions on the left hand
and right hand sides, to obtain the same reading for
dimension A on both sides.
INCORRECT
CORRECT
Adjust the parallelism by the same amount on the right

and left hand sides whilst ensuring that dimensions A
remain identical on both sides.
INCORRECT
INCORRECT
First adjust dimensions A to make them the same on both

sides and then adjust the parallelism by the method
described in
2
Front axle fault finding
DEFECT
POSSIBLE CAUSE
Castor incorrect
Suspension arm bent

Side member bent
Camber + kingpin correct

but, Camber incorrect
Kingpin incorrect
Suspension arm bent
Side member bent
Camber correct
but
Kingpin incorrect
Stub axle carrier bent
Kingpin correct
but
Camber incorrect
Stub axle carrier bent
Parallelism variation incorrect
See castor
Suspension arm bent

Side member bent
-
Parallelism incorrect by more than 6 mm.
RH or LH stub axle carrier bent.
30-16
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GENERAL
30
This fault finding sequence is applicable to all the

braking systems and braking components used on
our current range of vehicles.
During fault finding notice is only to be taken of
those items that are relevant to the vehicle
described in this Workshop Repair Manual.
The fault finding sequence can be broken down
into two distinct sections that make finding the
fault easier:
I
II
I
The effect as noted on the pedal

The effect on the vehicle behaviour.
THE EFFECT AS NOTED ON THE PEDAL
FAULT
POSSIBLE CAUSE
Stiff pedal :
Heavy pressure required to obtain poor
deceleration
- Assistance fault
- Pads or shoes that are :
- greasy,
- glazed or of the incorrect type,
- overheating owing to constant pressure on
the brake pedal (descending an incline),
incorrect type.
- Pistons sticking,
- A crushed or kinked pipe,
- Worn pads or linings: almost no friction
material left, commencement of metal to metal
contact (loud noise).
Spongy pedal:
- Air in the system : incorrectly bled.
Note : as the servo effect on present day vehicles

is very high, one frequently gets the impression
that the pedal is spongy. To determine whether
the brakes are effective or not, one of two tests
can be carried out.
- Internal leakage within the braking circuit.
1.
With the vehicle moving

A subjective test: the ratio between the
pedal travel and braking effect.
2.
With the vehicle stationary and the engine

switched off
Carry out an additional test on the pedal
travel: depress the brake pedal 5 times to
empty the brake servo before taking the
results of the test as valid.
- Insufficient fluid in the reservoir (braking

system external leakage).
30-17
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GENERAL
30
Pedal travel excessive
- Brake shoes incorrectly adjusted
This test is to be carried out with the vehicle

stationary and the engine switched off.
Drum brakes
- Manual adjustment : shoes too far from the
drums.
Note : one must depress the brake pedal 5 times,

to empty the brake servo, before the results of
this test can be considered as valid.
Disc and drum brakes

- Automatic adjustment : handbrake cable too
tight.
Note : if the handbrake cable is not too tight
when in the released position, the wear will
automatically be taken up when the brake pedal
is depressed.
- Excessive and uneven wear on the pads or
shoes (pads tapered or hollow).
- Too much free travel at the master cylinder.
- Brake fluid boiling or overheated.
Pedal going right down to the floor
- Brake fluid leakage (check the system for leaks)
Test to be carried out with the vehicle stationary

and the engine switched off.
- Defective cup washer between the two master

cylinder circuits.
Note : one must depress the brake pedal 5 times,

to empty the brake servo, before the results of
this test can be considered as valid.
- Brake fluid boiling.
II
EFFECT ON VEHICLE BEHAVIOUR
FAULT
POSSIBLE CAUSE
Brakes "self-applying"
- Insufficient lead on the linings

- Linings slightly greasy
- Return springs require replacing
Brakes judder
- Oval drums
- Excessive disc run-out
- Discs of uneven thickness
- Abnormal deposits on the discs (corrosion
between the pads and the discs).
30-18
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GENERAL
30
- Check front suspension and steering.
Vehicle pulling to one side (at the front)
- Caliper piston sticking*.

- Tyres (wear - inflation pressure).
- Crushed or kinked brake pipe*.
*WARNING : on vehicles with negative offset
front axle geometry, pulling to one side is the

result of a fault on the circuit on the opposite side.
Vehicle pulling on one side (at the rear)
- Compensator or brake pressure limiting valve

(adjustment - operation)
- Piston sticking.
- Shoes incorrectly adjusted.
manual adjustment : shoes too far from the
surfaces of the drums.
Automatic adjustment : handbrake cable too
tight.
NOTE : If the handbrake cable is not too tight,
when in the released position, the wear will be

automatically taken up when the brake pedal is
depressed.
- Return springs.
Brakes overheating
- Master cylinder clearance insufficient and

preventing the master cylinder returning to
the released position.
- Piston sticking or not returning correctly.
- Crushed or kinked pipe.
- Handbrake control sticking.
- Handbrake control incorrectly adjusted.
30-19
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GENERAL
SPECIAL TOOLING REQUIRED
M.S. 815
Brake bleeding equipment
For vehicles equipped with a brake servo, it is

important that, no matter what the method of
bleeding used, the servo system should not be
operating during the bleed operation.
-
The system is bled using equipment M.S. 815

on a four post lift with the wheels on the
ground.
Connect the pipes of the M.S. 815 to the bleed

screws on the:
master cylinder
wheel cylinder
- compensator or pressure limiting valve.
Connect the equipment to a source of
compressed air (minimum pressure 5 bars).
Connect the filling system to the brake fluid

reservoir.
Open the fluid supply and wait until the

reservoir is full (both sections).
Open the compressed air valve.
As these vehicles are equipped with an "X" type

circuit, proceed as follows:
-
Open:
- the bleed screw on the rear right hand
wheel and allow the fluid to run out for
approximately 20 seconds,
-
the bleed screw on the front left hand

wheel and allow the fluid to run out for
approximately 20 seconds
Take no notice of air bubbles in the bleed

equipment pipes.
Proceed in the same way on the rear left hand

wheel and the front right hand wheel.
Check that the brake pedal is firm when

pressed (press it down several times).
Repeat the bleed operation if necessary.
Top up the brake fluid level in the reservoir

after disconnecting the equipment.
30-20
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30
GENERAL
30
86037R
30-21
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FRONT AXLE
Sub-frame
31
SPECIAL TOOLS REQUIRED
Mot. 1152
Set of tools for removing and

refitting connection stud
Composition of the tool Mot. 1152 :
Rear sub-frame mounting bolt
8.5
Removing the connection stud on the vehicle.

Use a four post lift, taking the weight under the
body.
a threaded rod with two nuts.
an extractor tube (A) with a washer (B),
a support ring (C) with shoulder.
a simple support ring (D).
Raise the front of the vehicle.

Remove the rear bolt from the sub-frame where
the connection stud is located.
Slacken the second rear bolt, but do not remove
it.
92774R
92708S
31-1
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FRONT AXLE
Sub-frame
Wedge a nut between the stud and the body, and
screw the threaded rod into it.
31
Check that the sub-frame support ring, with

shoulder, has not moved during removal of the
connection stud.
Dimension A = 3.5 mm or B = 17 mm.
If this ring has moved, reposition it and apply 2
welding beads at (S).
92708-1S
Fit the extractor tube (A) and washer (B).

92710R
Remove the connection stud by means of the second nut.
Connection stud removed.
92708-2R
92708-3S
31-2
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FRONT AXLE
Sub-frame
31
REFITTING
Remove the sub-frame bolt and rings (C) and (D).
Refitting the connection stud on the vehicle.
Tighten the sub-frame bolts to a torque of 8.5

daN.mm, with the connection stud pressed on.
Insert the two rings between the sub-frame and

the body.
Centre the ring (C) using its shoulder, followed by
ring (D).
Coat the connection stud with soapy water, and
press it on using the sub-frame bolt.
92708-6S
92708-4R
When the stud has been pressed halfway home,

insert washer (B).
92708-5R
31-3
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FRONT AXLE
31
Nut securing lower arm to sub-frame

Nuts on stub axle carrier keys
Anti-roll bar bearing nut
Lower ball joint joint
Wheel bolts
9
5.5
3.5
7.5
9
REMOVAL
With the vehicle resting on its wheels, remove the

anti-roll bar bearings (1) from the lower
suspension arms.
90130R
the two bolts (3) that secure the suspension

arm to the sub-frame.
85886R
Pull the anti-roll bar downwards.

With the vehicle on axle stands, remove:
-
the nut and the key (2),

85875R
the suspension arm.
31-4
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FRONT AXLE
31
REFITTING
Note: ensure that the plastic protective washer A

is in position on the lower ball joint shaft.
Fit :
- the suspension arm,
- the two bolts (3), without tightening them,
- the ball joint shaft into the stub axle carrier
and tighten the nut (2) on the key to the
specified torque.
With the vehicle resting on its wheels :
Refit the anti-roll bar without tightening its
bearings.
"Bounce" the suspension and tighten the
suspension arm mounting nuts and the anti-roll
bar bearing mounting nuts to the specified
torques (tightening position: vehicle unladen).
Lower suspension arm rubber bushes
REPLACING
To ensure that the rubber bushes remain central

with reference to the suspension arm centreline,
they are to be replaced one at a time.
Push out one of the worn bushes on the press
using a tube with an outside diameter of 44 mm.
Fit a new bush to obtain :
dimension A = 147 0.5 mm.
Push the second bush out on the press and fit the
second new bush as described above to obtain :
dimension A = 147 0.5 mm.
90404R1
31-5
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FRONT AXLE
Lower suspension arm ball joints
REMOVAL
If the gaiter is damaged, the complete ball joint

must be replaced.
Carry out the same operations as for removing the
lower suspension arm.
Loosen, without removing, the two bolts (3)
mounting the suspension arm to the sub-frame.
85875R1
Remove :
-
the two ball joint mounting bolts (4) ,

the ball joint.
REFITTING
Note: ensure that the plastic protective washer A

is in position on the lower ball joint shaft.
Fit the ball joint and tighten its bolts to the
specified torque.
Then complete the operation in the same way as
for refitting the lower suspension arm.
31-6
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31
FRONT AXLE
Brake pads
GIRLING
31
Fre. 823
Piston return tool
REFITTING
Wheel bolts
Brake caliper guide bolts
Push in the caliper piston using tool Fre. 823.
9
3.5
REMOVal
Disconnect the wear warning light wire.

Push in the piston by pulling the caliper outwards,
by hand.
82160R
Fit the new pads, together with their springs,

ensuring that they are the correct way round.
81 589
90130-2R
Remove the guide bolts (7) using two spanners.

Do not clean these bolts.
Take out :
- the sliding caliper,
- the pads.
Checking
Check :
- the fitting and condition of the piston dust
cover and its retaining ring,
- the condition of the dust covers (8) on the
guides.
90130-1G
31-7
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FRONT AXLE
Brake pads
GIRLING
The pad with the wear warning light wire on it is

fitted to the inside.
Fit the caliper and its lower guide bolt (7) coated
with Loctite FRENBLOC.
Press down the caliper and fit the upper guide
bolt also coated with Loctite FRENBLOC.
Tighten the guide bolts to the specified torque
starting with the lower one.
Reconnect the warning light wire.
Press the brake pedal a number of times to bring
the piston into contact with the pads.
We would remind you that when replacing pads

or carrying out work on this type of caliper, the
guide bolts* must be automatically replaced and
tightened to a torque of 3.4 to 3.8 daN.m , starting with the lower bolt.
90130-3R
* bolts supplied in the spares kit.
31-8
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31
FRONT AXLE
Brake pads
BENDIX
Series IV
31
Fre. 823
Piston return tool
Wheel bolts
REMOVAL
Disconnect the wear warning light wire.

Push in the piston by pulling the caliper outwards
by hand.
Remove :
- the clip (1),
- the key (2),
- the pads.
83491R
REFITTING
Push in the caliper piston using tool Fre. 823.
90148R
Check the condition of the dust cover (5) and the

gaiters (6) that protect the caliper slides and
replace them if necessary. If they are replaced,
grease the end of the piston and both slides after
first cleaning them with methylated spirits.
90147R
31-9
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BENDIX
Series IV
FRONT AXLE
Brake pads
Fit the two anti-rattle clips (3) to the new pads.
31
correct direction of fitting :

- on the outside, the pad and the groove (B)
are offset towards the front of the vehicle,
- on the inside, the pad and the groove (B)
are offset towards the rear of the vehicle,
- the wear warning light wires are to be on
the same side as the bleed screw (V).
88244-1R
NOTE : these vehicles are equipped with offset
brake pads.
88 074
Special features of offset brake pads :
88219R
the offset pad only has one shoulder on it (A)

instead of the two on the symmetrical pad,
the groove (B) is offset when compared with

that of the symmetrical pad,
88220G
31-10
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BENDIX
Series IV
FRONT AXLE
Brake pads
31
Place the pads in the caliper and engage the key

(2).
Fit the clip (1) (there is only one clip per caliper).
NOTE : the clip is at the inside end of the caliper
(D), near the caliper bracket mounting bolt (C).
82762R
Reconnect the wear warning light wire.

31-11
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FRONT AXLE
Brake calipers
31
Blow out the piston, with compressed air, after

first placing a wooden block between the caliper
and the piston to avoid the piston being
damaged. Any impact mark on its skirt would
render it unusable.
85972S
Using a thin blade with rounded edges (for

example a feeler gauge) take out the square
section seal from its groove in the caliper.
85971S
Clean the parts with methylated spirits.

Replace any faulty parts with genuine
replacement parts and refit the seal, the piston
and the dust cover (fitting the retaining ring on
the GIRLING assembly).
31-12
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FRONT AXLE
Brake calipers
31
Tighten the bleed screw.
BENDIX Series IV
Wheel bolts
9
Caliper mounting bolts (BENDIX Series IV) 10
Guide bolts (GIRLING)
3.5
Place the caliper piston assembly on the stub axle

carrier and tighten the two bolts (A) to the
specified torque.
REMOVAL
Loosen the brake hose at the wheel cylinder end.

Remove the brake pads or linings (see
corresponding section).
Special features of the BENDIX Series IV
Remove the two bolts (A) securing the assembly to
the stub axle carrier.
94407-1S
Make sure that the locking plate is the correct way

round, and that it is in the correct position (underneath head of bolts).
All types
Check the condition of the pads. If they are greasy, replace them.
All types
The system may be partially bled only if the brake

fluid reservoir has not emptied during the operation. If it has, a complete bleed operation must be
carried out.
Unscrew the caliper piston from the hose

(providing a container to catch the brake fluid).

the pistons into contact with the pads.
Check the condition of the hose and replace it if

necessary (see the section on replacing a hose).
REPAIR
90149R
REFITTING
Any scoring of the caliper bore automatically involves the replacement of the entire caliper.
Screw the new caliper cylinder on to the hose.
Remove the brake caliper.
Loosen the bleed screw on the caliper cylinder and

wait till brake fluid runs from it (ensure that there
is enough fluid in the brake fluid reservoir).
Take off the dust cover (there is a retaining ring

on the GIRLING assembly).
31-13
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FRONT AXLE
Brake discs
The brake discs cannot be reground. A disc which
is heavily worn or scored must be replaced by a
new one.
31
BENDIX Series IV
Wheel bolts
Caliper mounting bolts
Caliper bracket mounting bolts
BENDIX Series IV
9
10
6.5
REMOVAL
Remove :
- the two bolts (A) that secure the brake
assembly in place.
GIRLING
90149R
- the two disc mounting bolts (B) using Torx T40

type Allen key (e.g. Facom RX40 + adaptor or
89-40).
- the disc.
91758R
88310-1R
REFITTING
Fit the disc to the hub and secure it in place with

its two bolts (B).
Refit the brake caliper, coat its bolts with Loctite
FRENBLOC and tighten them to the specified
torque.
31-14
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FRONT AXLE
Brake discs
31
REPLACING
Whenever a brake disc is replaced, it is essential

also to replace the pads.
To do this, first carry out the method described for
removing the pads and then that described for
replacing the caliper brackets (see the section
entitled "Removing-Refitting").
Special features of the BENDIX Series IV
To replace the disc, remove:
- the pads,
- the two bolts (C) from the caliper bracket.
90146R
31-15
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FRONT AXLE
31

M.S.
580
Rou. 15 -01
Inertia tool
Shaft end protector
Rou. 604 -01

T.Av. 476
Hub lock
T.Av. 1050-02
Hub extractor
Adaptor
T.Av. 1050-03
Shock absorber lower mounting bolt

Nuts on lower ball joint key
Track rod end nut
Brake caliper mounting bolt
Driveshaft nut
Wheel bolts
11
5.5
3.5
10
25
9
Checking the play

Mount a dial gauge on the hub and check that the
play is between 0 and 0.05 mm.
REMOVAL
Remove :
- the brake disc (see the corresponding section),
- the driveshaft nut using tool Rou. 604-01.
91752R1
91751R
Extract the hub using tool T.Av. 1050-02 + 105003 + M.S. 580.
31-16
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FRONT AXLE
Remove the inner track ring from the hub using a
jaw extractor type FACOM U53G +U53E and tool
Rou. 15-01.
31
Remove :
- the mounting bolts (1),
- the nut and the key (2),
91754R
83348G
the snap ring.
Push out the outer track ring, on the press, using

one of the inner track rings and leaving the ball
cages and seals in position.
Disconnect the track rod using tool

T.Av. 476.
79057S
91753R
31-17
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FRONT AXLE
31
Fit the thrust washer (1) to the hub followed, on

the press, by the bearing, using a tube, taking the
weight on the inner track ring.
REFITTING
Remove the two plastic protectors (A) from the

new bearing.
78624R
85902R
Fit the new bearing to the stub axle carrier, on the

press, together with the plastic ring (B), using a
tube. taking the weight on the outer track ring.
Refit the stub axle carrier to the vehicle.

Coat the driveshaft stub axle with Loctite
SCELBLOC.
Do not take the load on the inner track ring. This

could damage the bearing because the load
required to insert it is very high.
91748S
From then on carry out the removal operations in

reverse, tightening the nuts to the specified
torques.
79058-1S
Remove the plastic ring (B).

Fit the new circlip.
31-18
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FRONT AXLE
Stub axle carrier
31
The method of removing and refitting this

component is identical to that for replacing the
bearing.
NOTE: as a very high load is required to fit the
outer track ring (2) of the bearing into its bore,

the bearing must be replaced by a new one every
time this track ring is removed because the ball
track is marked by the operation.
78626-4R
31-19
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FRONT AXLE
Combined spring - shock absorber assembly
31
Nuts on shock absorber rod

Shock absorber cup mounting bolt
Wheel bolts
6
11
3
9
REMOVAL
With the vehicle supported on axle stands, on the

side concerned, remove :
- the wheel,
- the two shock absorber lower mounting bolts
(1),
92114R1
- the shock absorber, whilst pressing down the

lower suspension arm to avoid contact between the shock absorber and the driveshaft
gaiter.
REFITTING
Refitting is the reverse of removal, taking care not

to damage the driveshaft gaiter.
Place the upper cup bolts in the appropriate holes.
A manual steering
B power steering
90130R1
the two upper mounting bolts (2),
92114-1R
Tighten, to torque :
- the shock absorber lower mounting bolts (1),
- the upper mounting bolts (2).
31-20
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Tooling
SUS 1052
FRONT AXLE
31
Because of the high loads generated by the spring, it is essential to ensure that the tooling is in perfect
condition.
Sus. 1052
Tooling for working on front

springs and shock absorbers
Sus. 1052-02
R19 retaining shell;
Sus. 1052-03
R21 retaining shell
Use components (A) and (B) of tool

Sus. 1052.
90102S
Fit :
- the spring-shock absorber assembly
positioning the 2 half cups (A) and the two 1/2
shells (B),
90100R
Upper and lower compression plates assembly.

A
B
Thrust cup
Retaining shell marked R19
For B, C, D, L 539 and 53 D

B
Retaining shell marked R 21.
DISMANTLING THE SPRING - SHOCK ABSORBER

ASSEMBLY
Grip the lower part of tool Sus. 1052 in a vice.
92127R
31-21
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Tooling
SUS 1052
FRONT AXLE
the upper plate,

the two bolts that retain the upper shock
absorber cup in the specified holes (the
vehicle references are engraved on the upper
plate),
31
Compress the spring by approximately 10 mm.

Remove the nut from the shock absorber rod.
90104-2S
90104R1
Gradually and evenly release the spring pressure.

Remove parts (1) to (6) in that order.
the three compression bolts, injecting copious

quantities of oil into the reservoirs provided.
NOTE : as the threaded rods on the tool are

subjected to very heavy loads, it is essential that
they should be thoroughly oiled.
90104-1R
DI3102
Parts (4) and (5) form the front suspension pivot

point.
31-22
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Tooling
SUS 1052
FRONT AXLE
Assembly of Tool for B, C, D, L 539 AND 53 D
The upper plate (1) of these shock absorber assemblies is offset.
93255S
For this type of shock absorber it will be necessary

to use upper thrust cup Sus. 1052-03.
93254R
NOTE : depending on whether it is on the right or
left hand side, thrust cup Sus. 1052-003 has 2

drilled holes to enable the shock absorber pin to
be centred.
31-23
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31
Tooling
SUS 1052
FRONT AXLE
31
REASSEMBLING THE SPRING - SHOCK ABSORBER

ASSEMBLY
Place the following in position :

- the shock absorber (6),
- the bearing (5),
- the lower spring thrust cup (4),
- the spring on the lower cup, placing it against
its stop,
- the upper plate assembly with the upper
spring cup (1) in line with the correct
reference marks.
Ensure that the spring is correctly positioned
against the upper stop.
90104-2S
Gradually and evenly release the spring pressure.

Remove :
- the upper plate from the tool,
- the spring - shock absorber assembly from the
compression tool.
92128S
Compress the assembly and pass the shock

absorber rod through its hole.
Fit the nut and tighten it to the specified torque.
31-24
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With spring compressor
FRONT AXLE
31
Because of the high loads generated by the spring, it is essential to ensure that the tooling is in perfect
condition.
EQUIPMENT REQUIRED
Make
Type
Description
MG
M90
Spring compressor
M3
ZKL 2013
Spring compressor
Vice
NO2
ZI
FACOM
ZKL 0055
D83
Cup
Tool for removing the shock

absorber nut
RENA
Shock absorber upper mounting nut
REMOVAL
Fit the cups on the compression tool and place the

assembly in position on the spring.
96049S
Gradually and evenly reduce the spring pressure.

Remove parts (1) to (5) in the same order as for removing with the tool Sus. 1052.
95436S
Compress the spring until it slackens on the cup

supports.
Using tool FACOM D83 RENA remove the shock
absorber rod nut.
31-25
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With spring compressor
FRONT AXLE
31
REFITTING
Precautions to be taken before assembly

The shock absorbers must be stored horizontally
in the spares warehouse.
Under these conditions, shock absorbers designed
to operate vertically may deprime.
Consequently it is sufficient to pump them manually several times in the vertical position before
installing them on the vehicle.
If a spring requires replacing, and in order to facilitate refitting, make sure that the spring and cups
of the tool are in the correct position.
DI 3102
Tighten the nut (new) to the specified torque

using tool FACOM D83 RENA.
95435S
Make sure that the components are fitted the

right way round and in the correct order.
96049-1S
Release the spring pressure and remove the tool.
31-26
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FRONT AXLE
Anti-roll bar
31
Bearing mounting nuts
3.5
To carry out this operation first remove :

-
the exhaust downpipe,

the gear control (manual gearbox).
REMOVAL
Remove items (1) to (3) on each side.

Check the condition of the bearing assemblies and
their bushes and replace them if necessary.
85890R
1 Bearing on sub-frame
2 Bearing on suspension arm
3 Anti-roll bar
31-27
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FRONT AXLE
Anti-roll bar
31
When carrying out any work on the anti-roll bar

of these vehicles, only the bearings on arms (1)
need be coated with Molykote 33 Medium
grease.
85886R
Greasing of the bearings on sub-frame (2) is not

permitted (risk of the bar moving and noise)
90110R
REFITTING
Refit parts (3) to (1).

The bearings are to be tightened with the vehicle:
unladen.
31-28
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REAR AXLE
Rear axle
33
Bearing mounting nut

Wheel bolts
8
8
6
REMOVAL
With the vehicle on a two post lift, remove :

- the two shock absorber lower mounting bolts,
- the brake hoses,
- the handbrake secondary cables,
disconnecting them from the central control
under the vehicle.
92214R
REFITTING
Support the rear axle and remove :

- the four nuts that mount the bearings (A),
Refitting is the reverse of removal.

Bleed the braking system.
Adjust the handbrake control (see section 37).
92212R
the rear axle assembly.
NOTE : if one of the rear axle bearing mounting

bolts is damaged, it can be replaced by removing
the interior trim around the rear door or quarter
panel to gain access to the bolt backing plate.
33-1
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REAR AXLE
Brake drums
BENDIX
180 X 40
33
The two brake drums must be of the same diameter and therefore regrinding one of the drums
automatically involves regrinding the other. The maximum amount of metal that may be removed is 1 mm
on diameter.
Emb. 880
Rou. 943
Inertia extractor
Hub plug extractor
Wheel bolts
Hub nut
8
16
REMOVAL
Remove the hub plug: tools Rou. 943 +

Emb. 880.
92115R
Release the handbrake and slacken the

handbrake secondary cables to allow the lever to
move back.
90220G1
Pass a screwdriver through one of the wheel

mounting bolt holes on the drum and push the
handbrake lever to free the stud from the brake
shoe (E).
Remove :
- the nut and washer from the stub axle,
- the drum.
Help to release the lever by pushing it backwards.
Remove all dust from the drum and shoes.
33-2
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85 906
REAR AXLE
Brake drum
REFITTING
Fit :
- the drum,
- the washer and the nut, tightening it to
torque,
- the hub plug.
Adjust :
- the positions of the shoes by repeatedly
pressing down the brake pedal,
- the handbrake (see section 37 "Controls").
33-3
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33
REAR AXLE
Wheel cylinders
33
These vehicles are equipped with a fixed brake compensator that is integral with the wheel cylinder. If
either the wheel cylinder or compensator is faulty, replace the entire assembly. Any attempt at repair is
forbidden.
REFITTING
Wheel bolts
Hub nut
Bleed bolt
Pipe union bolt
Remove all dust from the drums and the shoes.
8
16
0 .8
1 .3
Refitting is the reverse of removal (see section

"Brake shoes").
REMOVAL
Check the cut off pressure.

Remove :
- the drum (see the corresponding section),
- the brake shoe (see the section entitled
"Brake shoes").
Slacken :
- the rigid pipe union on the wheel cylinder,
using a pipe spanner,
- the two bolts that secure the cylinder to the
brake backing plate and remove the cylinder.
Check the condition of the shoes. If, in particular,
they are greasy, replace them.
92116R
33-4
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REAR AXLE
Brake caliper
REFITTING
Wheel bolts
Brake caliper mounting bolt
33
Retighten the rigid pipe union, without locking it.
9
10
Fit the caliper, coat the bolts with Loctite

FRENBLOC and tighten them to torque.
REMOVAL
Lock the rigid pipe union.

Remove the brake shoes (see corresponding section).
Release the rigid brake pipe on the cylinder side.
Slacken the cylinder bleed screw and wait for the

brake fluid to run out (check that the compensation reservoir level is sufficient).
Disconnect the handbrake cable.
Retighten the bleed screw.

Check the condition of the shoes, and refit them.
Carry out partial bleeding of the system only if the
compensation reservoir has not emptied completely during the operation. Otherwise bleed the
system completely.
Press down the brake pedal several times to bring
the piston in contact with the shoes.
REPAIR
Remove the brake caliper.

The slightest scratch on the caliper bore automatically means replacement of the complete caliper.
It is not permitted to remove the inside of the piston (P).
88993R
Remove the two mounting bolts (A) on the stub

axle carrier.
Slacken the pipe union (allow for the escape of
brake fluid).
74194-1R
Place the caliper in a vice fitted with jaws.

Remove the rubber dust cover.
33-5
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REAR AXLE
Brake caliper
Remove the piston by unscrewing it with a square
section screwdriver.
33
Remove the sealing piston from its groove with a

steel blade with rounded edges.
Clean the parts with methylated spirits and refit
them.
Lubricate the seal and piston with brake fluid.
Progressively press the piston by hand to avoid
damaging the seal.
Press the piston home by screwing it with a
screwdriver until the piston rotates, but will
advance no further.
Position the piston so that the line (R) marked on
its support face is located on the bleed screw (P)
side, to allow correct bleeding of the caliper and
normal fitting of the shoes in the central groove
of the piston.
88306S
When the piston rotates, progressively apply

compressed air in the cylinder, taking care not to
remove the piston by force; insert a wooden block
between the caliper and piston to avoid damaging the piston.
Any impact mark or scratch will render the piston
unusable.
88311R
Coat the piston plunger with grease.

Fit the new protective cover.
88398S
33-6
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REAR AXLE
Mechanical brake caliper control
33
B. Vi.28-01
Fre. 1047
Claw extractor
Key for removing the handbrake
control on the rear caliper
REMOVAL
Place the caliper and its cap in a vice with jaws.

Remove :
-
the sealing cover (1),
the piston (2) by unscrewing it,
the clip (3).
Turn the dust cap (4) over (this cap is shrunk on to

the pin (7)).
Remove the circlip (5).
88393R
Compress the spring washers (6), tools Fre. 1047

+ B. Vi. 28-01.
74439-2R
Remove :
-
the pin (7) fitted with the dust cap (4) by

pulling the lever,
the thrust pin (8).
the spring (9),

the adjusting screw (10),
the washer (11),
the spring washers(6),
the ring (12) using a pin punch,
the O-ring (13).
Clean all the parts with methylated spirits.
33-7
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REAR AXLE
Mechanical brake caliper control
REFITTING
Fit :
- the O-ring (13),
- the ring (12) until it is flush with face (A) using a
tube of suitable diameter.
74486-1R
Check the positioning of the spring washers,

which must be fitted as shown in the diagram to
enable the handbrake lever to move to the "rest"
position.
Refitting is then the reverse of removal.
Position the piston so that the line (R) on its support face is facing the bleed screw (P).
88311R
33-8
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33
BENDIX
180 X 40
REAR AXLE
Brake shoes (drum brakes)
33
Emb. 880
Rou. 943
Inertia extractor
Hub plug extractor
REMOVAL
Wheel bolts
Hub nut
All the shoes or linings on a given axle must be replaced at the same time. Never fit linings of different makes or grades.
9
16
Remove the lower spring (2) using brake shoe

pliers.
Composition of the Bendix 180x40 RAI brake

(Automatic Wear Take-up System).
90217-1R
Fit a clip to the wheel cylinder piston.

90223R
A
B
C
P
F
1
2
3
4
Leading shoe
Trailing shoe
Fixed point
Brake shoe end
RAI
Upper return spring
Lower (end) return spring
Side retaining spring
Handbrake lever return spring
33-9
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BENDIX
180 X 40
REAR AXLE
Using a set of combination grips, remove the shoe

side retaining springs (R) whilst holding the
connecting rod (T) against the brake backing
plate.
33
On the work bench, remove the RAI and shoe assembly.

Release the handbrake lever.
86560-1
93725S
Unhook clip (E) with a small screwdriver.
90218-1G1
Slide each shoe end (P) alternately above the fixed

point (C). Lock the shoe ends one against the
other to remove the ends from the wheel cylinder.
Separate the assembly (RAI and shoes) from the
brake backing plate, then remove it after having
unclipped the handbrake cable.
93723R
33-10
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BENDIX
180 X 40
REAR AXLE
Rotate the leading shoe (A), in the direction of the

arrow, so that the bolt head is released from the
RAI. This enables the upper spring (1) to be
removed without force.
33
Marking and refitting the RAI component parts
Left toothed nut and bolt
93717-1R
The bolt has a left-hand thread, the toothed nut

has a slot (G) and the clip is not painted.
93724R
To remove the RAI assembly pull it in the direction of

the arrow (1), then rotat in the direction of arrow (2).
Remove the spring (4) and the handbrake lever.
Right toothed nut and bolt
93717S
The bolt has a right-hand thread, the toothed nut

has no slot, and the clip shows traces of paint.
93722R
33-11
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BENDIX
180 X 40
REAR AXLE
Left-hand RAI assembly
33
Refitting of the RAI (automatic wear take-up

system)
Make sure that the ratchet is in the correct
position.
1st fitting
93716R
Note the G (left-hand) in the casting and the

position of the bracket.
90222S
Right-hand RAI assembly
2nd fitting
93715R
93714-1S
Note the D (right-hand) in the casting and the

position of the bracket.
Refit the bracket, the solid section of which must

be positioned between the blade and the lever.
In both cases the clip attachment must not be

wedged between the bolt head and the toothed
nut. Leave a slight lateral clearance (J).
33-12
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BENDIX
180 X 40
REAR AXLE
33
93714S
Then assemble the levers with their respective

nuts and bolts, screw, pin and right-hand nut in
the right-hand lever, passing through the hole in
the bracket and the same for the left-hand RAI.
93720R
Place the upper spring (1) in the notches on the

two shoes, then pull in the direction of the
arrows. The bolt locator must be positioned in
that of the leading shoe (A).
On the bench, refit the RAI assembly and shoes

Refit the handbrake lever on the trailing shoe
with a new clip, then disarm the lever.
Position the spring (4) in the notch on the shoe,
paying attention to the direction of fitting, then
secure the shortest hook to the shoe.
93719R
93721R
Hook the RAI assembly on to the spring (4), then

pull in the direction of the arrows. The RAI
assembly automatically comes to rest in its
operating position.
33-13
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BENDIX
180 X 40
REAR AXLE
33
Attach clip (E) and re-arm the handbrake lever.
90217-1R1
ADJUSTMENT
93718R
Using a screwdriver adjust the diameter across the

shoes by turning the toothed wheel (F) to obtain a
diameter (X) of between :
179.2 mm and 179.5 mm.
REFITTING
Present the assembly on the vehicle.

Attach the handbrake cable to the lever.
Tighten the shoe ends and position the other ends
on the wheel cylinder pistons, taking care not to
damage the caps.
Position the shoes on the fixed point (C).
Fit the side retaining springs (3).
Remove the clips from the wheel cylinder pistons,
then refit the lower spring (2).
90223R1
Carry out the same adjustment on the other

backing plate assembly.
Refit the drums without tightening the nuts.
33-14
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BENDIX
180 X 40
REAR AXLE
Adjust the positions of the shoes by repeatedly
pressing the brake pedal (approximately 20
times).
Make sure that the automatic wear take-up
system is operating correctly (characteristic
"click" at the drums).
Remove the drums.
Make sure:
- that the cables are sliding correctly,
- that the handbrake levers (L) are correctly
supported on the shoes.
BENDIX
90223G
Progressively tension the cables at the central

adjuster so that the levers (L) start to move
between the 1st and 2nd notch of the travel of
the control lever and remain applied from the 2nd
notch.
Lock the central adjustment lock nut.
Refit:
- the drums and tighten the nuts to a torque of
16 daN.m,
- the plugs.
33-15
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33
BENDIX
203 X 38
REAR AXLE
33
Emb. 880
Rou. 943
Inertia extractor
Hub plug extractor
REMOVING
Wheel bolts
Hub nut
All the shoes or linings on a given axle must be

replaced at the same time. Never fit linings of
different makes or grades.
9
1 7.5
Composition of the BENDIX 203 x 38 RAI

(automatic wear take-up system).
Remove:
- the brake drum (see corresponding section),
- the lower spring (2) with brake shoe pliers.
98992R
A
B
C
P
F
1
2
3
4
Leading shoe
Trailing shoe
Fixed point
Brake shoe end
RAI
Upper return spring
Lower (end) return spring
Side retaining spring
Handbrake lever return spring
98993R
Fit a clip to the wheel cylinder pistons.
33-16
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BENDIX
203 X 38
REAR AXLE
Using a set of combination grips, remove the shoe

side retaining springs (R) whilst holding the
connecting rod (T) against the brake backing
plate (E).
33
On the work bench, remove the RAI and shoe

assembly.
Release the handbrake lever.
86560-1
99022S
Unhook clip (E) with a screwdriver.
98994G
Slide each shoe end (P) alternately above the fixed

point (C). Lock the shoe ends one against the
other to remove the ends from the wheel cylinder.
Separate the assembly (RAI and shoes) from the
brake backing plate, then remove it after having
unclipped the handbrake cable.
98995R
33-17
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BENDIX
203 X 38
REAR AXLE
Rotate the leading shoe (A), in the direction of the

arrow, so that the bolt head is released from the
RAI. This enables the upper spring (1) to be
removed without force.
33
Marking and refitting of the component parts of

the RAI (automatic wear take-up system)
Left-hand toothed nut and bolt
98997R
The bolt has a left-hand thread, the toothed nut

has two slots (G).
98996R
To remove the RAI assembly it pull it in the direction of

the arrow (1), then rotate in the direction of arrow (2).
Remove the spring (4) and the handbrake lever.
Right-hand toothed nut and bolt
98997-1R
The bolt has a right-hand thread, the toothed nut

has one slot.
98991-1R
NOTE : Remove all dust from the components
with a brake cleaning agent.
33-18
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BENDIX
203 X 38
REAR AXLE
Left-hand RAI assembly
33
Refitting the RAI

Make sure that the ratchet is in the correct
position.
98998R
98999S
Right-hand RAI assembly
Refit the bracket, the solid section of which must

be located between the blade and lever.
The body and bracket are reversed, but blade (5)

must be located on top.
In both cases the clip attachment must not be
wedged between the bolt head and the toothed
nut. Leave a slight clearance (J).
33-19
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BENDIX
203 X 38
REAR AXLE
33
99000S
Then assemble the levers with their respective

bolts and nuts, screws, pin and right-hand nut in
the right-hand lever, passing through the hole in
the corner plate. The same applies to the righthand RAI.
99002R
Place the upper spring (1) in the notches on the

two shoes, then pull in the direction of the
arrows. The bolt locator must be positioned in
that of the trailing shoe (A).
On the bench, refit the RAI assembly and shoes

Refit the handbrake lever on the trailing shoe
with a new clip, then disarm the lever.
Position the spring (4) on the notch on the shoe,
paying attention to the direction of fitting, and fit
the shortest hook on the shoe.
98996-1R
99001R
Hook the RAI assembly on the spring (4), then pull

in the direction of the arrows. The RAI assembly
automatically comes to rest in its operating
position.
33-20
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BENDIX
203 X 38
REAR AXLE
33
Attach the clip (E) and re-arm the handbrake

lever.
98993-1R
ADJUSTING
99003R
Using a screwdriver, adjust the diameter across

the shoes by turning the toothed wheel (F) to
obtain a diameter (X) of between
202.5 mm and 202.7 mm.
REFITTING
Present the assembly on the vehicle.

Attach the handbrake cable to the lever.
Tighten the shoe ends and place the other ends
on the wheel cylinder pistons, taking care not to
damage the caps.
Place the shoes on the fixed point (C)
Fit the side retaining springs (3).
Remove the clips from the wheel cylinder pistons,
then refit the lower spring (2).
98992-1R
Carry out the same adjustment on the other

backing plate assembly.
Refit the drums without tightening the nuts.
33-21
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BENDIX
203 X 38
REAR AXLE
Adjust the positions of the shoes by repeatedly
pressing the brake pedal (approximately 20
times).
Make sure that the RAI is operating correctly
(characteristic "click" at the drums).
Remove the drums.
Make sure that:
- the cables are sliding correctly,
- the handbrake levers (L) are correctly
supported on the shoes.
98992-1R1

notch.
Tighten the central adjusting lock nut.
Refit:
- the drums and tighten the nuts to a torque of
17.5 daN.m,
- the plugs.
33-22
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33
REAR AXLE
Brake pads (disc brakes)
33
Wheel bolts
REMOVAL
REFITTING
Remove:
- the clip (1)
- the key (2),
- the pads.
Push in the caliper piston and tighten it using a

square section screwdriver until it rotates but goes
in no further.
88992R
88311R
Check the condition of the dust cover (5) and the

gaiters (6) that protect the caliper slides and
replace them if necessary. If they are replaced,
grease the end of the piston and both slides after
first cleaning them with methylated spirits.
Position the piston so that the line (R) on its support surface faces the bleed screw (P).
88394R
33-23
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REAR AXLE
Brake pads (disc brakes)
33
Fit the anti-rattle clips (3) to the new pads.
88244R
Place the pads in the caliper, making sure that

they are the right way round.
Engage the key (2) and refit the clip (1) (there is
only one clip per caliper).
NOTE: the clip (1) is at the inside end of the caliper
near bolt (4).
82762R

33-24
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REAR AXLE
Disk brakes
33
Emb. 880
Rou. 943
Inertia extractor
Hub plug extractor
Wheel bolts
Hub nut
Caliper bracket
9
16
10
This vehicle is equipped with a hub/brake disc assembly which cannot be reground. If heavily
worn or scored it must be replaced by a new assembly.
REMOVAL
Remove :
- the brake pads (see corresponding section),
- the two caliper bracket securing bolts (A).
88310-2R
NOTE : If a hub/disc assembly is to be replaced, re-
fer to the "Bearing" section.
REFITTING
Fit the hub/disc/bearing assembly on the stub axle

previously coated with oil SAE 80 W.
Refit:
- the stub axle nut and tighten it to torque,
- the hub plug,
- the brake caliper bracket, coat the bolts with
Loctite FRENBLOC and tighten them to torque,
- the brake pads (see corresponding section).
88992R1
- the hub plug, tool Rou. 943+

Emb. 880,
- the stub axle nut (3),
- the hub/disc/bearing assembly.

33-25
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REAR AXLE
Hub bearings
33
Emb.
880
Rou.
943
Tav.1050-02
Inertia extractor
Hub plug extractor
Hub extractor
REMOVAL
Hub nut
Wheel bolts
Remove :
- the hub plug using tools Rou. 943 +
Emb. 880,
16
9
CHECKING
Check the end play in the bearing with a dial

gauge mounted on the drum. It should be : 0 to
0.03 mm max.
92115R
the drum (see the corresponding section).
Extract from the drum :

- the bearing retaining circlip,
- the bearing, using a tube (1).
DI3305
85907R
33-26
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REAR AXLE
Hub bearings
REFITTING
Using a tube (2) and a press, fit the bearing until it

is against its shoulder.
Fit:
- a new circlip,
- the drum to the stub axle which has previously
been oiled with oil grade SAE 80W ,
- the new lock nut, tightening it to torque,
- the hub plug.
Adjust:
- the positions of the brake shoes by repeatedly
pressing the brake pedal,
- the handbrake (see section 37 ~Controls").
33-27
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33
REAR AXLE
Hub bearings
33
Emb.
Rou.
T.Av.
880
943
1050
Inertia extractor
Hub plug extractor
Hub extractor
Wheel bolts
Hub nut
Brake caliper bracket
9
16
10
CHECKING
Check the end play in the bearing with a dial

gauge mounted on the drum. It should be : 0 to
0.03 mm max.
88992R1
the nut and the stub axle washer,

the hub/disc/bearing assembly.
Extract from the hub/disc: :

- the bearing retaining circlip,
- the bearing, using a tube (1).
DI3306
REMOVAL
Remove:
- the brake pads (see corresponding section),
- the caliper bracket (two bolts (A)),
- the hub plug: tools Rou. 943 + Emb. 880.
85907R
33-28
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REAR AXLE
Hub bearings
VEHICLES EQUIPPED WITH DISCS
REFITTING
Using a tube (2) and a press, fit the bearing until it

is against its shoulder.
Fit:
- a new circlip,
-
the disc to the stub axle which has previously

been oiled with oil grade SAE 80W ,
the new lock nut, tightening it to torque,
the hub plug,
the caliper bracket, coat the two mounting

bolts with Loctite FRENBLOC and tighten to
torque,
the brake pads (see corresponding section).
Press down the brake pedal a number of times to

bring the piston into contact with the pads.
33-29
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33
REAR AXLE
Shock absorbers
-
Upper securing nut

Lower securing bolt
33
the shock absorber.
2
6
REMOVAL
With the vehicle resting on its wheels, remove :

- the upper mounting (1) from inside the
vehicle,
DI3307
PRECAUTIONS TO BE TAKEN BEFORE FITTING
Shock absorbers are stored horizontally in the

parts stores.
Under these conditions, it is possible for a shock
absorber that is designed to work vertically to
become deprimed.
85919R
Consequently, before fitting it to the vehicle, it

should be held vertically and pumped several
times by hand.
the lower mounting (2).
REFITTING
Fit :
- the shock absorber,
- the nuts and mounting bolts (after first
greasing them with MOLYKOTE BR2 grease).
Tighten the nuts and bolts to torque.
Refit the rubber caps.
92117R
33-30
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REAR AXLE
Anti-roll bar on tubular type rear axle
Bar mounting bolt
4.5
REMOVAL
92211R
1
2
Mounting bolts
Handbrake cable retaining clips
Raise the vehicle on a lift with its wheels hanging

free.
Remove the bolts (1) and the clips (2) from either
side and retrieve the captive nuts.
Remove the bar.
REFITTING
Fit, on either side

- the clips (2),
- the bolts (1) with their captive nuts.
Tighten the bolts to torque.
33-31
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33
REAR AXLE
Half suspension arms on tubular type rear axle
REFITTING
Bearing mounting nut

Anti-roll bar mounting securing bolt
Wheel bolts
33
Check that the bearing tracks or the needle races

are in perfect condition. If not, replace them (see
section entitled "Rear axle bearings - tubular type
rear axle".
As the needle races are greased for life, it is not
necessary to regrease them.
8
4.5
9
6
NOTE: new suspension arms as supplied by the
REMOVAL
Parts Department are fitted with bearing tracks

or needle races (depending on the size).
Insert the two half suspension arm assemblies one
into the other until the correct dimension (B) is
obtained.
With the vehicle supported on a two post lift,

remove :
- the anti-roll bar,
- the shock absorber lower mounting bolt,
- the handbrake secondary cable, disconnecting
it from the central control under the vehicle,
- the brake hose,
- the two nuts that securing the bearing (A).
NOTE: dimension (B) corresponds to the distance
between the same anti-roll bar securing points on

the suspension arms. It is therefore possible to
obtain this dimension by placing the anti-roll bar
in its location and checking its securing bolts enter
correctly. Ensure that it is fitted the correct way
round.
92211R1
Slacken the two nuts (A) on the bearing on the

other side to be able to free the half suspension
arm and remove its anchor points.
Remove the half suspension arm by separating it
from the other.
86320R
Refitting is then the reverse of removal.

NOTE: If one halff suspension arm assembly is
replaced, bond the brake backing plate mounting

bolts with Loctite FRENBLOC.
Adjust the handbrake control (see section 37).
33-32
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REAR AXLE
Bearings on tubular type rear axle
33
This operation is carried out after first removing the entire rear axle assembly and separating the two
suspension arms.
T. Ar. 960
Bearing extractor
T. Ar. 960-02
Bearing extractor + spacer
Grind almost through the bearing tracks on the

male arm (right hand), with a straight grinder,
taking care not to mark the tube.
REMOVAL
Remove from the female arm (left hand):

-
the outer bush (6), using tool T.Ar. 960,
the inner bush (7) using the small end of tool

T.Ar. 960.
90864S
Split the bearing tracks with a cold chisel and

remove them.
86182R
86180R
33-33
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REAR AXLE
Bearings on tubular type rear axle
Cut and remove the seal (5).
33
Fit :
-
the small needle race to mandrel (A),
mandrel (A) into the tube using mandrel (B) as

a guide.
90863R
REFITTING
90866R
Tool T.Ar. 960-05. is required to fit needle races

and their tracks.
Push them in on the press until mandrel (A) is

flush with face (2) on mandrel (B)
90874R
90868R
33-34
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REAR AXLE
Bearings on tubular type rear axles
Fit :
- the large needle race to mandrel (B),
33
Push down, with the press until mandrel (B)

makes contact with the tube.
90865R
90868-2R
Remove mandrels (B) and (A).

Fit a new seal (5) to the male tube.
-
The bearing tracks have a lead chamfer at one

end.
mandrel (B) into the tube using mandrel (A) as

a guide.
It is essential to ensure that they are the correct

way round with chamfer (4) positioned as shown
in the drawing to ensure that that there is
sufficient bearing area to fit the track.
90868-1R
90941R
33-35
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REAR AXLE
Bearings on tubular type rear axles
33
Fit :
-
the large bearing track into the sleeve (D),

the assembly of sleeve (D) and (C) over the
tube.
90867-3R
Push down on the press until sleeve (C) is flush

with edge (3) of the tube.
90867-5R
Push down the assembly (D) and (C) until sleeve

(C) is flush with edge (3) of the tube.
90867-4R
Remove sleeves (C) and (D).

IMPORTANT
When pushing in the bearings, if the load is being

taken on the axle mounting bearing assemblies, it
is essential to ensure that the suspension bars are
correctly located in their anchor points (there is a
risk of them coming out).
Recentralise them if necessary.
Assemble the two half suspension arm assemblies.
90867-2R
Fit :
- the small bearing track in the sleeve (C),
- the sleeve (C) over the tube with sleeve (D)
acting as a guide.
NOTE : It is not necessary to grease the needle

races. They are supplied ready greased.
Then reconnect and refit the rear axle to the
vehicle (see corresponding section).
33-36
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REAR AXLE
Suspension bars - tubular type rear axle
33
Emb. 880
Inertia extractor
A
B
C
D
E
Shock absorber upper mountings

Shock absorber lower mountings
2
6
REMOVAL
Nut 14 mm diameter
Nut 12 mm diameter
12 mm diameter threaded rod 660 mm long
Washers inside diameter 12 mm
Spacer inside diameter 12.5 mm outside
diameter 20 mm, 60 mm long
Weld
With the vehicle wheels hanging free, remove the

shock absorber on the side concerned.
Extract the bar, from one side, using tool
Emb. 880.
75505R
Pre-adjust the tool to obtain dimension "X".

See the section "Value and settings" for
dimension X, depending on the type of vehicle.
92213R
REFITTING
To place the suspension arm in the correct

position for fitting the bar, a special tool must be
made up locally.
75329R
33-37
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REAR AXLE
Suspension bars - tubular type rear axle
Fit the tool in place of the shock absorber.
75 422-2
92119G
Coat the splines on the suspension bar with grease

MOLYKOTE BR2, insert it into the bearing and
into the suspension arm determining, by turning
the bar, the position in which it will enter freely
into the splines on both the arm and the bearing.
Remove the tool and refit the shock absorber.
Lower the vehicle on to its wheels and measure
the underbody heights (see section entitled
"Underbody height - Tubular type rear axle").
Check and, if necessary, adjust the headlights.
33-38
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33
REAR AXLE
Underbody height - tubular type rear axle
33
CHECKING
Remove the bar.
Park the vehicle, unladen but with its fuel tank

full, on a flat horizontal surface.
As 3 mm is the minimum adjustment that can be

obtained by moving one differential spline, it is
only possible to adjust the height of the vehicle in
multiples of 3 mm.
Lower the suspension arm to offset the bar by the
number of splines that represents the height to be
taken up:
Example : 10 mm = 3 splines
Refit the bar so that it engages, freely, into the
splines on both the arm and the bearing.
Check and, if necessary, adjust the headlights.
92118G1
GOOD ROAD VERSIONS
See section entitled "value and settings" for

value H4-H5, depending on the type of vehicle.
ADJUSTING
Only the underbody height is adjustable by

turning the torsion bars.
Determine the dimension "X", on the vehicle, by
adjusting the bracket (D) on the locally
manufactured tool until the bar can be slid, by
hand, into its anchor points.
33-39
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REAR AXLE
Torsion bars on four bar type rear axles
33
DI3308
This type of rear axle consists of :

-
two suspension arms connected by an "L" section beam. This assembly (1) cannot be dismantled. If any
part is distorted, the entire assembly must be replaced.
two bars known as anti-roll bars (3).
two bars known as suspension bars (4).
a double shackle (2) that connects the bars.
This assembly is secured to the body by two pivot bearings mounted on rubber bushes.
NOTE: It is forbidden to use the "L" section beam (1) as a jacking point to lift the vehicle.
33-40
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REAR AXLE
Torsion bars on four bar type rear axles
33
EXTRACTION OF THE BARS FROM THEIR SPLINES
Remove the wheels.

Emb. 880
Inertia extractor
SUSPENSION BARS
ANTI-ROLL BARS
Release the suspension bars from their splines

using inertia extractor tool Emb. 880.
Release the anti-roll bars using inertia extractor

tool Emb. 880.
92120-1R
92120R
33-41
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REAR AXLE
Underbody height - four bar type rear axle
CHECKING
Park the vehicle, unladen but with its fuel tank

full, on a flat horizontal surface.
91936
92118G1
GOOD ROAD VERSIONS
See the section "value and settings" for value H4

- H5, depending on vehicle type.
The fault that requires adjustment may take one

of three forms:
A
B
C
correct height on one side, but excessive

right/left hand difference,
incorrect height and excessive right/left hand
difference,
incorrect height, but correct right/left hand
difference.
33-42
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33
REAR AXLE
In this new position, refit :

- the anti-roll bar at the point where it will slide
in freely and check the number of splines
offset on the arm and double shackle,
- the two suspension bars without offsetting
the marks.
Fit :
- the shock absorbers,
- the wheels.
ADJUSTING
1.
AFTER REPLACING A REAR AXLE
The height is correct on one side but the

difference between the LH and RH sides is
excessive
33
Any difference between the RH and LH sides must

always be taken up by adjusting the anti-roll bar
on the lowest side.
With the vehicle resting on its wheels, check and if

necessary adjust the headlights.
NOTE: it is essential to adjust on the lowest side

and bring it up to the same as the highest side.
B
Mark the positions in the bearings and in the
double shackle:
- of the two suspension bars,
- of the anti-roll bar on the lowest side.
Fit the tools set to the dimension "X" that
corresponds to the vehicle type.
If the heights are incorrect and the difference

between the RH and LH sides is excessive
The difference between the RH and LH sides must

always be taken up by adjusting the anti-roll bar
on the lowest side.
NOTE: it is essential to adjust on the lowest side
and bring it up to the same as the highest side.
Remove:
- the suspension bars,
- the anti-roll bar which has been marked.
Measure the dimension between the centre of the
wheel and the ground (on the side without an
anti-roll bar).
Mark the positions in the bearings and in the

double shackle:
Remove:
- the suspension bars,
- the anti-roll bar which has been marked.
wheel and the ground (on the side without an
anti-roll bar).
92118-1S
Reduce this dimension by the amount of

difference between the RH and LH sides already
measured by increasing dimension "X" on the
tool.
NOTE: do not alter the adjustment of the tool on
the other side.
92118-1S
33-43
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REAR AXLE
Reduce this dimension by the amount of
difference between the RH and LH sides already
measured by increasing dimension "X" on the
tool.
33
Refit the suspension bars at the point at which

they will slide in freely.
Fit :
- the wheels.
NOTE: do not alter the adjustment of the tool on

the other side.
With the vehicle resting on its wheels, check and

if necessary adjust the headlights.
In this new position, refit the anti-roll bar at the

point where it will slide in freely.
2.
Then, by adjusting both tools, reduce or increase
the dimension between the centre of the wheel
and the ground, simultaneously on both sides, by
the height difference measured on the highest
side when the vehicle was checked.
READJUSTING THE SUSPENSION HEIGHT

ON A VEHICLE
When adjusting the suspension height on a

vehicle that has already seen service, it is
essential to determine the point at which the bars
enter freely.
In this position, refit the suspension bars at the

point at which they will slide in freely.
Remove the wheels and shock absorbers.
Fit :
- the wheels.
Fit the special tools in place of the shock

absorbers, setting them at a dimension "X" that
corresponds to the free position of the suspension
arms.
With the vehicle resting on its wheels, check and

if necessary adjust the headlights.
C
If the heights are incorrect but the difference

between the RH and LH sides is correct
The underbody height is adjusted by turning the

suspension bars.
Mark the positions of the two suspension bars in
their bearings and in the double shackle.
Remove the suspension bars.
wheel and the ground (on both sides).
By adjusting both tools, reduce or increase this
dimension, simultaneously on both sides by the
amount of height difference measured when the
vehicle was checked.
92119G
33-44
http://vnx.su
REAR AXLE
A
If the difference between the RH and LH sides

is excessive
33
If the heights are incorrect but there is no

difference between the RH and LH sides
Mark the positions, in the bearings and the

double shackles :
Remove the three bars using tool Emb. 880.
Mark the positions of the two suspension bars in

the bearings and in the double shackle.
92120-1R
92120R
Thoroughly clean and grease the anchor points

and the bars.
Thoroughly clean and grease the anchor points

and the bars.
Find, by altering dimension "Y" on the side on

which the anti-roll bar has been removed, the
position at which the bar will slide in freely, that
corresponds to the two position marks. From this
position, adjust both tools simultaneously to
determine the position at which the suspension
bars will slide in freely , that corresponds to the
position marks.
Adjust both tools simultaneously to determine the

points at which the bars slide in freely, that
correspond to the position marks.
Remove the two bars using tool Emb.880.
Tighten the tools at the dimensions "Y" thus

obtained.
In this new position, carry out the normal
adjustment (see the section on "Adjusting after
replacing the rear axle" *).
Tighten the tools at the dimensions "Y" thus

obtained.
(*) WARNING : when re-adjusting, it is the

dimension "Y" that is to be used as the
starting point for this adjustment and not the
dimension "X" stated in this manual.
In this new position, carry out the normal

adjustment procedure (see the section on
"Adjustment after replacing the rear axle").
33-45
http://vnx.su
TUBULAR REAR
AXLE
REAR AXLE
33
Saw through the inner bush taking care not to cut

into the suspension arm tube.
This operation is to be carried out after first

removing the suspension arms and suspension
bars from the vehicle.
REMOVAL
Totally immerse the bearing in brake fluid to

soften the rubber in the rubber bush.
75362S
REFITTING
The new bearing is fitted to the suspension arm,

on a press, ensuring that the bush is correctly
positioned in the suspension arm at the correct
spacing.
DI3309
Using a two or three arm extractor, remove the

outer part of the bearing by tearing the rubber.
Position
Ensure that dimension "X" between the thrust
face of the bearing and the stub axle centreline is
correct.
All types
X = 15 mm
85909S
85910R
33-46
http://vnx.su
TUBULAR REAR
AXLE
REAR AXLE
Spacing
In this position, push the bearing into the arm
until the bearing dimension between centres is :
Y = 1268 1 mm
DI3304R
Fit the suspension arm to the vehicle.
33-47
http://vnx.su
33
REAR AXLE
FOUR BAR TYPE

REAR AXLE
33
This operation is carried out after first removing

the rear axle and the suspension bars from the
vehicle.
REMOVAL
Weld a spacer (e.g. a nut) to the centre tube of the

bearing.
92220-1R
Spacing
90 241
With the bearing in this position, push it in until

the bearing dimension between centres is :
Y = 1268 1 mm
92220G
Extract the bearing - bush assembly on the press.
REFITTING
The bearing is fitted to the suspension arm on the

press ensuring that its position and spacing, with
reference to the suspension arm, are correct.
Position
Ensure that dimension "X" between the thrust
face of the bearing and the centre line of the stub
axle is correct.
92220R1
Fit the rear axle assembly to the vehicle and refit

the suspension bars (see the corresponding
section).
All types
X = 24 mm
33-48
http://vnx.su
WHEELS AND TYRES

Specifications
35
WHEELS
The identification marking on the wheels can take one of two forms :
- an engraved mark in the case of pressed steel wheels,
- a cast-in mark in the case of light alloy wheels.
The identification mark provides the main dimensional specifications of the wheel.
It may be in complete form :
Example : 5 1/2 J 14 4 CH 36
or simplified form
Example : 5 1/2 J 14
WHEEL
TYPE
WIDTH
(in inches)
RIM
PROFILE
(in inches). At
tyre bead
Number
of holes
Tyre
retaining
profile
Offset
in
mm
5 1/2 J 14
4 CH 36
5 1/2
14
CH
36
NOMINAL
The wheel bolts are on a pitch circle diameter of :

100 mm.
Maximum permissible run-out : 1.2 mm
measured at the wheel rim (point G).
Maximum eccentricity : 0.8 mm measured on the
tyre bead locating surface.
DI3501
35-1
http://vnx.su
WHEELS AND TYRES

Specifications
35
TYRES
The identification marking may take one of two forms, for any given type of tyre.
Example :
or
175
175/70 S R 13
175/70 R 13 80 S
70
13
70
13
80
1
175
85920R
175
70
13
80
Width of tyre :
Expressed in millimetres (or in inches) and measured at

the widest point on the tyre.
l = 175 mm
Series or h/l ratio :
h/l = 0.8 (normal)

h/l = 0.7 (low)
h/l = 06 (extra low)
no inscription
70
60
Maximum speed :
Up to 180 km/h
Up to 190 km/h
Up to 200 km/h
Up to 210 km/h
Up to 230 km/h
More than 230 km/h
S
T
U
H
V
Z
Tyre structure :
Cross ply
Radial
Bias belted
no inscription
R
B (Bias belted)
Wheel diameter
Expressed in inches or in millimetres.

C = 13 inches
Reference stating the load that can be carried by each tyre.
35-2
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WHEELS AND TYRES

Specifications
35
These tyres are of the tubeless type.

Their inflation pressures must be checked when they are cold. The rise in temperature that occurs whilst the
vehicle is being driven causes the pressure to increase by 0.2 to 0.3 bars.
If the pressures are ever checked when the tyres are warm, allow for this increase in pressure and never
deflate them.
These vehicles are equipped with four wheels to which chains cannot be fitted. If you want to use chains you
must fit 5 j 14 wheels and 165/65 - 14 M + S tyres.
Wheel balancing
BALANCE WEIGHTS
Use only the balance weights supplied by the Parts

Department :
-
which are fixed by hooks to pressed steel

wheels (the hook forms part of the weight),
which are fixed by hooks (flat hooks) or which

are self-adhesive for light alloy wheels.
A
B
Pressed steel wheels

Light alloy wheels
88659R
35-3
http://vnx.su
WHEELS AND TYRES

Specifications
Types
B 530 - C 53A - B 535

C 530 - L 53 A - C 535
L 530 - B 53 G - L 535
S 530 - L 53 G
B 531 - B 53 W
C 531 - C 53 W
L 531 - L 53 W
B 53 A - S 53 W
B533 - B53F - 353D - B53Z
C533 - C53F - 353F - C53Z
L533 - L53F - 453A - L53Z
B536 - B53V - 453C
L536 - C53V - 453D
B538 - B53Y - 453F
C538 - D53V - 553A
L538 - C53Y - 553C
B53C - D53Y - 553D
C53C - L53Y - 553F
D53C - 353A - 853A
L53C - 353C - 853F
B534 - B53J - B53Z
C534 - C53J - C53Z
L534 - L53J - L53Z
S534 - S53J
B532 - S537
C532 - B53B
L532 - C53B
B537 - L53B
C537 - B53H
L537 - L53H
B539 - C53D
C539 - D53D
L539 - L53D
B53D
B53K - B53T - 453H
C53K - C53T - 553H
L53K - L53T
S53K - S53T
Wheels
5 x 13
Tightening
torque for
wheel nuts
(daN.m)
Run-out
(mm)
1,2
5 1/2 x 13
35
Inflation
pressure (1)
Tyres
FRONT REAR
145 R 13 S
165/70 R 13 T
175/70
175/70
175/65
175/65
R
R
R
R
13
13
14
14
T
H
T
H
2.0
2.2
2.0
2.2
2.2
2.2
5 1/2 x 14
1,2
5 x 13
5 1/2 x 13
1,2
5 x 13
1,2
155 R 13 T
165/70 R13T
2.0
2.2
6 1/2 x 15
1,2
195/50 R13V
2.2
2.2
5 1/2 x 13
5 1/2 x 14
1,2
165/70 R 13 T
175/70 R 13 T
175/65 R 14 T
2.2
2.2
165/70 R 13 T
175/70 R 13 T
For vehicles equipped with automatic transmission increase the pressure by 0.1 bar on the front wheels.
(1) Fully laden and motorway use.
35-4
http://vnx.su
STEERING
Axial ball joints
36
Dir.
812 -01
Dir.
or
832 -01
476
T.Av.
Spanners for tightening axial

ball joints
Ball joint nut

Axial ball joint
3.5
5
Axial ball joints with flat locking washers.
90145R
86111G
86 114
Disconnect the track rod end using tool T.Avv.476
86 112
REMOVING THE BALL JOINT : assembly (2) must be

replaced by a new one. If the slots on the ball
joint are not damaged, the ball joint can be reused.
85965R
Remove:
- the ball joint casing, counting the number of
threads engaged to be able to pre-adjust the
parallelism when refitting.
- the rack gaiter.
REMOVAL
Loosen the lock nut (E) whilst holding the axial

ball joint with an open ended spanner at (P).
36-1
http://vnx.su
STEERING
Axial ball joints
Loosen the axial ball joint using spanner Dir. 81201 or Dir. 832-01 whilst holding the stop washer
(2) with a C spanner to prevent the rack rotating.
36
NOTE : before tightening the ball joint using
spanner Dir. 812-01 or Dir. 832-01, check that the

tabs on the locking washer (2) are in line with the
flats (B) on the rack.
Refit the gaiter and its clip.
Screw the ball joint into the sleeve by the same
number of turns as was noted during removal.
Reconnect the steering bar to the stub axle
carrier.
Check and, if necessary, adjust the parallelism
then tighten the lock nut on the sleeve.
82367R1
REFITTING
Fit the following to the rack (4) :

- the stop washer-locking washer assembly (2),
- the axial ball joint (1) after coating its thread
with LOCTITE "FRENBLOC" .
83510-1R2
36-2
http://vnx.su
STEERING
Manual steering box
36
DI3602
T.Av. 476
Cut the ring (2) that retains the rubber protector.
Track rod end nut

Axial ball joint
Steering box mounting bolt
3.5
5
5
REMOVAL
Disconnect the ball joints using tool T.Av. 476.
92215R1
85965R
36-3
http://vnx.su
STEERING
Manual steering box
Push back the protective cover towards the
bulkhead and remove :
- the eccentric bolt (1) on the steering column
universal joint,
To do this :
- Loosen the lock nut (E) while holding the axial
ball joint, using an open ended spanner at (P),
- unscrew the ball joint casings, noting the
number of turns of thread engaged.
92216R
36
90145R
the two bolts (2),
REFITTING

When fitting a new steering box, fit the ball joint
casings in the positions noted during removal.
Refit the steering box and steering bar assembly
to the vehicle.
Position the universal joint and tighten the
eccentric bolt.
Fit the rubber protector and secure it with a new
PVC ring.
Check the parallelism.
85879R
the steering box.
Never unscrew the axial ball joints from the

steering rack unless they are to be replaced.
If the steering box is to be replaced, the ball joint
casings at the stub axle carrier end are to be
removed for fitting to the new one.
36-4
http://vnx.su
STEERING
Anti-rattle bearing on manual steering boxes
36
Dir.
Dir.
T.Av.
812 -01
or
832 -01
476
Spanners for tightening

the axial ball joints
Wheel bolts
Track rod end nut
Axial ball joints
8
3.5
5
REMOVAL
Support the front of the vehicle on axle stands

and remove the wheel on the opposite side to the
steering column.
Remove :
- the rack gaiter,
- the axial ball joint (see the corresponding
section).
Turn the steering to full lock until the rack is no
longer projecting from its housing and thus
releases the anti-rattle bearing.
16193
REFITTING
Carefully clean the rack and the anti-rattle

bearing location. Coat them with MOLYKOTE
BR2 grease.
Fit the new anti-rattle bearing with the steering in
the same position as during removal, taking care
to insert its three lugs into the slots (A).
16193-1
Grind off the sharp end from a flat screwdriver

and lever out the anti-rattle bearing.
16193-2
Move the rack back into the bearing.

Refit the following to the rack :
- the stop washer with a new locking washer,
- the axial ball joint,
- the ball joint casing at the stub axle carrier
end.
Check and, if necessary, adjust the parallelism.
36-5
http://vnx.su
ENGINE
TYPE F
STEERING
36
DI3606
Mot. 453-01
T.Av. 476
Hose clamps
Remove the eccentric bolt (1) from the steering

column universal joint.
Track rod end nut

Axial ball joint
Steering box mounting bolt
3.5
5
5
REMOVAL
Disconnect the ball joints using tool T.Av. 476.
92059R
85965R
36-6
http://vnx.su
ENGINE
TYPE F
STEERING
Place a clamp Mot. 453-01 on each of the hoses

leading from the oil reservoir.
36
the mounting for the bracket securing the low

pressure pipe.
92123R1
92121R
Remove :
- the air filter casing,
- the mounting for the bracket securing the
high pressure pipe.
the piece of connecting hose from the low

pressure pipe,
92122R
92124R
36-7
http://vnx.su
ENGINE
TYPE F
STEERING
the exhaust down pipe, disconnecting it from

the manifold and its central connection under
the vehicle.
36
Fully unscrew the pipes leading to the cylinder

(have a container ready to catch the oil).
90200R
92125R
Under the vehicle, unscrew then remove the pipes

leading to the cylinder (provide a container to
catch the oil).
90201R
92126R
the pipes leading from the oil reservoir and

the high pressure pump to the rotary valve.
NOTE : fit plugs to the take-offs on the steering
box to prevent dirt entering the unit.
Entirely remove the low pressure pipe.
36-8
http://vnx.su
ENGINE
TYPE F
STEERING
Remove:
- bolt (2) from the right hand steering box
mounting,
- the four bolts that secure the steering box to
the sub-frame.
36
To do this :
- loosen the lock nut (E) whilst holding the axial
ball joint with an open ended spanner at (P),
- unscrew the ball joint casings, noting the
number of turns of thread engaged.
92123R
Lower the steering box and remove the right

hand support.
Take out the box through the left hand cowl side
panel.
90145R
REFITTING
If a new steering box is to be fitted :

-
fit the ball joint casings in the positions noted

during removal,
remove the right hand support from the

steering box together with the pipes leading
to the cylinder, plugging the take-offs to
prevent dirt entering.
Place the steering box in position.

Refit the right hand support and bolt (2).
Fit: :
- the pipes from the cylinder to the valve and to
the steering box body, without tightening
them,
- the four steering box mountings, tightening
them to the specified torque.
90060S
Never unscrew the axial ball joints from the rack

assembly unless they are to be replaced.
Tighten the pipes leading to the cylinder and the

bolt on the right hand support.
If the steering box is to be replaced, the ball joint

casings at the stub axle carrier end will have to be
removed for fitting to the new one.
36-9
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ENGINE
TYPE F
STEERING
Reconnect the pipes leading to the rotary valve,
correctly positioning the low pressure pipe.
Tighten the mountings on the pipe retaining
brackets and the piece of connecting hose.
Correctly position the universal joint and tighten
the eccentric bolt.
Refit:
- the exhaust down pipe,
- the ball joints on the stub axle carriers,
- the air filter casing.
Remove clamps Mot. 453-01.
Fill the system with oil up to the marker on the
filter in the reservoir.
Turn the steering to the left and to the right
(without the engine running) to fill the system
with oil.
Repeat this operation with the engine running
then top up the level in the reservoir (see section
13 "Filling the system").
Check and, if necessary, adjust the parallelism.
36-10
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36
STEERING
Steering box plunger
36
ADJUSTING
If there has been a complaint of the steering box rattling, before considering replacing the steering box,
ensure that its plunger is correctly adjusted.
The steering box must be removed before

carrying out this operation.
1.
Determining the source of the rattle
Grip the steering rack bar on the same side as the

plunger and check the amount of axial play (by
pulling it backwards and forwards). If there is
play accompanied by a rattling noise, the plunger
is responsible.
2.
Adjusting
Loosen the adjusting nut (1) by lifting out the

points where the flange on the nut is peaned into
the housing (A).
Tighten the adjusting nut by two notches, using a
10 mm allen key, and check whether the play has
disappeared.
Maximum permissible take-up : 3 notches.
Relock the nut by peaning the flange on the nut
into two diametrically opposed slots on the
steering box housing.
83920R
36-11
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STEERING
Steering column
36
DI3607
REMOVAL (with Airbag option)
Steering wheel nut

Eccentric bolt
Removing the Airbag cushion (without removing

the steering wheel)
4
3
WARNING : It is forbidden to handle pyrotechnic
REMOVAL (without the Airbag option)
systems (airbag and pre-tensioners) near a source

of heat or a flame; there is a risk of triggering
them.
Remove :
- the lower cover under the steering wheel,
- the steering column upper and lower half
cowlings,
- the steering wheel after first marking its
position.
Remove the airbag by means of its two bolts

located behind the steering wheel (tightening
torque: 0.5 daN.m). Disconnect its connector and
connect the dummy ignition module of XRBAG
Ele. 1288 taking care to avoid discharging the
battery as the warning light flashes.
NOTE: If the steering wheel is to be removed,
disconnect the batteries by means of the small
black 4 track connector.
IMPORTANT : Never reconnect the airbag cushion
and the battery on a steering wheel that has been
removed as there is a risk of triggering.
36-12
http://vnx.su
STEERING
Steering column
36
90285S
Remove :
- the controls after first disconnecting them,
- the two bolts (1) that secure the dashboard to
the steering column,
96682R3
Loosen the screws on the steering column switch

assembly, without actually removing the switch
and push it down to release the retaining cone.
92209R
36-13
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STEERING
Steering column
-
the eccentric bolt (2) on the universal joint.
36
Remove :
- the four steering column mounting bolts,
POWER STEERING
92059R
92210R1
MANUAL STEERING
Cut the ring that retains the rubber protector and

push back the protector towards the bulkhead.
the lower left hand dashboard mounting (see

section 57),
the lower cover from the heater controls,
the three dashboard mounting bolts (see
section 57).
Slightly lift the dashboard to free the clip (3).

Take out the steering column after first
disconnecting the steering lock switch.
Power steering
Free the gaiter (E) from the bulkhead and remove
it at the same time as the steering column.
92216R
36-14
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STEERING
Steering column
REFITTING
36
SPECIAL FEATURES FOR REFITTING THE STEERING

WHEEL EQUIPPED WITH AN AIRBAG
Check the length of the retractable shaft (see the

It is essential to replace its nut (prebonded

nut) and tighten it to the specified torque (4.5
daN.m).
Reconnect the batteries
Fit the steering column.

Lift the dashboard and insert the clip (3) in its
location.
IMPORTANT : before reconnecting the drivers airbag cushion the following procedure must be carried out for checking operation of the system :
Check that the warning light flashes when the
battery box is connected to the computer.
Power steering
Engage the gaiter (E) on the bulkhead.
Connect :
- the dummy ignition module to the connector of the drivers airbag cushion and check
that the warning light is extinguished,
- the drivers airbag cushion in place of the
dummy ignition module (tightly clamp
connector (E), tight connection).
Check that the warning light is extinguished
and screw the cushion back on to the steering
wheel. If the warning light does not operate as
indicated above, consult the repair manual entitled "Airbag and belt pre-tensioners" (first
generation) Part Number 77 11 176 120, and
check the system with the XRBAG module (El.
1288).
DI3608
Resecure :
- the steering column,
- the dashboard.
Tighten the two airbag cushion mounting bolts

to a torque of 0.5 daN.m.
Reconnect the steering lock switch.
WARNING :
Fit :
- the two bolts (3),
- the control switches to the steering column
and reconnect them,
- the upper and lower steering column half
cowlings,
- the lower cover under the steering wheel,
- the lower cover for the heater control
assembly,
- the steering wheel in the position marked
during dismantling,
- the eccentric bolt (1).
Failure to follow these instructions may prevent the systems from operating normally
and even result in accidental triggering.
It is not permitted to carry out work on the

airbag cushion or pretensioners with an ohmmeter or other electrical measuring instrument as this may result in triggering of the
system.
36-15
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STEERING
Steering column
36
Manual steering
Refit the rubber protector and secure with a new
PVC ring.
92215R
36-16
http://vnx.su
STEERING
Steering column
3
ADJUSTING THE CLEARANCE UNDERNEATH THE

STEERING WHEEL
36
In all cases, before tightening eccentric bolt

(1)
When reconnecting the steering column/steering

pinion the following points must be followed:
1
Insert block Dir. 1189 between the steering

wheel and the half cowlings.
92216R3
The clevis must be bonded to the pinion to ensure

that the centre of the clevis and centre of the pinion are in line when tightening.
93707R
For adjustable steering columns refitting must

be carried out with the steering wheel in the
low position.
36-17
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STEERING
Steering column
36
A locking lever under the steering column enables the driver to adjust the height of the steering wheel to suit
his own convenience. In certain cases, the stiffness of this locking system may require adjusting.
ADJUSTING THE STIFFNESS OF THE LOCKING

SYSTEM
Remove the lower cover under the steering

wheel.
Loosen the lever clamp nut (1).
Bring the steering column shaft into the lower
position.
87848-1R
Position the locking lever (3) at a distance X = 30

mm from the steering column support.
Refit:
- the nut (1),
- the lower cover under the steering wheel.
Check that the lever is readily accessible, if not
increase or reduce the above dimension by 10
mm.
87848R
Lock the steering column by tightening the nut (2)

with the locking lever (3).
36-18
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STEERING
Retractable steering column shaft
36
REMOVAL - REFITTING
These vehicles are equipped with an assembly consisting of a retractable shaft, a steering wheel shaft and a
steering column shaft that cannot be dismantled. If it is found impossible to fit the eccentric bolt on the
universal joint, check that the length of the shaft is correct. If it is not, replace the entire assembly (see the
section on the steering column).
CHECKING
92218R
LEFT HAND DRIVE
RIGHT HAND DRIVE
Manual steering
L = 408 1 mm
Manual steering
L = 406 1 mm
Power steering
L = 355.5 1 mm
Power steering
L = 354.5 1 mm
36-19
http://vnx.su

Master cylinder
37
M 10 x 100
M 12 x 100
Brake servo mounting bolt
1.3
1.3
1.3
REMOVAL
Empty and remove the brake fluid reservoir by

pulling it upwards.
91101R
NOTE : these vehicles are equipped with master
cylinders that are an integral part of the brake

servo. Whether the brake servo leaks or not
depends directly on the master cylinder. When
carrying out any work on these components, fit a
new seal (A).
Fit the master cylinder, aligning it with the brake
servo, so that the thrust rod (P) correctly enters
into its location on the master cylinder.
92219R
Remove:
- the pipes, marking their positions,
- the two nuts securing it to the brake servo.
REFITTING
Check the length of the thrust rod.

All types, both LH and RH drive.
Dimension X = 22.3 mm.
DI3710
This dimension is adjusted, depending on the

model, at adjusting stud (P).
Reconnect :
- the pipes in the positions marked before they
were removed,
- the brake fluid reservoir, pressing it down to
clip it into the master cylinder.
37-1
http://vnx.su

Brake servo
37
REFITTING
Before refitting, check:

Master cylinder to brake servo

Brake servo to bulkhead
All left hand drive types :

- dimension L = 124.5 mm, adjustable on
certain models by means of rod (C),
- dimension X = 22.3 mm, adjustable on certain
models by means of stud (P).
1.3
2
The brake servo cannot be repaired. The only

operations that can be carried out on it are
replacing :
- the air filter,
- the non-return valve.
All right hand drive types :

- dimension L = 117.5 mm, adjustable on
certain models by means of rod (C),
- dimension X = 22.3 mm, adjustable on certain
models by means of stud (P).
REMOVAL

Remove the master cylinder.
Disconnect the vacuum hose from the brake servo.
Remove the pin from the clevis that connects the
brake pedal to the thrust rod.
Slacken the nuts that secure the brake servo in
place and remove the unit.
91101R1
Fit the master cylinder (see the instructions in the

section concerned).
90383R
37-2
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Brake servo
37
Mot
453 -01
Hose clamps
EQUIPMENT REQUIRED
NAUDER* vacuum pump

CHECKING THE UNIT FOR LEAKS
When checking the brake servo for leaks, ensure that there is an absolute seal between it and the master
cylinder. If there is any leakage at this point, replace seal (A).
DI3701
The brake servo is to be checked for leaks, on the

vehicle, with the hydraulic system in operating
condition.
If the vacuum falls by more than 33 mbars (25

mm/Hg) in 15 seconds, there is a leak which may
be at either:
Connect the NAUDER* vacuum pump between

the brake servo and a vacuum source (the inlet
manifold) using a "T" union and a piece of pipe
which is as short as possible.
the non-return valve (replace it by a new one),
the thrust rod diaphragm (in this case replace

the brake servo).
Run the engine at idling speed for one minute.

If the brake servo fails, the braking system will still
operate but the pressure required at the pedal
will be much higher to give the same amount of
braking as would be obtained with servo assisted
brakes.
Pinch flat the pipe (clamp Mot. 453-01) between

the "T" union and the vacuum source.
Stop the engine.
*use as vacuum gauge.
37-3
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Brake servo air filter - Non-return valve
37
REPLACING THE NON-RETURN VALVE
This operation can be carried out on the vehicle.
REPLACING THE AIR FILTER
REMOVAL
Disconnect the vacuum inlet pipe from the brake

servo.
Pull and twist the non-return valve to free it from
its rubber sealing washer.
83 212
75 564
91101G
74883S
It is not necessary to remove the brake servo to

replace its air filter (F).
REFITTING
Check the condition of the sealing washer and the

non-return valve.
Extract the old filter (F) from under the pedal

assembly, using a screwdriver or metal hook. Cut
the new filter at A (see illustration) and place it
round the rod. Then push it into its location
ensuring that it covers the entire bore to avoid the
possibility of unfiltered air entering.
Replace any faulty parts.

Refit the assembly.
37-4
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Pedal assembly
SPECIAL FEATURES
After removing the brake control it is essential to

refit it with bolts that have an underhead length
of 20 mm max (A).
DI3726
37-5
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37

Handbrake lever
REPLACING
Release the handbrake and remove nut (1) and its

washer.
Release the control linkage from the clip (2) and
from the brake compensator.
92217R3
Remove :
- the cover from the seat belt anchor points,
- the two bolts from the seat belt anchor point.
Make a slight cut in the carpeting (3).
PHOTO
NOTICE R9
Disconnect the handbrake switch wire.

Unscrew the two bolts that secure the lever
support to the floor.
Remove the handbrake lever assembly.
On refitting, adjust the handbrake lever travel.
37-6
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37

Handbrake control
37
Remove :
ADJUSTING
If the handbrake is incorrectly adjusted, with the

cable too tight :
-
the automatic brake shoe wear take-up system cannot operate,
both rear wheels,
both drums.
Check that the automatic wear take-up system is

operating correctly by turning the toothed wheel
(D) (ensure that it will rotate in both directions),
then reduce the tension at the wheel by 5 to 6
teeth.
the brake pedal travel is too long.
Under no circumstances are the cables to be retensioned to remedy this fault.

It will only reappear in a very short time.
BENDIX
The handbrake is not a wear take-up system, it

must only be adjusted when one of the following
has been replaced:
- the shoes or linings,
- the cables,
- the control lever.
Any adjustment other than following these operations is forbidden.
With the vehicle raised on a lift that locates under
the body, slacken nut (1) to release the central
brake compensator fully.
90 328
92217R2
90223G1
37-7
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Handbrake control
Ensure :
- that the cables slide freely,
- that the handbrake levers (B) locate correctly
on the shoes.
BENDIX
90 328
90223G

notch.
Tighten the lock nut.
Fit the drums.
After lowering the vehicle to its wheels :
Adjust the shoes by gradually but firmly
depressing the brake pedal a number of times
whilst listening for the automatic wear take-up
system to operate.
37-8
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37

Handbrake control
DISC BRAKES
Ensure:
- that the cables slide freely.
- that the handbrake levers travel correctly and
move them as far as they will go towards the
rear of the vehicle.
88993R1
Gradually tension the cables at the central adjuster until the stop (A) comes into contact with the
lever, without moving it.
Complete the adjustment so that the levers start
to move between the 1st and 2nd notch of the
travel of the control lever and remain applied
from the 2nd notch.
Tighten lock nut (1).
92217R2
37-9
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37

Brake hoses
37
These vehicles are fitted with brake hoses that have no copper seals.
The seal is obtained by contact between the taper on the hose shoulder (A) and the bottom of the tapping.
B = 1.3
C = 1.3
84619R
PRECAUTIONS TO BE TAKEN WHEN REMOVING - REFITTING A WHEEL CYLINDER OR A HOSE
For reasons of safety, to prevent the brake hose from twisting and avoid any risk of it making contact with a
suspension component, the operations must be carried out in the following order:
REMOVAL
REFITTING
Unscrew the union (1) between the rigid pipe and

the hose (2) to the point at which the spring (3) is
released. This will free the hose from the splines
(4).
Place the caliper in position on the brake assembly

and screw the hose into it, tightening it to a
torque of 1.3 daN.m.
With the wheels hanging free and the steering in
the "straight ahead" position, position the female
end of the hose on the retaining (5) (the hose
must not be twisted) and fit :
- the spring (3),
- the rigid pipe to the hose, taking care to
prevent the hose from turning when the
union is screwed in.
85536R
Unscrew the hose from the caliper and, when

applicable, remove the caliper.
37-10
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Brake compensator
37
TESTING PRINCIPLE
These vehicles are equipped with fixed brake

compensators that are integral with the wheel cylinders.
The pressure readings are taken in an X configuration, i.e. on opposite sides of the vehicle, by
comparing the pressure at the rear wheels with a
given pressure on the front wheels.
It is essential to test both circuits.
I
: front right / rear left hand circuit
II
: front left / rear right hand circuit
The fixed compensator is integral with the wheel

cylinder
This type of compensator can only be tested ; if
the pressure is incorrect, replace the complete
compensator - wheel cylinder assembly.
TESTING PRINCIPLE
X53 with ABS option and X53 sports version.

These vehicles are equipped with a load sensitive
compensator. The pressure readings are taken in
an X configuration, by comparing the pressure at
the rear wheels with a given pressure at the front
wheels.
These dual compensators have two totally separate bodies which act in an X configuration on
one front wheel and one rear wheel.
I :
front right / rear left hand circuit
II :
front left / rear right hand circuit
Load sensitive compensator

On load sensitive compensators the adjusting system enables the rear pressure to be adjusted according to the front pressure.
The adjusting system acts simultaneously on both
bodies. If the pressure is incorrect on only one of
the two bodies, replace the compensator.
85925S
37-11
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Brake compensator
37
ESSENTIAL TOOLING REQUIRED
Fre. 244 -04

or
Pressure gauge for testing

the compensator pressure
Fre. 1085
settings
TESTING
TEST PRESSURES
Connect two pressure gauges (A) Fre. 244-04 or

Fre. 1085 :
- one to the front right hand wheel,
- the other to the rear left hand wheel.
The compensators on these vehicles can only be

tested. If the readings are incorrect, replace the
entire wheel cylinder.
See the section "Values and settings" for the
compensator values, depending on vehicle type.
Bleed the pressure gauges : screw (P).
92129R
Gradually press down the brake pedal until the

test pressure (see pressure chart) is obtained at
the front wheels;. Then read the corresponding
pressure at the rear wheels; correct if necessary.
Carry out the same operations on the other
circuit, i.e.:
- one on the front left hand wheel,
- the other on the rear right hand wheel.
If there is a considerable difference (pressures
outside the tolerances), replace the wheel
cylinder. The assembly cannot be repaired.
37-12
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Testing - Adjusting
37
The brake compensator must be tested and

adjusted with the vehicle on the ground,
unladen, and with one person on board the
vehicle.
Fre. 1085 Pressure gauge for testing

the compensator pressure settings
Since the compensator has two separate bodies,
it is essential to test them one after the other.
ADJUSTING
TESTING
Connect two pressure gauges Fre. 1085 :

- one on the front right hand wheel,
- the other on the front left hand wheel.
Bleed the braking system (the pressure gauge is
bled using screw P).
90269G
78457S1
To adjust:
Gradually press down the brake pedal until the

test pressure (see pressure chart) is obtained at
the front wheels. Then read the corresponding
pressure at the rear wheels; correct it if
necessary.
release nut (A) and alter the position of rod

(B) in sleeve (C).
37-13
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Testing - Adjusting
See the section "Values and settings" for the

compensator settings, depending on vehicle type.
NOTE : it is not permitted to alter the position of
nut (F).
90268R
37-14
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37

Clutch cable
37
REMOVAL
REFITTING
Unhook the cable from the fork, in the engine

compartment.
From inside the engine compartment, feed the

cable through into the passenger compartment.
Inside the vehicle, remove the transverse

ventilation ducting.
Inside the vehicle, check that the rockers (1) and

(2) can freely return to their released position.
Press down the pedal to pull the cable.

Lift out the cable end from its location on the
wear take-up quadrant and the eye (A) on the
toothed cam .
DI3727
Pass the cable through the eye (A) on the toothed

cam and place the cable end in its location on the
toothed quadrant (S).
Fit the cable to the clutch fork.
92191R
Pull out the cable sleeve stop from the support on

the pedal assembly.
Remove the complete cable via the engine
compartment.
89204S
Check that the cable sleeve stop is correctly

aligned on the bulkhead.
Press down the brake pedal to pull the cable
sleeve stop into the bulkhead. The system adjusts
itself automatically.
37-15
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Clutch automatic wear take-up system
37
SECTION
85872-1S
EXPLODED VIEW
DI3728
37-16
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37
PRINCIPLE OF OPERATION
TESTING
WEAR TAKE-UP
To ensure that the system operates correctly,

check :
1 that the toothed cam (C) pivots round its pin,
2 that the rockers (1) and (2) return freely to the
released position.
Spring (R) applies a constant tension to the wear

take-up quadrant (S).
As the cable is permanently under tension, it pulls
on the fork and keeps the thrust bearing in
permanent contact with the diaphragm.
The adjustment is automatic.
"DECLUTCHING" MOVEMENT
When the pedal is pressed down, its toothed cam

(C) engages with the teeth on the wear take-up
quadrant (S) to prevent it from pivoting and to
allow it to pull the clutch cable.
DI3727
3.
Pull the cable at the clutch fork on the

gearbox.
There should be at least 2 cm of "slack" in the

cable.
85872-1R
89204S
These checks enable it to be verified that the

toothed cam (C) and the toothed
quadrant (S) are free in the "clutch engaged"
position.
37-17
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4
Check the fork movement. It should be :

X = 17 to 18 mm
91830R1
These tests must be carried out before any

rectification work on the actual clutch unit.
37-18
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37

The vehicles are equipped with a double locking
external gear control that prevents any possibility
of selecting reverse instead of first without the
latch being lifted.
37
PRINCIPLE OF OPERATION
The upper latch (A) operates through a cable (C)

on a second latch (D) at the bottom of the lever.
The locking effect is therefore obtained by a
synchronised upper stop (H) and lower stop (B).
NOTE : this control system must be adjusted with
first gear engaged.
DI3703
DI3707
37-19
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EXPLODED VIEW AND TIGHTENING TORQUES
DI3729
1
2
3
4
5
6
7
8
9
10
Link
Return spring on 3rd/4th line
Casing
Pad
Lever and latch assembly
Protective gaiter
Gear lever knob
Circlip
Bush
Sleeve
37-20
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37

CONSUMABLES
Nuts mounting casing to body

Bolt mounting link to clevis
37
1.5
3
Grease grade 33 Medium :

Shift lever pivot point
REMOVAL
REFITTING (Special operations)
From inside the vehicle, release the gaiter (6) from

the console.
Coat the shift lever pivot points with grease grade

33 Medium.
Under the vehicle, disconnect :

- the flexible exhaust pipe mountings,
- the return spring (2),
- the link (1) from the lever clevis.
Bond the knob (7) to the lever.

Adjust the gear control.
Remove the nuts which secure the casing to the

body and take out the lever - casing assembly
whilst pulling the exhaust pipe to one side.
Tighten the nuts and bolts to the specified

torques.
DI3730
Grip the gear lever clevis in a vice fitted with soft

jaws and remove :
- the knob (7),
- the gaiter (6),
- the circlip (8).
Remove the lever and latch assembly from the
casing.
NOTE : the Parts Department supplies the lever
and latches as a complete assembly.
37-21
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37
B.Vi. 1133
Tool for locking the type JB

gearbox input lever in 1st
Bolt securing link to clevis
ADJUSTING
Select 1st gear at the gearbox.
92079R
DI3702
37-22
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Fit tool B.Vi. 1133 to take up the play.
37
Fit the link (1) to the lever clevis leaving a space of

approximately 5 mm between the link and the
clevis body.
Bring the lower latch on the lever against the
inclined plane on the casing, placing a 2 mm
feeler gauge between them.
92080R1
92450S
At the same time pull the outer end of the tool

downwards and swing it through 45 degrees until
it makes contact with the lug on the housing.
In this position, tighten bolt (V).

Remove the feeler gauge and refit the return
spring (2).
92450-1R
92431R
37-23
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Check the resulting clearance "Y" which should
be between 2 and 5 mm.
DI3705
Remove special tool B.Vi. 1133.

Check that the gears select correctly.
37-24
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37
MB

37
EXPLODED VIEW
DI3731
REMOVAL
REFITTING
Remove :
It is essential to move the automatic transmission

to position "D".
Passenger compartment side:

- knob (2) by pulling vigorously upwards.
Automatic transmission side

Before refitting the cable, check dimension (A)
between the support face of the cable on sheath
stop (9) and mounting ball joint (10).
Under the vehicle

- the protective cover.
Dismantle the cable stops (7).
A = 131 mm
Remove :
- the four nuts (3) retaining control unit (5) and
withdraw it from underneath,
- the cable retaining clips (1).
If necessary slacken the two nuts (12) to obtain

this dimension.
37-25
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MB

37
ASSEMBLY
Assemble the cable :

- on the automatic transmission (still in the "D"
position),
- on the control unit (5) (still in the "D"
position), and tighten sheath stop (8) one
quarter of a turn.
Replace control unit (5) on the vehicle.
Replace knob (2).
Check that the gears select correctly and that the
starter engages in the "P" and "N" positions, and
check the "Park" function.
If the adjustment is incorrect, loosen sheath stop
(8), moving it one quarter of a turn, and pull or
push the cable, depending on the adjustment
required.
93611R
Control unit side
Do not forget to retighten sheath stop (8) at the

end of the operation.
Place the selector in the "D" (Drive).

Align the two screen and repeater reference
marks before tightening the four bolts (11).
93612R
CHECKING THE CABLE
By moving it one quarter of a turn, loosen sheath

stop (8) and make sure that the cable slides easily.
37-26
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AD4

37
EXPLODED VIEW
DI3732
REMOVING
REFITTING
Remove :
It is essential to move the automatic transmission

to position "D".
Passenger compartment side:

- knob (2) by pulling vigorously upwards.
Automatic transmission side

Before refitting the cable, check dimension (A)
between the support face of the cable on sheath
stop (9) and mounting ball joint (10).
Under the vehicle

- the protective cover. (6)
Dismantle the cable stops (7).
A = 131 mm
Remove :
- the four nuts (3) retaining control unit (5) and
withdraw it from underneath,
- the cable retaining clips (1).
If necessary slacken the two nuts (12) to obtain

this dimension (see diagram below)
37-27
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AD4
37
CHECKING THE CABLE
By moving it one quarter of a turn, loosen sheath

stop (8) and make sure that the cable slides easily.
ASSEMBLY
Assemble the cable :

- on the automatic transmission (still in the "D"
position),
- on the control unit (5) (still in the "D"
position), and tighten sheath stop (8) one
quarter of a turn.
94898R1
Replace control unit (5) on the vehicle.
A = 131 mm
Replace knob (2).
Control box (5) side
Check that the gears select correctly and that the

starter engages in the "P" and "N" positions, and
check the "Park" function.
Place the selector in the "D" (Drive).

Align the two screen and repeater reference
marks before tightening the four bolts (11).
If the adjustment is incorrect, loosen sheath stop

(8), moving it one quarter of a turn, and pull or
push the cable, depending on the adjustment
required.
Do not forget to retighten sheath stop (8) at the
end of the operation.
93612R
37-28
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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMSS

Bendix ABS
LOCATION AND COMPOSITION (Left hand drive)
92736R
38-1
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38
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS

Bendix ABS
LOCATION AND COMPOSITION (Right hand drive)
92736-1R
38-2
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38

Bendix ABS
38
The ABS system comprises the following components:

1 Brake pressure unit (BPU), comprising two "master cylinder"
distributor assemblies (A) and a regulation unit (B).
2 Electric pump unit (EPU) .
3 Computer, incorporating a self-checking device.
4 Wheel rotation speed sensors.
5 Targets embedded in the driveshafts at the front, and in the disc
hubs at the rear.
6 Two warning lights on the instrument panel.
7 Dual brake compensator.
8 Four disc brakes.
9 A diagnostic socket enabling the XR25 kit to be connected.
10 Wiring connection plate assembly
DI3883
38-3
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Bendix ABS
38
LOCATION AND COMPOSITION (left hand drive)
DI3884
38-4
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Bendix ABS
38
LOCATION AND COMPOSITION (right hand drive)
DI3885
38-5
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Bendix ABS
LOCATION AND COMPOSITION
38
FRONT SENSORS
RADIAL AND NON-ADJUSTABLE
The hydraulic unit is of modular design and is

fitted in place of the brake servo master cylinder
assembly.
It comprises :
A brake pressure unit (1) (BPU), comprising
two "master cylinder" distributor assemblies
(A) and one regulation unit (B).
An electric pump unit (2) (EPU), comprising a

pump (C) driven by an electric motor, a
pressure accumulator (D) and 3 pressostats (E).
A reservoir with integrated nivocode (3).
This system operates without vacuum

amplification.
COMPUTER (3)
92721R
This is located in the heating compartment

opposite the battery.
Targets (5) embedded in the hubs (cannot be
removed) for the rear.
REAR SENSORS
TANGENTIAL AND NON-ADJUSTABLE
91339R
It analyses the information from the wheel

sensors and controls the electric inlet and outlet
valves, depending on the information received.
SPEED SENSORS (4) AND TARGETS (5)
The speed sensors are mounted on the stub axle

carriers and receive the information via toothed
targets.
92720R
Targets (5) embedded in to the driveshafts for the

front wheels.
Number of teeth on the targets : 48
38-6
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Bendix ABS
ABS CONTROL RELAYS
38
NOTE :
These are located on the connection plate.
The spare 25 A relays have a mounting bracket

which must be removed before they are fitted to
enable the cover to be fitted on to the plate.
The computer is supplied with + 12 V after
ignition by means of a 15 A fuse located on the
accessories plate.
A 10 A fuse protects the supply to the warning

lights
(ABS -
etc...).
NOTE : the diagnostic socket is located in the
passenger compartment, underneath the

dashboard, in the relay and fuse compartment.
93441R
A
B
C
D
E
Pressure alarm relay

EPU control relay (301)
30 A fuse (260) EPU
Starting cutout relay
Safety relay, soldered (428)
25 A black
50 A green
25 A black
92733R
92827S
38-7
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Bendix ABS
38
The following are connected to the connection

plate :
The wiring loom is soldered to the connection

plate located alongside the computer in the
heating compartment.
- a 2 track connector for supplying the electric

pump unit,
- a 6 track connector for the pressure switches,
- a 12 track connector for the regulating
solenoid valves of the braking pressure unit.
NOTE : whenever work is done on this system the
wiring must always be correctly routed

throughout the vehicle.
It is necessary to remove the heating
compartment partition to free the ABS wiring.
92735S
It comprises several connections which end:

- at the computer by means of a 35 track
connector,
- at the instrument panel by means of a 6 track
connector,
- at the reservoir by means of a 4 track
connector,
- directly to the front sensors without
intermediate connectors ,
- to the rear sensors by means of two 2 track
connectors located near the left rear axle
mounting.
93447R1
92723S
38-8
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Bendix ABS
2nd assembly
The components of the Bendix ABS for versions
AC - PAS - ABS remain unchanged. Only the relay
plate assembly (1) and the computer (2) have been
moved and are now located in the engine
compartment around the right front wheel arch.
96584R
38-9
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38

Bendix ABS
38
PRINCIPLE OF OPERATION (hand brake lever in zero position)
When the ignition is switched on one of two cases arises:

- The vehicle is in regular use, the warning light
illuminates and extinguishes after about 3 secs.
- After the vehicle has been stationary for a long time, lights
and
illuminate simultaneously
and extinguish after a time of up to 30 seconds: the time for the pressure in the accumulator to increase
(> 90 bars).
In these two cases the computer automatically initiates a self-checking and initialisation sequence.
The intensity of light
is not absolutely constant, but this is not regarded as a fault.
Starting phase :
- If you have waited for the lights to extinguish, light
is illuminated and extinguished after approx.
3 secs, and light
is only illuminated during the starting phase..
- If you have not waited for the warning lights to extinguish, two cases arise :
the vehicle is in regular use, the warning light

remains illuminated and does not extinguish until
you return to the start position (ignition key) after approximately 3 seconds.
after the vehicle has been stationary for a long time, lights
and are extinguished after a time of up to 30 seconds.
and
illuminate simultaneously
Whilst the vehicle is being driven :

Pressing the brake pedal enables the pressure to be transferred from the electric pump unit to the brakes.
The pressure is metered in proportion to the load applied to the brake pedal.
During braking, if the computer is informed of a sudden deceleration by the sensors on one or more wheels,
and if it detects that this wheel or wheels are tending to lock, it initiates the following procedure:
- for a front wheel :
fast pressure
relief :
the working solenoid valve closes the high pressure inlet and opens the return to the
reservoir.
slow pressure
relief :
the restrictive solenoid valve closes the direct return to the reservoir and forces
the brake fluid to cross the calibrated openings to provide a slow fall in pressure.
- for the rear wheels :
fast pressure
relief :
the working solenoid valve closes the high pressure inlet and opens the return to
the reservoir. At the same time the difference between the high pressure and the
pressure of return to the reservoir closes a mechanical valve.
38-10
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Bendix ABS
38
OPERATING PRINCIPLE
If the wheels recover speed, there is :

- for a front wheel :
slow inlet: the working solenoid valve opens the high pressure and closes the return to the reservoir.
fast inlet: the two solenoid valves are at rest, the high pressure passes directly to the brakes
- for the rear wheels :
slow inlet:
the working solenoid valve opens the high pressure and closes the return to the
reservoir. In parallel with the mechanical valve, which is always closed, the brake
fluid passes through the calibrated openings until the pressure difference is zero.
The procedure is then repeated until the vehicle stops.

It should also be noted that the rear axle assembly is regulated by the "Select Low" system, which means
that the wheel with the lowest adherence causes the same regulation on both rear wheels.
Faults:
A fault which puts the regulation device out of action is indicated to the driver by the illumination of the
warning lights on the instrument panel.
a) Illumination of warning light

Depending on the type of fault detected by the computer, the vehicle has :
- normal braking without ABS,
- braking in defect mode (see table on following page).
b) Illumination of warning light
The illumination of this warning light alone indicates, apart from the handbrake is still applied, that there
is a drop in the fluid level in the brake fluid reservoir.
c)
Illumination of warning lights
A brake fluid leak will cause the illumination of the warning light
, if the the fluid level continues to
drop the warning light
will illuminate and the system will enter defect mode.
If the pump no longer operates, or operates without creating an increase in pressure, the braking pressure
assembly will operate as two single master cylinders, operating side by side. In this case, braking is without
assistance.
38-11
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Bendix ABS
Safety:
In the case of non-assisted braking it is normal for
the brake pedal travel to be very long. The
pressure in the brake circuits does not increase
until the brake pedal is pressed very quickly at the
end of its travel. It serves no purpose to pump it
as in the case of a conventional master cylinder.
In all cases where a fault is detected, the computer
will lock the system in an irreversible operating
mode called "defect mode" (see table on next
page).
The fault which has caused the warning light to
illuminate may be displayed from the diagnostic
socket by means of of the XR25 kit and the
appropriate cassette.
When a fault arises after the ignition is switched
off, this is stored in the memory of the computer.
This memory may be consulted at any time by
means of the XR25 and the appropriate cassette.
Important recommendation:
On completion of the repair it is important to
delete the fault memory by entering the
following command in the XR25: GO**.
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38

Bendix ABS
38
REGULATION IN DEFECT MODE
CONSEQUENCES
FAULTS
1 front sensor
2 front sensors
REMEDIES
A single wheel checked on

front axle
W. light
Front axle not checked
W. light
illuminated
ABS no longer applied to this wheel

illuminated
ABS no longer applied to front axle

1 rear sensor
or
"Select Low" reduced to 0 or

speed incoherence
2 rear sensors
More checking of rear axle
1 front solenoid valve
As 1
As 1
2 front solenoid valves
As 2
As 2
&
Rear solenoid valve
As 3
As 3
Electric pump unit
Pressure reduced to 90 bars
W. light
Illumination of
ABS not applied anywhere on the vehicle
illuminated
ABS suppressed
Entire brake system without h. pressure
High pressure braking

pressure unit hose
(fracture)
No high pressure
Fall in pressure
W. light
Electric pump unit feed

hose
Loss of pressure to 90 bars
illuminated
ABS suppressed
W. light
illuminated
ABS suppressed
Electric pump unit feed

hose
Reduction in fluid level in

reservoir
Illumination of
Pump stopped
Illumination of
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Bendix ABS
OPERATING PRINCIPLE
38
Pressure < 160 bars :

- the 160 and 180 bar pressure switches are
closed,
Pressure accumulator
The accumulator enables a certain pressure
reserve to be maintained in order to limit the
operating time of the hydraulic pump and
guarantee braking in the event of failure.
- the hydraulic pump operates - relay (301)

controlled.
Pressure switches
Pressure between 160 and 180 bars :

- the 160 bar pressure switch is open,
The purpose of the two pressure switches is to

regulate the hydraulic pressure between 160 and
180 bars.
- the 180 bar pressure switch is closed,
A third 90 bar pressure switch alerts the computer

and illuminates the ABS warning light if there is a
considerable drop in the hydraulic pressure.

remains controlled.
Pressure > 180 bars :

- the 160 and 180 bar pressure switches are
open,
- the hydraulic pump does not operate (relay
at rest)
Pressure drops below 180 bars (but > 160

bars).
- the 180 bar pressure switch closes,
- the hydraulic pump does not operate - relay
(301) at rest.
94721R
- the 160 bar pressure switch closes,

controlled.
Operating tolerance :
90
+5
0 bars
160
+5
0 bars
180
+5
0 bars
Pressure drops below 160 bars :
38-14
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Bendix ABS
Operating principle of dual alarm device
incorporated in the brake fluid reservoir
38
2nd test
Switch off the ignition.
NOTE : the alarm device is integrated in the
reservoir. If it does not operate replace the

complete reservoir.
1.
Lower the pressure in the accumulator by pressing

the brake pedal about twenty times.
when the following warning light initially

illuminates:
Switch on the ignition and the pump will run to

fill the accumulator.
Press the plunger as far as it will go; the pump
must stop. Release the plunger and it must
restart.
2.
if the level continues to fall, the ABS warning

light illuminates and since relay (301) is no
longer being supplied with power, the electric
pump unit does not operate in order not to
consume, from a probable leakage, the
remaining brake fluid, which may also supply
the braking pressure unit in defect mode.
TESTS
1st test
Switch on the ignition.
The reservoir plug is fitted with a plunger which
enables the float to be lowered.
Using a screwdriver, press down this plunger and
check that the nivocode warning light is
illuminated (hand brake in position of rest).
92728S
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Bendix ABS
REMOVING - REFITTING THE COMPONENTS
REMOVAL
I - FRONT WHEEL SENSOR

Remove :
- the wheel,
- the sensor mounting bolt (1).
Wheel bolts
Sensor mounting bolts
38
7 to 9
0.8 to 1
The front speed sensors are connected directly to

the wiring loom soldered to the connection plate.
Thus in order to replace them the existing wiring
must be cut and the new sensor reconnected by
means of a sealed "MIC" connector.
The Parts Department supplies a repair kit,
comprising :
- a sensor fitted with a clip support connector,
- a kit for making up the tab support connector.
92721R1
Unclip the wire from the supports, remove the

ringed sheath. Cut the wire at the position of the
connector (coloured zone).
Remove the sensor.
REFITTING THE TAB SUPPORT CONNECTOR
Push the sensor wire into the heat shrinkable

sleeve.
Strip the wires over a length of 5 mm with a pair
of PRONER pliers.
93448R
1
2
3
4
5
Sensor
Tab support connector
Tabs
Split sealing sleeves
Heat shrinkable sleeve
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Bendix ABS
For correct crimping of the terminal connectors
(as the original) use a pair of PRONER pliers Ele.
1146 , which can be ordered from the Parts
Department under Part Number 00 00 114 600.
38
Arrange the heat shrinkable sleeve as high as

possible on the connector.
Using a hot air blow torch shrink the sleeve,
starting at the top of the connector (rotate it as it
heats up).
Heat the bottom of the sleeve so that the sealant
melts.
WARNING: do not overheat, the insulation on the
wires must not melt.
90899G
Fit the tab, with crimp connection (A) on the

stripped wire and crimp connection (B) on the
insulation.
Select the correct crimp cut on the pliers and
crimp the wire at (A), then move to the upper
notch and crimp the insulation (B).
90898-2S
IMPORTANT : extreme care must be taken when

making this connection to ensure perfect sealing.
The sealant must be melted behind the sleeve and
the wires must be in perfect condition.
Check that lug (C) has emerged completely.

Insert the tabs right into the connector (clear
locking sound).
Arrange sealant sleeves on the wires 5 mm from
the connector bushes.
REFITTING
Fit the sensor, previously coated with grease

Multifunction 77 01 422 308, then clip the wire
into its supports and reconnect it.
Cut one end of the ringed sleeve if it is too long.
The wiring and its mountings must be correctly
routed.
90898-2S1
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Bendix ABS
II - REAR WHEEL SENSORS
REFITTING
Fit the sensor, previously coated with grease

Multifunction 77 01 422 308, then clip the wire
into its supports and reconnect it.
Wheel bolts
Sensor mounting bolts
38
7 to 9
0.8 to 1
NOTE : to eliminate the risk of faults make sure

that the connector is properly connected.
REMOVAL
Remove :
- the wheel,
- the sensor mounting bolt (1),
- the sensor from its mounting.
III - FRONT WHEEL TARGET
Wheel bolts
Driveshaft nut
7 to 9
24 to 26
Because the target is embedded in the driveshaft,

this operation is carried out after the driveshaft
has been removed.
REMOVAL
Extract the target in the press using an extractor.
92720R1
Unclip the wire from its mountings..

Disconnect the sensor from its connector (2) under
the vehicle close to the left rear axle mounting.
91663S
92722R
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Bendix ABS
38
REFITTING
REFITTING
Coat the target with LOCTITE SCELBLOC and refit

it using a mallet, tapping lightly on the outside of
the target.
Refit the three computer mounting bolts, then

those of the plate.
Reconnect the computer, making sure of a perfect
connection of the 35-track connector (clipping).
Make sure that you tap rap regularly to prevent

the target from twisting, and check that it is
pressed home on the driveshaft.
NOTE: exercise great care when refitting: the

three mounting points = ABS earth.
NOTE: the Parts Department supplies spare
machined driveshafts not fitted with ABS targets.

It will therefore be necessary to retain the target
to realign the driveshafts. However, the target
only is also available from the Parts Department.
V - BRAKING PRESSURE UNIT, ELECTRIC PUMP

UNIT AND RESERVOIR ASSEMBLY (left-hand
drive)
IV - COMPUTER
Braking pressure unit on bulkhead
This is located in the heating compartment (on

the left-hand side).
REMOVAL
Disconnect the battery

Remove :
- the bar between the shock absorber turret,
- the air filter.
NOTE : the operating pressure of the ABS system
is between 160 and 180 bars. It is also necessary
to reduce the pressure before carrying out any
work on the hydraulic circuit.
To do this bolt (5) located under the electric
pump, and accessible from underneath the
vehicle, must be slackened one turn.
92735S
REMOVAL

Remove the seal and the protective case.
Disconnect the connector.
To facilitate removal of the computer it is
recommended that the three bolts securing the
plate to the body be removed in order to remove
the plate - computer - relay box assembly,
providing access to the bolts securing the
computer to the plate.
92724R
NOTE: do not slacken bolt (5) more than 2 turns

(this may damage the O ring)
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Bendix ABS
It is possible to check that the accumulator is
actually empty by checking the brake fluid level in
the reservoir, which must be approximately at the
upper reference mark (B).
38
Remove:
- the A.E.I.,
- heating compartment flap,
92729R1
93447R
Unclip the expansion bottle and remove it.
- the 4 brake pipes and the high pressure union

(E) after marking them.
If only the bottle is being removed, 2 clamps Mot.

453-01 should preferably be fitted to avoid
emptying the pipes.
Drain the reservoir at the unions (C).
92730R3
92732R
Disconnect the connector.

Remove the 3 nuts (D).
Remove the reservoir and disconnect the other 2
pipes.
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Bendix ABS
Inside the vehicle, remove the pin from the clevis
connecting the brake pedal to the thrust rod after
removing the clip.
38
Release the wiring and disconnect it from the

connection plate.
92735S
Remove the lower protective case, nuts (F).

94692R
Retain the spacer.

Unscrew the braking pressure unit mounting nuts
on the pedal assembly plate.
93445R
94693S
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Bendix ABS
38
Remove wiring mounting bolt (2) and the 2 bolts

(H).
94692R
- the two electric pump unit support mounting

bolts (H),
- the lower protective case, nuts (F),
- the 4 brake pipes and the high pressure union
(E) (marked when removed).
93446R
Remove the braking pressure unit and electric

pump unit assembly.
IMPORTANT :
The interlocking of the 2 compensator rods in the

braking pressure unit is designed specifically for
the pedal support.
Therefore, NEVER:
handle the braking pressure unit by the
compensator,
separate the clevis - thrust rod assembly of the
braking pressure unit.
pull or push on the wiring.
REFITTING
Fit :
- the braking pressure unit and electric pump
unit assembly, not forgetting the reinforcing
plate and the braking pressure unit connecting
seal,
- the four mounting nuts on the bulkhead,
- the spacer, the pedal clevis pin and the locking
clip.
92730R2
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Bendix ABS
-
the heating compartment flap, with the wiring,

the brake fluid bottle and connect the hoses,
the A.E.I.,
the electrical wiring, bolts (G), and the
positioning clips,
- the air filter,
- the bar between the shock absorber turrets.
93447R
Fill with brake fluid and proceed to bleed (see

corresponding section)
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38

Bendix ABS
38

actually emptied by checking the brake fluid level
in the reservoir, which must be approximately at
the upper reference mark (B).
ELECTRIC PUMP UNIT - ACCUMULATOR PRESSURE SWITCH ASSEMBLY
(right-hand drive)
Drain plug
Hose union
eElectric pump unit lock nuts
0.8 to 1
1.3
0.8

is between 160 and 180 bars. It is also essential to
reduce the pressure before carrying out any work
on the hydraulic circuit.
To do this the bolt (5) located under the electric

pump unit, which is accessible underneath the
92729R
Unclip the expansion reservoir and remove it.

Fit two clamps Mot. 453-01 to avoid emptying the
pipes.
Drain the reservoir from unions (C).
92724R
NOTE: do not slacken bolt (5) more than 2 turns

(this may damage the O ring).
92732R
Disconnect the reservoir connector.

If the reservoir has to be replaced, remove the
three nuts (D).
Release the reservoir.
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Bendix ABS
Disconnect :
- the other pipes,
- the rigid pipe of the HP hose
38
- the two upper mounting nuts.
94695R
To facilitate the operation remove the

accumulator with tool Mot.445.
94699R
Remove:
- the two lower mounting nuts,
94697R
Remove :
- the heating partition,
- the electric pump unit after releasing the
wiring.
94694R
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Bendix ABS
Removing the brake pressure unit involves prior

removal of the engine and transmission assembly
(see section 13).
PRECAUTIONS :
1.
2.
38
Do not knock against, or rest the part on :

- the low pressure inlet pipe,
- the pressure switches,
- the accumulator.
Braking pressure unit on pedal

assembly plate
Hydraulic union
Drain plug
Do not pull or push on the wiring.
2
1.3
0.8 to 1
REFITTING

Fit :
- the electric pump unit (without the
accumulator), fitted with the hose,
- the four mounting nuts,

- the accumulator fitted with a new O ring, and

lock it,
- the rigid pipe on the HP hose,
- the wiring and the heating compartment flap
mountings,
93447R
94699-1R
- the brake fluid bottle (if necessary), and

connect the hoses,
Press the brake pedal twice.
- the air filter.

Fill with brake fluid and proceed to bleed (see the
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Bendix ABS

actually emptied by checking the brake fluid level
in the reservoir, which must be approximately at
the upper reference mark (B).
38
Remove :
- the heat shields.
92729R
Drain the reservoir at the unions (C).

94700S
- the heating compartment flap.
92732R
93447R
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Bendix ABS
Disconnect:
- the four brake pipes and the high pressure
union after marking them.
38
Slacken the nuts securing the braking pressure

unit to the pedal assembly plate.
94693S
94696S
- the hoses.
Release the wiring and disconnect it from the

connection plate.
Inside the vehicle, remove the clevis pin

connecting the brake pedal to the thrust rod,
after removing the clip.
92735S
Remove the braking pressure unit.
94692R
Retain the spacer.
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Bendix ABS
38
- the four brake pipes and the high pressure

union (marked when removed).
IMPORTANT :
The interlocking of the 2 compensator rods in the

braking pressure unit is designed specifically for
the pedal support.
Therefore, NEVER:
handle the braking pressure unit by the
compensator,
separate the clevis - thrust rod assembly of the
braking pressure unit .
94696R1
93446S1
REFITTING
Fit :
- the braking pressure unit assembly, not
forgetting the connecting seal,
- the four mounting nuts on the pedal plate,
- the spacer,
- the pedal clevis pin and the locking clip
the hoses,
the heat shields,
the wiring and the locking clips,
the heating compartment flap.
NOTE : when replacing the pipes it is essential to
replace the heat shields before proceeding to fit

the threaded unions.
Refit the engine and transmission assembly.
Fill with brake fluid and proceed to bleed the
system completely (see corresponding section).
94692R
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Bendix ABS
38
REPLACEMENT OF ACCUMULATOR - PRESSURE SWITCHES
Mot. 445
Strap wrench
Right-hand drive
Drain plug
Pressure switch
0.8 to 1
0.7- 1.3


Left-hand drive
94699-1R
REMOVAL
With the accumulator empty and the ignition off,

remove the accumulator with an Mot.445
spanner.
92724R
94697R
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Bendix ABS
REMOVING PRESSURE SWITCHES
The Parts Department supplies a kit of 3 pressure

switches.
For vital safety reasons never invert the wire
connection on the pressure switches or their
position on the electric pump unit.
94721R
90 bar pressure switch (A) :

Grey wire - track C1 of the 6 track connector on
the connection plate.
160 bar pressure switch (B):
Black wire - track B1 of the 6 track connector on
the connection plate.
180 bar pressure switch (C):
Black and grey wires - tracks A2 and B2 of the 6
track connector on the connection plate.
If the pressure switch wire loom is to be removed,
make sure that the earth wire is connected to the
pump body.
REFITTING
Fit the accumulator provided with a new O ring,

and lock it.
Proceed to bleed the entire braking system (see
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38

Bendix ABS
38
XR25 FAULT FINDING
The XR25 is vital for all fault finding on the ABS,

regardless of the origin of the faults.
It has a microprocessor and allows all the
information from the various sensors to be read ,
together with fault finding messages from the
computer.
It also allows the memory of the computer to be
erased after each operation on the ABS.
92655R2
NOTE : the warning light "V" must be
extinguished. If it is illuminated, disconnect then

reconnect the diagnostic socket. If it remains
illuminated, check the XR25 wiring and the
battery voltage.
92656S
Connect the XR25 to the vehicles diagnostic

socket and set the selector to "S5".
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Bendix ABS
38
Analysis of system operation using the XR25 and the latest cassette.
Vehicle stationary, ignition on.
Enter code
The display shows:
1
2X
5
(1 second) then
BENDIX make
Computer number
Product tested - ABS
or
dialogue has not been established
Bargraph 1 RH side must be illuminated. It extinguishes during dynamic tests of the solenoid valves (key G..*).
If one or more bargraphs are illuminated, a fault is present.
If they are flashing, a fault is memorised.
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Bendix ABS
FI21605
Bargraphs on a coloured background are fault bargraphs

Bargraphs on a white background are status bargraphs
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38

Bendix ABS
38
CODE PRESENT (only bargraph illuminated normally - no fault)

Illuminated: correct (extinguishes if key G is pressed).
If it extinguishes after entering
D
0
5
there is a communication fault between the XR 25 and the computer.
Check:
- Correct connection of the 2 ABS wires to the + battery terminal:
- pump motor feed
- feed to power circuit for main relay on ABS plate
- Correct connection of connection R36 (ABS/dashboard) located near the battery;
- The diagnostic connection to the computer: continuity between track 12 of computer and
track 5 of diagnostic socket.
If incorrect, check the following continuities:

- between track 12 of computer and track A2 of connection R36;
- between track A2 of R36 and track 5 of diagnostic socket.
Check:
- voltage at track 6 of diagnostic socket;
- presence of earth at track 2 of diagnostic socket;
- computer power supply:
presence of earth at track 27.
If not present, ensure continuity with earth M19;
presence of voltage greater than 10 volts at track 2.
If not present, check:
- battery voltage;
- ABS 15 A fuse n 13 on relay plate;
- starter cut-out relay.
Remove the starter cut-out relay and shunt terminals 3 and 4 on the base. Under these
conditions, are there V > 10 volts at track 2 of the computer?
NO:
Break in wiring, check following continuities:
- between track 2 of computer and 4 of starter cut-out relay base;
- between track 3 of starter cut-out relay base and track A1 of ABS/dashboard
connection R36;
- between track A1 of R36 and track 2A of ignition switch via 15 A fuse.
Check operation of ignition switch.
YES: check for absence of voltage at terminal 2 of starter cut-out relay base:
- if there is no voltage, replace the relay (contact faulty);
- if voltage is present, check operation of the ignition switch.
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Bendix ABS
2 Pressure fault (pressure < 90 bar).

Enter #06 and read the data displayed on the centre display of the XR 25.
If LR is displayed:
Break in pressure alert relay energising circuit; perform the following checks:
- continuity between track 2 of computer and track 2 of pressure warning relay base;
- continuity between track 9 of computer and track 1 of pressure warning relay base
(via 27 k resistance on relay plate).
Check continuity of the pressure alert relay coil between tracks 1 and 2 of the relay.
Short circuit to earth on track 9 of computer.
If LP is displayed:
Check:
- connections of 160 and 90 bar pressostat, 6-track pressostat connector on relay plate and
Nivocode connector;
- correct operation of pump motor
- (see fault finding aid 1-4).
2 Supply voltage fault (V > 16.5 or < 9.5 volts).

Check computer power supply:
Presence of earth at track 27. If not, ensure continuity with earth M19;
presence of voltage greater than 10 volts at track 2. If not, check:
- battery voltage;
- ABS 15 A fuse n 13 on relay plate;
- the starter cut-out relay:
no
Remove the starter cut-out relay and shunt

terminals 3 and 4 on the base. Under these
conditions, is V > 10 volts at track 2 of the
computer?
Break in wiring, check the following

continuities:
- between track 2 of computer and 4 of
starter cut-out relay base;
- between track 3 of starter cut-out relay base
and track A1 of ABS/ dashboard R36
connection;
- between track A1 of R36 and track 2A of
ignition switch via 15 A fuse.
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yes
Check that no voltage is present at

terminal 2 of starter cut-out relay
base:
- if voltage is not present, replace
the relay;
- if voltage is present, check the
operation of the ignition switch.
38

Bendix ABS
38
Computer cut off: first check the connectors connected to the connection plate and clean them
3 with NETELEC, part n 77 11 171 287. Switch the ignition off and on again and erase the
computer memory (GO**), re-enter D05.
If 3L is still illuminated without illumination of 3R, 6R, 7R or 7L, replace the relay plate.
Otherwise, deal with the other bargraphs.
3 Diode cut.
Replace the relay plate.
Permanent relay control

Replace the computer.
Main relay (428) energising circuit fault.

Disconnect the 35 track connector from the computer and measure the resistance of the main
relay coil between tracks 8 and 19 on the connector.
5 - If the resistance is between 50 and 60 , check the connections on the 35 track connector. If
the fault persists replace the computer.
- Otherwise check the lines between the computer and the main relay base:
- 8 computer connector / 2 relay
- 19 computer connector / 1 relay
Repair the wiring if necessary. If the fault persists, replace the computer.
Main relay energising circuit fault (short circuit between tracks 8 and 19 of 35-track connector).
5
Check insulation between these tracks. If there is a short circuit, replace the relay plate.
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Bendix ABS
38
Internal computer control.
6 Erase the computer memory (control G0**).

If the fault persists, replace the computer.
Fault on ABS warning light line.

7 Check ABS warning light bulb.
Check warning light wiring: continuity between warning light and track C1 of dashboard/ABS
(R36) connection and between C1 of R36 and track 26 of computer connector.
Diode short-circuited
Replace relay plate.
Solenoid valve control fault (system cut off)

8 FRH solenoid valve terminal 5 35-track connector
9 FLH solenoid valve terminal 22 35-track connector
10 RRH solenoid valve terminal 24 35-track connector.
Ignition off, disconnect the 12 track connector from the solenoid valve assembly and measure
the voltage on track B3 of the connector.
8
9 Do you read 0 Volts?
10
8
9
10
NO
Replace the relay plate
YES
Measure the resistance of the suspected solenoid valve between earth and the
computer connector track specified above.
What resistance value is measured?
R = 0 short circuit on solenoid valve coil replace the brake pressure assembly
1 < R < 5 Test the connections on the 35 track connector. If the connector is correct,
and if the fault persists, replace the computer.
Solenoid valve control fault (system cut off).

8 FRH restriction solenoid valve terminal 4 35-track connector
9 FLH restriction solenoid valve terminal 21 35-track connector
10 RLH solenoid valve terminal 23 35-track connector.
Perform the same operations for illumination on the left.
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Bendix ABS
11
12
13
14
15
16
FRH solenoid valve circuit fault, terminal 5 of 35-track connector

FRH restriction solenoid valve circuit fault, terminal 4 of 35-track connector
FLH solenoid valve circuit fault, terminal 22 of 35-track connector
FLH restriction solenoid valve circuit fault, terminal 21 of 35-track connector
RRH solenoid valve circuit fault, terminal 24 of 35-track connector
RLH solenoid valve circuit fault, terminal 23 of 35-track connector
Illuminated on left: circuit open - on right: short circuit.
17
18
FLH
FRH
RLH RRH
Wheel sensor circuit fault.

Check sensor connector if rear sensor fault.
If connector is correct, check resistance of sensor between terminals 17 and
34 RRH - 15 and 32 RLH - 16 and 33 FRH - 18 and 35 FLH.
If R = replace the sensor if it is a front sensor.

On the rear sensor, repeat measurement on connector at sensor end located near left-hand
mounting of rear axle.
If R still =, replace the sensor.
If 1 < R < 1.45 k, check wiring between sensor and 35-track connector.
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Bendix ABS
38
Special notes for Renault 19 vehicles with AC - PAS - ABS

The introduction of a new computer with new monitoring modes for "wheel sensor information" (bargraph
19 on the Bendix ABS diagnostic fiche) means that the computer must be identified before beginning fault
finding (after entering code D05).
Identifying the computer
D05 then :
#14 : old version, central display shows 9
#14 : new version, central display shows 35
Old generation computers (# 14 9)
Bargraph
Fault finding
Sensor info fault
Enter #07 and read information on XR25 central display (2 cases possible)
Front left
Front right
19
(if #14 9)
Localisation of faulty front wheel

Example
If the fault is on the front left wheel dash displayed corresponds to the faulty wheel
(left hand display)
On cassette n 11, the horizontal dash for wheel localisation does not exist, but does
exist on the following cassettes. This dash makes left / right identification easier.
Localisation of the faulty wheel is followed either by
(examples above)
or
If
is displayed, preceded by the wheel localisation:
Coherence fault for at least one front wheel speed info :

- Check target conformity. (number of teeth, not round...).
- Check sensor fitting and tightness, as well as the air gap over one revolution.
- Check the tyres on the vehicle are all the same. (identical rolling radius).
- Check the wheel bearings do not have a high degree of play.
If these points are correct, there is a short circuit in the sensor wiring , check the
insulation of the sensor at fault on the 35 track connector.
If correct, erase the memory and try to reproduce the fault.
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Bendix ABS
Bargraph
38
Fault finding
If
Sensor info excess frequency fault :

- there may be electrical interference : check the routing of the wiring for the faulty
sensor (ensure it avoids all high frequency generating units).
- there may be mechanical interference : check the sensor is tight (vibration) and the
sensor / target air gap (risk of interference).
Front wheels air gap: 0.15 / 1.15 mm
19
(if #14 9)
Sensor information fault

This fault is taken into account for a speed greater than 15 mph (24 km/h).
Check the conformity, mounting and tightness of the sensor / toothed wheel assemblies
at the rear and the air gap over one revolution.
Rear wheels air gap : 0.20 / 0.80 mm
Check the insulation of the sensors via the intermediate connector at the rear left.
If correct, there is a fault on the 2 front sensors (simultaneously).
Check the conformity and mounting of the sensor / toothed wheel assemblies at the
front and the air gap over one revolution.
Front wheels air gap: 0.15 / 1.15 mm
Check the insulation at the 35 track connector.
Erase the memory and try to reproduce the fault on a road test. If the fault reappears,
carry out a complete check of the ABS wiring and replace the computer if the fault
persists.
38-41
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Bendix ABS
38
New generation computers (# 14 35)
Bargraph
Fault finding
Wheel sensor information fault.
Enter #07 and read the display of the XR25 (4 cases are possible)
Front left
Front right
19
(if #14 35)
Localisation of the faulty wheel
Rear left
Rear right
Example
If the fault is on the front left wheel the dash displayed corresponds to the faulty
wheel (display at the top left).
On cassette n 11, the horizontal dash for wheel localisation does not exist, but does
exist on the following cassettes. This dash makes left / right identification easier.
Localisation of the faulty wheel is followed either by
(examples above)
or
If
Coherence fault for at least one wheel speed info :

- Check target conformity. (number of teeth, not round...).
- Check sensor fitting and tightness, as well as the air gap over one revolution.
- Check the tyres on the vehicle are all the same. (identical rolling radius).
- Check the wheel bearings do not have a high degree of play.
38-42
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Bendix ABS
Bargraph
38
Fault finding
If these points are correct, there is a short circuit in the sensor wiring , check the
insulation of the sensor at fault on the 35 track connector. For the rear sensors, check the
insulation via the intermediate connector located at the rear left.
If correct erase the memory and try to reproduce the fault.
If
Sensor info excess frequency fault :

- there may be electrical interference : check the routing of the wiring for the faulty
sensor (ensure it avoids all high frequency generating units).
- there may be mechanical interference : check the sensor is tight (vibration) and the
sensor / target air gap (risk of interference).
Front wheels air gap:
Rear wheels air gap:
19
(if #14 35)
0.15 / 1.15 mm
0.20 / 0.80 mm
This fault is taken into account for a speed greater than 15 mph (24 km/h).
Information fault for the 4 sensors.
This indication on the XR25 shows a fault on the 4 speed sensors, either a coherence
fault for the speed information or a sensor signal excess frequency fault.
This fault is taken into account under conditions of extreme use or during external
interference.
Erase the computer memory and try to reproduce the fault on a road test. If the fault
reappears, carry out a complete check of the ABS wiring and replace the computer if the
fault persists.
20
Present if XR 25 memorisation function is in use.
The XR 25 memorisation function enables the various values of parameters accessible via the # key (followed
by 2 figures) to be fixed and stored in memory for future use.
Once communication between the XR 25 and the computer has been established,
enter
at the required time to obtain this function.
0
This memory is erased by entering
38-43
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Bendix ABS
HYDRAULIC TEST
Key G (control mode enabling solenoid valves to be checked and activated).
Raise the vehicle so that the wheels can be turned and

check that they turn freely.
Hold the pedal down to prevent the wheel being tested

from turning if driven manually (do not exert excessive
pressure on the brakes, so that the wheel is at the
unlocking point).
Enter D05 then G01* (1: rear left-hand wheel)
The wheel should be temporarily released for

approximately 1 second.
yes
no
Incorrect
Switch the ignition off then on.
Enter D05 (pay no attention to
bargraph 3L flashing).
Repeat this test on the other wheels.

To do so, enter the following codes:
G02* : RRH
G03* : FRH
G04* : FLH
Pressure on brake pedal too high. Repeat

test using reduced pressure.
When G01* is entered, slight noise from

the movement of the solenoid valve should
be heard (3 times), then at the end of the
cycle, bargraph 3 left should illuminate
(computer cuts out).
G05* : FRH restriction

G06* : FLH restriction
if
No locking
No solenoid valve noise
Hydraulic problem
Replace braking pressure hydraulic unit
At the end of tests on all 4 wheels, erase the computer memory
38-44
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Bendix ABS
38
ADDITIONAL TESTS
After initialising the system, on the keyboard enter:
front right-hand wheel speed (in km/h)
XXX
#
front left-hand wheel speed
XXX
#
rear right-hand wheel speed
XXX
#
rear left-hand wheel speed
XXX
#
vehicle speed
XXX
These checks enable the wheel speeds to be displayed (target and sensor check) and the sensor allocation to
be checked.
enables the origin of the incident to be located - pressure fault when bargraph
2 left is illuminated.
enables the origin of the sensor data fault to be determined when bargraph 19
right or left is illuminated.
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Bendix ABS
38
Switch on the ignition without starting the

engine.
On the keyboard enter the code:
ERASING THE MEMORY
Connect the XR 25 to the diagnostic socket on the

vehicle and set the selector to "S5".
The display shows:
Then:
XX
Enter:
The display shows:
92655R
Validate the erase request using
A second later the centre display shows:
The memory has been erased.
38-46
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Bendix ABS
FAULT FINDING
M.S. 1048
Bornier for testing using the XR25 or a multimeter
This is a base of 35 contacts identical to those on the ABS computer on a printed

circuit with electrical contacts numbered from 1 to 35.
Each number corresponds to an electrical connection in the vehicle wiring and is
marked on the operational diagrams.
It is used to allow rapid access without reference errors for testing all the
electrical connections at the main ABS connector.
89024R2
Vehicle wiring
Contacts giving access points for testing
NOTE:
Never disconnect the computer when the circuit has a voltage applied.
Testing of earths and resistances must be carried out with the battery
disconnected.
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38

Bendix ABS
38
Allocation of diagnostic socket terminals
CONNECTION TO VEHICLE
1
2
3
4
With the ignition switched off, disconnect the

ABS computer from its base and connect the
bornier in position.
5
6
7
8
9
10
11
12
Fault finding information AT "A4"

Earth
Foolproofing
Cruise control fault finding
information
ABS fault finding information
+ 12 Volts after ignition
Fault finding information AT "M"
To electronic fault warning light
Injection fault finding information
Not allocated
The diagnostic socket allows the connection of

the XR25 test kit for microprocessor systems.
92726S
Principle of the checking method :

Place the testing pin of the XR25 or of the
multimeter in contact with the numbers indicated
on the bornier.
Control units which can be used:
XR 25 :
- measurement of continuity using the
buzzer,
- voltage measurement using the voltmeter.
88113S
Resistance of the solenoid valves :

1 to 5
Multimeter :
- resistance measurement,
- voltage measurement.
Resistance of the sensors :

1 000 to 1 400
Sensor signal :
1 turn/second,
"Alternating " voltage between 50 and 2 000 mv
Control of safety relay (E) on board (425):
between tracks 8 and 19 of the 35 track bornier
50 to 60
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Bendix ABS
38
Allocation of the computer connector pins

PIN No.
ALLOCATION
Not connected
+ 12 volt after ignition input
Electric earth
Front right restriction modulator
Front right inlet/pressure relief modulator
Not connected
Not connected
ABS safety relay contact
90 bar pressure switch
10
Not connected
11
Not connected
12
Diagnostic socket
13
Not connected
14
Not connected
15
Rear left hand wheel sensor
16
Front right hand wheel sensor
17
Rear right hand wheel sensor
18
Front left hand wheel sensor
19
ABS safety relay contact
20
Electric earth
21
Front left hand restriction modulator
22
Front left inlet/pressure relief modulator
23
Rear left inlet/pressure relief modulator
24
Rear right inlet/pressure relief modulator
25
Not connected
26
ABS warning light return
27
Electric earth
28
Electric earth
29
Not connected
30
Not connected
31
Not connected
32
Rear left wheel sensor
33
Front right wheel sensor
34
Rear right wheel sensor
35
Front left wheel sensor

DI3835
38-49
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Bendix ABS
6 track connector for pressure switch board
connection
38
WIRING DIAGRAM NOMENCLATURE
94717R
12 track connector for braking pressure unit

board connection
104
Ignition switch
107
Battery
118
ABS computer
150
Rear right wheel sensor
151
Rear left wheel sensor
152
Front right wheel sensor
153
Front left wheel sensor
156
Hand brake switch
207
Nivocode sensor
225
Diagnostic socket
247
Instrument panel
260
Fuse
301
ABS electric pump unit relay
361
ABS hydraulic system
425
ABS board
428
Main relay (soldered)
435
ABS solenoid valve assembly
M18
ABS earth
M19
ABS electronic earth
R1
Dashboard /rear right connection
R35
Pedal assembly/dashboard connection
R36
ABS/dashboard connection
Pressure alarm relay
Ignition cutout relay
94718S
38-50
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Bendix ABS
38
DI94918
38-51
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Bendix ABS
38
ADDITIONAL CHECKS
II - Checking rear wheel sensor connectors
I - Target/sensor air gap
If the ABS warning light illuminates intermittently, check as a priority the wheel sensor connectors
and clean them with NETELEC, Part Number 77 01
408 464.
(Place the target so that the top of one tooth is

parallel with the sensor)
Front sensor X = 0.15 to 1.15 mm
92722S
(Check the front sensor connectors if necessary).

92721-1R
Rear sensor X = 0.20 to 0.81 mm
92720-1R
Target conformity :
Number of target teeth : 48
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Bendix ABS
III - Marking the pipes (left-hand drive )
38
IV - Marking the pipes (right-hand drive )
92730R2
94696R1
View from underneath
For obvious safety reasons it is essential never to

invert the braking pressure unit pipes and sensor
connectors.
DI3806
38-53
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Bendix ABS
38
To carry out the different pressure checks (IV to VI) it is necessary beforehand to fit a pressure gauge,
proceeding as follows:
Fre. 1085
Complete brake system test kit
Fit end piece (D) and pressure gauge

Fre. 1085.
Drain plug
Bleed screw
0.8 - 1
0.6-0.8
FITTING OF PRESSURE GAUGE
Depressurise the accumulator by slackening bolt

(5) at least one turn, then retightening it, and
pressing the brake pedal once.
94698R
Place a pipe connected to a reservoir on the

pressure gauge bleed screw.
92724R
Open the bleed screw.

Remove the bolt indicated in the diagram below.
Switch on the ignition and press the brake pedal.
Wait until the fluid flows without bubbles, and
close the screw.
Switch off the ignition and release the brake
pedal.
DI3886
38-54
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Bendix ABS
38
IV - Checking the accumulator
CHECKS
CORRECT VALUES
ADDITIONAL CHECKS
Checking the accumulator

Reduce the pressure (bolt 5).
Check electric pump unit priming.
92724R1
Retighten bolt (5).

The pressure increases to a

value of between 50 and 70
bars.
The pressure gauge needle

must stabilise at this value
before continuing to rise.
If the value is incorrect, replace the

accumulator.
91582S1
Checking hydraulic accumulator

depressurising time (engine warm,
system temperature 60 to 80o C).
Check :
- the tightness of the pressure
release screw,
- for the absence of an external leak.

Wait until the pump stops.
Check the time it takes to resume
operation (without pressing the
brake pedal).

electric pump unit assembly.
Minimum time : 2 mm
Maximum time : 9 mm
38-55
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Bendix ABS
38
V - Checking charging times and 160 and 180 bar pressure switches
CHECKS
CORRECT VALUES
ADDITIONAL CHECKS
Accumulator charging time

Check :
Reduce the pressure (bolt 5).
- the operation of the pump,

- the condition of the filter in the
Banjo union,
Charging time
40 to 60 seconds
- the condition of the high pressure

hose and pipes.
Pressure between
180 and 190 bars
If the pressure value is incorrect ( >

190 bars), replace the 180 bar
pressure switch.
The pressure must be between

155 and 165 bars
If the pressure value is incorrect,

replace the 160 bar pressure switch.
92724R1
Retighten bolt (5).

91582S1
Press the brake pedal several times.
NOTE : the pump restarts after 2 to 4
presses of the brake pedal.

91583S1
Check the pressure at which the

pump restarts.
Re-inflation time
160 / 180 bars
3 to 10 seconds
38-56
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Bendix ABS
38
VI - Checking 90 bar pressure switch
CHECKS
CORRECT VALUES
ADDITIONAL CHECKS
Checking 90 bar pressure switch.

Check :
Wait for the pump to stop.
- warning light bulbs,

Disconnect the supply to the electric
pump unit motor (2 track connector
on board 425).
- warning light fuses,

- pressure alarm relay,
Warning lights extinguished.
Switch on the ignition again and

press the brake pedal several times.
- continuity.
91583S1
Check that the warning lights

+
illuminated for a pressure
of :
Reconnect the 2 track connector to

the board (425).
90
+5
0 bars
The pump operates,

the warning lights
+
are extinguished
38-57
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pressure switch.

Bendix ABS
38
VII - Checking for internal leaks
CHECKS
CORRECT VALUES
ADDITIONAL CHECKS
Checking for internal leaks

Fit 2 pressure gauges on the front
wheel calipers.
After 5 minutes there must be

no loss of pressure
(1 bar max.)
Check for the absence of an external

leak.
Replace the braking pressure unit
assembly.
91563-4R3
91582S1
Wait for the pump to stop.

Using a pedal press, adjust the
pressure on the front wheels to
100 bars.
REMOVING THE PRESSURE GAUGES
After a pressure gauge has been removed it is necessary to bleed the hydraulic circuit at the point where it
was connected.
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Bendix ABS
38
VIII - Checking the alarm device
CHECKS
CORRECT VALUES
ADDITIONAL CHECKS
Checking operation of dual alarm

device incorporated in the brake
fluid reservoir.
Using a screwdriver, press the plug
plunger enabling the float to be
lowered.
Check :
- the warning light bulb,
Check that the nivocode
warning light illuminates
(hand brake in position of rest)
- the continuity of the electrical

circuit.
The alarm device is integrated in the
reservoir, if it fails to operate, replace
the complete reservoir.
92728S1
2nd check
Reduce the pressure in the
accumulator by pressing the brake
pedal about twenty times.
Switch the ignition on, the pump
operates to fill the accumulator.
Press the plunger as far as it will go
the pump must stop
Release
the pump must

restart
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In case of failure (pump does not

stop), replace the reservoir.

Bendix ABS
38
BRAKE COMPENSATOR
Principle of checking operation

These vehicles are equipped with a load sensitive
brake compensator. The pressure readings are
taken in an X configuration, by comparing the
pressure at the rear wheels with a given pressure
at the front wheels.
These dual compensators have two totally
separate bodies which act in an X configuration
on one front wheel and one rear wheel.
I
front right/rear left hand circuit
II
front left / rear right hand circuit
Load sensitive compensator

On the load sensitive compensators the adjusting
system enables the rear pressure to be adjusted
as a function of the front pressure.
The adjusting system acts simultaneously on the
two bodies. If the pressure on one of the two
bodies is incorrect, replace the compensator.
85925S
38-60
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Bendix ABS
BRAKE COMPENSATOR
Checking - Adjusting
93449G
92 719
To adjust : slacken nut (A) and alter the position

of rod (B) in sleeve (C).
NOTE : it is not permissible to alter the position of

nut (F).
38-61
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38

Bendix ABS
Fuel tank
(driver in vehicle)
Vehicle type
Test pressure (Bar)

Front

integrated in the wheel cylinder
B, C, L
533
53C
53Y
534
53J
53K
38
Rear
60
34
+0
-4
100
40
+0
-8
With ABS
(after
05/92)
B, C, L
53T
53V
53Z
With ABS
3, 4, 5
53A
53B
53F
With ABS
B, C, L, S
53F
538
53K
53T
53Z
Without
ABS
(after
11/94)
3, 4, 5
53C
53D
53H
Without
ABS (after
11/94)
90966S1
Full
38-62
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Bendix ABS
Fuel tank
(driver in vehicle)
Vehicle type
Test pressure (Bar)

Front
B, C, L, D
539
53D
(before
05.92)
B, C, L
53A
53S
53B
538
With ABS
53F
With ABS
(after
05.92)
B, C, L
3, 4, 5
53C
53D
53H
38
60
Rear
47
+0
-8
100
52
+0
-8
100
49
+0
-8
With ABS
90966S1
Full
D53D (after 05.92

853C
B, C, L, S
3, 4, 5
53F
538
53K
53T
53Z
53C
53D
53H
Without
ABS
(after
11/94)
Without
ABS
(after
11/94)
38-63
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Bendix ABS
Fuel tank
(driver in vehicle)
Vehicle type
Test pressure (Bar)

Front
533
53C
53F
534
53J
53K
53Y
With ABS
(before
05/92)
B, C
53M
ABS
B, C, L
53D
(After
05.92)
B, C, L, D, S
38
Rear
100
43
+0
-8
100
52
+0
-8
90966S1
Full
D
8
53C
53Y
With ABS
(after
05.92)
53V
53A
53F
With ABS
38-64
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Bendix ABS
CHECKING LEVEL - BLEEDING
38
II - COMPLETE BLEEDING
I - CHECKING THE LEVEL

The brake fluid level is checked with the ignition

switched on: accumulator filled to MAXIMUM
reference mark.
815
Fre. 1 085
M.S.
Bleeding device
Complete kit for brake system
Switch on the ignition and wait for the pump to

stop.
If necessary top up the fluid level to the
MAXIMUM mark (B) (vehicle with new shoes or
linings)
Precaution to be taken before carrying out any

work on the bleed screws:
NEVER open the wheel cylinders : foot on the
brake pedal, accumulator full.
The accumulator is loaded to 180 bars. Before
carrying out any operation it is essential to
determine whether or not it needs to be emptied
by reducing the pressure as follows:
Reducing the pressure in the accumulator
The accumulator pressure is reduced by
slackening bolt (5) one turn. This bolt can be
reached from underneath the vehicle.
92729R1
Left-hand drive
NOTE : the capacity of the brake fluid reservoir is
intended to compensate for the fluid flowing

from the accumulator when it is emptied.
92724R
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Bendix ABS
38
Right-hand drive
91582S
Remove the protective plate (right-hand drive).
94699-1R
Fill the high pressure(HP) hose by slackening

union (E) (braking pressure unit connection)
several turns.
Tightening torque of bolt (5) : from 0.8 to 1

daN.m.
When the pedal is pressed, the different bleed
screws must always be slackened and tightened
progressively.
Left-hand drive
Between each operation check the level of the

brake fluid in the reservoir.
1. Priming of the electric pump unit

Depressurise the accumulator by means of bolt
(5).
Fill the reservoir with brake fluid.
Switch on the ignition. If the electric pump unit
does not operate, first check that the float in the
reservoir is not stuck in the bottom position by retightening the plug and pressing the plunger.
92730R
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Bendix ABS
Right-hand drive
38
2. Bleeding the electric pump unit and the failure

chamber
Fill the reservoir with brake fluid.
Connect bleed screws (3) and (4) to M.S. 815 and
slacken them.
DI3886R
94696R
Allow to drain.
Switch on the ignition, electric pump unit

operates.
Retighten union (E).

Allow to drain until the emulsion has

disappeared.
Retighten bolt (5).
Retighten (3) and (4) with the engine running.

Allow to run until stopped by pressure switch.
(5).
Allow the brake fluid to stand for about 3
minutes.
Retighten bolt (5) and restart the above operation
3 times in succession (complete elimination of the
emulsion on releasing the accumulator pressure).
94699-1R
38-67
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Bendix ABS
38
Refit the protective braking pressure unit plate

(right-hand drive).
3. Bleeding the braking pressure unit (simulation

spring zone)
(5), then retighten it.
Press the brake pedal.
Open bleed screws (3) and (4).
With the pedal pressed, retighten (3) and (4).
Release the brake pedal.
Repeat the operation as many times as necessary
until the emulsion disappears.
The result of the operation may be considerably
improved by pressing slowly and gently on the
brake pedal.
4. Bleeding at the plate bolts
94700R
The pump is used as a circulator.

5. Bleeding at the calipers

The pump is used as a circulator.
Slacken bolts (1) and (2) one turn.

Place a hose, connected to a bottle, on the bleed
screw concerned.
Open the bleed screw.
Switch on the ignition and press the brake pedal.
Wait until the fluid is flowing without bubbles,
and close the screw.
Switch off the ignition and release the brake
pedal (avoids inflating the accumulator between
each wheel).
DI3886R1
Press the brake pedal.
Carry out the same procedure for the other

wheels.
Switch on the ignition, the electric pump unit

operates.
After 30 seconds tighten bolts (1) and (2), with the
engine running.
Release the brake pedal.
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Bendix ABS
38
Press the brake pedal sharply, it should have a

minimum pressure of approximately 30 bars in the
front wheel cylinders.
6. Checking bleeding
If you do not have 30 bars, check the bleeding of

the pressure gauges, if it is correct, restart
operation 3.
Connect two pressure gauges Fre. 1 085 to the

front wheels.
7. Topping up reservoir
See level check.
Warning : the Parts Department supplies the
braking pressure unit and electric pump unit with
bolts (1), (2) and (5) slackened a maximum of 2
turns.
III - PARTIAL BLEEDING
When one or more calipers are to be replaced,

partial bleeding is possible.
Point 5 of the complete bleeding method must be
repeated (bleeding at the calipers).
92727R1
91563-4R3
38-69
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Bendix ABS
FAULT CHART FOR
38
ABS BENDIX
EFFECT OBSERVED ON OPERATION OF ABS AND BRAKE WARNING LIGHTS
1 - When the ignition is switched on/engine is started/engine running

1.1 - ABS warning light not illuminated during initialisation
+ illumination of brake warning light
1.3 - ABS warning light remains illuminated after initialisation without illumination of brake warning light
1.4 - ABS warning light remains illuminated after initialisation + illumination of brake warning light (after 30 s)
1.5 - Dim illumination of ABS warning light
2 - While driving/braking without ABS regulation
2.1 2.2 2.3 2.4 2.5 -
Illumination of ABS warning light alone

Illumination of ABS warning light + brake warning light
Random illumination of ABS warning light
Illumination of brake warning light alone
Illumination of ABS warning light only at high speed,
always in same speed bracket
3 - While braking with ABS regulation

3.1 - Illumination of ABS warning light during ABS braking
(with or without prior extinguishing)
3.2 - Illumination of ABS warning light at end of ABS braking
or delayed after ABS braking.
4 - Other cases
4.1 - Warning light remains illuminated after ignition is
switched off
38-70
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Bendix ABS
2
38
EFFECTS OBSERVED ON OPERATION OF ABS BRAKES WITHOUT ILLUMINATION OF

WARNING LIGHT
1 - Locking of one or more wheels

2 - Divergence from trajectory
2.1 - Pulling
2.2 - Wandering
3 - Unexpected operation of ABS (while driving)
3.1 3.2 3.3 3.4 -
On poor roads
On good roads
At low speed
When using special equipment (car telephone, CB radio,
etc.)
3.5 - Other cases linked to the external environment
4 - Effects on brake pedal
4.1 - Erratic/spongy pedal
5 - Noise
5.1 - From pump, unit or piping
6 - Other effects
6.1 - Frequent pump motor operation
6.2 - Prolonged activation of pump motor
38-71
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Bendix ABS
1
38
Effect on operation of ABS and brake warning lights
1 - When ignition is switched on/engine is started/engine running

Connect the XR 25 to the vehicles diagnostic socket.

Set the ISO unit to position S5, and use the latest
version of the XR 25 cassette.
Switch on the ignition and enter the code D05 on the
keyboard. Does bargraph 1 illuminate?
yes
yes
no
Is bargraph 7 illuminated?
Communication fault between XR 25 and

ABS computer:
no
Recheck
your
diagnosis
On the left:
ABS warning light line
interruption.
- Check 10 A stop light fuse n 29.
- Check continuity between track
26 of computer and track C1 of
ABS/dashboard R36
connection.
- Check continuity between track
C1 of R36 and warning light.
- Check condition of warning
light bulb and for presence of
+ after ignition at warning
light.
On the right:
The diode on the plate has shortcircuited.
- Replace the relay plate.
Check connection of R36 connection

(ABS/dashboard) located near battery;
Check connection between diagnostic
socket and computer: continuity between
track 12 of computer and track 5 of
diagnostic socket.
If incorrect, check following continuities:
- Between track 12 of computer and
track A2 of the ABS/dashboard
connection;
- Between track A2 of ABS/dashboard
R36 connection and track 5 of
diagnostic socket.
Check voltage at track 6 of diagnostic
socket (V > 10 volts).
Check for the presence of earth at track 2
of diagnostic socket.
Check computer supply:
- Presence of earth at tracks 3, 20, 27
and 28. If not, check continuity with
earth M19.
- Presence of voltage > 10 volts at track
2.
If not, check:
- Battery voltage;
- ABS 15 A fuse n 13 of relay plate;
- Starter cut-out relay: remove
starter cut-out relay and shunt
terminals 3 and 4 on the base.
Under these conditions, is
V > 10 volts at track 2 of computer?
no
yes
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Bendix ABS
1
38
(continued)
Break in wiring.
Check following continuities:
- Between track 2 of computer and 4
of starter cut-out relay base;
- Between track 3 of starter cut-out
relay base and track A1 of ABS/
dashboard R36 connection;
- Between track A1 of R36 and track
2A of ignition switch via 15 A fuse.
- Check for absence of voltage at terminal

2 of starter cut-out relay base:
- If no voltage is present, replace the
relay (contact faulty);
- If voltage is present, check operation
of ignition switch.
Additional checks
Check operation of brake warning light by

applying the handbrake.
If it does not illuminate, push down the
button on the reservoir using a screwdriver.
Does the brake warning light illuminate?
no
yes
Check warning light bulb

and for presence of + after
ignition at warning light.
Check continuity of brake
warning light lines.
Check operation of handbrake switch and continuity

between it and the warning light.
If it illuminates, check operation of 90 bar pressostat:
ignition off, drain the high pressure system (at the
pedal or via drain plug n 5) and switch on the ignition.
If, in addition to the ABS warning light, the brake
warning light does not illuminate either, disconnect the
one-track connector from the 90 bar pressostat and
check earth continuity at pressostat end. Is there
continuity?
yes
no
Replace 90 bar pressostat
(tightening torque: 0.7 to
1.3 daNm).
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Reconnect 90 bar pressostat and

check operation/supply of pressure
warning relay and corresponding
continuities.

Bendix ABS
1
38

1.2 - No illumination of ABS warning light during initialisation + illumination of brake
warning light
Use XR 25 to check illumination of bargraph n 7 (for non-illumination of ABS warning

light) + check brake fluid level, Nivocode operation and insulation of brake warning light
lines (for illumination of brake warning light).
1.3 - ABS warning light remains illuminated after initialisation, without illumination of
brake warning light
Use XR 25 to check for illumination of bargraphs.

Check earth insulation of ABS warning light line.
Disconnect R36 connection (ABS/dashboard)
located near the battery and
switch the ignition on again.
Does the warning light illuminate again?
no
yes
Check insulation of ABS warning light line

between R36 and warning light.

Reconnect the R36 connection and disconnect the computer connector.
Connect bornier M.S. 1048
and a voltmeter between terminals 20 and 26. Switch on the ignition.
What is the voltage measured?
-
Between 0.5 and 1 V approximately: the connections are correct; main relay or
computer faulty:
- Switch off the ignition and reconnect the computer.
- Disconnect the 12-track solenoid valve connector on the plate and switch
on the ignition. What is the voltage at track A2 of the 12-track connector.
. V battery:
main relay contact correct Replace the computer.
. 0 volts:
relay contact faulty
Replace the plate.
0 volts: earth insulation fault on line or diode short-circuited.

- Disconnect 6-track solenoid valve connector from plate and measure
voltage at diode terminals with ignition on (between track 26 of computer
and A2 of 12-track). What is the voltage measured?
. 0.5 < V < 1 volt:
Earth insulation fault on line between track 26 of
computer and C1 of R36 connection.
. 0 volt:
diode short-circuited. Replace the plate.
Continued over
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Bendix ABS
1
38
Checking the computer supply
Presence of earth at tracks 3, 20, 27 and 28. If not present, check continuity with earth
M19.
Presence of voltage > 10 volts at track 2. If not present, check:

- battery voltage;
- ABS 15 A no. 13 fuse on relay plate;
- starter cut-out relay; remove the starter cut-out relay and shunt terminals 3 and 4
on the base.
Under these conditions, is V > 10 volts at track 2 of computer?
NO - Break in wiring; check following continuities:

- Between track 2 of computer and 4 of starter cut-out relay base;
- Between track 3 of starter cut-out relay base and track A1 of ABS/dashboard
R36 connection;
- Between track A1 of R36 and track 2A of ignition switch via 15 A fuse;
- Check operation of ignition switch.
YES - check absence of voltage at terminal 2 of starter cut-out relay base.

- If voltage is not present, replace the relay (contact faulty).
- If voltage is present, check the operation of the ignition switch.
Checking the operation of starter cut-out relay during starting phase
In starting phase, check for absence of voltage at terminal 2 of computer.

If voltage is present: fault on the starter cut-out relay energising circuit; check for the
presence of voltage at terminal 2 of relay base during starting phase.
-
If not, check, with ignition off:

- continuity between terminal 2 of relay base and track B1 of R36;
- continuity between track B1 of R36 and terminal 2B of ignition switch;
- operation of ignition switch.
If so, check continuity between earth M18 and terminal 1 of relay base. If earth is
correct, replace starter cut-out relay.
Checking the operation of the main relay (contact sticking)
Disconnect the connector from the solenoid

valve unit.
With the ignition on, measure the voltage at
terminal B3 of the connector, harness end.
Is the voltage > 10 volts?
no
yes
Replace the relay plate.
Recheck your diagnosis
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Bendix ABS
1
Effect on operation of ABS and
38
brake warning lights

1.4 - The ABS warning light remains illuminated after initialisation, with illumination of
brake warning light
(after 30 seconds)
Use XR 25 to check for illumination
of bargraphs
(certainly bargraph 2 left for pressure fault).
If bargraph 2 is illuminated on left,
enter #06 and read information on XR 25 centre
display.
If LP is displayed
If LR is displayed
- Check connections of 160 and 90 bar

pressostat, of 6-track connector of pressostat
on relay plate and Nivocode connector.
Check coil or pressure warning relay

coil circuit.
- Check operation of pump motor:

- Switch off the ignition;
- Drain the high-pressure circuit:
unscrew drain plug n 5 a maximum of 1
turn and depress the brake pedal once.
- Switch on the ignition.
yes
Does the pump motor turn?

no
B
- Check operation of Nivocode:
Disconnect connector from Nivocode and
check level is correct, continuity between
tracks 2 and 3 of Nivocode. If incorrect,
replace the reservoir.
- Check motor supply:
Disconnect 2-track connector from motor
and measure the voltage.
- If the voltage is > 10 volts, replace the
elect. pump assembly..
- If voltage = 0, disconnect 160 bar pressure
switch connector and earth the track.
Does the motor turn?
no
yes
Replace 160 bar

pressostat.
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Bendix ABS
1
Effect on operation of ABS and
38
brake warning lights

(continued)
- Check 30 A fuse on relay plate.

- If it has blown, replace it after switching off the ignition and repeating
the motor operation test.
- If the fuse blows again, look for a short circuit on the pump motor line.
- If it does not blow, check the current consumed by the motor by checking
that no other consumer units are connected.
It should be < 25 A. It if it higher, replace the elect. pump assembly.
- Check for the presence of voltage at track 1 of the motor connector. If not
present, check continuity between + BAT and this track 1 via 30 A fuse.
- Check continuity between earth and track 2 of motor connector. If no
continuity, check operation of motor relay. Disconnect motor relay and
shunt tracks 3 and 5 of base. Does the motor operate?
- NO - Check continuity between earth and terminal 3 of motor relay base
and between terminal 5 and track 2 of motor connector.
- YES - Check for presence of voltage at terminal 1 of motor relay base
(ignition on). If not present, check continuity between this terminal 1 and
terminal 2 of Nivocode.
If these checks are correct, replace the relay plate.
Drain circuit and measure operating time of pump motor.

40 < T < 60 seconds:
- Pump brake pedal with ignition on and monitor change in travel. Does it become
spongy?
- NO: Normal elect. pump assembly. operation
- YES: Check condition of filter at pump output.
1 < T < 1.5 minutes:
- Check operation of pressostats:

Switch off ignition and redrain the HP circuit.
Fit pressure gauge Fre. 1085 + union in place of one of the brake pressure assembly
bleed screws.
Switch on ignition and measure pressure in the circuit when the pump stops.
- If the pressure is not between 180 and 190 bar, replace 180 bar pressostat (tightening
torque 0.7 to 1.3 daNm).
- If the pressure is correct, depress the brake pedal and reduce the pressure.
The pump should restart at a value between 155 and 165 bar.
If not, replace 160 bar pressostat.
- Check tightness of screw 5 (0.8 to 1 daNm). If pump is worn, replace elect. pump
assembly.
T > 1.5 minutes:
Check tightness of elect. pump assembly. drain plug (screw n 5 at torque 0.8 to 1 daNm).
Check that connecting pipe between reservoir and pump is not clamped or blocked.
Pump deprimed: reprime + bleed.
Fracture of motor/pump mechanical connection.
Pump worn, replace elect. pump assembly.
If fault (bargraph 2) persists, check operation of 90 bar pressostat. If there is continuity

between earth and track C1 of 6-track connector on relay plate (system under pressure),
replace 90 bar pressostat (tightening torque: 0.7 to 1.3 daNm).
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Bendix ABS
1
38

1.5 - ABS warning light dimly illuminated
The brightness of the ABS warning light is not strictly constant, but this does not mean
there is a fault.
If there is a fault, it is due to the ABS earth. Check the mounting of the computer/relay
plate support bracket (self-tapping screw). Earths M18 and M19 are taken from this
support bracket.

2.1 - Illumination of ABS warning light alone
Check the system using the XR 25.

If there is no obvious fault, check using the XR 25 during a road test.
2.2 - Illumination of ABS warning light + brake warning light
Same as test 1.4.
2.3 - Random illumination of ABS warning light
Check the system using the XR 25.

Check the electrical connections, particularly on the level of +supply and earth, since a
cut-out could be interpreted as a contact interruption.
2.4 - Illumination of brake warning light
Check position of handbrake.

Check fluid level in reservoir and operation of Nivocode: insulation between tracks 1 and 4.
Replace reservoir if faulty.
Check correct operation of handbrake switch.
Check earth insulation of brake warning light lines.
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Bendix ABS
1

2.5 - Illumination of ABS warning light, only at high speed, always in
same speed bracket.
Check the system using the XR 25 for probable illumination of bargraph 19.
This phenomenon is often caused by mixing tyres of different sizes or using special
equipment (snow tyres, etc.).
- Check that the vehicle is fitted with four identical tyres.
- Check whether there is excess play in the wheel bearings and repair if necessary.
- Check whether there are any damaged teeth on the targets.
- Check the air gaps and the mounting of the speed sensors.
If the fault persists, road test the vehicle to reproduce the fault.
During the test, use functions #01, 02, 03 and 04 to detect a potential sensor fault.
After the test, repeat the check using the XR 25.
3 - While braking with ABS regulation

3.1 - Illumination of ABS warning light during ABS braking
(with or without prior extinguishing)

Check the system using the XR 25 for probable illumination of bargraphs 17, 18 or 19.
Check operation of solenoid valves (test explained under Wheel locking).
3.2 - Illumination of ABS warning light at end of ABS braking, or delayed after ABS
braking
Check the system using the XR 25 for probable illumination of bargraph 2 right, linked to a
battery charging fault.
4 - Other cases
4.1 - ABS warning light remains illuminated after the ignition is switched off
Since the warning light line is usually earthed by the main relay, the fault can only be
caused by the warning light positive supply.
- Check operation of the ignition switch.
- Check supply only at warning light + after ignition.
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38

Bendix ABS
2
Effects observed on operation of ABS brakes without illumination of warning light
1 - Locking of one or more wheels
Remember:
Immobilisation of the wheels of a vehicle with ABS brakes, or tyre squeal

which feels to the customer like locking, can be linked to a normal system
reaction and should not always be assumed to be faults:
- Locking authorised below 4 mph (6 km/h) (system not active).
- Braking with ABS regulation on very poor road surfaces (loud squealing).
On the other hand, if the wheel(s) is/are truly locked

Possible inversion of speed sensor connections.
Check sensor voltages:
- Raise the vehicle so that the wheels can be
turned. Connect a multimeter in AC voltage
position between terminals 17 and 34 of the
bornier.
- Turn the rear right-hand wheel sharply.
Is the alternating current between
0.5 and 3 volts?
no
yes
Check:
- Sensor mounting
- Air gap (0.2 to 0.81 mm)
- Target mounting.
If there is still no value measured, turn
the other wheels to confirm any
possible electrical inversion of the
sensors and repair the wiring.
Perform the same test on the other

wheels:
- Front left-hand wheel: between
tracks 18 and 35 (air gap 0.15 to
1.15 mm)
- Front right-hand wheel: between
tracks 16 and 33 (air gap 0.15 to
1.15 mm)
- Rear left-hand wheel: between
tracks 15 and 32 (air gap 0.2 to 0.81
mm).
Before reconnecting the sensors,
smear them with Multi-purpose
grease, part n 77 01 422 308
Continued over
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38

Bendix ABS
2
Effects on operation of ABS brakes without illumination of warning light
(continued)
If the fault persists:
Possible reversal of hydraulic unit piping.

Check operation of solenoid valves and ensure
consistency of results obtained (locking of the
correct wheels).
Raise the vehicle so that the wheels can be turned
and check that they turn freely.
Hold the brake pedal down to prevent the wheel
to be tested from turning when driven manually.
Enter D05 then G01* (for RLH wheel).
Is the RLH wheel temporarily
released for 1 second?
no
yes
Brake pedal pressure too high.

Repeat the test with lower pressure.
When request G01* is made, the
movement of the solenoid valve (3 times)
should be just audible then bargraph 3L
may illuminate at the end of the cycle.
- If there is no release, switch the
ignition off then on, enter D05 and
reuse the same code, watching to see
if another wheel is released
(confirming reversed piping: repair).
- If there is no release and no solenoid
valve noise there is a hydraulic fault,
replace the braking pressure unit.
Switch the ignition off then on.

Enter D05 (pay no attention to flashing of
bargraph 3L).
Repeat the test on the other wheels:
enter the following codes:
- G03* : FRH
- G05* : FRH restriction
- G02* : RRH
- G04* : FLH
- G06* : FLH restriction
When all 4 wheels have been tested,
erase the computer memory (function
GO**)
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38

Bendix ABS
2

2.1 - Pulling
Connect XR 25 ,
enter D05 to deactivate the ABS and road test the
vehicle without ABS.
Does the fault persist under these conditions?
yes
no
Check tyre pressures, front

axle, calipers and pads or,
possibly, for leaks in the
circuit.
Check:
Possible inversion of speed sensor connections.
- Test sensor voltage (see test for 1st case of
wheel locking )
Possible inversion of hydraulic unit piping
- Test operation of solenoid valves (see test for
1st case of wheel locking).
Check balance of pressure on front calipers:
- De-pressurise accumulator by loosening drain
plug (n 5) by one turn and then retighten.
- Connect 2 pressure gauges Fre. 1085 to the
front caliper bleed screws and bleed them (by
switching on the ignition and depressing the
brake pedal).
- Depress the brake pedal hard and compare
the pressures at both calipers.
Are the pressures identical?
(L/R difference: max 4 bar).
no
yes
Replace the brake pressure

assembly (imbalance in travel
of limiter rods).
Recheck your
diagnosis
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38

Bendix ABS
2

2.2 - Wandering
Connect XR 25 ,
enter D05 to deactivate the ABS and road test the
vehicle without ABS.
no
yes
Normal behaviour linked to operation of

system in regulation phase, mainly on surfaces
with uneven adherence.
If the fault is particularly significant, check
adjustment of brake limiter.
Road-holding fault not linked to ABS system.

Check tyre pressures, front axle, calipers and
pads or, possibly, for the presence of leaks in
the circuit.
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38

Bendix ABS
2
38
3 - Unexpected ABS operation (while driving)

3.1 - On poor road surfaces
On poor road surfaces it is normal to hear louder squeal than on good road surfaces. The
resulting impression is of a variation in efficiency, which is normal.
This phenomenon is accentuated on vehicles with highly reduced efficiency shock
absorbers Check shock absorbers + condition of tyres.
3.2 - On good road surfaces
Check conformity of wheel targets.

Check adjustment of brake compensator.
3.3 - At low speed
(fault similar to loss of brakes)

Check mounting of speed sensors and air gaps (air gap front wheel: 0.15 to 1.15 mm; rear
wheel: 0.2 to 0.81 mm).
Check conformity of speed sensors.
3.4 - When using special equipment (car telephone, CB radio, etc.).
Check that the equipment has been correctly installed, without modifying the original
wiring, especially the ABS wiring.
3.5 - Other cases linked to the external environment
Near radars, radio transmitters or in highly metallic zones, the ABS system may be disrupted
by interference. If the drivers foot is on the brake pedal, he may notice and be surprised by
the ABS system operating when it should not.
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Bendix ABS
2
4 - Effects on brake pedal

4.1 - Erratic / spongy pedal
Check visually for any external leaks and repair leaking parts.
It is possible that the filter on the Banjo connection screw at the brake pressure assembly
end of the HP pipe is clogged: replace the screw.
5 - Noise
5.1 - Noise from pump, pipes or unit
- Unit vibration: Check presence and condition of units mountings.

- Piping vibration: check that all pipes are correctly clipped into their mounting clips and
that there is no contact between pipes or between pipes and bodywork.
Check that there is no contact between any element in the engine compartment and the
brake pressure assembly, the elect. pump assembly. and the HP pipe.
6 - Other cases
6.1 - Very frequent pump motor operation
A) Check correct torque tightness of drain plug n 5 (0.8 to 1 daNm).

B) Check accumulator operation.
- Switch off the ignition and drain the HP circuit by loosening screw n 5 by one turn.
- Fit a pressure gauge Fre. 1085 + union in place of bleed screw n 4 of brake pressure
assembly and bleed the pressure gauge (by switching on the ignition and depressing
the brake pedal).
- With screw n 5 retightened, switch on the ignition and monitor the pressure gauge.
Does the pressure increase immediately to between 50 and 70 bar and continue
increasing after a few seconds?
- NO - If the pressure remains very low, check elect. pump assembly. priming.
If it immediately rises to a high pressure, replace the accumulator.
Continued over
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38

Bendix ABS
2
38
Continued
- YES
C) Check operation of 160 and 180 bar pressostats.
- Switch off the ignition and redrain the HP circuit via screw n 5.
- With screw n 5 retightened, switch on the ignition and measure the pressure in the
circuit when the pump stops.
If the pressure is not between 180 and 190 bar (160 bar), check connection of 180 bar
pressostat and replace it if necessary (tightening torque: 0.7 to 1.3 daNm).
If the pressure is correct, depress the brake pedal and reduce the pressure.
The pump should restart at a value between 155 and 165 bar (recharging time should be
between 3 and 10 seconds).
If not, replace 160 bar pressostat.
D) Check losses of pressure in the pump:
- Drain the circuit via drain plug n 5.
- Screw n 5 retightened, switch on the ignition and wait until the pump has been
stopped for 3 minutes.
- Measure the pressure in the circuit.
- Check the loss of pressure after 5 minutes.
If the loss of pressure is > 1 bar, replace the pump.
Otherwise, the operating frequency is normal.
6.2 - Prolonged activation of pump motor
Check that piping is not clamped between reservoir and pump.

Check that there are no external leaks.
Check the operating time and the pressures obtained as a function of the time.
-
Increase in pressure 0 -- 180 bar: 40 to 60 s.
Pump reactivation at 155/160 bar with rise to 180 bar in 10 seconds maximum.
If these times are not obtained, replace the electric pump assembly.
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Bosch ABS
38
Identification of Renault 19 vehicles fitted with BOSCH ABS

From now on Renault 19 vehicles will be fitted with BOSCH ABS except for:
- automatic transmission versions,
- Turbo Diesel versions ,
- the 16 valve version (X53D) with air conditioning.
These models (AT, Turbo Diesel and X53D/AC) will retain the BENDIX ABS system.
Introduction
The BOSCH ABS 2E system comprises a hydraulic unit with an integral computer and four inductive sensors
which measure the speed of each wheel via a toothed wheel.
The hydraulic assemble is located in the engine compartment. The brake pipes connect the dual master
cylinder to the various wheels via the hydraulic assembly.
The flow, delivered by the two master cylinder circuits, at the moment of braking, passes via three solenoid
valves. These ensure the independent regulation of the front left hand wheel, the front right hand wheel and
the rear axle wheels.
The vehicle has an X pattern braking circuit and so there is separation between the two rear brakes using a
mechanical device known as the piston plunger.
The device comprises four separate channels. The two rear channels operate at the same pressure according
to the select Low principle; the lowest adherence wheel causes the same regulation on the rear wheels.
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Bosch ABS
38
94917R1
NOTE : The diagram is a general diagram only; it should never be used as a reference for the take off points
and circuit allocations. When replacing one of the component parts of the braking circuit on a vehicle, always
mark the pipes before removal to ensure they are reconnected in the same position.
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Bosch ABS
38
Apart from the braking components:

- brake calipers,
- dual master cylinder (with non-return valves),
- dual load sensitive compensator (5),
which are conventional parts, the ABS system comprises:
- one wheel speed sensor per wheel (3),
- four targets (4), embedded :
- at the front on the driveshafts
- at the rear on the hubs,
- a hydraulic assembly (1) comprising :
- one regulation solenoid valve for each front wheel,
- one solenoid valve and a piston plunger for the rear axle,
- and a hydraulic pump,
- a computer (2) (integral in the hydraulic assembly) with a self-test facility,
- a warning light on the instrument panel,
- a diagnostic socket allowing connection of the XR 25.
ABS 2 E - 4 channels - 4 sensors
DI3818
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Bosch ABS
38
DI3887
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Bosch ABS
Front wheels
Targets embedded in the driveshafts.
Speed sensor (3) and target (4)
38
Radial, non-adjustable sensors.
A magnetic sensor is composed of a permanent

magnet, a polar mass and a coil.
The magnet creates a magnetic flux which is
channelled by the polar mass.
This flux is disturbed by the variation in air gap
(when a tooth passes near the polar earth),
creating an electrical voltage at the terminals of
the coil.
The sensors deliver an alternating electrical
voltage. The frequency of the signal is
proportional to the speed of the wheel.
94868R
Rear wheels
Targets embedded in the hubs (cannot be
removed).
Tangential, non-adjustable sensors.
DI3888
1
2
3
4
Magnet
Field lines
Polar mass
Target
The speed sensors are mounted on the stub axle

carriers and receive information via the toothed
targets (26 teeth at the front and the rear).
96955S
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Bosch ABS
The speed sensors are connected to the computer
via connectors located:
38
For the rear:

Next to the left hand mounting for the rear axle
assembly.
For the front:

On the side of the shock absorber turret in the
engine compartment.
96954S
NOTE : only the length of the polar core is
different between the front and rear sensors.
96953-1R
Connector for front left hand speed sensor (A).
Fitting precautions
The sensor must be pressed in by hand, after
coating it with multipurpose grease, Part Number
77 01 422 308.
Do not tap the sensor to fit it, or pull or push on
the wiring.
96956-1R
Connector for front right hand speed sensor (B).
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Bosch ABS
It analyses the information from the wheel

sensors and controls the regulation solenoid
valves depending on this information.
38
The computer
NOTE : the diagnostic socket is located in the
The integral computer is mounted on the

hydraulic assembly pump motor.
passenger compartment, under the dashboard, in

the relay and fuse compartment.
94640S
It includes, amongst others, two microprocessors

which independently carry out the same
programme to give a maximum level of safety.
92827S
As soon as a wheel is tending to lock, the solenoid

valves and the pump motor are activated via the
two relays mounted on the top of the computer.
This allows connection of the XR25 for testing

microprocessor systems.
The integration of the electronic function into the

hydraulic assembly and corresponding reduction
in weight has lead to reduction in wiring and
number of connectors (hence greater reliability)
and makes the unit easier to fit to the vehicle.
Communication between the computer and the

fault finding equipment allows:
the computer to be identified.
memorised fault information to be read
The main functions carried out by the computer

are:
system parameters to be read (wheel speeds,

voltage...).
- preparation of the signal,
the solenoid valves, pump motor and warning

light bulb to be operated.
the memory to be erased.
- regulation,
- self-testing (safety monitoring),
- fault finding.
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Bosch ABS
38
The hydraulic assembly
The hydraulic assembly with integral computer is

located in the engine compartment on the left
hand side under the master cylinder.
94640R1
96953S
It comprises:
- three regulating solenoid valves,
- a piston plunger (P) to ensure hydraulic
separation of the the two rear brakes ,
- a pump driven by an electric motor (special
note: reduced power - limitation of maximum
pressure). It should be noted that the role of
the pump is to return the fluid during the
"elimination" phase to the master cylinder in
order to generate the required drop in
pressure; this causes the characteristic pedal
movement.
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Bosch ABS
ABS 2 E HYDRAULIC ASSEMBLY
DI3889
1
2
3
4
5
6
7
Solenoid valves
Pump relay
Solenoid valves relay
Motor
Pumping component
Accumulator
Piston plunger
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Bosch ABS
OPERATING PRINCIPLE
Regulating solenoid valves
The hydraulic pressure from the two master

cylinder circuits at the moment of braking passes
via three solenoid valves and a piston plunger to
ensure independent regulation of the front left,
front right and rear channels.
The three way solenoid valves have the same
operating principle as before; a variable current
passes through the coil, depending on the phase
of regulation allowing either:
- phase 1 :
communication between the master cylinder
and the brake cylinder (normal braking),
- phase 2 :
this communication to be cut, preventing the
increase in pressure in the brake cylinder,
- phase 3 :
communication between the brake cylinder
and the return pump,which drops the pressure
in the brake cylinder and "releases the brakes"
at the wheel.
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Bosch ABS
PRESSURE INCREASED PHASE (PHASE 1)
DI3890
1
2
3
4
the force at the pedal is directly applied to the wheel,

the current at the solenoid valve is zero,
the ABS does not operate,
the wheel deceleration does not exceed the limit of
adherence.
Computer
Accumulator
Motor
Pump
5
6
7
8
Solenoid valve
Master cylinder
Wheel sensor
Target
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Bosch ABS
PRESSURE MAINTAINED PHASE (PHASE 2)
DI3890R
- the deceleration threshold is exceeded,

- the current in the solenoid valve (5) equals "i" average,
- the hydraulic circuit between the solenoid valve and the
wheel is isolated,
- deceleration increases as well as slip.
1
2
3
4
Computer
Accumulator
Motor
Pump
5
6
7
8
Solenoid valve
Master cylinder
Wheel sensor
Target
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38

Bosch ABS
PRESSURE REDUCED PHASE (PHASE 3)
DI3890R1
1
2
3
4
the slip threshold is exceeded,

the current in the solenoid valve equals "i" maximum,
the pump (4) operates,
the pressure drops,
the wheel deceleration reduces.
Computer
Accumulator
Motor
Pump
5
6
7
8
Solenoid valve
Master cylinder
Wheel sensor
Target
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Bosch ABS
OPERATING PRINCIPLE
Rear circuits (Special note)

Braking at the rear wheels is regulated according
to the Select Low principle, which means that the
two rear channels operate at the same pressure;
the wheel with the lower adherence causes the
same regulation at both rear wheels.
Hydraulic separation
The vehicle has an X pattern braking circuit.
Separation between the two rear brakes is
ensured by a mechanical device known as the
piston plunger (P).
Precaution :
The bleeding procedure must be observed (order
of bleeding).
If this order is not observed, air may enter the
plunger which will cause the pedal travel to
lengthen.
The piston plunger

In connection with the rear regulation solenoid
valve (E), this ensures the equivalent regulation at
the other wheel at the same time. The pressures in
the rear brake cylinders are approximately
identical to within friction forces.
There are three operating phases depending on
the position of the rear solenoid valve
1.
Braking without regulation
2.
Pressure maintained
3.
Pressure reduced
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Bosch ABS
38
OPERATING PRINCIPLE
Braking without regulation
DI3891
Compensator
Front left brake cylinder (via solenoid valve)
Rear regulation solenoid valve
Front right brake cylinder (via solenoid valve)
Piston plunger
Rear left brake cylinder
CL
Valve
Rear right brake cylinder
P1
Position 1
Rear axle assembly
P2
Position 2
P3
Position 3
In the braking without regulation phase, the piston plunger is not operational (position 1 of rear solenoid
valve (E) and valve (CL) open).
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Bosch ABS
38
OPERATING PRINCIPLE
Pressure maintained
DI3891R
(Position 2 of the rear solenoid valve)

The pressure in chamber B and that in the rear brake cylinder (4) is stable. The piston plunger moves to the
left under the action of the pressure at A (master cylinder).
Valve (CL) is now closed.
This movement continues until the pressures at B and C are equalised (A and D are at master cylinder
pressure).
The pressures in the two rear brake cylinders are stable and identical (to within friction values).
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Bosch ABS
38
OPERATING PRINCIPLE
Pressure reduced
DI3891R1
(Position 3 of the rear solenoid valve)

The pump partially returns the volumes of chamber B and the rear brake cylinder (4) to the master cylinder.
The drop in pressure at B allows the piston plunger to move to the left.
Valve (CL) remains closed.
The increase in volume at C causes a drop in pressure in the rear brake cylinder (3).
The pressures in the rear brake cylinders (4) and (3) are identical to within friction values.
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Bosch ABS
REGULATION
SUMMARY OF PRINCIPLE
Sensor
Wheel
signal
speed
Analysis of the
signal
Regulation
strategy
Order of
regulation
Hydraulic
intervention
Modification
of speed
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Bosch ABS
38
REGULATION
The target / sensor assembly monitors the movement of the wheel. If a wheel is tending to lock, deceleration
and slip increase quickly.
When certain critical thresholds are exceeded the regulation cycle begins to operate.
Determining the reference speed
The computer permanently receives signals from the sensors from which the wheel speeds are calculated.
When the vehicle is not braking, the vehicle speed corresponds to the speed of the non-driven wheels.
When the vehicle is braking, all the wheels are slipping to a greater or lesser extent and their speed will
therefore differ from the vehicle speed.
Two reference speeds are calculated:
- the "vehicle" reference speed allows calculation of the deceleration of the vehicle(speed of the fastest
wheel),
- the "slip" reference speed allows calculation of slip (speed of the 2nd fastest wheel).
To begin regulation, a certain wheel instability threshold must have been exceeded.
If the wheel deceleration threshold is reached, regulation begins by moving the solenoid valve to the
pressure maintained position.
During this very brief period, the vehicle deceleration is calculated and the type of adherence evaluated (high
or low).
If the slip threshold defined by the reference slip is exceeded, the drop in pressure is initiated until the wheel
has reaccelerated to a value allowing the pressure to be increased again by stages.
If the wheel instability returns, the second regulation cycle is begun with a drop in pressure and so on until
the vehicle stops.
During braking with ABS regulation, this cycle may be repeated from 4 to 10 times a second. The system will
operate after only a few tenths of a second.
Each time the system operates the brake pedal pulsates to a greater or lesser extent, accompanied by the
characteristic noises caused by the modulation in braking pressure between the hydraulic pump and the
regulating solenoid valve, and by any tyre squeal.
Special note:
When braking on non-symmetrical ground, a side slip torque appears which tends to turn the vehicle towards
the side with the high adherence coefficient. The driver must react to this at the steering wheel. To avoid this
phenomenon, these vehicles are fitted with a side slip torque time delay. In this case, the braking pressure of
the wheel with high adherence increases in stages to its maximum value. This reduces the reaction required
to keep the vehicle on course and allows the driver to remain in control of the situation.
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Bosch ABS
38
SELF TESTING
Safety - Monitoring
A certain number of tests are carried out when the ignition is turned on and each time the vehicle starts,
under the following conditions:
1.
Test after switching the ignition on or initialisation test

During this phase, the following points are checked:
- internal microprocessor tests.
- tests of connections (voltage supply, solenoid valve relays, disconnection, solenoid valve connections
and electrical continuity of the motor).
- fault memory operation.
This phase leads to the "ABS" warning light being extinguished after two seconds if all the tests are
correct.
2.
Tests carried out after the vehicle has moved off for the first time
This concerns the first few rotations of the wheels after the ignition has been switched on. This test is
carried out as soon as the perceived vehicle speed reaches 3.75 mph (6 km/h).
- checking the operation of the solenoid valve pressure drop (the three solenoid valves are operated*
for a few ms).
- in this phase, the system checks that all the solenoid valves operate identically and that their electrical
resistance is within the permitted limits.
- test of the pump motor*. In this phase the return information from the pump motor is checked after
operation of the motor for a few ms.
- checking the speed sensor signals (monitoring after moving off for the first time and disconnection of
the ABS at 7.5 mph (12 km/h) if a fault is detected).
These tests are completed before the vehicle reaches 9 mph (15 km/h).
(*) Note: this self test generates pulses which may be felt at the brake pedal and this phenomenon should
in no way be considered as a fault.
3.
Tests carried out when the vehicle moves off at other times:
These tests are carried out after moving off when the vehicle speed exceeds 3.75 mph (6 km/h) on
condition that the vehicle speed exceeded 12.5 mph ( 20 km/h) the last time the vehicle moved off.
- test of solenoid valve current patterns.
- test of the pump motor.
- test of the speed sensor signals (monitoring and disconnection of the ABS at 12.5 mph (20 km/h) if a
fault is detected).
These tests are completed before the vehicle reaches 15.5 mph (25 km/h).
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Bosch ABS
38
Faults
The fault detected by the self test immediately switches the circuit off or does so after ABS regulation,
depending on the case.
The driver is shown this information by the ABS warning light.
Summary table for ABS 2E self testing
Component tested
Test type
ABS warning light
Visual
Solenoid valve
connections: front
left, front right
and rear
CO
CC
CC+
CC - (CP)
Sensor
connections: front
left, front right,
rear left and rear
right
Test conditions
Warning light illuminates

for 2 seconds after
switching ignition on
As soon as ignition on
for V > 6km/h
for V > 6 km/h
Outside regulation:
Detection when ignition
switched on
During regulation:
Fault on 1 front wheel (up
to end of regulation)
Logical or
resistance
monitoring
Stop switch
connections
CO (computer
track 9 stop bulb
earth)
Customer complaint
Fault
memorised
Does not illuminate
No
No ABS + warning light

illuminated
Yes

illuminated
Yes
ABS retained for other

wheels.
Braking pressure increases
up to master cylinder
pressure at faulty wheel.
Then for V > 20 km/h

(after starting again)

illuminated
Fault on 1 rear wheel (up to

end of regulation)
ABS retained for 2 front

wheels
(rear pressure = 0)
Then for V > 20 km/h

(after starting again)

illuminated
Yes

illuminated
Yes
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Yes

Bosch ABS
Pump motor
connections
CO (computer,
pump motor
earth via pump
motor)
CC
Pump motor relay

connections
CC power circuit
Feed

illuminated
Yes
For V > 6 km/h

illuminated
Yes
(Pump motor permanent

control)
Yes

illuminated
Yes
CO power circuit For V > 6 km/h

illuminated
Yes
For V > 6 km/h

illuminated
Yes
As soon as ignition on if
line "L" is earthed
Warning light flashing
No
1. Vehicle speed< 6 km/h

illuminated
No
CC -
Voltage drop
U battery
< 9.4 V
If under voltage< 1 min

illuminated
Yes
2. Vehicle speed> 6 km/h

Taken into account
Yes
immediately
illuminated

illuminated
Yes
CC control circuit As soon as ignition on after

30 seconds filtering

illuminated
Yes
CO power circuit As soon as ignition on after


illuminated
Yes

illuminated
Yes
If under voltage> 1 min
Solenoid valve
relay connection

illuminated
CC control circuit For V > 6 km/h
CO control
circuit
Fault finding
connection
38
CC power circuit
CO control
circuit
As soon as ignition on after

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Bosch ABS
Toothed wheel
Coherence
38
1. Fault declared after 2

min filtering
If speed of one wheel >
25 % of reference
speed

illuminated
Yes
2. If regulation continues
for more than 60 seconds

illuminated
Yes
Key:
Electrical connection or component in open circuit
Electrical connection or component in short circuit
Electrical connection or component to + 12 V
CC - (CP) Electrical connection or component in short circuit to earth or permanent control
CO
CC
CC+
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Bosch ABS
38
If there is a fault, after switching the ignition off,this fault is stored in the computers memory.
This memory may be consulted at any time using the XR25 and the appropriate cassette. Switching the
ignition off and on again however may modify the interpretation of the bargraphs in certain cases. To avoid
any confusion, carry out a road test with the vehicle showing a fault (intermittent or permanent illumination
of the ABS warning light) before reading the diagnostic signal, without switching the ignition off.
The fault mechanism is as follows:
A maximum of three faults may be stored:
Definition of a fault
a)
Permanent fault:
A fault is declared to be "permanent" when it appears (ABS warning light illuminated) (shown on the
XR25 by the fixed illumination of a bargraph other than 1 and 4).
b)
Intermittent fault:
A fault is declared to be "intermittent" after it has been stored and has disappeared (shown on the
XR25 by the bargraph flashing).
Operation:
A counter allocated to each memory allows the system to distinguish between a permanent fault and an
intermittent fault.
When a fault appears, the counter is set to 20. If the fault is then recognised as being intermittent, the
counter decreases each time the ignition is switched on. In this way, if the fault no longer appears, the fault
will be automatically erased from the memory after the ignition has been switched on for 20 times.
There is no fault hierarchy, but if a permanent fault appears, it will take the place of an intermittent fault
with the lowest counter count if all three memory slots are occupied.If several faults appear at the same
time, only one will be memorised. It is therefore important to carry out a new check after a road test, after
repairing this fault.
Condition for entering fault finding:
- If no faults are present Speed < 6 mph (10 km/h)
- If faults are present Possible regardless of speed
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Bosch ABS
38
FAULT FINDING WITH THE XR25
The XR25 is vital for all fault finding on the ABS,

regardless of the origin of the fault.
Communication between the computer and the
XR25 allows:
- the computer to be identified

- memorised fault information to be read.
- system parameters to be read (wheel speed,
voltage...).
- the solenoid valves, pump motor and ABS
warning light to be operated.
- the memory to be erased (to be carried out
after every operation on the ABS)
92656S
Initialising dialogue:
After connecting the XR25 at the end of a road
test without switching the ignition off after
completing the test
- Set the ISO selector to S8.
- Contact the computer using :
sends a signal on the 2 lines (K

and L) at the same time
When dialogue has been initialised, the ABS

warning light should illuminate, confirming that
the ABS is in fault finding mode (ABS warning
light is illuminated before entering fault finding
mode if there is a permanent fault).
92655R
NOTE : Warning light "V" must be extinguished. If
it is illuminated, disconnect then reconnect the

diagnostic socket and if it remains illuminated,
check the XR25 wiring and the battery voltage.
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Bosch ABS
38
Analysis of system operation using the XR25 and the latest cassette after a road test where the ABS warning
light illuminated.
At the end of the test, without switching off the ignition, connect the XR25.
Enter code
Position the ISO selector on S8.

The central display shows:
2
XX
5
(1 second) then
Bosch make
Computer number
Product tested is ABS
or
Shows dialogue has not been
established
If the initialisation procedure has been carried out correctly:
-
the ABS warning light on the instrument panel must be illuminated, regardless of its previous status:
illuminated (permanent fault present) or extinguished (no permanent fault present)
the central display should show
ABS WITH NO FAULT
(2 bargraphs illuminated)
Bargraph n 1 RH side: code present
Bargraph n 4 RH side: stop circuit - pedal not depressed
ABS WITH FAULT(S)

IMPORTANT DEFINITIONS :
Intermittent fault: is a fault which occurred (ABS warning light on instrument panel illuminated) and
disappeared by itself at a given moment (after the ignition had been switched off and on again). This
type of fault is shown by a flashing bargraph.
Permanent fault: is a fault which is present when fault finding using the XR25. This type of fault is shown
by a permanently illuminated bargraph
IMPORTANT :if
is entered when the computer is in the test sequence, the fault finding may
appear after anything up to 40 seconds. To reduce this time, enter : G13*
(beep ), then
D
1
1
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Bosch ABS
38
FI21611
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Bosch ABS
38
The following fault finding is only to be used after a road test causing the ABS warning light to illuminate.
The XR 25 must only be connected at the end of the road test, without having switched off the ignition after
the test.
CODE PRESENT: ILLUMINATED: CORRECT (extinguishes if key G is used).
If it is extinguished after having entered D11, check:

- that the ISO selector switch is in the correct position: S8;
- that you are using the correct XR 25 cassette version and the correct code (D11);
- that the battery voltage is > 9.4 0.4 volts;
- that the ABS 15 A fuse on the relay plate has not blown;
- that the computer is in accordance with the vehicle type;
- that the R36 connection (black and grey) is correctly connected (next to the battery);
- the continuity and insulation of the diagnostic socket/computer connection lines:
. track 10, diagnostic socket and 12, computer, via R36 grey track B
. track 11, diagnostic socket and 15, computer, via R36 black track B2;
- that track 2 of the diagnostic socket is earthed; track 6 to + battery;
- that the computer is correctly supplied: Earth on track 3 of 4 track connector, + after
ignition at 1 and + before ignition at 2 of same connector.
If the fault persists after these checks, replace the computer.
COMPUTER FAULT
FLASHING:
STEADY:
Erase memory (GO**) and confirm the fault.

Check the 4 and 15 track connectors on the ABS plate and the ABS
electronic earth. If the fault persists, replace the computer.
SUPPLY FAULT
Check:
- the battery voltage (> 9.4 0.4 volts),
- the computer feed voltage using # 06,
- connection of the 4 and 15 track connectors on the ABS plate;
- presence of earth at track 3 of 4 track connector
- presence of + before ignition between terminals 3 and 2 of 4 track connector
- presence of + after ignition between terminals 3 and 1 of 4 track connector.
If the fault persists after testing replace the computer.
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Bosch ABS
38
STOP CIRCUIT
ILLUMINATED ON LEFT:
CORRECT IF PEDAL DEPRESSED
ILLUMINATED ON RIGHT:
CORRECT IF PEDAL NOT DEPRESSED.
By depressing the brake pedal, check alternating RIGHT/LEFT illumination of bar graph 4.
YES
: Normal circuit operation.
NO
: What fault is noted in the operation of bargraph 4 ?
BARGRAPH 4 PERMANENTLY ILLUMINATED ON LEFT : The stop lights are permanently
illuminated.
Adjust stop switch or replace if necessary.
Otherwise check the wiring downstream from the switch (insulation).
BARGRAPH 4 EXTINGUISHED ON LEFT FOR FULL LOAD: do the stop lights illuminate when the
brake pedal is pressed?

NO
YES
: Check the condition and adjustment of the stop switch and the 10 A lights fuse.
Check connection R35 (dashboard / pedal mounting) : presence of + after ignition
on track B1 and the following continuities:
- between track B1 and track 3 on the stop switch,
- between track A4 and track 1 on the stop switch.
: Bargraph 4 should not be illuminated on the right for no load and bargraphs 7, 8, 9
and 10 should be illuminated.
There is a break between track 9 of the computer and track A4 of connection R35
(dashboard / pedal mounting) via black connection R36 (ABS/dashboard) track C2.
BARGRAPH 4 EXTINGUISHED ON RIGHT FOR NO LOAD+ BARGRAPHS 7, 8, 9 and 10

ILLUMINATED:
When the brake pedal is depressed, does bar graph 4 illuminate on left?
: Stop lights do not illuminate :
- the two stop lights bulbs have blown.
- there is a poor earth on the stop lights bulbs,
- there is a break between track B5 of connection R35 (dashboard / pedal
mounting) and track C5 of R1 (dashboard/ rear right).
Check the connections on connection R35 and the presence of a shunt between
tracks A4 and B5.
NON : The stop lights illuminate.
YES
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Bosch ABS
38
PUMP MOTOR CIRCUIT FAULT

BAR GRAPHS 5 + 8, 9 AND 10 ILLUMINATED
Erase the computer memory (G0**).

Enter the code for ending fault finding (G13*).
Switch the ignition off then on again.
Enter code D11 again. Is bar graph 5 illuminated ?
- YES
: Check the earth of the pump motor (earth wire on motor).

Remove the cowling from the hydraulic assembly and check the tightness of the
Torx bolt marked "+".
If the fault persists, remove the computer plate and feed the pump motor directly
(single terminal under plate).
Does the pump motor operate?
- NO : replace the hydraulic assembly.
- YES: replace the computer.
- NO
: Switch the ignition off, replace the pump motor relay and carry out a road test.
Replace the computer if bar graph 5 illuminates again.
SOLENOID VALVE RELAY CIRCUITS
ONLY BAR GRAPH 6 ILLUMINATED OR BAR GRAPHS 6 + 8, 9 AND 10 ILLUMINATED
Replace relay.
STOP SWITCH FAULT

ONLY BAR GRAPH 7 ILLUMINATED OR BAR GRAPHS 7 + 8, 9 AND 10 ILLUMINATED
When the brake pedal is activated, does bar graph 4 illuminate on left?
YES : Stop lights do not illuminate :
- the two stop lights bulbs have blown.
- there is a poor earth on the stop lights bulbs,
- there is a break between track B5 of connection R35 (dashboard / pedal
mounting) and track C5 of R1 (dashboard/ rear right).
Check the connections on connection R35 and the continuity between tracks A4 and
B5 (stop switch side).
NON : The stop lights illuminate.
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Bosch ABS
38
PERMANENT CONTROL SOLENOID VALVES (these bar graphs indicate a status, not a fault)
BAR GRAPH 8 FRONT LEFT-HAND SOLENOID VALVE
BAR GRAPH 9 FRONT RIGHT-HAND SOLENOID VALVE
BAR GRAPH 10 REAR SOLENOID VALVE
Bar graphs 8, 9 and 10 are never illuminated alone under given test conditions:
8
9
10
Bar graphs 8, 9 and 10 illuminated with bar graph 5:.

deal with bar graph 5;
Bar graphs 8, 9 and 10 illuminated with bar graph 11, 12 or 13:
.
deal with bar graph 11, 12 or 13;
- Bar graphs 8, 9 and 10 illuminated with bar graph 17 or 18:
.
deal with bar graph 17 or 18.
SOLENOID VALVE CIRCUIT FAULTS

BAR GRAPH 11
FRONT LEFT SOLENOID VALVE
(tracks 1 and 2 of 6 track connector)

BAR GRAPH 12
FRONT RIGHT SOLENOID VALVE
11
12
13
BAR GRAPH 13
REAR SOLENOID VALVE

Bar graph 11, 12 or 13 + bar graphs 8, 9 and 10:
Check connection of 6 track connector to hydraulic unit.
Check resistance of faulty solenoid valve coil. Correct value: approximately 1 .
If incorrect, replace hydraulic unit.
If correct, replace computer.
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Bosch ABS
17
18
FLH
FRH
RLH RRH
WHEEL SENSOR CIRCUIT
Check connector of faulty sensor.

If connector is correct, check resistance of sensor at 20 C
If value is other than 1.2 k 0.5, replace sensor.
Check continuities between connector of sensor in question and computer:

Front left sensor
track 2 sensor /
track 1 sensor /
track 2 sensor /
track 1 sensor /
track 1 sensor /
track 2 sensor /
track 2 sensor /
track 1sensor /
Front right sensor :

Rear right sensor :
Rear left sensor
7 computer
13 computer
5 computer
10 computer
6 computer
14 computer
2 computer
4 computer
Check:
- the insulation between the two sensor lines.
- the quality of the sensor mounting (tightening torque: 9 Nm)
- the target / sensor gap over 1 revolution of the wheel in question :
Front wheel : 0.40 mm < air gap < 1.20 mm ;
Rear wheel
: 0.40 mm < air gap < 1.90 mm.
After the operation, check the operation of the sensor using functions #01, #02, #03 and
#04 of the XR 25:
#01: front right wheel speed
#02: front left wheel speed
#03: rear right wheel speed
#04: rear left wheel speed
BAR GRAPH 17 OR 18 FLASHING
Check:
mounting of sensor.
sensor connections.
Check routing and mounting of cables.
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Bosch ABS
38
INCORRECT TOOTHED WHEEL
19 Check:
- the coherence of the wheel speeds using a dynamic test (use functions #08 and #09 on the
XR25),
- the quality of the sensor mountings.
Check:
- the air gaps
Front 0.4 mm < air gap < 1.2 mm

Rear 0.4 mm < air gap < 1.9 mm
- the conformity of the targets:
- condition of the teeth,
- 26 tooth target.
20 Present if XR 25 memorisation function in use.
The memorisation function using the XR 25 enables the values of of the various parameters accessible via key
# (followed by 2 figures) to be fixed and memorised for future use.
Once communication between the XR 25 and the computer has been established, to obtain this function,
enter
when required by the user.
0
This memory is erased by entering
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Bosch ABS
38
DISPLAY OF BAR GRAPHS ON XR 25 AFTER ROAD TEST

+ SWITCHING IGNITION OFF AND ON
Bar graphs 1, 2, 3 and 4
: same function as without switching ignition off
Bar graph 5 flashing
: as for bar graphs 5 + 8, 9 and 10 without switching the ignition off (ABS
warning light is extinguished)
Bar graph 6 only or

bar graphs 6 + 8/9 and 10
: as for bar graphs 6 + 8, 9 and 10 without switching the ignition off (ABS
warning light is illuminated)
Bar graph 7
: same function as without switching ignition off
Bar graph 8 + 9 and 10
: shows ABS system is not operational and a road test is required to

determine what component is at fault
Bar graph 11 or 12
or 13 flashing
on right and left hand sides
: as for bar graph 8, 9 and 10 + 11 or 12 or 13 (ABS warning light is

extinguished)
Bar graph 17 or 18
flashing on right or
left hand sides
: as for bar graph 17 or 18 + 8, 9 and 10 (ABS warning light is extinguished)
Bar graph 19
flashing
: as for bar graph 19 without switching ignition off
AFTER REPLACEMENT OF A HYDRAULIC ASSEMBLY:
Check the system using the "G" function on the XR25 :

-
G3*
G4*
G5*
G7*
G8*
FRONT LEFT SOLENOID VALVE

FRONT RIGHT SOLENOID VALVE
REAR SOLENOID VALVE
ABS WARNING LIGHT
PUMP - MOTOR RELAY
AFTER ANY OPERATION ON THE ABS SYSTEM :
- Re-initialise the system (switch the ignition off then on again),

- Carry out a road test then check using the XR25,
- Erase the computer memory (G0**).
Validate the end of the test : G13*.
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Bosch ABS
38
ADDITIONAL TESTS
After initialising the system, enter
front right wheel speed (in km/h)
front left wheel speed
rear right wheel speed
rear left wheel speed
battery voltage (volts), example :

maximum voltage read = 12.06
(computer voltage regulation)
front left wheel speed (XX) and front right wheel speed (YY) in km/h
from 0 to 99 km/h :
direct reading
> 100 km/h
: no hundreds
Same as for #08, for rear wheels
These tests allow :

(1) the wheel speeds to be displayed and sensor allocation to be checked (checking of target and sensor
pairing),
(2) the feed voltage to the solenoid valves after the solenoid valve relay to be displayed.
IMPORTANT: when communication between the computer and the XR25 has been established, the warning
light is illuminated and the ABS function is no longer ensured.
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Bosch ABS
Command mode
IMPORTANT: to use the command mode, the ABS system must be operational ( no faults present).
Hydraulic test : button G (command mode allowing checking of the operation of the solenoid valves)
Lift the vehicle so the wheels may be turned and

check they turn freely.
Hold down the brake pedal to prevent the wheel

being tested from turning when turned by hand
(do not press too hard on the brake to ensure the
wheel is at the locking limit.)
Enter
Then
The display shows:
The front left wheel

releases temporarily (5 times)
Same for
Front right wheel solenoid valve
Solenoid valve for rear left and right

hand wheels
and
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38

Bosch ABS
38
Checking the ABS warning light
Enter
the warning light

should extinguish for
2 seconds
Checking operation of the relay and pump

Enter
the pump motor

should operate for 2
seconds
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Bosch ABS
ERASING THE MEMORY
Switch the ignition on but do not start the engine.

Enter code
The display shows:
then:
Enter :
The display shows:
Validate the erase request using

A moment later, the display shows:
The memory has been erased.

Validate the end of the test:
The display shows:
then:
A moment later the ABS warning light should extinguish:

(if no faults are apparent).
- switch the ignition off
- disconnect the XR25
- refit the diagnostic socket cover.
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38

Bosch ABS
38
CHECKING THE WIRING
El. 1286
Bornier for testing the wiring using

the XR25 or multimeter
This is a base with 15 contacts identical to those

on the ABS computer, on a printed circuit with
electrical contacts numbered from 1 to 15.
Connection
Ignition off, disconnect the ABS computer from its
base and connect bornier El. 1286 in its place.
Each number corresponds to an electrical

connection in the vehicle wiring and is indicated
on the diagram on the next page.
Principle of the testing method

Apply the test pin of the XR25 or the multimeter
to the numbered indicated on the bornier.
It is used for quick and accurate testing of all the

electrical connections on the main ABS connector.
Test equipment which may be used
XR 25 :
- measure continuity using the buzzer,
- measure voltage using the voltmeter.
Multimeter
- measure resistance,
- measure voltage.
Solenoid valve coil resistance :

approximately 1.2 .
Pump / motor coil resistance:
approximately 0.5 to 1 .
Sensor resistance (at 20C)
approximately 1.2 k.
Pump / motor relay:
Coil resistance approximately 55 .
Solenoid valve relay:
Coil resistance approximately 55.
96953S
NOTE:
Never disconnect the computer when a

voltage is applied to the circuit.
Earths and resistances should be measured

with the battery disconnected.
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Bosch ABS
38
DI96913
38-126
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Bosch ABS
38
Allocation of the 15 track computer connector

pins
WIRING DIAGRAM KEY
Components:
104 Ignition switch
107 Battery
118 ABS computer
150 Rear right wheel sensor
151 Rear left wheel sensor
152 Front right wheel sensor
153 Front left wheel sensor
160 Stop switch
172 Rear right light
173 Rear left light
225 Diagnostic socket
247 Instrument panel
260 Fuse box
361 "ABS" hydraulic assembly
425 ABS plate
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
ABS warning light

Rear left sensor earth
Rear left sensor signal
Front right sensor earth
Rear right sensor signal
Front left sensor earth
Stop switch
Front right sensor signal
Diagnostic line L
Front left sensor signal
Rear right sensor earth
Diagnostic line K
Connections:
R1
Dashboard/rear right
R35 Dashboard/ pedal mounting
R36 ABS / Dashboard(grey and black)
Earth:
ME Bodywork earth
Resistance of the solenoid valve coils:
approximately 1.2
94716R
Resistance of the sensors (at 20C) :

approximately 1.2 k
NOTE:
Never disconnect the computer when a voltage is

applied to the circuit.
Earths and resistances should be measured with
the battery disconnected.
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Bosch ABS
38
CONNECTORS
Connection
R36 black (2)
R36 grey (1)
Allocation
Location on the vehicle

Next to the battery (see diagram below)
ABS/dashboard
R35 black
dashboard/ pedal mounting
Passenger compartment front left pillar
R1 brown
dashboard/rear right
Passenger compartment front right pillar
96956R
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Bosch ABS
Allocation of diagnostic socket terminals
38
Position of the relays on the computer plate
94640R
A
B
Solenoid valve relay

Pump / motor relay
88113S
4 track connector (361) on computer plate

1
AT A4 diagnostic connection
Earth
Mechanical foolproofing
Not used
Not used
+ 12 V after ignition
AT M diagnostic information
To electronic fault warning light
Injection fault finding information
10
Diagnostic line "L" (ABS)
11
Diagnostic line "K" (ABS)
DI3892
1
2
3
4
+ after ignition (UZ)

+ before ignition (Bat +)
Earth (-)
ABS warning light (Sila)
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Bosch ABS
38
REMOVING - REFITTING THE COMPONENTS

1 - FRONT WHEEL SENSOR
Wheel bolt
Sensor mounting bolt
9
0.8 to 1
REMOVAL
Remove:
- the wheel,
- the sensor mounting bolt.
96953-1R
Front left speed sensor connector (A).
94868S
Release the wire from the mountings.

Disconnect the connector on the side of the shock
absorber turret in the engine compartment.
96956-1R
Front right speed sensor connector (B).

Remove the sensor.
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Bosch ABS
38
2 - REAR WHEEL SENSOR
Wheel bolt
Sensor mounting bolt
9
0.8 to 1
REMOVAL
Remove:
- the wheel,
- the sensor mounting bolt (1),
- the sensor from its mounting.
96954S
REFITTING THE SENSORS (front or rear)
Fit the sensor after coating it in Multipurpose

grease Part Number 77 01 422 308 then clip the
wire into its mountings and reconnect it.
Check the recommended air gap over one
revolution of the wheel using feeler gauges.
NOTE : ensure the connector is correctly

connected, to avoid the risk of faults.
96955R
The sensor must be fitted by hand. Do not hit it

during fitting.
Release the wire from its mountings.
Do not pull or push on the wiring.
Disconnect the sensor from its connector located

under the vehicle, near the left hand mounting
for the rear axle assembly.
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Bosch ABS
4 - REAR WHEEL TARGET
3 - FRONT WHEEL TARGET
Target (4) embedded in the hub (cannot be

removed).
Wheel bolt
Driveshaft nut
9
24 to 26
The target is embedded in the driveshaft so this

operation takes place after removal of the
driveshaft.
REMOVAL
Extract the target using an extraction tool on the

press.
94862-1R
91663S
REFITTING
Coat the target with Loctite SCELBLOC and refit it

using a mallet, tapping progressively on the
outside of the target.
Take care to tap evenly to avoid the target
twisting and check it is correctly fitted in the
driveshaft.
NOTE: The Parts Department supplies machined
driveshafts without the ABS target. The target
must therefore be retained to refit to a new
driveshaft. Separate targets are however also
available from the Parts Department.
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38

Bosch ABS
38
Remove the 6 mounting bolts and remove the

computer - relay plate.
5 - COMPUTER
Computer mounting bolt
1.5
REMOVAL

Remove the upper cover.
94640S
REFITTING
Ensure the plate mounting bolts are correctly

+ which
tightened, especially bolt (D) marked
ensures the + 12 Volts feed to the pump motor.
Take care to ensure the wiring is correctly routed.
Check the system using the G functions on the
XR25 .
94865S
Carry out :
- a road test then check using the XR25,
- erase the computer memory (G0**).
Disconnect:
- the 4 track connector (1),
- the 15 track connector (2),
- the 6 track connector (3).
Validate the end of the test : G13*.
DI3892R
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Bosch ABS
Remove the 3 hydraulic assembly mounting bolts.
6 - HYDRAULIC ASSEMBLY
Remove the hydraulic assembly / mounting

assembly.
Pipe bolts
38
1.2 to 1.6
Plug the assembly openings.

REFITTING
REMOVAL
Fit the hydraulic assembly ensuring the pipes are

correctly located.

Remove:
- the air filter unit,
- the strap retaining the cooling circuit reservoir
bottle and move it to one side.
Disconnect the 15 track connector.
Remove the upper cover.
Disconnect:
- the 4 track connector,
- the 6 track connector.
Release the 3 mounting bolts on the hydraulic
assembly mounting (necessary to remove the
master cylinder).
DI3893
VL
VR
HL
HR
Front left (yellow)

Front right (green)
Rear left (blue)
Rear right (red)
Connect the connectors.

Fit:
- the upper cover,
- the earth wire on the pump / motor.
Ensure the wiring and connections are correctly
routed.
96953-1S
Remove the master cylinder.
Refit the master cylinder and bleed the hydraulic

circuit, following the order of operations (see
following page).
Slacken the 4 unions on the hydraulic assembly,

using a pipe wrench.
NOTE : never reconnect the battery and switch
Disconnect the earth wire on the pump motor.
the ignition on unless the complete hydraulic

circuit has been fully bled.
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Bosch ABS
38
BLEEDING
IMPORTANT
The order of operations for bleeding the ABS

hydraulic circuit MUST be observed:
1
Front left wheel caliper
Front right wheel caliper
Rear left wheel caliper
Rear right wheel caliper
94917R
The anti-lock system should never be made to operate if the system has not been bled. If the return pump
takes in air, it is extremely difficult, if not impossible to bleed it.
For this reason, the hydraulic assembly supplied by the Parts Department is supplied filled with brake fluid.
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Bosch ABS
BLEEDING USING A BLEEDING KIT
BLEEDING WITHOUT A BLEEDING KIT
Connect the bleeding kit to the brake fluid

reservoir.
The sequence of operations is the same as

opposite and must also be followed.
1.
38
Attach the tube to the bleed screw of the

corresponding wheel cylinder.
Connect the tube to the bleed screw of the

Open the corresponding bleed screw and wait

until the fluid flowing out contains no
bubbles (approximately 30 seconds).
Open the bleed screw in question.
Depress the pedal several times until there are

no more bubbles.
During the bleeding procedure, make sure

that the fluid level is always between
minimum and maximum marks.
Shut the bleed screw.

It is essential to follow the sequence of
bleeding operations:
COMPENSATOR CONTROL (Special notes)
a) Bleed, from the master cylinder towards

front left;
b) from the master cylinder towards front
right;
c) from the master cylinder towards rear
left;
d) from the master cylinder towards rear
right.
When the vehicle is with its wheels "hanging

free", this type of control allows force to
maintained at the lever so the compensator
remains with the "valves open" during the
bleeding operation.
b) Follow the bleeding procedure using the

pedal, making sure that the brake fluid level is
always between minimum and maximum
marks, during the procedure.
The sequence of operations given under 1) must
also be carefully followed.
Connect the tube to the bleed screw of the

Open the bleed screw in question.
Depress the pedal approximately 20 times.
Check and top up the brake fluid level as

necessary.
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Bosch ABS
38
ADDITIONAL TESTS
2 - CHECKING THE WHEEL SENSOR CONNECTORS
1 - TARGET / SENSOR GAP
If the ABS warning light illuminates

intermittently, first check the wheel sensor
connectors and clean them with NETELEC Part
Number 77 01 408 464.
(Position the target so that the top of one tooth is

parallel to the sensor).
Front sensor:
X = 0.40 to 1.20 mm
DI3894
96954S
Rear sensor:
NOTE:
X = 0.40 to 1.90 mm
When disconnecting the connectors, avoid
using a sharp tool which could damage the
retaining lugs on the 2 parts of the connector.
Take care to observe the correct wiring routing
and connections (the reliability of the ABS
system depends on this).
96955-1S
Sensor resistance : approximately 1.2 k
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Bosch ABS
Hydraulic assembly pipe markings
DI3893
VL
VR
HL
HR
:
:
:
:
Front left
Front right
Rear left
Rear right
(yellow)
(green)
(blue)
(red)
For obvious safety reasons, never incorrectly

connect the sensor connectors or the hydraulic
assembly pipes.
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Bosch ABS
38
COMPENSATOR
OPERATING PRINCIPLE
These vehicles are fitted with a load sensitive

compensator. The pressure is read in an X pattern,
by comparison between the pressure at the rear
wheels and a given pressure at the front wheels.
These dual compensators have two totally
separate bodies which operate in an X pattern on
one front wheel and one rear wheel.
Both circuits must be checked:
- I : front right/ rear left
- II : front left/ rear right
On the load sensitive compensators, the

adjustment allows the rear pressure to be altered
in relation to the front pressure.
The adjustment acts simultaneously on both
bodies. If the pressure is incorrect on one of the
two bodies, replace the compensator.
85925S
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Bosch ABS
Fuel tank (driver on

board)
Vehicle type
Test pressure (Bar)

Front

integrated in the wheel cylinder
B, C, L
533
53C
53Y
534
53J
53K
38
Rear
60
34
+0
-4
100
40
+0
-8
With ABS
(after
05/92)
B, C, L
53T
53V
53Z
With ABS
3, 4, 5
53A
53B
53F
With ABS
B, C, L, S
53F
538
53K
53T
53Z
Without
ABS
(after
11/94)
3, 4, 5
53C
53D
53H
90966S1
Full
Without
ABS
(after
11/94)
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Bosch ABS

board)
Vehicle type
Test pressure (Bar)

Front
B, C, L, D
539
53D
(before
05/92)
B, C, L
53A
535
53B
538
With ABS
53F
With ABS
(after
05/92)
B, C, L
3, 4, 5
53C
53D
53H
38
100
Rear
47
+0
-8
100
52
+0
-8
100
49
+0
-8
With ABS
90966S1
Full
D53D (after 05/92

853C
B, C, L, S
3, 4, 5
53F
538
53K
53T
53Z
53C
53D
53H
Without
ABS
(after
11/94)
Without
ABS
(after
11/94)
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Bosch ABS

board)
Vehicle type
Test pressure (Bar)

Front
533
53C
53F
534
53J
53K
53Y
With ABS
(before
05/92)
B, C
D53M
ABS
B, C, L
53D
(after
05/92)
B, C, L, D, S
53C
53Y
D
8
53V
53A
53F
38
Rear
100
43
+0
-8
100
52
+0
-8
90966S1
Full
With ABS
(after
05/92)
With ABS
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Bosch ABS
38
Checking and adjustment of the braking compensator must be carried out with the vehicle on the ground
and one person on board.
Fre.
1085
Pressure gauge for checking

brake limiter adjustment
If the difference is great (values exceed

tolerances), replace the compensator; no
operations are permitted.
As the compensator has two separate bodies, one

must be checked after the other.
CHECKING
ADJUSTMENT
Connect two pressure gauges Fre. 1085 :

- one at the front left,
- one at the rear right.
Bleed the circuit (the pressure gauge is bled
through screw P).
94589R
Slacken nut (A) and move adjuster (N) to tighten

or slacken the spring (R) until the correct value is
obtained.
94593R
Progressively press the brake pedal to obtain the

adjustment pressure for the front wheels (see
table of values). Read the corresponding pressure
for the rear wheels and correct it if necessary.
Carry out the same process on the other circuit.
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Bosch ABS
REPLACING THE COMPENSATOR
The Parts Department supplies pre-set

compensators fitted with a spacer.
Ensure:
- the vehicle meets the conditions for adjusting,
- fit the new compensator in position.
Slacken nut (A).
Attach the spring loop (R) to the suspension.
Press lever (L) and tighten the adjuster (N) until it
touches the lever.
Tighten the lock nut (A).
Remove the spacer (E).
Bleed and check the circuit (see "Checking Adjusting").
94641R
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Bosch ABS
BOSCH 2E ABS FAULT FINDING CHART
FAULTS NOTED IN THE OPERATION OF THE ABS WARNING LIGHT
1 - When the ignition is turned on

1.1 - The warning light does not illuminate
1.2 - Permanent illumination of the warning light
1.3 - The warning light is dimly illuminated
1.4 - The warning light flashes
1.5 - The warning light illuminates again after a delay (after 5 seconds)
2 - When the engine is started

2.1 - The warning light does not extinguish
2.2 - The warning light illuminates again
3 - When the vehicle first moves off

3.1 - The warning light illuminates when the vehicle starts moving
3.2 - The warning light flashes when the vehicle starts moving
4 - During braking with ABS regulation

4.1 - The warning light illuminates when ABS regulation is complete
4.2 - The warning light flashes during ABS braking
4.3 - The warning light illuminates during ABS braking
4.4 - The warning light illuminates after a delay when ABS regulation is
complete
5 - While driving
The warning light illuminates
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Bosch ABS
BOSCH 2E ABS FAULT CHART
FAULTS NOTED IN ABS OPERATION WITHOUT ILLUMINATION OF THE WARNING LIGHT
1 - One or more wheels lock
2 - Direction not maintained

2.1 - Pulling to one side
2.2 - Wandering
3 - Unexpected ABS operation

3.1 - When first moving off at 6 km/h (3.75 mph) (after the engine has
been started)
3.2 - While driving
3.2.1
at low speeds / pedal only slightly depressed
3.2.2
on poor road surfaces
3.2.3
when using special equipment
(car phone, CB...)
3.2.4
other cases connected with the external environment
4 - Reactions felt at the brake pedal
4.1 - Hard pedal
4.2 - Spongy pedal
4.3 - Long pedal travel
4.4 - Vibrations /jerky pedal operation
5 - Noises
From the pump, the hydraulic assembly or the hydraulic pipes.
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Bosch ABS
1
38
Faults noted in the operation of the ABS warning light

1.1 - The warning light does not illuminate
Connect the XR25 to the vehicles

diagnostic socket. Set the ISO switch to
position S8 and use the latest XR25
cassette .
Enter code D11 on the keyboard.
Does the warning light illuminate after
the initialisation period ? (5 seconds)
Use function G7* on the XR25.

Does the warning light extinguish for 2
seconds ?
yes
yes
no
Recheck
your diagnosis
Is bargraph 1 illuminated ?
no
Replace the computer
no
yes
Check the continuity of the 2 warning
light lines : between the warning light
and track 4 of the 4 track connector on the
hydraulic assembly and between the
warning light and track 1
of the 15 track computer connector.
Also check the 10 A fuse and the bulb.
Does the fault still persist?
yes
no
Earth track 4 of the 4 track

connector for the hydraulic
assembly or track 1 on the
15 track connector. Does the
warning light illuminate?
no
Recheck
your
diagnosis
Correct
Communication fault between the XR25 and the ABS

computer.
Check the battery voltage (> 9.4 0.4 volts)
and the 15 A fuse on the accessories board.
Check for an earth on track 2 on the diagnostic socket
and + before ignition on track 6.
Check the insulation from earth of the lines between
the computer and the diagnostic socket as well as the
continuity of these lines :
- between track 10 on the diagnostic socket and track
12 on the computer and
- between track 11 on the diagnostic socket and track
15 on the computer.
Check the connection of the 2 connectors R36
(ABS/dashboard) and the computer feed on the 4
track connector :
- earth on track 3,
- + after ignition on track 1,
- + before ignition on track 2.
yes
After repair, re-enter code D11.

Does the warning light illuminate after the
initialisation period ? (5 seconds)
The warning light circuit is

correct.
Replace the computer. Does
the fault persist?
no
yes
Correct
Recheck
your
diagnosis
yes
no
Recheck
your
diagnosis
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Bosch ABS
1

1.2 - Permanent illumination of the warning light

cassette .
Are only bargraphs 1 and 4 illuminated ?
(normal situation with no fault)
no
Locate the fault corresponding to the

fault bargraph and repair.
Road test the vehicle and retest with the
XR25.
Is a new fault shown ?
no
yes
yes
yes
Use function G7* on the XR25 and
watch the ABS warning light.
Does it extinguish for about 2
seconds ?
Does the fault persist?

no
yes
Correct
no
Check:
- battery voltage ( > 9.4 0.4 volts),
- the insulation of the two warning light circuit lines :
- between the warning light and track 4 on the 4
track connector and
track connector .
Check the 2 connections ABS/dashboard R36.
(One of these lines may be earthed).
After repair, does the fault persist ?
no
Correct
yes
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Bosch ABS
1

1.3 - The warning light is dimly illuminated

cassette .
no

XR25.
no
yes
yes
Check the insulation of the two warning light circuit

lines :
track connector and
track connector .
(One of these lines may be earthed).
Also check the condition of the ABS earths and the 4
and 15 track connectors.
After repair, does the fault persist ?
Correct
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no
Correct
yes
38

Bosch ABS
1


cassette .
Turn the ignition on and enter code
D11 on the keyboard.
Does bargraph 1 remain illuminated ?
Communication fault between the XR25 and the

ABS computer
Check the wiring for diagnostic lines K and L
(earth).
no
yes
no
yes
Correct
Are only bargraphs 1 and 4
illuminated ?
yes
no

XR25.
no
Does the fault

persist?
no
yes
yes
Check the insulation of the two warning light circuit lines :

- between the warning light and track 4 on the 4 track
connector and
- between the warning light and track 1 on the 15 track
connector . (One of these lines may be earthed).
Also check the condition of the ABS earths and the 4 and 15
track connectors. After repair, does the fault persist ?
Correct
no
Correct
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38

Bosch ABS
1

1.5 - The warning light illuminates again after a delay (after 5 seconds)
Connect the XR25 to the vehicles diagnostic socket. Set the ISO
switch to position S8 and use the latest XR25 cassette .
Turn the ignition on and enter code D11 on the keyboard.
Bargraph 5 should be illuminated to show a fault in the pump
motor circuit.

2.1 - The warning light does not extinguish
As for 1.2

2.2 - The warning light illuminates again

cassette .
no

XR25.
no
yes
yes

no
Incorrect contact between connectors.

Battery voltage too low
(< 9.4 0.4 volts).
Correct
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yes
38

Bosch ABS
1

As for 1.4

3.1 - The warning light illuminates
As for 1.3

As for 1.4 and 2.3

4.1 - The warning light illuminates when ABS regulation is complete
XR25
For verification of feed in particular.
If the fault persists, check the battery voltage (minimum : 9.4 0.4 volts) and check the wiring.

4.2 - The warning light flashes during ABS braking
As for 4.1
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38

Bosch ABS
1

4.3 - The warning light illuminates during ABS braking
XR25
Check the wiring (intermittent breaks in the circuit).
If the fault persists: there is probably some external interference.

4.4 - The warning light illuminates after a delay when ABS regulation is complete
XR25
5 - While driving
The warning light illuminates
XR25
If the fault persists: there is probably some external interference.
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Bosch ABS
2
Faults noted in ABS operation without illumination of the warning light
1 - One or more wheels lock
Reminder: the locking of the wheels on a vehicle fitted with ABS or tyre squeal which
the customer takes to be the wheels locking may be part of a normal system reaction
and should not be automatically considered as a fault :
- wheel permitted to lock below 1.72 mph (2.75 km/h) (system is not active),
- ABS regulated braking on very poor road surfaces (high degree of tyre squeal).
On the other hand, if the wheel(s) are actually locking, lift the vehicle so the wheels
may be turned and check :
- for a possible inversion of the wheel sensor connectors. Use functions #1 #2 #3 and
#4 while turning the appropriate wheel and check the coherence of the results
obtained.
If no speed is shown on the XR25, turn the other wheels to confirm the sensor
connectors have been incorrectly connected and then reconnect them correctly.
- Check for a possible incorrect connection of the pipes on the hydraulic assembly. Use
functions G3* G4* and G5* while pressing the brake pedal and check for temporary
releasing of the brakes on the wheel or wheels in question.
If the 5 cycles are not performed on the wheel being tested, (wheel free to turn
during the test), check the cycles are not being applied to another wheel (confirms
the hydraulic pipes are incorrectly connected).
If the 5 cycles are not performed on another wheel and the pipes are correctly
connected, replace the hydraulic assembly.
Also check the sensor / target air gap over one turn of each wheel :
Front wheels : 0.4 mm < air gap < 1.2 mm
Rear wheels
: 0.4 mm < air gap < 1.9 mm
If the fault persists, replace the hydraulic assembly.
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Bosch ABS
2
38

2.1 - Pulling to one side
Remove the ABS fuse from the accessories board

and carry out a road test with the ABS non-operational.
no
yes
If the pedal travel is relatively long, bleed the braking circuit

following the recommended order.
If pedal travel is correct, check the tyre inflation pressures,
the front axle assembly or check for a possible leak in the
braking circuit.
Lift the vehicle so the wheels may be turned and check :

- for a possible inversion of the wheel sensor connectors. Use functions #1 #2 #3
and #4 while turning the appropriate wheel and check the coherence of the
results obtained.
If no speed is shown on the XR25, turn the other wheels to confirm the sensor
connectors have been incorrectly connected and then reconnect them correctly.
- Check for a possible incorrect connection of the pipes on the hydraulic assembly.
Use functions G3* G4* and G5* while pressing the brake pedal and check for
temporary releasing of the brakes on the wheel or wheels in question.
If the 5 cycles are not performed on the wheel being tested, (wheel free to turn
during the test), check the cycles are not being applied to another wheel
(confirms the hydraulic pipes are incorrectly connected).
If the 5 cycles are not performed on another wheel and the pipes are correctly
connected, replace the hydraulic assembly.
Also check the sensor / target air gap over one turn of each wheel :
Front wheels : 0.4 mm < air gap < 1.2 mm
Rear wheels
: 0.4 mm < air gap < 1.9 mm
If the fault persists, replace the hydraulic assembly.
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Bosch ABS
2
38

2.2 - Wandering
and carry out a road test with the ABS nonoperational.
yes
no
Roadholding fault not connected with the ABS system
Normal behaviour caused by the ABS system during

the regulation phase, especially for non-symmetrical
adherence or poor road surfaces.

3.1 - When first moving off at 6 km/h (3.75 mph) (after the engine has been started)
System reaction for checking of various components felt at

the brake pedal as vibration : normal operation.

3.2 - While driving
3.2.1 At low speeds or when pedal only slightly depressed
Connect the XR25 to the vehicles diagnostic socket.

Set the ISO switch to position S8 and use the latest
XR25 cassette . Turn the ignition on and enter code
D11 on the keyboard. Are only bargraphs 1 and 4
illuminated ?
no
yes

Turn the ignition off and on again.
no
It is possible that vibration being felt at the brake pedal is due to the
system reacting to the following particular conditions :
- crossing speed bumps,
- going round a tight bend where the rear inside wheel lifts off the
ground.
If the problem is different, check the speed sensor connectors (micro
breaks in the circuit) and check the air gaps.
38-156
http://vnx.su
yes

Bosch ABS
2

3.2 - While driving
3.2.2 On poor road surfaces
On poor road surfaces it is normal to feel jerky operation

and vibration of the brake pedal as well as increased tyre
squeal compared to driving on good road surfaces.
The resulting impression of variation in the efficiency of
the system is normal.

3.2 - While driving
3.2.3 When using special equipment (car phone, CB ...)
Check that this equipment has been correctly fitted and

the original wiring, in particular for the ABS system, has
not been altered.

3.2 - While driving
3.2.4 Other cases connected with the external environment
When driving near to radars, radio emitters

or in areas where there is a large amount of metal,
the ABS system may be affected by interference.
The driver may be surprised by unexpected regulation felt
at the brake pedal.
38-157
http://vnx.su
38

Bosch ABS
2

4.1 -Hard pedal

and carry out a road test with the ABS nonoperational.
yes
no
Fault is not in the ABS system
Check the speed sensor connectors for micro cut-outs

in the circuit and check the air gaps over one turn of
the wheel :
Front wheels:
air gap between 0.4 and 1.2 mm
Rear wheels : air gap between 0.4 and 1.9 mm

4.2 - Spongy pedal
There is air in the braking circuit. Bleed the circuit following the special order for bleeding at the wheels.
After the operation does the fault persist or has the pedal
travel been extended?
no
Correct
no
Correct
yes
Air in the piston plunger.

Carry out a specific bleeding operation for this fault.
Does the fault persist after this second bleeding operation?
yes
Replace the hydraulic assembly
38-158
http://vnx.su
38

Bosch ABS
2

4.3 - Long pedal travel
Air in the primary braking circuit.

Bleed following the manufacturers instructions.

4.4 - Vibrations and/or jerky pedal operation
Reaction at the brake pedal due to self testing of various

components at 3.75 mph
(6 km/h) when the vehicle first moves away, or during an
ABS regulation phase.
5 - Noises
From the pump, the hydraulic assembly or the hydraulic pipes
- Assembly vibration : check the presence and condition of the

assembly rubber mountings.
- Pipe vibration: check that all the pipes are correctly clipped
into their mounting hooks and they do not touch each other
or neighbouring components.
To determine what is causing the noise, the functions G3* G4*
and G5* on the XR25 may be used.
38-159
http://vnx.su
38
Sheet metal work

GENERAL
LOWER STRUCTURE
UPPER BODY SECTION
BODY PROTECTION
SIDE OPENINGS
BONNET AND TAILGATE
77 11 190 877
NOVEMBER 1996
are constructed".
Edition Anglaise

Renault.
Renault S.A. 1988
http://vnx.su
EXPLODED VIEW
PRS4011
http://vnx.su
Panels
Contents
Pages
40 GENERAL
Vehicle dimensions
Lifting
Description of parts (exploded
views)
Description of symbols
Opening clearances
Collision damage assessment
Dimensions of the lower structure
Main bodywork dimensions
Body jig bench
Special tools
Pages
42 UPPER FRONT STRUCTURE

40-1
40-2
40-7
A
B
C
40-11
40-18
40-20
40-27
40-32
40-34
40-35
40-42
D
E
F
G
H
I
J
Wing
Complete radiator grille upper cross
member
Part radiator grille upper cross
member
Bonnet lock support
Headlight carrier panel
Part front wing panel (front section)
Wheel arch (shock absorber turret)
Part heater bulkhead partition
Part windscreen aperture lower
cross member
Front pillar upper stiffener
42-1
42-4
42-6
42-7
42-8
42-9
42-10
42-14
42-16
42-18
41 LOWER STRUCTURE
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
Complete front end cross member

Part front end cross member
Complete front end panel
Part front end panel
Side member closing panel
Front side member front section
Part front side member front section
Front side member rear section
Front side cross member
Front half unit
Part centre floor panel
Rear floor panel (part centre
section)
Rear floor panel
Utility vehicle floor panel
Lateral side member lower section
Lower side spacer
Sill closing panel stiffener
Front pillar lower section stiffener
Floor and cross member side
stiffener
Floor panel upper cross member
Assembled rear end panel
Part rear end panel cross member
Body
41-1
41-3
41-4
41-5
41-6
41-7
41-9
41-10
41-12
41-13
41-16
41-17
41-18
41-22
41-23
41-25
41-26
41-28
43 UPPER SIDE STRUCTURE

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
Front pillar lower section

Front door pillar by cutting at
windscreen upright
Door hinges (on front pillar)
Front door pillar
Front pillar
Front door pillar seal fastening
(KSM)
Centre pillar
Centre pillar lining
Sill panel
Body side
Part sill panel
Sill panel
Sill panel front stiffener
Sill panel rear stiffener
Roof arch
41-29
41-30
41-31
41-34
41-36
http://vnx.su
43-1
43-3
43-5
43-6
43-8
43-9
43-10
43-15
43-19
43-21
43-22
43-23
43-27
43-29
43-30
Contents
44 UPPER REAR STRUCTURE

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
2A
Complete wing panel

Complete rear wing panel
Part wing panel
Part rear wing panel
Quarter panel lining
Assembled wing panel lining
Wing panel lower front lining
Wing panel upper front lining
Wing panel rear lining
Tailgate upper rain channel
Outer wheel arch
Complete quarter panel arch
Part quarter panel arch
Backrest mounting stiffener
Outer wheel arch stiffener
Upper cross member between
wheel arches
Hood compartment base partition
Hood compartment rear cross
member
Jack support (right hand side)
Centre shelf
Half unit
Rear end panel
Rear end panel lining and
assembled end panel
Part end panel cross member
Rear end panel extension piece
Side rain channel
Boot lid rain channel
Lighting support panel
45 UPPER BODY SECTION

44-1
44-8
44-13
44-25
44-26
44-32
44-36
44-37
44-38
44-39
44-40
44-44
44-46
44-47
44-48
44-49
44-51
44-53
44-54
44-55
44-56
44-58
44-64
44-70
44-71
44-73
44-75
44-77
44-79
A
B
C
D
E
F
Roof panel
Windscreen surround
Linings and stiffeners
Windscreen pillar lining
Windscreen aperture upper cross
member
Rear roof cross member
45-1
45-7
45-9
45-10
45-11
45-12
46 BODY PROTECTION
A
B
Sub-frame front protector

Wheel arch mud shield
46-1
46-2
47 SIDE OPENINGS
A
B
C
D
Door hinges
Front door panel
Rear door panel
Front door - rear door
47-1
47-2
47-4
47-6
48 BONNET AND TAILGATE

A
B
C
D
E
F
Bonnet
Tailgate
Boot lid
Hood cover panel
Broken boot lid counter balance ball
joint
Roof cross member (noise
reduction)
http://vnx.su
48-1
48-3
48-5
48-11
48-13
48-14
GENERAL
40
Engine
Vehicle type
Cubic
capacity
(cm 3)
Clutch type
Type
B530 - C530 - L530

S530
C1G
1237
180 CP 3300
JB0 - JB1 - JB4 - JB5
B531 - C531 - L531
C1J
1397
180 CP 3300
JB0 - JB1 - JB4 - JB5
C2J
1397
180 CP 3300
JB0 - JB1 - JB4 - JB5
B532 - C532 - L532
C3J
1390
180 CP 3300
JB0 - JB1
B53G - B537 - C537

L53G - L537 - S537
E6J
1390
180 CP 3300
JB0 - JB1 - MB1
B53A - C53A - L53A
E7J
1390
180 CP 3300
JB1 - MB1
B535 - C535 - L535
E7J
1390
180 CP 3300
JB1 - MB1
B53W - C53W - L53W
E7F
1171
180 CP 3300
JB0 - JB1 - JB3
B53E - B53M - B533

B536 - C53E - C53M
C533 - L533 - L536
F2N
1721
200 CP 4000
JB0 - JB1 - JB3 - AD4
B53B - B53C - B53F

C53B - C53C - C53F
D53C - L53B - L53C L53F
F3N
1721
200 CP 4000
AD4 - JB3 - MB3
B53V - B53Y - B538

C53V - C53Y - C538
D53V - D53Y - L53V
L53Y - L538 - 353A
353C - 353D - 353F
453A - 453C - 453D
453F - 453H - 553A
553C - 553D - 553F
553H - 853A - 853C
853F
F3P
1794
200 CP 4000
AD4 - JB3 - JC5
B53D - B539 - C53D

C539 - D53D - L53D
L539
F7P
1764
200 CP 4400
JB3 - JC5
B53I - B53J - B53K

B53T - B53Z - B534
C53I - C53J - C53K
C53T - C53Z - C534
L53I - L53J - L53K
L53T - L53Z - L534
S53I - S53J - S53K S534
F8Q
1870
B53H - B53P - C53P

L53H - L53P
Manual and automatic gearbox type
200 CPV 4600

JB1 - JB3 - JC5
200 CPV 3500
40-1
http://vnx.su
GENERAL
Vehicle dimensions
B53
Phase I
91936R1
Mark
2.545
4.155
1.418
1.416 unladen
1.406 to 1.417
1.676 or 1.694
40-2
http://vnx.su
40
GENERAL
Vehicle dimensions
B53
Phase II
40
95890R
Mark
0.813
2.540 - 2.544 (1)
0.805 - 0.809 (1)
4.158 - 4.166 (1)
0.120 (2)
1.426
1.684 - 1.696 (1)
1.400 - 1.420 (1) - (3)
1.406 - 1.417 (1)
(1) Depending on version with option

(2) Laden
(3) Unladen
40-3
http://vnx.su
GENERAL
Vehicle dimensions
L53 Saloon
Except Sport
92866R
Mark
2.545 or 2.540 *
4.262
1.412 unladen
1.418
1.406 to 1.417 *
1.684 or 1.694 *
* Depending on version
40-4
http://vnx.su
40
GENERAL
Vehicle dimensions
B - C - L539
Sport
40
92764R
Mark
B and C
A
L
2.540
4.150
4.259
1.389
1.400
1.429
1.406
1.684
40-5
http://vnx.su
GENERAL
Vehicle dimensions
D53
Cabriolet
94726R
Mark
2.545
4.155
1.375 5
1.418
1.406 to 1.417
1.676 or 1.694
40-6
http://vnx.su
40
GENERAL
Lifting
40
LIFTING USING A JACK FROM THE SIDE
USING AXLE STANDS
Use cross piece Cha. 280-02.
To place the vehicle on axle stands, the stands

must be positioned under jacking points (1)
provided for lifting the vehicle using the jack
supplied with the vehicle.
Take the load under the front door sill.

Position the body sill flange correctly in the cross
piece groove.
To position the axle stands at the rear, lift the

vehicle from the side.
87709R
85679-1G7
40-7
http://vnx.su
91936G3
GENERAL
Lifting
40
Safety symbol (special precautions to be taken while working)
Cha.
280 -02
Cha.
or
408 -01
Cha.
408 -02
Adjustable cross piece on trolley

jack
Adjustable dowel on trolley jack
Appropriate axle stands must be used if a

trolley jack is used.
For B537 and C537 type vehicles, make a clearance

notch in cross piece Cha. 280-02 to prevent it from
coming into contact with the exhaust.
USING A TROLLEY JACK FROM THE REAR
The vehicle must not be lifted by taking the load

under the front suspension arms.
The rear of the vehicle MUST NOT be lifted by

taking the load under the rear axle. Lift each
wheel separately taking the load at the lifting
points provided for the on-board jack.
Depending on the type of trolley jack , use dowels

Cha. 408-01 or Cha. 408-02 to fit cross piece Cha.
280-02.
To lift the front or the rear, take the load under
the lifting points provided for the on-board jack.
USING A TROLLEY JACK FROM THE FRONT
Apply the handbrake or chock the rear wheels.

Use cross piece Cha. 280-02.
Take the load under the front sub-frame.
Ensure that the cross piece does not come into
contact with the gearbox or the exhaust
downpipe.
92556R
40-8
http://vnx.su
GENERAL
Lifting
40
AXLE STANDS
WHEEL FREE LIFT
To place the vehicle on axle stands, the stands

must be positioned:
- either under the jacking points provided for
lifting the vehicle using the on-board jack,
- or under the pads located behind the stiffeners.
SAFETY ADVICE
To position the axle stands at the rear, lift the

vehicle sideways.
In general, never use a two post lift when a four

post lift is suitable.
Several possibilities must be considered:

1 - REMOVAL OF COMPONENTS
If this is not possible, fit the lifting pads under the

sill flange at the lifting points provided for the onboard jack.
FRONT
98703S
REAR
85679-1G7
98336G
98704S
The pads must be placed to the right of the

jacking points. They must be engaged in the openings in the sill panel flanges.
40-9
http://vnx.su
GENERAL
Lifting
2 - SPECIAL CASE FOR REMOVAL - REFITTING OF
THE ENGINE AND TRANSMISSION ASSEMBLY
40
FRONT
In this case, the vehicle body must be connected to

the arms of the two post lift using special pads.
FOG :
Part number FOG 449 8111 - 449 8411

or
CHEMICO :
Part number 39 2550 0001

or
SCHENCH
Part number 776 684
98705S
LASHING FOR TOWING
REAR
FOR TOWING REFER TO THE CURRENT

LEGISLATION FOR EACH COUNTRY.
NEVER USE THE DRIVESHAFTS AS TIE-DOWN
POINTS.
The towing points are only to be used for towing

on the road. They must never be used for pulling
the vehicle out of a ditch, for any other similar
operations or for lifting the vehicle directly or indirectly.
98702S
40-10
http://vnx.su
B53 / C53
GENERAL
Description of parts (exploded views)
40
PRS4012
9
10
11
12
13
14
15*
16*
17
18
18A
19
19A
20
20A
LOWER STRUCTURE ALL TYPES
1
2
2A
2B
3
4
5
6
7
8
8A
8B
Sill closing panel

Centre floor panel
Centre floor panel cross member
Front seat mounting cross member
Front 1/2 unit (wheel arch)
Rear 1/2 unit (wheel arch)
Assembled rear floor panel with side
member
Rear floor panel rear section
Part rear floor panel
Part rear floor panel
* Steel part with high degree of flexibility
40-11
http://vnx.su
Rear floor panel front section

Rear floor panel
Floor panel stiffener cross member
Fuel tank mounting cross member
Cross member under rear floor panel
Rear side member
Front side member closure panel
Part front side member
Lower front cross member
Part lower cross member
Assembled front panel
Part assembled front panel
B53 / C53
GENERAL
40
PRS4013
66
67
68
69
70
71
71A
72
UPPER STRUCTURE
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
Front roof panel cross member

B53 roof drip moulding lining
Roof panel
B53 quarter panel lining
Quarter panel arch
Rear outer wheel arch
Quarter panel lining (C53)
Sill panel partition (C53)
Door pillar lining (C53)
Body top lining (C53)
Centre pillar lower lining
Front wing bracket
Front wing
72A
72B
73
73A
74
75
75A
76
Front wheel arch

Front wheel arch extender
Diesel engine mounting cup
Bonnet lock support
Front upper cross member
Part front upper cross member
Inner wheel flange panel - front pillar
lining
Part inner wheel flange panel - front
pillar lining
Part inner wheel flange panel - front
pillar lining
Heater bulkhead partition
Bulkhead
Windscreen aperture lower cross member
Part lower cross member
Bonnet
40-12
http://vnx.su
B53 / C53
GENERAL
40
PRS4014
90A
90B
91
92
93
94
95
96
97
97A
97B
98
99
UPPER STRUCTURE
80
81
82
83
84
85
86
87
88
89
90
Tailgate
Front door
Rear door
Rear door panel
Front door panel
Lighting support
Rear end panel
Assembled rear end panel with cross
member
Rear end panel lining
Sill panel (C53)
Wing panel (C53)
Part wing panel in line with cross-section A

Part wing panel in line with cross-section B
Body top (roof drip moulding) (C53)
Sill panel (B53)
Body top (B53)
Front pillar
Body side
Centre pillar
Rear wing panel (B53)
Part rear wing panel (cross-section A)
Part rear wing panel (cross-section B)
Wing panel upper rain channel
Wing panel lower rain channel
40-13
http://vnx.su
B53 / C53 / L53
GENERAL
LOWER STRUCTURE
PRS4015
1 Rear floor panel with side member

2 Part rear floor panel (rear section)
3 Rear floor pnel
4 Rear side member
5 Part rear end panel cross member
40-14
http://vnx.su
40
L53
SALOON
GENERAL
40
UPPER STRUCTURE
PRS4016
1
2
3
4
5
6
7
8
9
10
Roof panel
Boot lid
Counter balance ball joint
Boot lid strut
Quarter panel arch
Outer wheel arch
Wing panel side rain channel
Wing panel
11
12
13
14
15
16
17
18
19
Rear end panel cross member

Rear end panel cross member blanking piece
Rear end panel side extender
Jack support (right hand side only)
Rear centre shelf
Half unit
40-15
http://vnx.su
D53
CABRIOLET
GENERAL
40
PRS4017
1
2
3
4
5
6
7
8
9
Windscreen surround
Rear floor panel upper cross member
Floor panel and cross member side stiffener
Lower side spacer
Sill panel stiffener
Sill panel outer panel
Bare sill panel outer panel
10
11
12
13
14
15
16
17
18
40-16
http://vnx.su
Door panel
Door
Front pillar
Front wing
Front pillar lower lining
Windscreen aperture upper cross member
D53
CABRIOLET
GENERAL
40
PRS4018
28
29
30
31
32
33
34
35
36
37
Upper cross member between wheel

arches
Hood compartment rear cross member
Hood compartment cover
Boot lid
Hood compartment cover hinge
Boot lid hinge
Lighting support component
38
39
40
41
42
43
44
45
46
47
40-17
http://vnx.su
Lighting support component stiffener

Rear wing panel
Outer wheel arch
Centre pillar
Boot lighting support
GENERAL
40
MIG stitch welding

Note: for good quality welding, it is
recommended that a gas composed of
Argon + 15% CO2, which is considered
to be an active gas, is used (MIG)
Cut using a cold chisel
Grind the weld fillet or spot welds

Straight grinding wheel fitted with a
75mm diameter 1.8 to 3.2 mm thick
Bakelite disc.
Plug welding
MIG welding
Rotary grind the spot welds

20,000 rpm straight grinding wheel with
a 10 or 16mm diameter spherical cutter.
Inject wax into the hollow sections

Gun under pressure fitted with a
flexible end piece.
Rotary grind the spot welds

Spot weld drill. Speed of rotation 800 to
1,000 rpm.
Safety symbol
This means that the welding operation
in question concerns one or more
aspects of vehicle safety
Unpick the metal strip
Lead fill
Hot air gun
Nozzle output temperature 600 min.
Palette+ 33% lead stick+ tallow
Note: to a large extent, the soft solder
finish compensates for the risks of
deformation due to welding
Clean the surfaces to be welded

100 mm fibre disc
Cut using a hacksaw

Pneumatic power hacksaw
Application of electrically weldable

mastic
This conductive mastic, inserted
between two panels to be spot welded,
seals the panels and prevents corrosion
of the spot welds
Cut the part by grinding the flange or

grind down the remaining bits of spot
weld
Angle grinder fitted with a rubber
backing pad and a 120 to 180 mm P36
grade fibre disc
Application of aluminium based paint

This must be applied to the mating
surfaces of each of the parts to be plug
welded. This paint is conductive and
can withstand high temperatures; it
gives anti-corrosion protection around
welds.
Release brazed joint
Dimensions and types of electrodes to

be used for the operation:
L = 100
L = 100
Apply a bead of extruded mastic

gun with a manual or pneumatic
cartridge
crimping or mating mastic with one
or two parts
L = 100 +flat
L = 250
L = 350 +ball joint
Apply mastic by spraying

gun under pressure
anti-chipping and anti-corrosion
mastic with two parts
L = 330
40-18
http://vnx.su
GENERAL
LOCATION OF
OPERATIONS
TYPES OF TOOL AND

ORDER OF OPERATIONS
LOCATION OF
OPERATIONS
40
TYPES OF TOOL AND
ORDER OF OPERATIONS
WELDING (cont)
CUTTING-UNPICKING
or
saw
saw
plug weld
chisel
stitch weld
FINISHING
rotary
grind
unpick
clean
stud
extractor
grind
unpick
clean
PROTECTION OF CRIMPED WELD JOINTS
rotary grind
sand
bead of mastic in cartridge
unpick
clean
bead and spraying of mastic

ANTI-CHIPPING PROTECTION
grind
spraying of mastic
release
brazed joint
sand
PROTECTION OF HOLLOW SECTIONS
WELDING
electric spot welder
stitch
weld
grind
L (en
mm)
1-2
3-4
5
6
8
100
100
250
350
330
injection using angled nozzle

PAINTING STYLED AREAS
aerosol can
lead
fill
40-19
http://vnx.su
B53
Phases I and II
GENERAL
Opening clearances
40
91936-4R
92309-1R1
40-20
http://vnx.su
B53
Phases I and II
GENERAL
Opening clearances
92309-1R2
40-21
http://vnx.su
40
L53
Saloon
GENERAL
Opening clearances
40
92866R1
93126R
NOTE: for front section parts, refer to the B53 diagrams on previous pages.
40-22
http://vnx.su
D53
Cabriolet
GENERAL
Opening clearances
40
94726R1
40-23
http://vnx.su
D53
Cabriolet
GENERAL
Opening clearances
40
94772-3R
94772R
2
94772-4R
94772-1R
3
94772-5R
94772-2R
40-24
http://vnx.su
D53
Cabriolet
GENERAL
Opening clearances
40
10
94772-6R
94772-9R
11
94772-7R
94772-10R
94772-8R
40-25
http://vnx.su
D53
Cabriolet
GENERAL
Opening clearances
40
12
94772-11R
40-26
http://vnx.su
GENERAL
40
CHECKING THE FRONT CROSS MEMBER AND THE FRONT END PANEL SUB-FRAME MOUNTING (1)
Compare lengths:
CG = DH
CH = DG
If lengths (CH - DG) and diagonals (CG - DH) are not identical, point (3) on the sub-frame must be checked as
shown on the following pages.
If points (1) and (2) are correct, the front axle angles must be checked and adjusted.
If the front axle cannot be adjusted, it will then be necessary to change front axle components (stub axle
carrier, etc.).
PRS4019
C
85591R
85593R
40-27
http://vnx.su
GENERAL
40
CHECKING THE CENTRE SECTION (3) OF THE SUB-FRAME
Compare lengths:
EI = FJ
EJ = FI
If points (2) and (3) are correct, it will be possible to straighten or partially change the front section of the side
member and refit a new cross member without having to place the vehicle on a body jig bench. Point (1) is
aligned using the engine sub-frame, after having changed the sub-frame if necessary.
If all the sub-frame check points (1), (2) and (3) are correct, it will then be necessary to check and adjust the
front axle.
If adjustment is not possible, front axle components must be changed (stub axle carrier, etc.).
If points (1) and (3) are not correct, the vehicle must be placed on the bench in order to change the front
section of the side member.
PRS4020
E
J
85860-1R
85592S
40-28
http://vnx.su
GENERAL
40
CHECKING THE LATERAL SIDE MEMBERS (6) (REAR ARM MOUNTINGS)
Compare lengths:
GO = HP
GP = HO
Following a side or rear impact, if there is a difference in length, the vehicle must be placed on the frame
bench in order to re-align the lateral side member or partially change it.
IT IS NOT NECESSARY TO REMOVE THE FRONT MECHANICAL COMPONENTS IN ORDER TO PLACE THE
VEHICLE ON THE JIG BENCH FOLLOWING A REAR OR SIDE IMPACT. SUPPORTS SPECIALLY PROVIDED FOR THE
PURPOSE MUST BE PLACED AT POINTS (2).
If there is no difference in length, check points (4) as shown below.
92381R4
O
85588S
H
85593R
40-29
http://vnx.su
GENERAL
40
CHECKING THE ENDS OF THE REAR SIDE MEMBER (4)
Compare lengths:
EK = FL
EL = FK
If points (4) and (6) are correct and there is no apparent distortion, repair is possible without using the bench
on condition that the upper structure is not too badly damaged and not too many parts need to be changed.
If there is a difference in length (FK - EL), the method of repair to be used (on or off the bench) depends on
the number of upper structure parts to be changed.
PRS4021
F
K
85595R
85589S
40-30
http://vnx.su
GENERAL
40
CHECKING THE REAR ARMS (5)
Compare lengths:
FM = EN
Following a rear impact or a wheel impact, it is possible to quickly check whether or not the arms are
deformed.
If the diagonals are different, change the rear arms.
This operation for checking the arms (5) must be followed by a trammel gauge check of the mounting of the
arms to the lateral side members (6).
PRS4022
M
85589S
40-31
http://vnx.su
85594R
GENERAL
40
REMINDER OF ALIGNMENT
The intersection of the three planes X - Y -Z determines initial point 0 of the vehicle and the three reference
lines:
1
Dimension start line:
L - D - C (position of body jig bench bracket at X, in relation to this line).
Body centreline:
A - D - C (position of body jig bench bracket at Y, in relation to this line).
Base line:
L-D-B
(position of body jig bench bracket at Z, in relation to this line).
The bodywork repair body jig brackets and their positions on the bench are designed in accordance with
these three lines.
PRS4023
40-32
http://vnx.su
ALL TYPES
GENERAL
40
92381R3
40-33
http://vnx.su
D53
Cabriolet
GENERAL
Main bodywork dimensions
40
NOTE: the dimensions are measured in the centreline of the various welded nuts.
PRS4027
40-34
http://vnx.su
GENERAL
Body jig bench
-
BRACKETS AND REFERENCE POINTS
40
drilling of the shock absorber upper cup

mounting holes.
SUB-FRAME FRONT MOUNTING
(refer to the method described in sub-section 41)
DIESEL ENGINES UPPER MOUNTING
92631S
Jig used for repairing the front of the vehicle,

with the front sub-frame removed.
92662S
This enables positioning of the lower cross

member and the end of the side member.
The jig is used to position the engine mounting securing cup so that it can be welded to the cowl
side panel.
FRONT SHOCK ABSORBER UPPER MOUNTING
SUB-FRAME REAR MOUNTING
92633S
A - Repairing the front

(front sub-frame removed)
92632S
The jig allows positioning of the side member or

the front 1/2 unit.
Jig used for repairing the front of the vehicle,

front sub-frame removed.
This allows:
- positioning of the wheel arch or the 1/2 unit,
40-35
http://vnx.su
GENERAL
Body jig bench
B - Repairing the rear
(front sub-frame fitted)
40
REAR AXLE MOUNTING
A - Repairing the front

(rear sub-frame fitted)
The jig allows the front of the vehicle to be

supported and aligned on the bench.
The jig allows the rear of the vehicle to be

supported and aligned on the bench.
92634S
FRONT SEAT CROSS MEMBER
92637S
When the jig is centred along the length of the

vehicle, it enables the vehicle to be supported and
aligned when major repairing is being carried
out:
Eg. : front or rear unit
B - Repairing the rear

(rear sub-frame removed)
The jig allows positioning of the side member or
the rear unit.
It also allows alignment of the rear section of the

front side member.
92635S
92636S
40-36
http://vnx.su
GENERAL
Body jig bench
40
REAR SHOCK ABSORBER UPPER MOUNTING
REAR SIDE MEMBER REAR END PANEL
During repairing of the rear, with the rear subframe removed, the jig allows positioning of the
1/2 unit (assembled wheel arch).
During repairing of the rear, the jig allows

positioning of the side member or the rear unit.
92638S
92640S
FUEL TANK MOUNTING CROSS MEMBER
During repairing of the rear (sub-frame removed),

the jig allows positioning of the fuel tank cross
member.
92639S
40-37
http://vnx.su
GENERAL
Body jig bench
40
FITTING CELETTE BRACKETS
PRS4024
40-38
http://vnx.su
GENERAL
Body jig bench
40
FITTING BLACKHAWK BRACKETS
PRS4025
40-39
http://vnx.su
D53
Cabriolet
GENERAL
Body jig bench
40
FITTING CELETTE BRACKETS
PRS4026
40-40
http://vnx.su
GENERAL
Body jig bench
40
PART NUMBERS FOR SPECIAL TOOLS
Figure
Description
Special heads for the CELETTE body jig bench
MZ system
Please contact your local After Sales Office for further
details.
92 673
Special heads for the BLACKHAWK body jig bench

MS system
Please contact your local After Sales Office for further
details.
92 674
40-41
http://vnx.su
GENERAL
Special tools
FRONT END PANEL JIG
92301R
Car. 1138-02
Part number 00 00 113 802
Points (A), (B), (C) and (D) are the reference points
for positioning the jig on the vehicle. Before fitting the jig, it is necessary to ensure at damage assessment that the reference points are correct.
Points (E), (F), (G), (H) and (J) are mainly used for
mounting and positioning the replacement parts.
However, if either point (A) or (B) cannot be used
as a reference point, the points on the opposite
side to the impact act as reference points.
40-42
http://vnx.su
40
GENERAL
Special tools
40
Flush fitting adjustment
TOOL FOR REMOVING DOOR HINGE PINS
This is obtained by pulling or pushing one or two

hinges using tool Car. 956 fitted to impact extractor M.S. 580.
Adjustment range: 3 mm
97129R
Car. 1055-02
Part number 00 00 105 502
Fitted to the FENWICK REN. 1303 type slide hammer.
85700-2S
Tilt adjustment
ADJUSTING THE DOORS
It is possible to adjust the door clearances, front to

rear and tilt, without removing the door from the
vehicle, using a claw lever on the male hinges:
Wilmonda BHA part number
(Supplier: Z. INTERNATIONAL)
85899R
40-43
http://vnx.su
LOWER STRUCTURE
Complete front end panel cross member
This operation is to be carried out on a body jig
bench. Refer to sub-section
40 for instructions
on fitting the components.
41 A
Welding
COMPOSITION OF THE REPLACEMENT PART
Assembled part with engine sub-frame mounting

stiffeners.
92567S
2
PRS4112
BUTT WELDING JOINT ON THE SIDE MEMBER
Thickness of panels (mm)

Cross member:
Cowl side panel:
1.25
1

Cross member:
Side member:
Side member closure panel:
Unpicking
1.25
1.25
0.8
Unpicking
3 spot welds
10 spot welds
92567-1S
41-1
http://vnx.su
LOWER STRUCTURE
Complete front end panel cross member
3
BUTT WELDING JOINT ON THE HEADLIGHT

CARRIER PANEL

Cross member:
Headlight carrier panel:
41 A
BUTT WELDING JOINT ON THE LOCK SUPPORT

1.25
0.8
Cross member:
Lock support:
Unpicking
Unpicking
8 spot welds
One 15mm MAG weld fillet
4 spot welds
Welding
Welding
92562S
92561-1S
41-2
http://vnx.su
1.25
1.5
LOWER STRUCTURE
Part front end panel cross member
Phase II vehicles
41
Phase I vehicles
This operation is a variation on the previous one.

Therefore, only its special points are described
below.
It is not necessary to use the body jig bench for
this operation. Front panel jig Car. 1138 is
sufficient.
For this operation, lock support (2) below must be
ordered as well.
PRS4113
Same as previous part.
In order to carry out this operation on Phase I vehicles, the closure panel (3) above must be removed from the new replacement part.
PRS4127
41-3
http://vnx.su
LOWER STRUCTURE
Complete front end panel
41
Welding
Special replacement part consisting of:

- upper cross member
- lower cross member
- lock support
-
92563S
PRS4128
For phase I vehicles:

At A : cut out the two phase II headlight mounting lugs.
At B :
Add 2 washers (diameter 6 18) to

compensate for the enlargement of the
cut-outs.

92565-1S
Refer to the previous operation.
BUTT WELDING JOINT ON THE COWL SIDE

PANEL
PANEL
Thickness of the panels (mm)

Upper cross member:
Lower cross member:
Cowl side panel:
1.2
0.8
1.25
1
Unpicking
92567-1S
18 spot welds
41-4
http://vnx.su
LOWER STRUCTURE
Part front end panel
Therefore, only its special points are described below.
Welding
It can only be carried out on phase I vehicles which

do not have a lower cross member closure panel
(refer to the part lower cross member operation).
92561-4S
PRS4115
NOTE: cut (A) will only be made on the opposite
side to the impact.
41-5
http://vnx.su
41 D
LOWER STRUCTURE
Side member closure panel
This operation is carried out in addition to:
41
Welding
- straightening of the front section of the side

member following removal of the front lower
cross member,
- partial replacement of the front section of the
side member following removal of the front
lower cross member,
- complete replacement of the front section of
the cross member.
Panel only
92568S
PRS4116
UNPICKING
- 3 spot welds on the front cross member,

- 10 single layer spot welds on the side member.
+
6 two layer spot welds
2 MAG weld fillets (15 mm x 2)
41-6
http://vnx.su
LOWER STRUCTURE
40 for instructions
41
Welding
Part only without closure panel (the closure panel

must be ordered separately).
92567S
PRS4117
BUTT WELDING JOINT ON THE CLOSURE

PANEL
BUTT WELDING JOINT ON THE LOWER CROSS

MEMBER

Cross member:
Side member:
Closure panel:
1.25
1.25
0.8
Unpicking
10 spot welds
41-7
http://vnx.su
LOWER STRUCTURE
3
41
Unpicking
BUTT WELDING JOINT ON THE WHEEL ARCH

Side member front section:
Closure panel:
Wheel arch:
1.25
0.8
0.7
Welding
Unpicking
+
18 spot welds
Two 15mm MAG weld fillets
Welding
92569S
92566-2S
92570S
BUTT WELDING JOINT ON THE REAR SECTION

OF THE SIDE MEMBER
After painting and before refitting the trim,

protect the hollow sections with wax.

Side member rear section:
Wheel arch:
1.25
2
0.7
41-8
http://vnx.su
LOWER STRUCTURE
Part front side member front section
below.
PRS4118
Welding
92571S
41-9
http://vnx.su
41 G
LOWER STRUCTURE
40 for instructions
41 H
Welding
(1)
(2)
(3)
(4)
(5)
Bare side member

Side cross member
Jack support
Sub-frame support
Stiffening plate
92572S

protect hollow sections with wax.
PRS4119
BUTT WELDING JOINT ON THE FRONT SECTION
BUTT WELDING JOINT ON THE FLOOR

Floor stiffener:
Floor:
2
2
0.6
Unpicking
From inside the vehicle:
32 spot welds
41-10
http://vnx.su
LOWER STRUCTURE
3
BUTT WELDING JOINT ON THE INNER SILL

PANEL

Side cross member:
Jack support:
Inner sill panel:
Sill panel:
41 H
BUTT WELDING JOINT ON THE SEAT CROSS

MEMBER
Thickness of panel (mm)

1
2
1.5
1

Seat cross member:
Unpicking
2
1.25
Unpicking
+
9 spot welds
6 two layer spot welds
Welding
Welding
92577S
92576S
D = 6 mm


41-11
http://vnx.su
LOWER STRUCTURE
41
Welding
(1) Bare side cross member

(2) Jack support
92574S
PRS4120
BUTT WELDING JOINT ON THE INNER SILL

PANEL
BUTT WELDING JOINT ON THE FLOOR

92575S
D = 5.5 mm

Side cross member:
Side member:
1
2
+
9 spot welds
41-12
http://vnx.su
LOWER STRUCTURE
Front half unit
41

40 for instructions
(1)
(2)
(3)
(4)
(5)
(6)
Side member front section

Wheel arch
Shock absorber cup
Wheel arch extender
Cowl side panel
92567-1S
BUTT WELDING JOINT ON THE UPPER CROSS

MEMBER
Reminder
PRS4121
92563S

MEMBER
Reminder
BUTT WELDING JOINT ON THE HEATER

BULKHEAD PARTITION
CHAMBER
Reminder
92567S
92564S
41-13
http://vnx.su
LOWER STRUCTURE
Front half unit
41
92641S
92570S
BUTT WELDING JOINT ON THE BULKHEAD
Reminder
COWL SIDE PANEL PARTIAL CUT
On the vehicle, cut the cowl side panel in line

with the dotted line on the diagram below.
This line is level with the plenum chamber.
Cut the replacement part in line with the
continuous black line on the diagram. This line
is 60 mm from the line cut on the vehicle.
92564-1S

REAR SECTION
Reminder
92573S
92569S
41-14
http://vnx.su
LOWER STRUCTURE
Front half unit
7
DRILLING THE SHOCK ABSORBER UPPER

MOUNTING
41
SPECIAL FEATURES OF DIESEL VEHICLES
With the vehicle positioned on the body jig bench,

after welding the wheel arch, drill the front shock
absorber upper mounting.
On these vehicles, the right hand wheel arch has

an additional support for the engine pendulum
mounting.
To do this:
- fit part (1) in the diagram below,
- counter bore the four holes (A) to a diameter of
8 mm.
Cup (C) must be welded during repair using a

body jig bench bracket supplied with the body jig
components.
Warning: part (1) is the same for both the right

and left hand sides, it must be pivoted through a
half turn when changing from one side to the
other.
92662R
92632R
41-15
http://vnx.su
LOWER STRUCTURE
41
Bare floor panel (panel only).

Cutting the replacement part
Cut (A) is made 20 mm above the round surface of
the tunnel.
Cut (B) on one side or other of the seat cross
member location, at the front if the rear section
of the floor panel is to be re-used, at the rear if
the front section of the floor panel is to be reused.
92646S
Example of the front section cut:

On the vehicle, use a chisel to cut the floor panel
level with the seat cross member in line with the
dotted line on the diagram below.
PRS4122
NOTE: if the rear section of the floor panel is to be
changed, the dotted line will be located at (C).
41-16
http://vnx.su
LOWER STRUCTURE
Rear floor panel (part centre section)
In addition to:
41
PREPARATION OF THE NEW PART
UPPER REAR STRUCTURE- End panel
44-U Method 3
Bare part
PRS4124
Cut the new part 20 mm beyond the cut made on

the vehicle, in order to be able to superpose by
plug welding.
PRS4123
CUTTING - UNPICKING
Welding
92369S
92369-1S
D = 0.7 mm
e = 1.7 mm
H = 50 mm
NOTE: the general procedure for changing a
welded component is described in Workshop

Repair Manual M.R. 502 section 4.

protect the hollow sections of the side members
with wax.
41-17
http://vnx.su
LOWER STRUCTURE
Rear floor panel
41
Addition to:
UPPER REAR STRUCTURE - End panel
44-U Method 3
Before changing the fuel tank support cross
member and the cross member under the floor.
COMPOSITION OF THE REPLACEMENT PARTS
(1) Rear floor panel bare part

(2) Fuel tank support cross member
Spare wheel well support
PRS4125
(3) Cross member under the floor panel

bare part

40 for instructions
CUTTING - UNPICKING
92370S
92371S
NOTE: the general procedure for changing a welded component is described in Workshop Repair Manual
M.R. 502 section 4.
41-18
http://vnx.su
LOWER STRUCTURE
Rear floor panel
41 M
UNPICKING THE CROSS MEMBERS ON THE OPPOSITE SIDE TO THE IMPACT
92374S
92372S
WELDING THE CROSS MEMBERS (right hand side)
PRS4126
92374-1S
D = 5.5 mm
Cut the new part 20 mm beyond the cut made on

the vehicle, in order to be able to superpose by
plug welding.
Position the cross member under the floor panel,

in relation to the fuel tank support cross member,
at the distance shown on the diagram.
41-19
http://vnx.su
LOWER STRUCTURE
Rear floor panel
(right hand side)
41 M
(left hand side)
92372-1S
92373S
D = 5 mm
WELDING THE FLOOR PANEL
92369-2S
92370-1S
D = 4.5 mm
41-20
http://vnx.su
LOWER STRUCTURE
Rear floor panel panel
92371-1S
e = 1.3 mm
H = 30 mm

protect the hollow sections of the side members
with wax.
41-21
http://vnx.su
41
S53
Utility
LOWER STRUCTURE
Utility vehicle floor panel panel
41 N
UNPICKING AND REMOVAL OF THE UTILITY VEHICLE FLOOR PANEL
PRJ4019
REMOVE:
the four lashing rings and the rear floor panel carpet,
side sections (1) and (2) secured to the floor panel and the body sides.
Unpick sections (3) and (4) of the load floor panel by grinding out the stitch welds without separating the two
sections.
Remove the load floor panel and load area partition assembly from the vehicle.
Re-use the 3 wheelbrace securing clips and the jack securing assembly.
REMINDER:
1/
Before starting the grinding operations, the internal surfaces of all of the windows and the dashboard
must be protected.
2/
Before fitting the rear seats, carry out a conventional paint application procedure on all of the ground
surfaces.
41-22
http://vnx.su
D53
Cabriolet
LOWER STRUCTURE
Welding
Bare part
Front section:
Photo page 41-1
PRS4106
JOINT WITH THE FLOOR PANEL, SILL PANEL

AND SILL PANEL STIFFENER

Lateral side member
Sill panel
1.5
1.5
1.5
Unpicking
42 spot welds on the floor panel.
22 spot welds on the sill panel.
Twenty 20mm MAG weld fillets.

Two 40mm weld fillets.
41-23
http://vnx.su
41 O
D53
Cabriolet
LOWER STRUCTURE
41 O
Centre section:
D = 8 mm
Photo page 41-2

Rear section:
Photo page 41-2
41-24
http://vnx.su
D53
Cabriolet
LOWER STRUCTURE
Lower side spacer
This part can only be changed after removal of the

lateral side member lower section.
41
Welding
Bare part
Photo page 41-3
PRS4107

JOINT WITH THE FLOOR PANEL AND THE

LATERAL SIDE MEMBER LOWER SECTION

Spacer
Side member lower section
Floor panel
1.5
1.5
0.88
Unpicking
Ten 20mm MAG weld fillets.
41-25
http://vnx.su
LOWER STRUCTURE
D53
Cabriolet
41 Q
This operation can only be carried out after

removal of the assembled sill panel.
Bare part
PRS4108
JOINT WITH THE FLOOR PANEL

sill panel stiffener
sill panel
1.5
1.5
Unpicking
41-26
http://vnx.su
D53
Cabriolet
LOWER STRUCTURE
Sill closure panel stiffener
Welding
On the joint near the front pillar, replace the inaccessible spot welds with MIG plug welds.
Photo page 41-5
D = 8 mm
JOINT WITH THE SILL PANEL FRONT STIFFENER
Refer to paragraphs : 43 - L - 1
41-27
http://vnx.su
41 Q
D53
Cabriolet
LOWER STRUCTURE
Front pillar lower section stiffener

removal of the front pillar.
41
Welding
Part only
Photo page 41-6
PRS4109
JOINT WITH THE COWL SIDE PANEL (pillar

lining) AND SILL PANEL LINING

Cowl side panel
Pillar stiffener
Sill panel lining
D = 8 mm
0.97
1.5
1.5
After painting and before refitting the trim, protect the hollow sections with wax.
31 spot welds.
41-28
http://vnx.su
D53
Cabriolet
LOWER STRUCTURE
Floor panel and cross member side stiffener
41
Welding
- Floor panel stiffener.

- Cross member stiffener.
Photo page 41-7
PRS4110
JOINT WITH THE CENTRE FLOOR PANEL AND

FLOOR PANEL CROSS MEMBER

Stiffener
Centre floor panel
Cross member
Centre pillar
Photo page 41-7

1.5
0.8
1.5
1.5
Unpicking
Thirty-six 25mm weld fillets.

41-29
http://vnx.su
D53
Cabriolet
LOWER STRUCTURE
Floor panel upper cross member
Welding
Part only
Photo page 41-8
PRS4111
JOINT WITH THE FLOOR PANEL AND CROSS

MEMBER STIFFENER

Cross member
Floor panel
Stiffener
1.5
0.88
1.5
Photo page 41-8
Thirty-three 25mm MAG weld fillets.

Two 50mm weld fillets.
31 spot welds.
D = 6 mm
41-30
http://vnx.su
41
LOWER STRUCTURE
L53
Saloon
41 U
Welding
Assembled part consisting of:

- rear end panel cross member
- rear end panel
- striker plate stiffener
- end panel cross member
The two blanking pieces (1) must be ordered
separately.
93125S
- 1 triple layer spot weld

(cross member - panel - lighting support)
PRS4105
- 4 triple layer spot welds

(cross member - lighting support - extender)
Special point
JOINT WITH THE LIGHTING SUPPORT PANEL

End panel cross member
Side panel
End panel extender
0.67
0.67
0.67
0.97
Unpicking
14 spot welds
93124R
After welding and before protecting the crimps,

fit the 2 metal blanking pieces (1) by clipping
them in place using the lugs.
41-31
http://vnx.su
L53
Saloon
LOWER SECTION
3
JOINT WITH THE END PANEL EXTENDER
JOINT WITH THE REAR SIDE PANEL

Rear end panel
End panel extender
41 U
Extreme rear cross member

Rear side member
0.67
0.67
1.25
0.97
Unpicking
Unpicking
24 spot welds
14 spot welds
1,25
1,00
93122S
93123S
41-32
http://vnx.su
L53
Saloon
LOWER STRUCTURE
4
41 U
JOINT WITH THE Rear floor panel panel

Extreme rear cross member
Rear floor panel panel
1.25
0.60
Unpicking
Welding
93121S
41-33
http://vnx.su
L53
Saloon
LOWER STRUCTURE
41
Welding
Panel only
PRS4104
93123-3S

End panel extender
Rear end panel
1 triple layer spot weld
JOINT WITH THE REAR END PANEL

1.25
0.97
0.67

Rear end panel
Unpicking
Unpicking
6 spot welds
2 spot welds
41-34
http://vnx.su
1.25
0.67
L53
Saloon
LOWER STRUCTURE
4
Welding
41
JOINT WITH THE REAR CROSS MEMBER
Reminder: see 41-U-3
93120S
93122S
JOINT WITH THE REAR FLOOR PANEL
PARTIAL CUT
Welding
93121S
93119S
41-35
http://vnx.su
LOWER STRUCTURE
Body
41
PRS4129
When a complete body is changed on a phase I vehicle, the Parts Department will supply a phase II type body.
It will therefore be necessary to carry out the following operations (the details are described in the operations
for each modified part, see contents).
For all types:
- cut out the headlight mounting lugs on the front panel upper cross member,
- add washers under the bonnet lock mountings,
- order a new set of sill moulding.
For vehicles fitted with rubbing strips, order special replacement adhesive clips (refer to the parts list).
For B, C and S53 type vehicles:
- drill the piston switch hole in the rear end panel,
- close the tailgate harness hole in the upper rain channel.
For C and S53 type vehicles, drill the centre pillar trim 17 mm higher in order to refit the original seat belts.
41-36
http://vnx.su
ALL TYPES

Wing
42 A
REPLACEMENT
92560R
A) Detach the bumper without removing it completely. To do this, remove:

- Two T20 Torx bolts (1)
- Two 10mm hexagonal bolts (2)
B) Remove the wheel arch protector
- One T20 Torx bolt (3)
- Three clips (4)
C) Detach the front end of the sill moulding:
- One T20 Torx bolt (5)
D) Slacken the bonnet strut mountings without removing them:
- Two 13mm hexagonal bolts (6)
E) Remove the wing mountings:
- Six 10mm hexagonal bolts (7)
- Two 11mm hexagonal nuts (8)
F) Using a hot air gun, soften the anti-chipping mastic inside the wing and then remove the wing.
42-1
http://vnx.su
ALL TYPES

Wing
When a front wing is changed on a vehicle fitted
with rubbing strips, a mounting hole must be drilled (see diagram).
92676R
NOTE: the strip is bonded using a bead of "paint
joint" type mastic.
42-2
http://vnx.su
42 A
D53
Cabriolet

Front wing
Photo page 42-1
PRS4207
The front wing is identical to that of the base

vehicle 53, but the lower rear section of it has
been modified.
This section is mounted using bolt (1) (see
diagram).
42-3
http://vnx.su
42 A

Complete radiator grille upper cross member
42
Welding
Refer to the diagram below.

NOTE: for phase I vehicles, cut out the headlight
mounting lugs at (A).
92561S
PRS4209
BUTT WELDING JOINT ON THE LOCK SUPPORT
Cross member:
Cowl side panel:

Cross member:
Lock support:

PANEL
1.2
1
Unpicking
1.2
1.5
Unpicking
3 spot welds
Welding
4 spot welds
92563S
42-4
http://vnx.su

Complete radiator grille upper cross member

CARRIER PANEL

Cross member:
1.2
0.8
Unpicking
7 spot welds
Welding
92563-2S
42-5
http://vnx.su
42

Part radiator grille upper cross member
below.
Identical to the previous part.
PRS4201
Welding
92561-2S
42-6
http://vnx.su
42

Bonnet lock support
1
BUTT WELDING JOINT ON THE RADIATOR

GRILLE UPPER CROSS MEMBER
Refer to the previous paragraph.

MEMBER
Refer to section 41-A.
42-7
http://vnx.su
42 D

42
Unpicking
4 spot welds
Welding
PRS4202


92565-1S

MEMBER
Refer to sub-section 41-A.

PANEL

Cowl side panel:
0.8
1
42-8
http://vnx.su

Part front wing panel (front section)
42
Welding
Part only, see diagram.

Cutting of the new part to :
Cutting of the part on the vehicle to :
X = 435 mm
X = 415 mm
92565S
PRS4203

PARTIAL CUT A
Refer to the relevant paragraph.

MEMBER
Refer to sub-section 41-A.

CARRIER PANEL
Refer to the relevant paragraph.
92563-1S

Wing panel:
Wheel arch:
1
0.7
Unpicking
9 spot welds
42-9
http://vnx.su

40 for instructions
42 G
Welding

(1)
(2)
(3)
(4)
Wheel arch
Wheel arch extender
Rubber bush support
Shock absorber cup
92566S
BUTT WELDING JOINT ON THE HEATER

BULKHEAD PARTITION
A - SHOCK ABSORBER CUP TO THE HEATER

BULKHEAD PARTITION
CHAMBER

Cup:
Heater bulkhead partition :
PRS4204
2
0.7
Unpicking
BUTT WELDING JOINT ON THE WING PANEL

FRONT SECTION
5 spot welds

REAR SECTION
(Shock absorber cup to the cowl side panel)

Shock absorber cup:
Wing panel:
2
1
Unpicking
6 spot welds
92641S
42-10
http://vnx.su

B - WHEEL ARCH TO THE HEATER BULKHEAD
PARTITION
Wheel arch:
0.7
0.7
42 G
Wheel arch:
Bulkhead:
Unpicking
Unpicking
7 spot welds
7 spot welds
Welding
Welding
92564S
0.7
0.7
92564-1S
42-11
http://vnx.su

5
42 G
DRILLING THE SHOCK ABSORBER UPPER

MOUNTING

Wheel arch:
Side member closure panel:
With the vehicle positioned on the body jig bench,

after welding the wheel arch, drill the front shock
absorber upper mounting.
0.7
1.25
0.8
2
To do this:
- fit part (1) in the diagram below,
- counter-bore the four holes (B) to a diameter of
8 mm.
Unpicking
Warning: part (1) is the same for both the right

and left hand sides, it must be pivoted through a
half turn when changing from one side to the
other.
21 spot welds
Welding
92566-1S
92632R1

42-12
http://vnx.su

7
SPECIAL FEATURES OF DIESEL VEHICLES
On these vehicles, the right hand wheel arch has

an additional support for the engine pendulum
mounting.
Cup (C) must be welded during repair using a
body jig bench bracket supplied with the body jig
components.
92662R
42-13
http://vnx.su
42 G

Consisting of:
- heater bulkhead partition
- component for joint with the windscreen
aperture lower cross member(1)
- battery support
- windscreen wiper motor support
- welded studs and nuts.
42 H
Plenum chamber:
Cowl side panel:
0.7
1
Unpicking
+
8 spot welds
Welding
PRS4205

92573-1S
42-14
http://vnx.su

3
42 H
PARTIAL CUT

Bulkhead:
0.7
0.7
Unpicking
+
12 spot welds per 1/2 partition (i.e. 24 for the
complete part)
92570-1S
Welding
92579S
Drilling of the bulkhead to a diameter of 5 mm

for plug welding.
42-15
http://vnx.su

Part windscreen aperture lower cross member
42
Welding
Consisting of:
- windscreen aperture lower cross member
- steering support (1)
- welded nuts and studs
Cutting of the new part to :
Cutting of the part on the vehicle to :
X = 320 mm
X = 300 mm
92578S
The welding operation above can only be carried

out with the front pillar removed.
PRS4206
BUTT WELDING JOINT ON THE FRONT PANEL

Windscreen aperture lower cross member:
Cowl side panel:
1
1
Unpicking
+
92573-2S
5 spot welds

42-16
http://vnx.su

Part windscreen aperture lower cross member
BUTT WELDING JOINT ON THE FRONT PILLAR
42
PARTIAL CUT

Windscreen aperture lower cross member:
Cowl side panel:
1
0.7
Unpicking
10 spot welds
92580S
Welding
92573-3S
92579-1S
Drilling of the cross member to a diameter of 5

mm for plug welding.
42-17
http://vnx.su

Welding
Part only
Photo page 42-2
PRS4208
JOINT WITH THE COWL SIDE PANEL AND THE

FRONT PILLAR

Stiffener
Cowl side panel
Front pillar
1.5
0.97
1.25
Unpicking
11 spot welds
Seven 30mm MAG weld fillets.
42-18
http://vnx.su
42

(7) Upper hinge
(8) Lower hinge
DISMANTLING
Remove:
- front door,
- front wing,
- dashboard,
- body side interior trim,
- front seat.
Maximum length of the new part: 570 mm.
Partially fold back the carpet.

Remove:
- bonnet opening control,
- electrical wiring in the pillar,
- sill panel moulding.
COMPOSITION OF THE SPECIAL REPLACEMENT
FRONT PILLAR
(1)
(2)
(3)
(4)
(5)
(6)
43 A
Front pillar
Upper hinge stiffener
Lower hinge stiffener
Door stop mounting
Wing mounting stud
Welded KSM
92363R
CUTTING - UNPICKING
92629R
92630R
Remove the damaged section in line with the diagrams above (refer to the key to symbols)
(A) drill right through the spot welds at the pillar - hinge stiffener - lining joints
(B) unpick using a chisel
43-1
http://vnx.su

92628-1R
43 A
92628R
e = 2.1 mm
H = 65 mm
Grind the bits of unpicked spot weld remaining on

the support panels.
Take a section of the new part which is
approximately 50 mm larger than that cut from
the vehicle.
B = 5 mm
WELDING
Position the new part on the vehicle so that it is

superposed, then secure it using a vice-grip
wrench.
Carry out the following:

retaining spot welds on the lines to be butt
welded.
Cut the two layers of metal simultaneously with a

hacksaw in order to facilitate the fit.
the spot welds. The corresponding (e) and (H)

values are given underneath each diagram.
PREPARATION BEFORE WELDING
Strip the internal and external surfaces of all areas

to be welded. (On the vehicle and on the new
parts) .
the MIG stitch welds.

the MIG plug welds at the lining and hinge
stiffener joints.
Coat the sections to be spot welded with a bead

of electro-plastic mastic. Apply aluminium paint
to the sections to be plug welded.
lead fill the butt welded sections, after

grinding down the weld fillet.
Adjust the new part, then secure it using a vicegrip wrench.
ANTI-CORROSION PROTECTION
After painting and before refitting the trim, inject

hollow section wax into the pillar.
43-2
http://vnx.su

Front pillar by cutting at the upright
DISMANTLING
Remove:
- front door,
- front wing,
- dashboard,
- body side internal trim,
- front seat.
Remove:
- bonnet opening control,
- electrical wiring in the pillar,
- windscreen,
- pillar upright seal,
- sill panel moulding.
Remove the electrical wiring.
PROTECTION
Protect the interior using a cover which is resistant

to welding and grinding damage.
43-3
http://vnx.su
43

Front pillar by cutting at the upright
92627R
43
92627-1R
Define cuts (A) and (B). The working method is

identical to that for changing the lower section of
the pillar.
Repair welding
e = 2.1 mm
H = 65 mm
Cuts (A) and (B) must be opposite an opening in

order to make it easier to protect the interior.
In order to ease cutting and unpicking, welding of
the butt welding joints will be shown.
D = 5 mm
Original welding
Spot welding
Lead fill the butt welded sections after grinding
down the weld fillet.
Stitch welding
After painting, inject hollow section wax into the

new part.
43-4
http://vnx.su
D53
Cabriolet

Door hinges (on the front pillar)
43
WELDING THE DOOR HINGES TO THE FRONT

PILLAR
When a front pillar is changed, the door hinges, to

be ordered separately, must be welded on.
To do this, follow the procedure below.
Temporarily spot weld the two male hinges to the
pillar using the part which has been removed to
mark the positions.
Fit the door, with the front wing removed, and
check that it is adjusted correctly before permanently welding the hinges in place.
92627-2R
B = 296 1 mm (theoretical value for information)
92630-1R
A = 115 1 mm (theoretical value for information)

1 = 20 mm
43-5
http://vnx.su
D53
Cabriolet

Assembled front pillar

removal of the upper pillar stiffener and is in
addition to the partial changing of the
windscreen frame.
Unpicking
50 spot welds
- Bare front pillar.

- Pillar stiffener tube.
- Internal pillar stiffener.
Three 30mm MAG weld fillets.

One 90mm MAG weld fillet.
Photo page 43-1
PRS4301
JOINT WITH THE WINDSCREEN PILLAR LINING
Refer to section: 45 ...
JOINT WITH THE PILLAR LINING AND SILL

PANEL

Front pillar
Pillar lining
Sill panel
1.25
0.97
1.5
1.5
D = 8 mm
43-6
http://vnx.su
43 D

Assembled front pillar
D53
Cabriolet
JOINT WITH THE INTERNAL PILLAR STIFFENER

Front pillar
Stiffener
1.25
1.5
Unpicking
Two 30mm MAG weld fillets.
Welding
Photo page 43-2
JOINT WITH THE WINDSCREEN FRAME
Reminder: see 45-B
After painting and before refitting the trim, treat

the hollow sections with wax.
43-7
http://vnx.su
43 D

Front pillar
C53
43
COMPOSITION OF THE SPECIAL REPLACEMENT

FRONT PILLAR
The parts warehouse supplies the B53 front pillar

(for reasons of standardisation).
When the front pillar of the C53 is changed, the
sill panel section must be cut in order to hold the
original butt welding joint more easily.
Dimension of the cut: 345 mm
92363R1
Welding
92626-1G
92626G
Original welding
Repair welding
Spot welding
D = 5 mm
43-8
http://vnx.su

Pillar upright joint mounting (KSM)
DIMENSION OF THE KSMS WELDED TO THE
UPRIGHT
92624R
At (A) KSM type welded mounting.

The other 4 mountings are rivets:
part number. 77 03 072 263
to be secured when the support is fitted.
It is essential that electro-plastic mastic is put into
the holes before riveting in order to ensure
sealing and prevent corrosion.
43-9
http://vnx.su
43

Centre pillar
DISMANTLING
Remove:
- rear door,
- body side trims,
- front seat,
- complete rear seat,
Remove:
- sill panel moulding,
- electrical wiring,
- front door striker,
- seat belt upper support,
- seat belt.
(1)
(2)
(3)
(4)
(5)
(6)
Centre pillar
Seat belt mounting
Upper hinge
Lower hinge
Hinge stiffener
Striker mounting retainer
Maximum length of the new part:

top
840 mm
bottom
1 230 mm
92363R2
43-10
http://vnx.su
43 G

Centre pillar
43 G
CUTTING - UNPICKING
92622R
Spot welding
Brazing
(B) sealing lining support.

92623R
(A) and (C) are the recommended cutting areas. To make cutting and unpicking easier, the original butt
welding joints are shown above.
NOTE: it is possible to make a cut at (C) to avoid having to change the part later.
Take a section of the new part which is approximately 50 mm larger than that cut from the vehicle.
Position the new section on the vehicle so that it is superposed, then secure it using a vice-grip wrench.
At (A) cut 15 mm longer, this section to be plug welded.
Cut the two layers of metal simultaneously with a hacksaw in order to facilitate the fit.
43-11
http://vnx.su

Centre pillar
43 G
Strip the internal and external surfaces of all areas to be welded. (On the vehicle and on the new parts).
Coat the sections to be spot welded with a bead of electro-plastic mastic (see the key to symbols at the
beginning of the section).
Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under each
welding diagram and coat with aluminium paint.
Adjust the new part, then secure it using a vice-grip wrench.
92622-1S
Repair welding
D = 4.5 mm
92621R
Lead fill at (A).

Lead fill the butt welded sections, after grinding down the weld fillet.
43-12
http://vnx.su

Centre pillar

new part.
92619S
92620S
Repair anti-corrosion protection.
43-13
http://vnx.su
43 G
D53
Cabriolet

Centre pillar
This operation can only be carried out after removal of the rear wing panel.
43 G
Welding
Part only
Photo page 43-10
PRS4304
JOINT WITH THE CENTRE LINING AND SILL

PANEL
D = 6 mm

Centre pillar
Lining
Sill panel
1.25
1.5
1.5
Unpicking
On the front right hand section, some spot welds

are made only after the wing panel has been
refitted.
30 spot welds
JOINT WITH THE WING PANEL LINING
Four 25mm MAG weld fillets

See 44 -D
15 MAG plug welds
43-14
http://vnx.su

43 H
COMPOSITION OF THE CENTRE PILLAR LINING
(1) Centre pillar lining, upper section

(2) Seat belt mounting nut
(3)
PRS4306
CUTTING - UNPICKING
92618S
92617S
Original welding
Stitch welding
Spot welding
NOTE: it is possible to change the complete centre pillar or make a cut at (A) to make a butt weld (if this
method is used, the roof trim does not have to be removed).
43-15
http://vnx.su

43 H
Strip the internal and external surfaces of all of the areas to be welded. (On the vehicle and on the new parts).
Spray zinc paint on the sections to be spot welded.
Prepare the sections to be plug welded. To do this, drill the first panel to diameter D shown under each
welding diagram and coat with aluminium paint.
Adjust the new part, then secure it using a vice-grip wrench.
92618-1R
92617-1S
Repair welding
D = 5 mm
Spot weld at (A).
43-16
http://vnx.su

92616S
Original welding
92616-1S
Repair welding
D = 6 mm
43-17
http://vnx.su
43 H
D53
Cabriolet

43 H
This operation can only be carried out after removal of the wing panel lower front lining and the
floor and cross member side stiffener.
- Centre pillar lining.

- Seat belt mounting stiffener.
Photo page 43-11
PRS4305
JOINT WITH THE FLOOR
JOINT WITH THE CENTRE PILLAR

Pillar lining
Floor
1.5
0.88
JOINT WITH THE WING PANEL LINING
Reminder: see 44-D
Unpicking
Seven 40mm MAG weld fillets.
43-18
http://vnx.su

Sill panel
43
The sill panel is supplied bare.
92363S
RECOMMENDATIONS FOR REPLACEMENT
Depending on the area which is deformed, it is possible to change the sill panel at several points (see
diagrams).
92363S1
92363S2
92363S3
92363S4
All of the cuts must be butt welded using MIG stitch welds, then lead filled.
43-19
http://vnx.su

Sill panel
43
92615S
92615-1R
92622S
92622-1R
Original welding
Repair welding
H = 35 mm
Spot welding
Brazing
(A)
(B)
After painting and before refitting the trim, inject hollow section wax.
43-20
http://vnx.su
D = 4.5 mm
D = 5 mm
ALL TYPES
Phase I

Body side
PRS4308
These parts are affected by the modification to

the sill panel moulding. The Parts Department will
supply them with the two phase II type mounting
rows.
When one of the parts is changed on a phase I vehicle, the holes of the lower row must be closed
using self-adhesive plugs before the anti-chipping
mastic is applied. These plugs are available from
the Parts Department (see PR).
NOTE: this course of action is already applied in
advance to production vehicles.
43-21
http://vnx.su
43

Part sill panel
D53
Cabriolet
43
Unpicking
Bare part
Photo page 43-3
Photo page 43-3
Before cutting the sill panel on the vehicle, the

spot welds at the joint of the sill panel with its
longitudinal partition must be unpicked.
Welding
The number of spot welds to be unpicked will

depend on the length of the partial cut.
- Make the plug welds for the joint with the

partition.
On the new part, drill 6.5mm diameter holes at

the butt welding joint with the longitudinal
partition.
- Spot welds for the joint with the inner sill

panel.
- Stitch welds at the ends of the partial cut.
For further information, refer to the previous
paragraph.
43-22
http://vnx.su

Assembled sill panel
D53
Cabriolet
This operation can only be carried out after removal of the front pillar and the wing panel.
- Sill panel.
-Longitudinal partition.
PRS4307
JOINT WITH THE FRONT PILLAR
Refer to section : 43 - D - 2
Note: If the front pillar has not been damaged, it
is preferable cut part of the sill panel. To do this,
refer to section: 43 - K.
JOINT WITH THE INNER SILL PANEL

Sill panel
Inner sill panel
Inner sill panel stiffener
Lateral side member
Unpicking
62 spot welds.
3 MAG spot welds
43-23
http://vnx.su
1.5
1.5
1.5
1.5
43
D53
Cabriolet

Welding
Photo page 43-5
43-24
http://vnx.su
43
D53
Cabriolet

Photo page 43-6
D = 8 mm
At the rear section, the sill panel lower joint is
made only after the wing panel has been refitted.
At the front section, the joint is only made after
the pillar has been refitted.
43-25
http://vnx.su
43
B - C - L53
Sport

Sill panel
43
Using the dimensions shown on the diagrams below, mark the location of the 4 mounting points A, B, C and
D. The dimensions are identical for B, C and L53 type vehicles.
92764R1
Points :
A
h = 25 mm
h = 25 mm
h = 22 mm
h = 11 mm
92309R
Drill the holes to 6 mm.

Apply sealing mastic to the edge of the holes and fit clips (3).
43-26
http://vnx.su
D53
Cabriolet

43
Welding
Bare part
Photo page 43-7
PRS4302
JOINT WITH THE FRONT PILLAR, COWL SIDE

PANEL AND WHEEL ARCH

Stiffener
Front pillar
Cowl side panel
Wheel arch
1.5
1.25
0.97
0.7
Unpicking
D = 8 mm
Four 20mm MAG weld fillets.
Twelve 40mm MAG weld fillets.
7 MAG plug welds.
43-27
http://vnx.su

D53
Cabriolet
JOINT WITH THE SILL PANEL
JOINT WITH THE FLOOR AND FRONT SIDE

MEMBER

Stiffener
Sill panel
1.5
1.5
43
Unpicking
Six 30mm MAG weld fillets.
Unpicking
7 spot welds.
Welding
7 MAG plug welds.
Photo page 43-8
One 30mm MAG welds fillet.
Welding
Photo page 43-8
D = 8 mm
43-28
http://vnx.su
D53
Cabriolet

This operation can only be carried out after removal of the rear wing panel.
43 N
Welding
Refer to paragraph: 44-A

Bare part
Photo page 43-9
PRS4303
JOINT WITH THE SILL PANEL AND WHEEL

ARCH
Photo page 43-9

Stiffener
Sill panel
Outer wheel arch
Inner wheel arch
1.5
1.5
0.88
1.2
Unpicking
16 spot welds.
D = 8 mm
43-29
http://vnx.su
B53
Phase II

Roof arch
This part can only be changed after removal of

the roof.
43 O
Welding
Part only.
95813R
PRS4309
JOINT WITH THE BODY SIDE

Body side
Stiffener
0.77
0.77
NOTE: at (C) apply two beads of filling mastic.
Unpicking
ATTENTION: when fitting a sun roof as an accesso-
ry, the roof arch must be cut.

The sun roof frame will then act as the stiffener.
4 spot welds
43-30
http://vnx.su
L53
Saloon

Complete wing panel
44 A
This operation is carried out with the roof removed.

Part only. The double seal support (1) must be

ordered separately.
93126R1
At (2), apply a bead of metal bonding mastic.

PRS4412
Welding
JOINT WITH THE ROOF

Wing panel
Roof
Body side support extender
0.67
0.67
0.67
Unpicking
93118S
44-1
http://vnx.su
L53
Saloon

Complete wing panel
44 A
Unpicking
JOINT WITH THE BODY TOP

Wing panel
Body side
0.67
1.1
21 spot welds
Unpicking

Welding
93116S
93117S
JOINT WITH THE QUARTER PANEL LINING

Wing panel
Roof drip moulding lining
Seat belt retractor support bracket
Body side upper extender
0.67
0.67
0.67
1.2
0.67
93115S
44-2
http://vnx.su
L53
Saloon

Complete wing panel
5
JOINT WITH THE SIDE RAIN CHANNEL

Wing panel
Side rain channel
44 A
JOINT WITH THE LIGHTING SUPPORT COMPONENT

0.67
0.87
Wing panel
Lighting support component
Unpicking
0.67
0.67
Unpicking
One 20mm MAG weld fillet - see JOINT note 6
8 spot welds
4 spot welds
Welding
Welding
93114S
93113S
Depending on method: see JOINT 6
44-3
http://vnx.su
L53
Saloon

Complete wing panel
Welding
A - With removal of the end panel cross member

Wing panel
End panel extender
44 A
0.67
0.97
Unpicking
NOTE: There is a spot weld located under the end
panel cross member (see welding). If the cross

member is not to be removed, a special cut must
be made on the panel.
4 or 5 spot welds depending on the

method
93111S
B - Without removal of the end panel cross

member
93112S
A - With removal of the end panel cross member

B - Without removal of the end panel cross
member
93112-1S
44-4
http://vnx.su
L53
Saloon

Complete wing panel
44 A
Welding
93110S
93109S
JOINT WITH THE REAR FLOOR
- 1 four layer spot weld


Wing panel
Rear floor
Outer wheel arch
Inner wheel arch
0.67
0.60
0.67
1.25
Unpicking
JOINT WITH THE OUTER WHEEL ARCH

Wing panel
Outer wheel arch
Inner wheel arch
Sill panel
6 spot welds
Unpicking
19 spot welds
44-5
http://vnx.su
0.67
0.67
1.25
1.5
1.5
1.1
L53
Saloon

Complete wing panel
9
Welding
44 A

Wing panel
Sill panel
0.67
1.1
Unpicking
6 spot welds
One 25mm brazed weld fillet

93108S
Welding
93106S

93107S
44-6
http://vnx.su

Complete wing panel
L53
Saloon
10
JOINT WITH THE DOUBLE SEAL

SUPPORT

Wing panel
Double seal support
0.67
0.67
Unpicking
3 spot welds
Welding
93105S
44-7
http://vnx.su
44 A
D53
Cabriolet

Welding
44 A
Bare panel.
Window frame stiffener.
Panel stiffener.
Striker stiffener.
Bumper stiffener.
Window guide upper stiffener.
Photo page 44-1
JOINT WITH THE BOOT LID RAIN CHANNEL

AND WING PANEL REAR LINING

PRS4413
Wing panel
Lining
JOINT WITH THE UPPER LINING
Unpicking
Wing panel
Lining
23 spot welds.
0.8
1.0
Unpicking
38 spot welds.
1 brazed weld fillet.
44-8
http://vnx.su
0.8
1.0
0.88
D53
Cabriolet

44 A
Note: When unpicking at the joint with the boot

lid rain channel, drill out the spot welds using a
spot weld rotary grinder. These holes will be plugged again by MAG welding.
Welding
Photo page 44-2
Photo page 44-2
The MAG welds shown are to be made on both

sides.
1
Photo page 44-2
JOINT WITH THE WHEEL ARCH AND SILL

PANEL

Wing panel
Sill panel
Wheel arch
Unpicking
11 spot welds.
44-9
http://vnx.su
0.88
1.5
0.8

D53
Cabriolet
Preparation before welding:
Photo page 44-3

Photo page 44-3
Welding
Photo page 44-3
Photo page 44-3
44-10
http://vnx.su
44 A
D53
Cabriolet

44 A
JOINT WITH THE SILL PANEL AND CENTRE

PILLAR

Wing panel
Sill panel
0.88
1.5
Photo page 44-4

Unpicking
15 spot welds.
1 brazed fillet.
Welds
Note: At the lower section of the sill panel, the
spot welds must be made in the recesses to avoid
welding four overlapping panels.

Wing panel
Centre pillar
Pillar lining
Unpicking
14 spot welds.
44-11
http://vnx.su
0.88
1.25
1.5

D53
Cabriolet
Welding
Photo page 44-5
Photo page 44-5
Hollow section protection:
Photo page 44-5

6
JOINT WITH THE SILL PANEL AND PANEL

STIFFENER

Stiffener
Sill panel
0.6
1.5
Unpicking
Photo page 44-5
44-12
http://vnx.su
44 A

Part wing panel (cut A)
44

- bumper mounting stiffener
- striker stiffener
92363R7
CUTTING - UNPICKING
92399S
92400-1S
(End panel - wing panel joint)
M.R. 502 section 44.
44-13
http://vnx.su

92402S
44
92404S
Remove the double seal support.
92403S
92363R3
Area not used
44-14
http://vnx.su

44
SUPERPOSED CUT
92405-1S
PRS4410
Welding
e = 1.4 mm
H = 30 mm
D = 5 mm
A:
e = 1.4 mm
H = 60 mm
PRS4411
e = 1.4 mm
H = 30 mm
D = 5 mm
44-15
http://vnx.su

92407S
44
92402-1S
e = 1.4 mm
H = 60 mm
D = 5 mm
D = 5 mm
92408S
92410S
e = 1.4 mm
H = 60 mm
D = 5 mm
44-16
http://vnx.su

Part wing panel (cut B)
44

- bumper mounting stiffener
- striker stiffener
92363R8
CUTTING - UNPICKING
92399S
92400S
(End panel - wing panel joint)
M.R. 502 section 44.
44-17
http://vnx.su

92401S
44
92404S
(end panel - wing panel joint)

Retain the edge of panel (A) and open it slightly in
order to superpose the new part and plug weld it.
See WELDING.
92363R6
Area not used
44-18
http://vnx.su

44
SUPERPOSED CUT
92406S
92405S
e = 1.4 mm
H = 60 mm
Welding
92405-2S
D = 5 mm
44-19
http://vnx.su

92407S
44
92408S
D = 5 mm
e = 1.4 mm
H = 60 mm
92409S
44-20
http://vnx.su
C53

92363R9
The general procedure for changing the panel is

identical to that for the B53, only the positions of
the superposed cuts are different.
Area not used
44-21
http://vnx.su
44
C53 / S53
Phase I

PRS4436
The Parts Department only supplies phase II type

parts which only have one row of rubbing strip
mounting holes. For phase I vehicles, remember to
order the adhesive clips for mounting the phase I
strip.
NOTE: as the last but one hole (A), is not used for
mounting the phase I strip, it must be closed to

seal effectively using an adhesive plug or a small
ball of mastic (see PR).
44-22
http://vnx.su
44
C53

Part wing panel (cut AB)
SPECIAL POINTS
PRS4414
The general procedure for changing the panel is

identical to that for the B53, only the positions of
the superposed cuts are different.
Area not used
44-23
http://vnx.su
44
L53
Saloon

Part wing pane (cut A)

Therefore, only its special points are described below.
44
Welding
Same as the previous part.
93104S
PRS4416
44-24
http://vnx.su
D53
Cabriolet

Part rear wing panel (cut A)
44
Partially remove the damaged part following the

recommendations for the previous operation.
PARTIAL CUT
Photo page 44-6

protect the hollow sections with wax (inner
section of the wing panel).
PRS4415
X = 920 mm.
Unpicking
Length of cut: 400 mm.
44-25
http://vnx.su
All types
Phase I

PRS4445
These vehicles are fitted with an adjustable seat

belt mounting. The Parts Department only supplies phase II type parts to which all types of seat
belt can be fitted. Mounting hole (A) has been
moved up 17 mm. Consequently, when either a
quarter panel lining or a complete body is changed on a phase I vehicle, the original hole in the
pillar trim must be extended 17 mm upwards (refer to the paragraph on pillar trim).
44-26
http://vnx.su
44
L53
Saloon

44
Special point for removal

- quarter panel lining,
- body side upper extender.
93099S
To gain access to the body side extender spot

welds, the roof drip moulding lining must be
partially removed. Cut it to the dimension
X = 125 mm
PRS4418
Welding

Body side
Roof drip moulding lining
0.67
1.1
0.67
0.67
Unpicking
93098S
8 spot welds
5 spot welds
44-27
http://vnx.su
L53
Saloon

44
Welding
93099-1R
93097S
Cut a piece of the new roof drip moulding lining

to the dimension Z = 145 mm.
On the diagram above, the dotted line represents
the cut carried out on the vehicle during the
unpicking operation. Dimension Y = 180 mm is
used to position the new part.
3
2
JOINT WITH THE REAR ROOF CROSS MEMBER

Outer wheel arch
Quarter panel arch
Side shelf

Roof
0.67
0.67
0.67
Unpicking
Unpicking
4 spot welds
9 spot welds
44-28
http://vnx.su
0.67
0.67
0.97
0.97
1.25
L53
Saloon

5
Welding
44
JOINT WITH THE SIDE SHELF

Side shelf
Quarter panel arch
Outer wheel arch
0.67
0.97
0.97
0.67
Unpicking
93096S
11 spot welds
Welding
JOINT WITH THE ROOF PANEL
93095S
93099-4S

Apply a bead of metal bonding mastic.
- 2 plug welds to be made from inside the vehicle
44-29
http://vnx.su
L53
Saloon

7
JOINT WITH THE WING PANEL
Reminder: see 44-A-3

Side rain channel
44
0.67
0.97
1.20
Unpicking
2 spot welds
Welding
93116S
93094S
93115S
44-30
http://vnx.su

L53
Saloon
93126R1
JOINT WITH THE QUARTER PANEL ARCH
Reminder: see 44-J-1
93093S
44-31
http://vnx.su
44
D53
Cabriolet

This operation can only be carried out after removal of the complete wing panel.
Welding
Upper front lining.

Lower front lining.
Rear lining.
Outer wheel arch.
Wheel arch stiffener.
Inner wheel arch.
Photo page 44-7
Photo page 44-7

PRS4417

Panel lining
Centre pillar
0.88
1.25
1.5
Unpicking
8 spot welds.
44-32
http://vnx.su
44

D53
Cabriolet

Welding (cont)
Photo page 44-8
Welding
Photo page 44-8
D = 6 mm
Photo page 44-8
JOINT WITH THE SILL PANEL AND WHEEL

ARCH

Panel lining
Sill panel
Wheel arch
Sill panel lining
0.88
1.5
0.88
1.5
1.5
Unpicking
11 spot welds.
44-33
http://vnx.su
44 D

D53
Cabriolet
44 D

Panel lining
Rear floor
Wheel arch
0.88
0.88
1.2
Photo page 44-9
Unpicking
25 spot welds.
Welding
Photo page 44-9

Panel lining
Lighting support
Unpicking
12 spot welds.
44-34
http://vnx.su
0.88
0.67

D53
Cabriolet
Welding (cont)
44 D
JOINT WITH THE WHEEL ARCH UPPER CROSS

MEMBER
Reminder: see 44-N
Photo page 44-10
Photo page 44-10
Note: For welding to the rear wing panel, refer to

paragraph: 44 -A
44-35
http://vnx.su
D53
Cabriolet

This operation can only be carried out after removal of the wing panel.
Welding
- Bare lining.
- Window winder support.
Photo page 44-11
PRS4419
JOINT WITH THE CENTRE PILLAR, SILL PANEL

AND WHEEL ARCH
D = 8 mm
Sill panel
Inner sill panel
Panel lining
Centre pillar
Centre pillar stiffener
1.5
1.5
0.88
1.25
1.5
Unpicking
15 spot welds.
44-36
http://vnx.su
44
D53
Cabriolet

44
Welding
- Hood mounting bracket.

- Stiffener.
Photo page 44-12
PRS4420
JOINT WITH THE WHEEL ARCH AND REAR

LINING

Panel lining
Inner wheel arch
Outer wheel arch
0.88
1.2
0.88
Refer to the "Assembled wing panel lining" operation: 44-D
Unpicking
15 spot welds.
44-37
http://vnx.su
D53
Cabriolet

44 G
Welding
- Counter balance stiffener.

- Counter balance joint.
- Lock stiffener.
Photo page 44-13
PRS4421
JOINT WITH THE WHEEL ARCH, BOOT LID RAIN

CHANNEL AND FRONT LINING
D = 6 mm
Rear lining
Front lining
Rain channel
Outer wheel arch
Inner wheel arch
0.88
0.88
0.88
0.88
1.2
JOINT WITH THE REAR FLOOR AND LIGHTING

SUPPORT
Refer to section: 44-2A
Unpicking
A - On the wheel arch:
10 spot welds
B - On the boot lid drip moulding:

5 spot welds.
C - On the front section:

5 spot welds.
44-38
http://vnx.su
All types
Phase I

Tailgate upper rain channel
The parts supplied by the Parts Department are of
the phase II type. Consequently, the wiring hole in
the upper rain channel must be closed.
(hole (B) on the diagram)
NOTE: For the type of blanking piece to be used,
refer to the vehicle PR.
95785R
44-39
http://vnx.su
44 H

Outer wheel arch
44
- bare outer wheel arch

- wheel arch stiffener
PRS4422
CUTTING - UNPICKING
92411S
92412S
NOTE: the general, procedure for changing a welded component is described in Workshop Repair Manual
M.R. 502 section 4.
44-40
http://vnx.su

Outer wheel arch
44
92414S
92413S
Welding
If the quarter panel arch is not to be changed,

unpick it from inside the wheel arch.
92411-1S
92415S
Joints with:
Inner wheel arch
e = 2 mm
H = 60 mm
e = 2.2 mm
H = 60 mm
e = 1.4
H = 60 mm
Spot welds (A) are to be unpicked from inside the

sill panel.
44-41
http://vnx.su

Outer wheel arch
44
92414-1S
92412-1S
D = 5.5 mm
Joints with:
Inner wheel arch
e = 2 mm
e = 1.4 mm
Quarter panel arch
e = 1.7 mm
Floor
e =1.4 mm
H = 60 mm
H = 60 mm
H = 60 mm
H = 60 mm
92415-1S
If spot welds (A) and (B) cannot be reached by the

spot welder, plug weld at D = 5 mm
e = 1.8 mm
H = 60 mm
D = 5.5 mm
44-42
http://vnx.su
D53
Cabriolet

Outer wheel arch

removal of the wing panel.
44
Welding
Reminder: see 44-A

- Bare wheel arch.

- Stiffener.
Photo page 44-14
PRS4423
JOINT WITH THE SILL PANEL AND INNER

WHEEL ARCH

Outer wheel arch
Inner wheel arch
Panel lining
Wheel arch stiffener
0.88
1.2
0.88
1.5
Photo page 44-14
Unpicking
31 spot welds.
D = 6 mm
44-43
http://vnx.su
L53
Saloon

44
Welding
Panel only.
PRS4424
93093S

Quarter panel arch
Side rain channel
0.97
0.67
0.67
0.97
Unpicking
2
11 spot welds

Quarter panel arch
Outer wheel arch
Unpicking
9 spot welds
44-44
http://vnx.su
0.97
0.67
0.67
L53
Saloon

Welding
93093-1S
44-45
http://vnx.su
44
L53
Saloon

Part quarter panel arch
below.
Panel only.
PRS4425
Welding (superposed)
93092S
44-46
http://vnx.su
44
L53
Saloon

Part only.
PRS4426

Stiffener
Wheel arch
1.5
0.67
0.67
Unpicking
8 spot welds
Welding
93091S
44-47
http://vnx.su
44
D53
Cabriolet

44
Welding

removal of the wing panel.
Reminder: see 44-A
- Bare part.
Photo page 44-15
PRS4428

Stiffener
Wheel arch
Panel lining
0.88
0.88
0.88
Unpicking
8 spot welds.
44-48
http://vnx.su
D53
Cabriolet

Upper cross member between wheel arches
This operation can only be carried out with the

hood compartment base partition removed.
44 N
Welding
Cross member.
Stiffening angle brackets.
Boot partition stiffeners.
Backrest locking supports.
Seat belt supports.
Photo page 44-16
PRS4429
Photo page 44-16

JOINT WITH THE WHEEL ARCHES

Cross member
Inner wheel arch
Wing panel lining
1.5
1.2
0.88
Unpicking
12 spot welds.
Twenty-two 30mm MAG weld fillets.
44-49
http://vnx.su
D53
Cabriolet

Upper cross member between wheel arches
Welding (cont)
Photo page 44-17
D = 8 mm
Note: The 12 spot welds are replaced with plug
welds.
44-50
http://vnx.su
44 N
D53
Cabriolet

This operation can only be carried out after removal of the hood compartment rear cross member
and the boot lid rain channel.
44 O
Welding
- Bare partition.
- Lighting support to be ordered separately.
Photo page 44-18
PRS4430
D = 6 mm
JOINT WITH THE CROSS MEMBER AND BODY

SIDES

Partition
Cross member
Wing panel lining
0.7
1.5
0.88
Unpicking
52 spot welds
44-51
http://vnx.su
D53
Cabriolet

1
JOINT WITH THE WHEEL ARCHES

Partition
Wheel arch
0.7
1.2
Unpicking
Welding
PHOTO PAGE 44-19
44-52
http://vnx.su
44 O
D53
Cabriolet

Hood compartment rear cross member
This operation is carried out in addition to changing of the boot lid rain channel (previous operation).
44
Welding
- Bare part
PHOTO PAGE 44-20
PRS4431
D = 6 mm

Cross member
Boot partition
Rain channel
1.5
1.0
0.88
Unpicking
60 spot welds.
44-53
http://vnx.su
L53
Saloon

Part only.
PRS4426

Stiffener
Wheel arch
1.5
0.67
0.67
Unpicking
8 spot welds
Welding
93091S
44-54
http://vnx.su
44 Q
L53
Saloon

Jack support (right hand side)
Part only.
PRS4427

Jack support
Outer wheel arch
1.2
0.67
0.67
Unpicking
3 spot welds
Welding
93090S
44-55
http://vnx.su
44
L53
Saloon

Centre shelf

- bare centre shelf
- rear screen lower cross member.
44
JOINT WITH THE SEAT BELT RETRACTOR

SUPPORT BRACKET
Centre shelf
Rear screen lower cross member
0.67
0.67
1.2
Unpicking
4 spot welds
Welding
PRS4432
Reminder: see 44-Y-1
93089S
93103S
44-56
http://vnx.su
L53
Saloon

Centre shelf
JOINT WITH THE CENTRE SHELF

Centre shelf
Side shelf
0.67
0.97
1.2
Unpicking
93087S
24 spot welds
Welding
93088S
44-57
http://vnx.su
44
L53
Saloon

Half unit
1

bench. Refer to sub-section 40 of the basic
manual.
44
JOINT WITH THE SIDE MEMBER CLOSURE

COMPONENT
Outer wheel arch

Inner wheel arch
Closure component

- wing panel,
- assembled outer wheel arch,
- assembled inner wheel arch,
- quarter panel arch,
- assembled quarter panel lining,
- assembled side rain channel,
- lighting support panel,
- end panel extender,
- assembled side shelf,
- backrest mounting stiffener,
- jack support (for right hand side only).
0.67
1.25
1.5
Unpicking
Five 20mm MAG weld fillets
3 spot welds
Welding
93085S
PRS4433
- One 20mm MAG weld fillet

- Two 25mm MAG weld fillets
44-58
http://vnx.su
L53
Saloon

Half unit
44
Welding
93086S
93084S
Four 20mm MAG weld fillets
3 triple layer spot welds


Inner wheel arch
Wing panel
Rear floor
Side member booster
1.25
0.67
0.60
2.00
Unpicking
93109S
19 spot welds
44-59
http://vnx.su
L53
Saloon

Half unit
44

Wing panel
Sill panel
Outer wheel arch
0.67
1.1
0.67
Unpicking
92415-1S
6 spot welds
4 spot welds
(A) 1 triple layer spot weld to be unpicked using

the spot weld drill
1 spot weld
One 25 mm brazed weld fillet
Welding
JOINT WITH THE REAR SHELF
Reminder: see 44-Y-1
93106S
93103S
44-60
http://vnx.su
L53
Saloon

Half unit
Reminder: see 44-S-2
44
JOINT WITH THE ASSEMBLED REAR END

PANEL
93089S
Reminder: see 44-S-3
93123S
6
93088S
JOINT WITH THE END PANEL CROSS MEMBER
93087S
93125S
44-61
http://vnx.su
L53
Saloon

Half unit
44
93124S
93117S
Reminder: see 44-C-1

93098S
93097S
93099-1S
44-62
http://vnx.su

Half unit
L53
Saloon
JOINT WITH THE ROOF PANEL
93099-4S
93118S
44-63
http://vnx.su
44

Rear end panel
44 U
METHOD 1
- bare end panel

- side brackets
- striker stiffener
PRS4434
CUTTING - UNPICKING
92364S
92365S
M.R. 502 section 4
44-64
http://vnx.su

Rear end panel
44 U
Welding
92364-1S
92365-1S
A=
e = 1.4 mm
H = 60 mm
e = 1.4 mm
H = 60 mm
End panel - cross member joint
92366-2S
44-65
http://vnx.su
e = 1.9 mm

Rear end panel
44 U
METHOD 2 (end panel with lining)

1 - bare end panel

- side brackets
- striker stiffener
2 - lining
PRS4435
CUTTING - UNPICKING
92364-2S
92365-2S
M.R. 502 section 4
44-66
http://vnx.su

Rear end panel
44 U
92366S
Welding
92367S
92365-3S
Fit the lining and make a few retaining spot

welds.
e = 1.4 mm
H = 60 mm
End panel - cross member joint
44-67
http://vnx.su
e = 1.9 mm

Rear end panel
92364-3S
44 U
92366-1S
e = 1.4 mm
H = 60 mm
e = 1.4 mm
H = 60 mm
92366-2S
44-68
http://vnx.su

Rear end panel
METHOD 3
44 U
WELDING
(end panel with lining and lower cross member)


- bare end panel
- side brackets
- striker stiffener
- lining
- lower cross member
92364-5S
PRS4437
CUTTING - UNPICKING
92364-4S
92366-2S

Repair Manual M.R. 502 section 4
44-69
http://vnx.su
B - C - S53
Phase I

Rear end panel lining and assembled end panel
PRS4446
The difference between phase I and phase II parts

is that the piston switch hole (B) has been
discontinued.
The Parts Department supplies both types of part,
with or without hole (B). When a complete body is
changed, the Parts Department will only supply
phase II type bodies on which it will be necessary
to cut hole (B) (see diagram below).
95788R1
Hole (B), (shaded area) is cut using a power

hacksaw after making two 8mm diameter holes
(C).
44-70
http://vnx.su
44
L53
Saloon

44 W
Unpicking
Panel only
The two blanking pieces (1) must be ordered
separately.
5 spot welds
Welding
PRS4438

93123-1S

Special point
93125S

End panel extender
Rear end panel
0.67
0.97
0.67
93124R
After welding and before protecting the crimps,

fit the 2 metal blanking pieces (1) clipping them in
place with the lugs.
44-71
http://vnx.su
L53
Saloon

3
PARTIAL CUT
93100S
44-72
http://vnx.su
44 W
L53
Saloon

Rear end panel extender
44
Reminder: see 44-W-2
Panel only
PRS4439
JOINT WITH THE END PANEL CROSS MEMBER

93123-1S
JOINT WITH THE REAR END PANEL

End panel extender
Rear end panel
Unpicking
1 spot weld
93125-1S
44-73
http://vnx.su
0.97
0.67
L53
Saloon

Rear end panel extender
4
Welding
44
93123-2S
93111S
JOINT WITH THE EXTREME REAR CROSS

MEMBER
Reminder: see 41-V-1
93123-3S
44-74
http://vnx.su
L53 Saloon
except Sport

Side bracket
44
Welding
Panel only
93103S
PRS4440
JOINT WITH THE REAR SHELF
1 triple layer plug weld after unpicking using a

spot weld drill.

Side bracket
Rear screen lower cross member
0.87
0.67
Unpicking
2
1 spot weld
JOINT WITH THE SEAT BELT RETRACTOR

SUPPORT BRACKET

Side rain channel
see welding
2 spot welds
Unpicking
11 spot welds
44-75
http://vnx.su
0.87
1.2
0.67
L53 Saloon
except Sport

Side rain channel
Welding
93101S

Side rain channel
Welding
93102S
44
0.87
0.67
Unpicking
3 spot welds
44-76
http://vnx.su
D53
Cabriolet

Welding
- Bare rain channel.

- Hood cover lock stiffeners.
- Boot lid hinge stiffeners.
Photo page 44-21
PRS4441
JOINT WITH THE HOOD COMPARTMENT REAR

PARTITION AND BOOT PARTITION

Rear partition
Boot base partition
Rain channel
1.5
0.7
1.0
Unpicking
50 spot welds.
44-77
http://vnx.su
44

D53
Cabriolet
JOINT WITH THE WING PANEL AND LIGHTING

SUPPORTS

Rain channel
Wing panel
Lighting support
1.0
0.88
0.67
Unpicking
54 spot welds.
Welding
PHOTO PAGE 44-22
44-78
http://vnx.su
44

44
2A
Welding
Bare part
PRS4442
CUTTING - UNPICKING
92368-1S
e = 1.4 mm
H = 60 mm

Repair Manual M.R. 502 section 4
92368S
IMPORTANT: unpicking must be carried out from
the inside.
44-79
http://vnx.su
B - C - S53
Phase I

PRS4447
Hole (B) has been added on phase II vehicles for

centring the rear light. Initially, hole (A) for centring the light on phase I vehicles has been retained but in the future, this will be discontinued for
reasons of economy. Consequently, when the
phase I light is to be re-used, it will be necessary to
cut the upper centring pin in order to fit it to the
phase II support.
44-80
http://vnx.su
44
2A
D53
Cabriolet

This part can only be changed with its stiffener
44
Welding
- Bare parts.
The lighting support and its stiffener must be
ordered at the same time, they each have a
separate part number.
Photo page 44-23
PRS4443
Thickness of panels mm)

Lighting support
Rain channel
Wing panel
End panel
Lighting support stiffener
0.7
1.0
0.88
0.7
1.0
Unpicking
42 spot welds.
1 brazed weld filet.
44-81
http://vnx.su
2A
D53
Cabriolet

Welding (cont)
Photo page 44-24
Photo page 44-24
44-82
http://vnx.su
44
2A
L53
Saloon

Part only
44
2A
JOINT WITH THE SIDE PANEL
PRS4444

93113S
Reminder: see 44-2H-3
JOINT WITH THE END PANEL SIDE MEMBER
Reminder: see 41-V-1
93101S
93125S
44-83
http://vnx.su
UPPER BODY SECTION

Roof panel
The roof panel is supplied bare, without cross
member or roof drip moulding.
45 A
DISMANTLING
Remove:
- seats,
- interior trims,
- windscreen,
- tailgate.
PROTECTION
Protect the interior using a cover which is resistant

to welding and grinding damage.
PRS4501
CUTTING - UNPICKING
Original welding
3 and 5 DOOR VEHICLES
5 DOOR VEHICLES
92607S
92609S
Roof: front cross member - 13 spot welds
92608-1S
92610S
Roof: body side - 14 spot welds
Roof: rear cross member - 40 spot welds
45-1
http://vnx.su
UPPER BODY SECTION

Roof panel
45 A
3 DOOR VEHICLES
92611-1S
92612S
Roof: body side - 14 spot welds

Original welding
Cut A
Cut B
PRS4502
Cut C
PRS4503
Spot welding
Fillet welding
Brazing
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Body side
Roof drip moulding
Roof panel
Rear cross member
Quarter panel top
Quarter panel upper stiffener
Structure bonding mastic (roof drip mouldings and
roof, cross members and roof joints)
45-2
http://vnx.su
PRS4504
UPPER BODY SECTION

Roof panel
45 A
Repair welding
3 and 5 DOOR VEHICLES
5 DOOR VEHICLES
92607-1S
92609-1S
92610-1S
92608S
45-3
http://vnx.su
UPPER BODY SECTION

Roof panel
45 A
3 DOOR VEHICLES
92611-1S
92612-1S
Repair welding
Cut A
Cut B
Cut C
PRS4502
PRS4503
PRS4504
D = 4.5 mm
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Body side
Roof drip moulding
Roof panel
Rear cross member
Quarter panel top
Quarter panel upper stiffener
Structure bonding mastic (roof drip mouldings
and roof, cross members and roof joints)
NOTE: make a brazed weld at the roof-front pillar
upright joint.
45-4
http://vnx.su
L53
Saloon
UPPER BODY SECTION

Roof panel
45 A
Only special points specific to L53 type vehicles

will be described for this operation. Refer to section 45-A for other joints.
Panel only
93118S
PRS4501
Roof
Roof cross member
Reminder:see 44-A-1
Unpicking
17 spot welds
93126R1
45-5
http://vnx.su
0.67
0.67
0.67
067
UPPER BODY SECTION

Roof panel
L53
Saloon
45 A
Welding
93083S
93099-2S
45-6
http://vnx.su
D53
Cabriolet
UPPER BODY SECTION

Windscreen surround
45
Welding
- Frame.
- Pillar closure panel.
- Upper linings.
For fitting, refer to section 40 "Bodywork

dimensions".
Photo page 45-1
PRS4506
Photo page 45-1

Frame
Lining
Front pillar
1.0
1.5
1.25
Unpicking
98 spot welds.
Six 30mm MAG weld fillets.
2 brazed weld fillets.
45-7
http://vnx.su
UPPER BODY SECTION

Windscreen frame
D53
Cabriolet
Welding (cont)
45
PARTIAL CUT
Photo page 45-2
Photo page 45-2
Photo page 45-2
45-8
http://vnx.su
UPPER BODY SECTION

Linings and stiffeners
45
PRS4505
Original welding
Joints (1) - (2) - (3) - (4) - (5) - (6)
NOTE: Joint (6): body side roof drip moulding
The repair welding is identical to the original

welding.
45-9
http://vnx.su
D53
Cabriolet
UPPER BODY SECTION

This operation is carried out in addition to changing of the windscreen frame.
Welding
Part only.
Photo page 45-3
PRS4507

Lining
Front pillar
Frame
1.5
1.25
1.0
Unpicking
31 spot welds.
45-10
http://vnx.su
45 D
D53
Cabriolet
UPPER BODY SECTION

Windscreen aperture upper cross member
This operation is carried out in addition to changing of the windscreen frame.
Welding
Bare part.
94955S
PRS4508
JOINT WITH THE WINDSCREEN APERTURE

FRAME

Cross member
Pillar lining
Frame
1.5
1.5
1.0
Unpicking
42 spot welds.
45-11
http://vnx.su
45
L53
Saloon
UPPER BODY SECTION

2
Panel only
JOINT WITH THE ROOF
Reminder : see 45-A-2
PRS4509
45
93083S
93099-2S
93097S
45-12
http://vnx.su
BODY PROTECTION
Sub-frame front protector
PRS4601
Remove the four bolts (1) and detach the protector from the 4 lugs (2).
46-1
http://vnx.su
46 A
BODY PROTECTION
Wheel arch mud shield
FRONT
46
REAR
PRS4602
PRS4603
46-2
http://vnx.su
SIDE OPENINGS
Door hinges
47 A
Special feature for the electrical wiring in the

doors: to make removal easier without having to
remove the trim, there is a connection unit located in each pillar.
Production fitting
92308R
(1) Welded hinges

(B) 6 mm diameter screw pin fitted on bushes (C)
(2) Torx end piece (T40)
After Sales fitting

when changing a door
PRS4701
(B) 6 mm diameter screw pin fitted on bushes (C)

(C) Special replacement bolted hinge
47-1
http://vnx.su
SIDE OPENINGS
Front door panel
47
COMPOSITION OF THE REPLACEMENT DOOR

PANEL
92614-1S
PRS4702
(1) Exterior panel

(2) Panel stiffener
(3) Sound proofing
CUTTING - UNPICKING
Take a section from the new part which is approximately 50mm larger then that cut from the vehicle.
superposed, then secure it with a vice-grip
wrench.
Cut the two layers of metal simultaneously using a
hacksaw to facilitate the fit.
Remove the panel and take off the surplus section
remaining on the door.
92614S
47-2
http://vnx.su
SIDE OPENINGS
Front door panel
47
Apply aluminium paint to the area which is to be

plug welded.
Fit the panel then secure it with a vice-grip
wrench.
Gradually crimp the edge of the panel.
92614-2S
D = 4.5 mm
door, particularly in the welded areas.
47-3
http://vnx.su
SIDE OPENINGS
Rear door panel
47
Drill out the three resistance spot welds at (A), panel - door inner panel joint.
COMPOSITION OF THE REPLACEMENT DOOR

PANEL
Remove the damaged section following the

recommendations of the previous diagrams (refer
to the key to symbols).
92333R
1
2
3
Exterior panel
Panel stiffener
Sound proofing
CUTTING - UNPICKING
92613-1S
Take a piece from the new part which is

approximately 50mm larger then that cut from
the vehicle.
superposed, then secure it with a vice-grip
wrench.
Cut the two layers of metal simultaneously using a
hacksaw to facilitate the fit.
92613-2S
Remove the panel and take off the surplus section

remaining on the door.
47-4
http://vnx.su
SIDE OPENINGS
Rear door panel
47
Apply aluminium paint to the area which is to be

plug welded.
Fit the panel then secure it with a vice-grip
wrench.
Gradually crimp the edge of the panel.
92613R
D = 4.5 mm

door, in particular in the welded areas.
47-5
http://vnx.su
SIDE OPENINGS
Front door - rear door
All types
Phase I
PRS4703
The lower side rubbing strip mounting row has

been discontinued. Consequently, as the Parts
Department only supplies phase II type parts, the
following must be ordered depending on the type
of rubbing strips in order to refit phase I type rubbing strips:
-
either self adhesive clips (A) for narrow rubbing strips (see PR),
or apply 6mm wide double sided adhesive

tape to the lower section of wide rubbing
strips (see PR).
47-6
http://vnx.su
47 D
BONNET AND TAILGATE

Bonnet
48 A
REMOVAL - REFITTING
The bonnet is removed via the four mounting bolts (A) on the strut.
PARTS CHANGED
PRS4802
PARTS RE-USED
PRS4803
48-1
http://vnx.su
BONNET AND TAILGATE

Bonnet
ADJUSTMENTS
Carry out in the following order:

1 - Adjusting via the struts
The clearance in mountings (A) allows
adjustment of:
- the peripheral bonnet clearances, alignment
and backward movement,
- the flush fitting (height) of the rear section of
the bonnet with the front wings.
The clearance of mountings (B) allows the rear
section of the bonnet to be moved sideways
without altering the height.
PRS4804
2 - Adjusting via the lock

The clearance in lock mounting bolts (C) enables
the flush fitting (height) of the front of the
bonnet to be adjusted.
NOTE: adjustment via the lock must never be

used for adjusting the alignment of the bonnet
centreline with the wings. The lock must operate
without any lateral stress.
48-2
http://vnx.su
48 A
BONNET AND TAILGATE

Tailgate
48
REMOVAL
92459-1S
Adjust the peripheral clearances with the roof and

the side panels using the mounting nuts.
92459R
Remove the rear headlining.

Unclip the counter balances.
Remove the 2 nuts (1).
ADJUSTMENTS
92458S
Adjust the flush fitting with the end panel and the
rear lights using the striker mounting bolts.
PRS4805
Adjust the flush fitting with the roof using shims

(2).
48-3
http://vnx.su
B - C - S53
Phase II
BONNET AND TAILGATE

Tailgate
48
95787R
The phase I part supplied by the Parts Department

consists of a phase II type inner panel and a phase
I type panel. Consequently, for correct sealing, it
will be necessary to close holes (A) and (B) in the
inner panel (refer to PR for the part numbers for
the blanking pieces)
48-4
http://vnx.su
BONNET AND TAILGATE

Boot lid
B - C - S53
SPORT
48
FITTING THE REAR SPOILER
PRS4806
1
2
Spoiler
Mounting stiffener
93175R
Using the diagram, mark the centrelines of the

spoiler mounting points starting from the edge of
the rear screen wiper hole (A).
Drill the 4 mounting points to a diameter of 8 mm.
Apply sealing mastic to the edge of the holes and
fit the spoiler.
From inside the tailgate, fit the 2 mounting stiffeners and secure using the 4 nuts.
48-5
http://vnx.su
BONNET AND TAILGATE

Boot lid
L53
Saloon
48
ADJUSTMENT
PRS4807
(A)
(B)
(C)
Adjustment of the clearances, alignment, backward movement,

flush fitting
Lateral adjustment of the rear section
Adjustment via the lock
48-6
http://vnx.su
L53 Saloon
Phase II
BONNET AND TAILGATE

Boot lid
PRS4808
On phase II vehicle the "Chamade" badge is no

longer fitted. The parts supplied by the Parts
Department are specific to each vehicle.
48-7
http://vnx.su
48
L539
Saloon
BONNET AND TAILGATE

Boot lid
48
DIMENSIONS FOR DRILLING THE REAR LIGHT EXTENDER MOUNTING HOLES
In order to standardise, the Parts Department will only supply undrilled boot lids.
Consequently, if the boot lid is changed on Sport type vehicles (L539), the lighting extender mounting holes
must be drilled by the repairer in line with the recommendations below.
FITTING LIGHTING EXTENDERS AND BADGES
Using the dimensions shown on the diagram below, mark the location of the six mounting holes for the rear
lighting extenders and the three mounting holes for the badges.
The holes must be drilled before painting in order to avoid any risk of corrosion.
97748R
A and B Existing holes
48-8
http://vnx.su
D53
Cabriolet
BONNET AND TAILGATE

Boot lid
48
PRS4809
94814-1R
94815R
After removing the counter balances, remove the

four bolts (A)
Different adjustments
48-9
http://vnx.su
D53
Cabriolet
BONNET AND TAILGATE

Boot lid
48
DIMENSIONS FOR DRILLING THE BADGE MOUNTING HOLES
In order to standardise, the Parts Department will only supply phase III boot lids.
Consequently, if the boot lid is to be changed on phase I and II D53 Sport type vehicles, the
mounting holes for the badges must be drilled by the repairer in line with the recommendations below.
Using the dimensions shown on the diagram below, mark the location of the 2 + 2 badge
mounting holes.
The holes must be drilled before painting in order to avoid any risk of corrosion.
98085R
A Existing holes
After painting and before refitting the trim, inject the hollow sections with wax.
48-10
http://vnx.su
D53
Cabriolet
BONNET AND TAILGATE

Hood cover panel
48 D
PRS4810
Removal
94793S
94794R
Disconnect the rear screen demisting harness
Remove the lock in order to unclip wire ( A )

Remove the jacks.
48-11
http://vnx.su
D53
Cabriolet
BONNET AND TAILGATE

Hood cover panel
48 D
94795R
Remove mountings (B).
48-12
http://vnx.su
L53
Saloon
BONNET AND TAILGATE

Broken boot lid counter balance ball joint
93143R
(1)
(2)
48
93142-1S
Ball joint part number 77 00 753 309

Nut
part number 77 01 422 012
Before fitting and tightening the ball joint, coat

the thread with Loctite
-
SCEL BLOC
SCEL METAL

or
NOTE: for the general procedure for fitting or
changing a tailgate or boot lid counter balance

ball joint, refer to Technical Note n 258.
93142R
Drilling for the ball joint
93143R1
Cut the ball joint thread to a length of 8 mm.
48-13
http://vnx.su
BONNET AND TAILGATE

Roof cross member (noise reduction)
X53
All types
48
Procedure for cutting the roof noise reduction cross member if an R19 sun
roof is to be fitted, for vehicles manufactured from 1st December 1991.
PRS4811
Checking for the presence of the noise reduction cross member.

(the special headlining is fitted with a boss)
Mark its location on the jig to be prepared when cutting the roof.
The roof and cross member are cut together in a single operation
using a "compass saw" type tool.
IMPORTANT : do not try to cut the roof and cross member separately or to
use cross member (A) as a lever as this will deform the roof drip mouldings
(B).
Before fitting the sun roof, it is essential to:

- smooth the cuts,
- reapply mastic between the roof and remaining ends of the cross
member (noise reduction function),
- apply anti-corrosion protection to all cuts.
48-14
http://vnx.su
GENERAL
Tooling
http://vnx.su
50
GENERAL
Tooling
http://vnx.su
50
GENERAL
Products
http://vnx.su
50
SIDE OPENING ELEMENTS

Front and rear door window winders
http://vnx.su
51

Front door lock
http://vnx.su
51

Window winder in front door
http://vnx.su
51

Front door electric window cable
http://vnx.su
51

Rear door lock
http://vnx.su
51

External door handle
http://vnx.su
51
OTHER OPENING ELEMENTS

Tailgate lock
http://vnx.su
52
OTHER OPENING ELEMENTS

Tailgate counterbalance
http://vnx.su
52
WINDOWS
Windscreen
http://vnx.su
54
WINDOWS
Windscreen
http://vnx.su
54
WINDOWS
Windscreen
http://vnx.su
54
WINDOWS
Windscreen
http://vnx.su
54
WINDOWS
Window in front door
http://vnx.su
54
WINDOWS
Window in rear door
http://vnx.su
54
WINDOWS
Window in rear door
http://vnx.su
54
WINDOWS
Base of window in rear door
http://vnx.su
54
WINDOWS
Rear screen
http://vnx.su
54
WINDOWS
Rear screen
http://vnx.su
54
WINDOWS
Rear screen
http://vnx.su
54
WINDOWS
Side panel window
http://vnx.su
54
WINDOWS
Side panel window
http://vnx.su
54
EXTERNAL PROTECTION
Front shields
http://vnx.su
55
EXTERNAL PROTECTION
Rear shields
http://vnx.su
55
EXTERNAL PROTECTION
Front wing protection strip
http://vnx.su
55
EXTERNAL PROTECTION
Rear door protection strip
http://vnx.su
55
EXTERNAL PROTECTION
Sill protection strip
http://vnx.su
55
EXTERNAL FITTINGS
Rear view mirror
http://vnx.su
56
EXTERNAL FITTINGS
Rear view mirror
http://vnx.su
56
EXTERNAL FITTINGS
Rear view mirror electric control
http://vnx.su
56
EXTERNAL FITTINGS
Rear number plate
http://vnx.su
56
LOWER INTERNAL FITTINGS

Dashboard
http://vnx.su
57

Dashboard
http://vnx.su
57

Dashboard
http://vnx.su
57

Dashboard
http://vnx.su
57

Rear door ashtray
http://vnx.su
57

Cente console
http://vnx.su
57
Heating and ventilation

HEATING
AIR CONDITIONING
77 11 190 859
NOVEMBER 1996
are constructed".
Edition Anglaise

Renault.
Renault S.A. 1988
http://vnx.su
EXPLODED VIEW
PRJ6000
http://vnx.su
Heating and Ventilation

Contents
Pages
61 HEATING
General
Operating principle
Distribution unit
Fan unit
Radiator
Resistance unit
Control panel
Control cables
61-1
61-4
61-7
61-9
61-10
61-11
61-12
61-13
62 AIR CONDITIONING
General
Operating principle
Fault finding
Operating diagram
Consumables
R12 / R134a conversion
Fan unit
Evaporator
Compressor
Compressor oil level
Condenser
Pressure relief valve
Dehydrating bottle
Electrical controls
http://vnx.su
62-1
62-5
62-9
62-47
62-48
62-49
62-53
62-55
62-56
62-61
62-62
62-64
62-65
62-66
R19
Phase I
HEATING
General
61
AIR DISTRIBUTION AND CIRCULATION
91936-2R
A External air intake

B Air distribution
C Air outlet in rear left hand wing
Central ventilator outlets

Windscreen de-mister outlet
Dashboard ventilator outlet
Lower ventilator outlets
Rear seat ventilator outlets (depending on
equipment level)
f Front side windows de-mister outlet
a
b
c
d
e
61-1
http://vnx.su
R19
Phase II
a
b
c
d
e
f
HEATING
General
Central ventilator outlets

Windscreen de-icer / de-mister outlets
Dashboard ventilator outlets
Lower outlets
Rear seat ventilator outlets (depending on equipment level)
Front side window de-mister outlet
61-2
http://vnx.su
61
HEATING
General
61
EXPLODED VIEW OF THE FAN AND DISTRIBUTION UNIT
92194R2
WATER BOX
PASSENGER COMPARTMENT
1
2
3
4
5
6
a
b
c
d
e
Heater radiator
Heater fan
Hot / cold air flap
Air distribution flaps
Air distribution cable
Air mixing cable
Air intake
Windscreen de-misting outlet
Dashboard ventilator outlets
Lower ventilator outlets
Rear seat ventilator outlets (depending on
equipment level)
61-3
http://vnx.su
HEATING
Operating principle
61
TEMPERATURE CONTROL KNOB (A)
Controls the hot / cold air flap (3).

R19 Phase I
R19 Phase II
92033-5R
95717R2
92196R
The fan has no heater valve and is permanently fed. Flap (3) controls the fresh air heating system.
61-4
http://vnx.su
HEATING
Operating principle
61
AIR DISTRIBUTION KNOB (B)
Controls the air distribution flaps (4).

R19 Phase I
R19 Phase II
92033-3R1
95717R3
92196-1R
61-5
http://vnx.su
HEATING
Operating principle
61
POSITION
POSITION
The air flow is directed only to the dashboard

ventilators (a) and (c).
The air flow is directed to the lower ventilators

(d), (e) and the dashboard ventilators (a) and (c).
Each ventilator has three settings :

- open or closed,
- up or down,
- left or right.
POSITION
POSITION
The air flow is distributed between all the

ventilators (a), (b), (c), (d), (e), (f).
The air flow is directed to the windscreen

ventilators (b), the side window ventilators (f),
and the dashboard ventilators (a) and (c).
The dashboard ventilators (a) and (c) may be

closed.
To improve de-misting and de-icing of the

windscreen, ventilators (a) and (c) may be closed.
FAN CONTROL KNOB (C)
Ventilation is by means of blown air. The amount

of air circulating in the passenger compartment is
determined by the position of knob (C).
NOTE : To improve de-misting and de-icing of the
windscreen, fan control knob (C) should be on the

last but one position (2).
92033-1R1
61-6
http://vnx.su
HEATING
Distribution unit
61
Mot. 453 -01

M.S. 583
Hose clamp
Hose clamp
Fit hose clamps Mot. 453-01 or Mot. 583.
REMOVAL

Remove:
- the dashboard (refer to relevant section),
- the upper seal on the water box and the
external air intake grilles.
Disconnect the fan feed connector (A).
92202R
Remove:
- the 2 radiator inlet hose clips,
- the fan unit from inside the vehicle together
with its control.
92283R
Remove the 2 fan mounting bolts (B) and remove

the fan from the drivers side (the water box can
only be removed in one position).
92200R
61-7
http://vnx.su
HEATING
Distribution unit
REFITTING
Fit the fan unit on the bulkhead (ensure that the

seals are in good condition).
Fit the fan with the 2 fan mounting bolts (B). Do
not tighten these two bolts. The fan unit is also
positioned on the dashboard by two bolts (C).
92283R
92203R1
Refit the dashboard.

Check the control cable adjustment and re-adjust
if necessary (see corresponding section).
Connect the radiator hoses.
Tighten the 2 fan mounting bolts (B) and refit the
feed connector (A).
Refit the air intake grilles and the water box seal.
Top up and bleed the engine cooling circuit (see
corresponding section) if necessary.
61-8
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61
HEATING
Fan unit
61
REPLACEMENT
The fan unit is removed after removing the upper

water box seal and the external air intake grille.
Remove the feed connector (A) and the 2
mounting bolts (B).
92223R
When refitting, put the motor back in position so

that the connector is not taut.
Refasten the two half covers using the clips (D)
provided in the kit and hot-crimp them.
Fit the new seal provided in the kit to the
assembly.
92283R
IMPORTANT: the seal must be in perfect
condition. If it is damaged, water may enter the

passenger compartment.
Remove the fan from the left hand side of the

vehicle (the water box can only be removed in one
position).
92200R
92223R1
Disconnect the motor connector.

Open the two half covers.
Pull the motor out as shown below.
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HEATING
Radiator
61
REPLACEMENT
The radiator is removed after removing the air

distribution unit.
Spread the 4 retaining clips (E) and remove the
radiator by pulling in the direction shown in the
diagram below.
92201R
NOTE: take care not to damage the radiator fins.
When refitting, ensure that the radiator is fitted

into the holder with its foam adjustment strips.
Ensure that the 4 tabs are correctly fastened.
Fit the 2 mounting bolts (F) onto the body of the
fan unit if the clips have broken.
90292R
61-10
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HEATING
Resistance unit
61
REPLACEMENT
The resistance unit is reached after removing the

water box upper seal and the external air intake
grille.
Disconnect connector (A) and remove the two
mounting bolts (G).
92283R1
Detach clips (H) and remove the resistance unit.

NOTE: if the resistance unit is being removed due
to damage, ensure that the fan rotates freely,

otherwise change it.
There are no special precautions for refitting the
resistance unit.
92204S
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HEATING
Control panel
61
REPLACEMENT
Remove the two mounting bolts for the lower

dashboard cover (J).
92224R
When refitting, change the cable sleeve stops and

the clips (M).
92289R1
Remove the two mounting bolts securing the

control panel to the dashboard (K).
92288R
Push the control panel in and release it from the

bottom.
The control panel facade may be changed by
removing the 4 retaining clips (L).
61-12
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HEATING
Control cables
REPLACEMENT
61
Place the air distribution control in

position
and the heating control on
maximum cold (blue spot).
The control cables can be removed without

removing the air distribution unit.
Refit the control panel to the air distribution unit.
Remove:
- the control panel as described on the previous
page,
- the 2 mounting bolts for the air deflector (N).
Align the flap control quadrant markers.
92203R
92207R
Unclip the cable to be changed and turn it 1/4

turn to release it from the flap control lever.
Refit:
- the mixing flap return spring (P) (only for air
mixing control),
- the air deflector and the lower dashboard
cover, bolts (N) and (J).
When refitting, clip the cable to the control panel

against the cable sleeve stops (clips M).
92289R1
92224R1
NOTE: the flap control cables are of a different
length, the longer one is for the mixing flap.
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AIR CONDITIONING
General
62
91096-1R
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AIR CONDITIONING
General
A Passenger compartment
B Engine compartment
C External air
D To mixing unit
E Scuttle panel
F External air or recycled air
1 Compressor
2 Condenser
3 Refrigerant reservoir
4 Tri-function pressostat
5 High pressure bleed
6 Pressure relief valve
7 Thermostat control for pressure relief valve
8 Evaporator
9 Low pressure bleed
10 Air conditioning fan
11 Cooling fan
12 Engine radiator
13 High pressure liquid
14 Low pressure vapour
15 High pressure vapour
62-2
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62
AIR CONDITIONING
General
62
RECOMMENDATIONS
MAINTENANCE
The quality of heating and ventilation repairs is

highly dependent on the rules below being
followed:
When a vehicle is fitted with air conditioning, the

engine may heat up more than on other vehicles.
It is recommended that the level of coolant is
checked more frequently.
Never leave:
- the pipes open to the air; risk of moisture
being absorbed,
- a can of oil open.
Every year, it is recommended that:

1.
the quantity of refrigerant in the air

conditioning circuit is checked.
2.
the condenser and the engine cooling

radiator are cleaned.
3.
the condition of the air conditioning system

condensation outlet is checked (blockage).
When topping up the oil using filling equipment:
Never use oil left over from a previous

operation. Use the exact quantity of oil
required for each operation.
Work cleanly. The smallest foreign body at the
unions could cause slow leaks or internal
malfunction.
Do not allow oil to come into contact with the

vehicles paintwork or plastic components.
Emphasise the importance of operating the

air conditioning system regularly, both in
summer and in winter.
The system must be filled with the correct and

precise quantity of refrigerant (refer to the
"Consumables" section). Too much or not
enough refrigerant reduces the performance
of the system and in extreme cases risks
damaging the compressor.
For the repair of major leaks, each time a

component is changed (compressor, condenser
etc...) or if the presence of moisture in the circuit is
suspected, change the dehydrating bottle and
create a vacuum. The same applies if the air
conditioning circuit has been left open for more
than 10 minutes without being plugged.
If the air conditioning system is not operated for

a prolonged period
If the system is not operated for a prolonged
period, in particular in winter, operate the
compressor periodically in order to prevent
destruction of the compressor rotor bearing races.
The needles mark the bearing races when the
assembly is immobilised in one position and
vibrate under the effect of the engine rotation.
Never fill an air conditioning system which

operates using R134a with R12 refrigerant
and vice versa.
This destruction is manifested by significant noise

when the compressor is operated again.
62-3
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AIR CONDITIONING
General
62
92419G
1
2
3
4
5
6
7
8
Fan unit
Fan
Evaporator
Fan control unit
Evaporator temperature sensor
Recycling motor
Component unit
A
B
C
External air intake

Recycled air intake
To air distribution unit
NOTE : the air distribution unit and the dashboard
are identical for versions with heating and

ventilation and versions with air conditioning.
62-4
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AIR CONDITIONING
Operating principle
62
SPECIFIC OPERATION FOR DIESEL AND TURBO DIESEL VERSIONS (see diagram on following page).
AIR CONDITIONING CUT-OUT
Principle of the system
Special notes
In order to improve moving away when on a slope

and to avoid stalling the engine, the air
conditioning compressor clutch is cut for 4
seconds.
The clutch pedal switch does not require any

special adjustment, other than when the clutch
pedal is not depressed, the switch plunger should
be fully depressed.
Conditions
Using an ohmmeter:
The clutch pedal must be depressed and the

accelerator pedal must be over a certain engine
load.
clutch pedal not depressed:

- switch resistance = 0 ohm
clutch pedal depressed:
- switch resistance= infinity
Operation
When the two conditions above are fulfilled
(switch circuit open), relay (661) cuts out and no
longer feeds the timer relay (635).
The AC compressor clutch control relay (584) is
therefore cut for 4 seconds by the timer relay.
Note
The diode stops the AC compressor clutch from
being fed by the pre-heating unit during starting
and engine warming.
62-5
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AIR CONDITIONING
Operating principle
PHASE I
62
PHASE II
92034-2R3
95718R2
TEMPERATURE CONTROL KNOB (A)
AIR FLOW CONTROL KNOB (C)
This control has the same function as described in

the heating and ventilation section when the air
conditioning control (D) is in position 0.
This control has the same function as described in

the heating and ventilation section.
There are 6 positions for fan speed in comparison
to the 3 positions for the heating and ventilation
version.
When the air conditioning control (D) is in the

position "NORM" or "MAX", air is first cooled and
dried by crossing the evaporator, then some of it
is heated by crossing the radiator.
POSITION 0: there is no ventilation, the air intake

is closed by the recycling flap.
When the control is turned to the extreme left,

the air is not heated and is therefore at its coolest
possible temperature.
The air conditioning system cannot be operated.

This position shuts off the complete system,
whatever the other control knob settings may be.
Moving the knob to the right allows the air

temperature to be controlled.
62-6
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AIR CONDITIONING
Operating principle
PHASE I
62
PHASE II
92034-1R1
95718R3
This position allows the passenger compartment

temperature to be lowered quickly and also
isolates the passenger compartment from the
external atmosphere ( driving in polluted areas).
AIR CONDITIONING CONTROL KNOB (D)
This control starts and stops the air conditioning

system.
Its use allows:
- the air temperature in the passenger
compartment to be lowered,
- the humidity level in the passenger
compartment to be reduced (improves demisting).
If this position is used for a prolonged period of

time, there may be a slight misting up of the air in
the passenger compartment.
It is therefore advisable to return to the "NORM"
position as soon as the polluted area is left or the
desired passenger compartment temperature is
reached.
POSITION 0: air conditioning is not operational,

the vehicle has the same heating and ventilation
system functions as a vehicle without air
conditioning.
NOTE: The air conditioning control only starts the
system operating if the air flow control (C) is set to

a position other than 0.
POSITION "NORM": air conditioning is

operational. This is the normal position for air
conditioning use. Fresh air is taken from outside
the vehicle and constantly renewed.
POSITION "MAX": air conditioning is operational.
Air is taken from inside the passenger

compartment and recirculated. No air is taken
from outside.
62-7
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AIR CONDITIONING
Operating principle
62
SPECIAL NOTES ABOUT THE SYSTEM
The temperature of the air from the evaporator is

not adjustable. It is automatically controlled by
the electronic thermostat and the sensor (S).
92287R
Moving the mixing flap control knob (A) allows

the desired air temperature to be set.
62-8
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AIR CONDITIONING
Fault finding - Customer complaints
62
Air conditioning
Lack of efficiency
Chart 1
No cool air
Chart 2
Air too cold
Chart 3
Recycling flap does not operate - Model year 1989 and 1990
Chart 4
Recycling flap does not operate - From model year 1991
Chart 5
Passenger compartment fan does not operate

Model year 1989 and 1990
Chart 7A
Passenger compartment fan does not operate

From model year 1991
Chart 7B
Air distribution problem
Chart 8
Air distribution problem when distribution control is in position :
Chart 9A
Air flow problem
Chart 9B
Air setting on hot
Chart 9C
Air setting on cold
Chart 9D
Engine cooling fan problem

Engine cooling fan only operates slowly
Chart 6
Passenger compartment problems

Controls difficult to operate
Chart 10
Smells in passenger compartment
Chart 11
Water in passenger compartment
Chart 12
e53531.1
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AIR CONDITIONING
Fault finding - Fault charts
62
FAULT CHART N 1 : Lack of efficiency
AC and fan on max,

engine at idle speed.
Does the compressor operate ?
no
See Chart 1A
yes
Check the compressor belt tension, the

clutch air gap and its condition (slipping).
Change the belt or the compressor
clutch.
no
Correct
yes
Check the evaporator sensor

resistance (*).
Change the sensor if necessary.
no
Correct
yes
Check that the recycling flap is in the recycling

position when AC is at max.
Is this correct ?
* If the sensor resistance is incorrect :

1) above max. level :
the compressor operates too
early and reduces its efficiency.
2) below min. level :
the compressor operates too
late, the evaporator freezes,
reducing its efficiency and the
air flow.
See Chart 4A (from model year 91).

no
Chart 4B (up to model year 90).
yes
Check that the mixing flap moves correctly and

readjust the cable if necessary.
no
Correct
yes
Is there an air flow problem ?
yes
See Chart 7A or 7B air flow or fan

problem
no
(See next page)

e53531.1
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AIR CONDITIONING
62
FAULT CHART N 1 : Lack of efficiency (cont)
A
Connect the HP/LP pressure gauges and check the
pressures. Vehicle stationary, engine at idle speed
and A/C MAX.
If the HP>25 bars :
there is too much refrigerant in the circuit,
the engine cooling fan is not operating
correctly,
the engine is getting too hot,
the condenser is dirty. The compressor
operates via the HP pressostat under these
precise conditions.
Is HP < 25 bars ?
yes
Using the HP pressure gauge check the engine

cooling fan control pressostat pressure
settings.
Pressures 16/19 bars 1.5 bar.
NOTE: If the setting is too high the
fan switches on and off too late and
thus reduces the efficiency of the AC
system.
Change the pressostat if necessary.
no
no
yes
Check that the sensor harness is clean.

Clean or change the condenser.
no
Correct
Correct
yes
Check the operation of the engine cooling fan at

top speed (passenger compartment fan and AC on
max.).
Fan operates if HP 19 bars.
Fan stops if HP 16 bars.
Fan operates for engine coolant temperature
92C.
Is the fan operation correct?
The humidity in the circuit may have

formed a plug of ice in the pressure
relief valve or the valve may be faulty
(slight lack of gas in the bulb).
Change the dehydrating bottle and the
pressure relief valve and top up the
refrigerant level.
no
See Chart 6
yes
Adjust the refrigerant level in the circuit. There
may have been too much refrigerant.
e53531.1
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AIR CONDITIONING
62
FAULT CHART N 1A : Lack of efficiency
AC and passenger compartment fan on max,

engine idling.
Does the compressor operate?
yes
See Chart 1.
no
Engine running at idle speed, AC and fan still on
max., check for bubbles in the dehydrating bottle
inspection glass.
If bubbles are seen, there is not enough
refrigerant in the circuit. Adjust the level.
no
Correct
yes
Connect the HP and LP pressure gauges.
Check the operation of the engine cooling fan at
top speed ( AC on max.).
- Fan operates if HP 19 bars
- Fan stops if HP 16 bars.
- Fan also operates for engine coolant
temperature 92C.
Is the fan operation correct?
no
If the fan control pressostat pressure settings

are too high, the fan starts and stops too late
and reduces the AC efficiency.
If this is the case, change the pressostat.
no
Check the evaporator sensor resistance.

yes
With the windows and doors closed, the vehicle in
a shady location, temperature 25 C, engine
idling, passenger compartment fan and AC on
max., measure the temperature of the air in the
central ventilator and check that the compressor
operates for a temperature < 4C.
Is this correct?
yes
no
yes
Correct
Check the pressures (passenger compartment fan
and AC on max).
If LP > 4 bars or HP=LP the pressure relief valve is
fully open.
If LP 0 bar the pressure relief valve is
closed.
Do you read these values ?
yes
Change the pressure relief

valve and adjust the
refrigerant level.
no
If various operations have been carried out on
the cooling equipment and oil has been
added, there may be too much oil in the circuit
(*).
If this is the case, remove the compressor
and check its oil level (see method in the A/C
workshop repair manual), drain the oil in the
pipes and the condenser, change the dehydrating
bottle and adjust the refrigerant level.
no
Correct
yes
* Attention: type 709 compressors

circulate more oil in the circuit
than 508 type compressors.
Change the AC compressor.

e53531.1
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AIR CONDITIONING
62
FAULT CHART N 2.1 : No cool air
Is the compressor operating ?
yes
See Chart 2.2.
no
Check the fuse or fuses, change if necessary.
no
Correct
yes
Fan and AC on max., check the 12 volt compressor
feed.
Is there+ 12 Volts ?
Check the clutch resistance

(3.2 0.5 ohms).
Change the clutch if necessary.
ye
no
For X53A (E7J 700 Bosch injection) ;X539; X53Y ; X53D ; X53F
: see Chart 2A
For X53C, X538 and X53V : see Chart 2B
For X53A (AC DELCO injection) : see Chart 2C
For X53A (E7J 745 Bosch injection) : see Chart 2K
For X535 (E7J 742 Bosch injection) : see Chart 2K
X533 ; X536 ; X537 ; X53H ; X53G

X53I;X53J ; X534 ; X53K ; X53Z
Check for + 12 volts on trifunction pressostat connector

track A1.
Is this correct?
yes
no
Shunt the tri-function pressostat

between tracks A1 and C1 and
check if the compressor operates.
Does it operate ?
yes
yes
See Chart 2H for

F8Q engine.
no
Press on a filling valve to see if there is

refrigerant in the circuit.
NOTE: with the engine stopped and cold,
the pressure gauges should read
between 5 and 7 bars HP and LP for
a workshop temperature of
20/25C.
Is this correct ?
Change the pressostat.
no
no
E6J ; C2J ; F2N
Check the wiring between :

- track C1 on pressostat and the
compressor connector.(1)
(1) for F2N 727
Check relay 720
and its wiring
Adjust the refrigerant

level.
(See next page)
e53531.1
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AIR CONDITIONING
62
FAULT CHART N 2.1 : No cool air (cont)
A/C and passenger compartment fan

on max.
Shunt the evaporator sensor and
check if the compressor operates.
Does it operate?
yes
Change the evaporator sensor.
no
on max.
Check for + 12 volts on output from
electronic thermostat unit track 5 or
track B1 of black connection R99 of
component unit.
Is there + 12 Volts ?
no

on max.
Check for + 12 Volts at electronic
thermostat unit input, track 7.
yes
yes
no
Year of manufacture 1989 ; 1990

X533 ; X536 ; X537
yes
Check the wiring continuity

between :
- 5 on electronic thermostat and B1
of black connection R99.
- B1 of black connection R99 and
A5 of brown connection R34.
- A5 of brown connection R34 and
A1 of the tri-function pressostat.
Chart 2D
Chart 2J
Other model years

and other vehicles.
Check the earth on track 6 of the

electronic thermostat unit and shunt
it between tracks 3 and 4.
Repair if necessary.
Is this correct?
no
Correct
yes
Change the electronic thermostat
unit.
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AIR CONDITIONING
62
FAULT CHART N 2.2 : No cool air (cont)
no
See Chart 2.1
yes
Adjust the refrigerant level.
no
See Chart 8
Air distribution problem.
no
Correct
no
Correct
yes
Check for bubbles in the inspection glass of the

dehydrating bottle, engine idling, A/C on max.
Are there bubbles ?
no
Check that the mixing flap moves when the

control is moved.
Is there movement?
yes
Visually check on the assembly that the flap travel

is correct.
Adjust if necessary.
yes
Connect the HP and LP pressure gauges and check

the pressures, engine idling, AC on max.
If HP=LP the pressure relief valve is fully open or
if LP 0 bar the pressure relief valve is closed.
If you read these values change the pressure relief
valve and adjust the refrigerant level.
yes
Change the compressor.
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AIR CONDITIONING
62
FAULT CHART N 2A : No cool air- X53A vehicles (E7J 700), X53Y Bosch monopoint injection, X539, X53D,
X53F Siemens multipoint injection

Connect the XR 25 (injection fiche 3).
Enter code D03, ISO selector on S8.
Put the passenger compartment fan and the AC
on max.
Does right hand bargraph 14 illuminate? (1)
no
See Chart 2F.
no
See Chart 2G.
(1) except for X53A, X53F

move on to the next point
yes
Does left hand bargraph 14 illuminate?
yes
X53D, X53Y, X539
yes
X53A - X53F see Chart 2I
Check for + 12 Volts on track 3 of relay 474.

no
Is there + 12 Volts on track 5
of relay 474 ?
no
Check the wiring between track 3

of relay 474 and the AC compressor
Repair.
yes
Check for +12 Volts on

track A1 of the tri-function
pressostat connector
Is this correct?
no
Check for + 12 Volts on

track B3 of the grey
connector R34.
Fan and AC on max.
Is this correct?
yes
yes
Check for + 12 Volts between tracks 1

and 2 of relay 474.
no
yes
Change relay 474.

- track 2 of relay 474 and track 22 on
the computer
- the shunt between track 1 and
track 5 of relay 474 (X53D)
yes
no

between tracks A1 and C1 and check
that the compressor operates. Does
the compressor operate?
Repair the wiring

between track 5 of relay
474 and track C1 of the
pressostat.
Press on a filling valve to see if
there is refrigerant in the circuit.
NOTE: with the engine stopped,
20/25C.
Is this correct ?
yes
Repair the wiring
between track B3
of connection R34
and track A1 of the
pressostat.
no
yes
Repair the wiring between

track B3 of connection R34
and the fuse box.
no
Adjust the
refrigerant level.
yes
Correct
The injection is preventing the AC
from operating - look for a possible
cause or change the injection
computer.
no
Change the tri-function pressostat

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AIR CONDITIONING
62
FAULT CHART N 2B : No cool air - X53C ; X538 ; X53V vehicles

on max.
Does right hand bargraph 14 illuminate?
no
See Chart 2F.
no
See Chart 2G.
yes
yes
no
Is there + 12 Volts on track 5 of
relay 474 ?
no
yes
yes

Repair.

track A1 of the trifunction pressostat
connector.
Is this correct?
no
yes
and 2 of relay 474.
no
Change relay 474.

the computer (or track 23 for F3P;
X538)
- the shunt between track 1 and track 5
of relay 474.
yes
no

yes
no
Correct
Injection is preventing the AC from

operating - look for a possible cause or
change the injection computer.
no
yes

track A5 of the brown
connector R34.
(Fan and AC on max).
Is this correct?
Repair the electrical

wiring between track 5
of relay 474 and track C1
of the pressostat.
between 5 and 7 bars HP and LP
for a workshop temperature of
20/25C.
Is this correct ?
yes
wiring between track
A5 of connection R34
and track A1 of the
pressostat.
Check on track B1 of the

black connector R99 of the
component unit for + 12
Volts (fan and AC on max).
Is there 12 Volts ?
no
yes
(See next page)

yes
no
(See next page)
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e53531.1
AIR CONDITIONING
62
FAULT CHART N 2B (cont) : No cool air - X53C ; X538 ; X53V vehicles
Adjust the refrigerant

level.
Change the tri-function pressostat.
Repair the wiring

between track B1 of
component unit and
track A5 of brown
connector R34.
yes
no
Check for + 12 Volts on track

5 of the electronic
thermostat (fan and AC on
max).
Is there 12 Volts ?

track 7 of electronic
thermostat (fan and AC
on max)
Is there 12 Volts ?
no

track 5 on the electronic
thermostat and track B1 on
the black connector R99.
yes
See Chart 2D.
Before changing the electronic

thermostat, check the earth on
track 6 and the shunt between
tracks 3 and 4.
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AIR CONDITIONING
62
FAULT CHART N 2C : No cool air - X53A AC Delco injection vehicles
Connect the XR 25 (injection fiche).

on max.
no
See Chart 2F
no
See Chart 2G
yes
yes
no
yes
yes
The injection computer is preventing

operation of the air conditioning. Look for a
possible cause (strategy) or change the
injection computer.
Repair.
no
Check for + 12 Volts between
tracks 1 and 2 of relay 474.
Is there + 12 Volts on track 5 of

relay 474 ?
yes
no
no

- track 2 of relay 474 and track 22 on the
injection computer
- track 1 of relay 474 and track 5 of the
fuel pump relay 236.

between 5 and 7 bars HP and LP
for a workshop temperature of
20/25C.
Is this correct ?
yes

track A1 of the tri-function
pressostat connector. Is this
correct?
no
yes
no
Repair the electrical wiring
between track 5 of relay 474
and track C1 of the
pressostat.
Change
relay 474.

connector R34.
(Passenger compartment
fan and AC on max.).
Is this correct?
no

yes
yes
yes
wiring between track
B3 of connector R34
and track A1 on the
pressostat.
Repair the electrical wiring

between track B3 of
connector R34 and the fuse
box.
no
Change the trifunction pressostat.

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AIR CONDITIONING
62
FAULT CHART N 2D : No cool air
Test conditions :
- Passenger compartment fan operating
- AC on MAX.
Is the vehicle
X533
model year 1989 or 1990 ?
X536
X537
yes
Refer to Chart 2E on the next page.
no
Check for + 12 Volts on track 3 of the AC relay
(ref 690) .
Is this correct?
yes
Repair the wiring between track 7 of the

electronic thermostat unit and track 3 on the
AC relay.
no
Check the wiring between tracks :

- 5 on relay 690 and A2 on black connector
R99.
- A2 on black connector R99 and + 12 Volts
at the fuse box.
no
Check for + 12 Volts on track 5 of the AC relay
Is this correct?
yes
Check + 12 Volts feed between tracks 1 and 2 of
relay 690.
Is this correct?
yes
Change the relay.
yes
Repair the wiring between track 2 on relay 690

and track B4 on connector R99.
Track B4 on connector R99 and vehicle earth
M11.
yes
Repair the wiring between track A1 of

connector R99 and track 1 on relay 690.
yes
Repair the wiring between track A1 on black

connector R99 and track B3 on the control
panel.
no
Check + 12 Volts on track 1 of relay 690.
Is this correct?
no
Check + 12 volts on track A1 of connector R99.
no
Check for + 12 Volts on track B3 of control panel
connector 319 (On/Off info).
Passenger compartment fan operating and AC on
NORM.
Is this correct?
no
Disconnect control panel connector 319 and check
the continuity between tracks B1 and B3 and
between tracks B1 and B4.
NORM.
Is this correct?
no
yes
Change the control panel.

Repair the earth on track A5 and + 12 Volts
on track B1 of control panel 319.
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AIR CONDITIONING
62
FAULT CHART N 2E : No cool air - Only for vehicles X533 ; X536 ; X537 ; Model Year 1989 or 1990.
Check for + 12 Volts on track A2 of black

connector R99.
yes

electronic thermostat and track A2 of
connector R99.
no
Repair the wiring between track A2 of black

connector R99 and + 12 Volts on the fuse box.
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AIR CONDITIONING
62
FAULT CHART N 2F : No cool air
Test conditions :
- Passenger compartment fan operating
- AC on MAX.
On brown connector R34, check for + 12 Volts on

track D5.
Is this correct?
yes
no
Check for + 12 Volts on track B4 of control panel

connector 319 (On/Off info).
Is this correct?
no
Repair the wiring between track 30 on the

injection computer (track 13 for X53A AC
DELCO injection) and track D5 of brown
connector R34.
If the fault persists, the injection computer is
at fault, preventing the AC system from
operating.
Check the continuity between track B4 of

black control panel connector 319 and track
D5 on brown connector R34.
Repair the wiring.
yes
With the black control panel connector

disconnected, check the continuity between
tracks : B1 and B4 - B1 and B3.
Is this correct?
no
yes
Repair the wiring between tracks :

- A5 of the control panel and earth M10.
- B1 of the control panel and the fuse box
(+after ignition).
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AIR CONDITIONING
62
FAULT CHART N 2G : No cool air

Test conditions :
- Passenger compartment fan operating at maximum speed
- AC on MAX.

Under these test conditions shunt the evaporator
sensor and check if the compressor operates and
left hand bargraph 14 illuminates (right hand
bargraph 18 for X53A AC DELCO injection).
Does the compressor operate ?
yes
Change the evaporator sensor.
no
Under these test conditions, check for
+ 12Volts on the brown connector
R34 on track A5.
no
yes X53F, X53V, X538, X53C

Shunt the tri-function
pressostat between tracks
A1 and C1 and check if the
compressor operates. Does
the compressor operate ?
yes
All types X53F, X53C,
X53V, X538
no

tracks :
- A1 on pressostat and A5
of brown connector R34.
- C1 on pressostat and 30
on injection computer.
If the fault persists, the
injection computer is at
fault, preventing AC
operation.
no
yes
Change the trifunction pressostat.
yes
track A5 of the brown
connector R34 and track 34
on the injection computer
(track 14 for AC Delco).
If the fault persists, the
injection computer is at
fault.

there is refrigerant in the
circuit.
NOTE: with the engine
stopped, the pressure gauges
should read between 5 and 7
bars HP and LP for a workshop
temperature of 20/25C.
Is this correct ?
Under these test conditions, check for + 12 Volts

on track B1 of the black connector R99 for the
component unit.
yes
Repair the wiring between track B1 on the

component unit and track A5 on brown
connector R34.
yes

electronic thermostat and track B1 of the black
connector R99.
yes
Before changing the electronic thermostat,

check the earth on track 6 and the shunt
between tracks 3 and 4.
no
Check for + 12 Volts (still under these test
conditions) on track 5 of the electronic
thermostat.
no
Check for + 12 Volts (still under these test
conditions) on track 7 of the electronic
thermostat.
no
See Chart 2D.

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AIR CONDITIONING
62
FAULT CHART N 2H : No cool air

Test conditions :
- Passenger compartment fan operating at maximum speed.
- AC on MAX.
- Shunt the tri-function pressostat between A1 and C1.
- Ignition on.
Pressostat shunt still in place, shunt the coolant

temperature switch between tracks 1 and 3 of the
black connector.
yes
Check the coolant temperature switch, it

should be closed for an engine coolant
temperature < 105C.
Before changing the temperature switch,
check that the engine is not overheating,
check the cooling system.
no
Repair the wiring between track C1 of the

pressostat and track 1 of the coolant
temperature switch.
no

coolant temperature switch and track 3 of
relay 584 or 474.
no
Check for + 12 Volts on track 1 of the coolant
temperature switch 248.
yes
Reconnect the coolant temperature switch.
Check for + 12 Volts on track 3 of relay 584 or 474
on the compressor.
yes
Check for + 12 Volts on track 4 of relay 584 or 474
on the compressor.
yes
Repair the wiring between track 4 of relay

584 or 474 and the compressor.
no
Check for + 12 Volts between tracks 1 and 2 of
relay 584 or 474.
no
Change relay 584 or 474 (it is stuck on track 5).
yes
Check for+ 12 Volts on track 3 of the timer 635.
no
yes
Up to year of manufacture 93
The PAS pressostat should be closed, check if
this is normal (strategy) or change the
pressostat.
After year of manufacture 93
There is a short circuit to +12volts between
track 1 of relay 474 and track 4 of timer 635.
(See next page)
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AIR CONDITIONING
62
FAULT CHART N 2H (cont) : No cool air

Test conditions :
- AC on MAX.
- Ignition on.
Check for + 12 Volts on track 1 of timer 635.

yes
Change timer 635.
no

relay 661.
no
Change relay 661 (it is stuck on track 5).
no
Repair the wiring or re-adjust the load switch

or change the switch.
yes
Check the adjustment and condition of the load

switch on the diesel injection pump and the
wiring continuity between :
- track 2 of relay 661 and B2 on the pump
connector 589
- track 2 of relay 661 and C2 on the pump
connector 589 (for X534, X53I and X53J).
Is this correct?
yes
Check the clutch switch 634 adjustment and the

insulation of the wiring from earth for tracks :
- 2 on the clutch connector and A2 on connector
R35.
- A2 of connector R35 and A2 of connector R34.
- A2 of connector R34 and track 2 of relay 661.
Repair the wiring if necessary.
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AIR CONDITIONING
62
FAULT CHART N 2I : No cool air

Test conditions :
- AC on MAX.
- Ignition on.
Shunt relay connector 474

between tracks 3 and 5.
Check for + 12 Volts on track:

- 3 for X53F,
- 5 for X53A,
of relay 474. Is there + 12 Volts ?
no
yes
no
X53F
yes
Repair the wiring

between:
- track 5 for X53F
- track 3 for X53A
of relay 474 and the
compressor.

relay 474.
no
X53A
Repair the wiring

474 and splice A in the
wiring of+ 12 Volts
after ignition for the
alternator.
yes
Repair the wiring

474 and + 12 Volts (fuse
20A) via the tri-function
pressostat (tracks
C1/A1).
Change relay 474.
no

no

- 1 on relay 474 and C7 on the brown connector
R34.
- C7 of the brown connector R34 and the
+ 12 Volts after ignition of the ignition switch.
yes
Check the wiring continuity between track 2 of

relay 474 and track:
- 7 for X53F
- 22 for X53A (E7J 700)
of the injection computer.
If the fault persists, the injection computer is at
fault as it is preventing the AC system from
operating.
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AIR CONDITIONING
62
FAULT CHART N 2J : No cool air - X533 ; X536 ; X537 ; Model Year 1989 and 1990
Connection to component unit R99 disconnected,

ignition off, passenger compartment fan
operating and AC on MAX.
Check the wiring continuity between tracks A1
and C4.
Is this correct?
no
Disconnect the control panel connector and

check the control panel continuity between
tracks B2 and B4 (passenger compartment fan
operating and AC on MAX).
Is this correct?
no
yes
yes

the control panel and
connector R99.
Check the wiring continuity between tracks :

R99 component
unit
connection
Is this correct?
C4
A1
3
4
yes
electronic
thermostat
B2
B4
A1
C4
no
Repair the wiring.
Check the earth on track 6 of

the electronic thermostat.
Is this correct?
Change the control

panel.

- 6 on the electronic thermostat and B4 on
the component unit connector R99.
- B4 on connector R99 and the vehicle earth
M11.
no
yes
Change the computer.
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AIR CONDITIONING
62
FAULT CHART N 2K : No cool air - X53A (E7J 745) - X535 (E7J 742) vehicles

on max.
Do left hand bargraphs 17 and 18 illuminate?
no
See Chart 2G
yes
The injection computer is preventing

operation of the air conditioning. Look for a
possible cause (strategy) or change the
injection computer.
no
yes
no
Is there + 12 Volts on track 5
of relay 474 ?
no

of relay 474 and the AC
compressor. Repair.
yes

track A1 of tri-function
pressostat connector.
Is this correct?
no

connector R34.
Fan and AC on max.
Is this correct?
yes
yes

and 2 of relay 474.
no
yes
Change relay 474.

the computer
- the shunt between track 1 and
track 5 of relay 474 (X53D)
no

that the compressor operates.
Repair the wiring

between track B3
of connection R34
and track A1 of the
pressostat.
no
yes
Repair the wiring

474 and track C1 of the
pressostat.
20/25C.
Is this correct ?
yes

track B3 of connection R34
and the fuse box.
no
Adjust the
refrigerant level.
yes
Change the tri-function pressostat.
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AIR CONDITIONING
62
FAULT CHART N 3 : Air too cold
Is the compressor
operating?
no
yes
Is the compressor still
engaged? (normal if HP 19
bars or engine coolant
temperature >92C
no
yes
Disconnect the
evaporator sensor.
Is the compressor
stopped?
yes
Check the evaporator
sensor resistance.
Is this correct?
yes
Connect the pressure

gauge and check the
pressostat pressures (411).
HP 16/19 bars 1.5 bar.
Change the pressostat if
necessary.
Check the evaporator sensor

resistance.
NOTE: If the setting is below the
min. threshold, the compressor
will operate late.
Does the fault persist ?
no
Change the evaporator
sensor.
Change the electronic

thermostat unit.
no
no
Before changing the electronic

thermostat, check there is no short
- circuit :
- For X53Z ; X533 ; X534 ; X536 ;
X537 ; X53G ; X53H ; X53J ;
X53K between track 5 on
thermostat and the compressor.
- For X538 ; X53A ; X53C ; X53D ;
X53F ; X53V ; X53Y ; X535
between track 5 on thermostat
and track 34 on injection
computer (track 14 for 53A AC
DELCO injection).
Also check that the computer is
not permanently earthing track :
- 22 for X539 ; X53A ; X53C ;
X53D ; X53Y BOSCH injection.
- 9 for X53A AC DELCO injection
- 23 for X538 and X53V
- 7 for X53F
- 20 for X535
Correct
yes
Check that the recycling flap is not

stuck in the recycling position.
Move the control switch with AC
on MAX and check if the flap
moves.
Does the flap move?
no
- Model Year 1989 and 1990

- Model Year 1991 onwards
:
:
see chart 4A
see chart 4B
yes
Check that moving the heating

control moves the mixing flap.
Does the flap move?
no
See Chart 8.
yes
Visually check on the assembly
that the flap moves correctly.
Re-adjust if necessary.
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AIR CONDITIONING
62
FAULT CHART N 4 : Recycling flap does not operate
Year of manufacture 1989 and 1990

Check that the connectors are connected
correctly. Is this correct ?
Repair.
no
yes
yes
Remove the recycling relay 475 and check if the

recycling flap is stuck.
Is it stuck?
yes
no
92034R1
With the passenger compartment fan operating,

check on the terminals of the recycling motor that;
Repair.
Change the motor
- Knob A on NORM there is+ 12 Volts

- Knob A on MAX there is - 12 Volts
(a difference in polarity should be noted).
Is this correct?
no
no
0 Volts read in both

positions.
no
No polarity difference between the 2

positions.
Permanent + 12 Volts.
Refer to Chart 4A on following page.
Open component unit (419) and

check for + 12 Volts on track 5
of relay 417.
Is this correct?
yes
12 Volts in 1 position, 0 Volts in the

other.
Repair the shunts on recycling relay
(417) between tracks :
- 2 and 3
- 1 and 4
Retest.
Is this correct?
yes
no
no
Correct
Repair the wiring between :
- track 5 on the recycling relay and track 7 on
the electronic thermostat (19).
- track 7 on the thermostat and track A2 on
connector R99
- Track A2 on the connector R99 and the fuse
box.
Retest.
Does the recycling motor operate?
no
yes
Change recycling
relay 417.

- track 7 of relay 417 and track 6 on the
electronic thermostat
- track 6 on the thermostat and track B4 on
connector R99
- track B4 on connector R99 and the vehicle
earth M11
Retest.
Does the recycling motor operate?
no
Correct
yes
Correct
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AIR CONDITIONING
62
FAULT CHART N 4A : Recycling flap does not operate

MAX.
Check for + 12 Volts on relay 417 between tracks
5 and 6.
yes
Change the recycling motor relay 417.
no
Repair the wiring.
no
no
Check the continuity between tracks :

- 6 of relay 417 and B3 of connector R99
- B3 of connector R99 and B3 of the control
panel 319.
Is this correct?
yes

MAX.
Disconnect the control panel connector 319 and
check the continuity between tracks B3 and A5 on
the control panel side.
Is this correct?
yes
Repair the wiring between track A5 on the control

panel connector and the vehicle earth M10.
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AIR CONDITIONING
62
FAULT CHART N 5 : Recycling flap does not operate
From year of manufacture 1991

Passenger compartment fan operating, AC on
MAX.
Check for + 12 Volts between track A3 and
track A1 of the recycling motor connector.
Check for +12 Volts on connector R99 between

tracks A2 and B4. (A2=+12 Volts, B4 = earth).
no
yes
yes
Under these conditions, check
for + 12 Volts on track B1 of
the motor connector.
Is this correct?
yes
no
- track B4 on connector R99
and earth M11
- track A2 on connector R99
and + 12 Volts after ignition.
Repair the shunt

between tracks A1 and
B1 of the recycling
motor connector.
yes
Passenger compartment fan

operating, AC on MAX.
Check for + 12 Volts between
tracks B3 and B1 (relay coil) (on
the recycling motor connector).
Is this correct?
yes
yes
no
no
Check the continuity between
track B3 of the recycling motor
connector and track B3 of black
connector R99.
Remove the
recycling motor
475 and check if
the flap is stuck.
Repair wiring between tracks:

- A2 of connector R99 and 5 of relay 690
- 5 of relay 690 and B1 of the recycling
motor connector.
- the shunt between A1 and B1 of the
connector for the recycling motor.
- B4 of connector R99 and A3 of the
connector for the recycling motor .
Repair.
Change motor 475.
no
Correct
yes
track B3 of the black connector
R99 and track B2 of the control
panel connector 319.
no
Correct
yes
Passenger compartment fan operating, AC on MAX. Disconnect

the control panel connector and check on the control panel side,
that the continuity between tracks B2 and A5 is correct.
Is this correct?
yes

track A5 of control panel
connector 319 and the vehicle
earth M10.
no
Change the
control panel.
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AIR CONDITIONING
62
FAULT CHART N 6 : Engine cooling fan only operates slowly
Is the fuse sound?
no
Change the fuse.
yes
Passenger compartment fan operating, AC on

MAX, engine idling.
Check the + 6.5 Volts feed between tracks 1 and 2
for the engine cooling fan.
Is there+ 6.5 Volts ? *
yes
* If the high pressure in the refrigerant circuit

is greater than 19 bars the voltage is + 12
Volts.
no
Shunt the pressure pressostat between tracks B1

and B2.
Does the engine cooling fan operate at top
speed?
Change the engine cooling

fan.
yes
no
Connect the HP and LP pressure gauges to the

AC circuit (filling point). Passenger compartment fan operating, AC on MAX.
Check the setting of the fan control pressostat.
- HP 19 bars : the fan operates at high
speed
- HP 16 bars : the fan operates at low
speed.
NOTE : The fan also operates for an engine coolant temperature 92C.
Is the pressure > 19 bars ?
no
yes
Change the tri-function

pressostat.
(See next page)
Under the same test conditions, engine idling.

If the HP is low and does not reach the setting
value for the pressostat, check for bubbles in
the dehydrating bottle. In this case there is a
lack of refrigerant in the circuit.
Re-adjust the refrigerant level.
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AIR CONDITIONING
62
FAULT CHART N 6 (cont) : Engine cooling fan only operates slowly
Shunt relay 336 between tracks 3 and 5.

Does the fan operate at high speed?
no

track 5 of relay 336.
yes
no
Repair the wiring

between track 5 of
the relay and the
alternator or the
battery.
yes

track 3 of relay and the
cooling fan.

and 2 of relay 336.
yes
Change relay 336.
no
Is there+12 Volts on track 1 of

relay 336 ?
no

- 1 on relay 336 and D1 on brown
connector R34.
- D1 on connector R34 and the fuse box.
yes

- 2 on relay 336 and B2 on tri-function
pressostat.
- B1 on the pressostat and the vehicle
earth.
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AIR CONDITIONING
62
FAULT CHART N 7A : Passenger compartment fan does not operate
Year of manufacture 1989 and 1990
Check the passenger compartment

fan fuse(s).
no
Correct
yes
Change the passenger compartment fan.
yes
Check the + 12 Volts feed between
the fan terminals.
Is this correct?
no
With the passenger compartment
fan operating, shunt the relay
connector 234 for the fan between
tracks 30 and 87.
Does the fan operate?
no

track 30 of relay 234 for
the passenger
compartment fan.
yes
yes
no
Check for + 12 Volts

on connector R99 for
the component unit
between tracks:
- A3 and earth
- C2 and earth
yes
no
See Chart 7C
Check for+ 12 Volts between tracks
85 and 86.
yes
Change relay 234 for

the passenger
compartment fan
no
Check for + 12 Volts between track
85 of relay 234 for the passenger
compartment fan
yes
no
- 85 on relay 234 for the passenger
compartment fan and track B3 on the
electronic module.
- B3 on the electronic module and track 5 on
relay 417.
- 5 on relay 417 and 7 on the electronic
thermostat.
- 7 on the electronic thermostat and A2 on
connector R99 for the component unit.
- A2 on connector R99 for the component
unit and the fuse box

tracks :
- 86 on relay 234 and 7 on
relay 417.
- 7 on relay 417 and 6 on the
electronic thermostat.
- 6 on the electronic
thermostat and B4 on
connector R99 for the
component unit
- B4 on connector R99 for the
component unit and the
vehicle earth M10.
Repair the wiring

between tracks :
A3 of
connector R99
and the fuse
box.
- C2 of connector
R99 and the fuse
box.
Repair the wiring
between tracks :
- A3 on connector R99
and track 30 on relay
234
- C2 on connector R99
and track 30 on relay
234.
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AIR CONDITIONING
62
FAULT CHART N 7B : Passenger compartment fan does not operate
From year of manufacture 1991
Check the passenger compartment fan fuse(s).

no
Correct
yes
Check the + 12 Volts feed between the fan
terminals.
Is this correct?
yes
Change the passenger compartment fan.
no
With the passenger

compartment fan operating,
shunt the relay connector 234
for the fan between tracks 30
and 87.
Does the fan operate?

track 30 of relay 234 for
the passenger
compartment fan.
no
no
yes
no

component unit between
tracks:
- A3 and earth
- C2 and earth
Is there + 12 Volts?
yes
See Chart 7C on following page
Check for+ 12 Volts between

tracks 85 and 86.
yes
no
234 for the passenger
compartment fan.
no
yes
Repair the wiring

between tracks :
A3 of connector
R99 and the fuse
box.
- C2 of connector R99
and the fuse box.
Change relay 234 for

the passenger
compartment fan.

tracks:
- 86 on relay 234 and B4 on
component unit (use the
appropriate wiring diagram
for the vehicle in question).
- Track B4 of connector R99
and the vehicle earth M11.
X538 ; X539
X53A ; X53C
X53D ; X53Y
X535 ; X53V
X53G ; X53Z

- 85 of relay 234 for the fan and track A2 of
connector R99 for the component unit (use
the appropriate wiring diagram for the
vehicle in question).
- A2 of connector R99 and +12 Volts fuse
box.
no
Repair the wiring

between :
- A3 and C2 shunt on
connector R99.
and 30 of relay 234.
X533
X536
X53F
X53I
X53K
; X534
; X537
; X53H
; X53J
Repair the wiring

between tracks:
- C2 on connector R99
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AIR CONDITIONING
62
FAULT CHART N 7C : Passenger compartment fan does not operate
Check for + 12 Volts between the

positive terminal of the passenger
compartment fan and the vehicle earth.
no
Repair the wiring between track

87 of relay 234 for the passenger
compartment fan and the
passenger compartment fan.
yes
X538 ; X539 ; X53A ;
X53C ; X53D ;
X53Y ;
X53V ; X535 ; X53G ; X53Z
X533 ; X534 ; X536 ;

X537 ; X53F ; X53H ;
X53I ; X53J ; X53K ;

the passenger compartment
fan earth and tracks A4 and B5
of the electronic module 6.
Is this correct?
no
Repair the wiring.
no

the passenger compartment
fan earth and the shunt for
tracks A4 and B5 of the
electronic module 6.
Is this correct?
yes
yes

track B3 of the electronic
module and earth on track
A2 and track B1.
Is this correct?

- B3 of the electronic module 6 and the fuse box.
- tracks B1 and A2 of the electronic module 6 and
the vehicle earth (use the vehicle wiring diagram in
both cases)
no
yes
Check for a voltage of 0 to 12

Volts on the electronic module
connector on track A1,
depending on the passenger
compartment fan control knob
position.
Do you read a voltage?
yes
yes
Change the electronic module
no
no

between tracks B4
and B3 of the
electronic module .
(See next page )
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AIR CONDITIONING
62
FAULT CHART N 7C (cont) : Passenger compartment fan does not operate
On the control panel connector

319, check for 0 to 12 Volts on
track A1 , which is dependent on
the position of the control knob
for the passenger compartment
fan.
Do you read a voltage?
yes

tracks :
- A1 on the control panel
and A4 on the black
component unit.
- A4 on the component
unit and A1 on the
electronic module.
no
With the control panel

connector disconnected, check
between tracks A1 and A2 that
the voltages in the table below
are correct (dependent on fan
control knob position).
- 0 > 50000
- 1 =
2900 to 3600
- 2 =
2200 to 2600
- 3 =
1400 to 1700
- 4 =
750 to 900
- 5 =
300 to 400
- 6 =
0 to
1
Is this correct ?
Check feeds for control

panel 319.
- Earth on track A2.
- + 12 Volts after ignition
on track B1
Is this correct ?
no
no
yes
Change control panel 319.

tracks :
A2 on control panel
and B2 on connector
R99 for the
component unit.
- B2 on connector R99 for
the component unit and
B4 on the computer.
yes

- A5 on the control panel and earth
M10.
- B1 on the control panel and + 12
Volts after ignition for the fuse
box.
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AIR CONDITIONING
62
FAULT CHART N 8 : Air distribution problem
Set the passenger compartment fan on maximum

and the temperature control on fully cold (blue
spot).
Move the air distribution control and check that
the air is being ventilated correctly.
Is this correct?
yes
Air distribution is correct. Return to the

customer and explain the operation of the
system in detail,
Eg : close ventilators to improve de-icing, ...
no
Visually check that moving the control moves the

flap.
Does the flap move ?
yes
Re-adjust the cable.
no
Check that the cable is correctly connected to the

control panel and the assembly.
no
Correct
yes
Check the moving parts on the assembly (pinions,

levers).
Are these correct?
no
Repair if possible otherwise

change the assembly or the
control panel.
yes
Remove the assembly, check the air distribution

flaps and change the assembly if necessary.
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AIR CONDITIONING
FAULT CHART N 9A : Air flow problem (air distribution control in position
62
)
For testing, position the temperature control on max. hot and the AC control on 0.
Check the operation of the passenger
compartment fan at all speeds.
Is this correct?
no
See Charts 7A and 7B
yes
Check the air intake circuit from the scuttle panel,

the heating member (water box)...
no
Correct
no
Correct
yes
Check the air extraction circuit.

yes
Remove the heating assembly; the heating

radiator is probably blocked.
Clean or change the heating radiator.
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AIR CONDITIONING
FAULT CHART N 9B : Air flow problem (air distribution control in position
62
)
For testing, position the temperature control on max and the AC on 0.

Is this correct?
no
yes

no
Correct
yes
Check the operation of the recycling flap.

Is this correct?
no
See Charts 4 and 5.
no
Correct
no
Correct
yes

yes
Check that the de-misting / de-icing ducts are

correctly connected.
yes

e53531.1
62-41
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AIR CONDITIONING
FAULT CHART N 9C : Air flow problem (air distribution control in position
62
and when the air
temperature control is on max. heat).

For testing, position the AC control on 0 and open all the dashboard ventilators.
Is this correct?
no
yes

no
Correct
no
Correct
no
Correct
yes

yes
Check that the ventilation ducts are correctly

connected.
yes

e53531.1
62-42
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AIR CONDITIONING
FAULT CHART N 9D : Air flow problem (air distribution control in position
62
and when the air
temperature control is on max. cold)

For testing, position the AC control on 0
Is this correct?
no
yes

no
Correct
yes

no
Correct
yes
Check that the ventilation ducts are correctly

connected.
no
Correct
yes

e53531.1
62-43
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AIR CONDITIONING
62
FAULT CHART N 10 : Controls difficult to operate
Check the cable path: stop the cable catching,

kinking or rubbing on collars etc, ...
Change the cable if necessary.
no
Correct
yes
Unhook the cable from the control panel or the

assembly and check the operation of the control
knob and the flap (mixing or distribution).
Is this correct?
no
Change the control panel or the heating /

ventilation assembly.
(If the flap is difficult to operate).
yes
If the controls are very difficult to operate, inform

your local After Sales Head Office (For UK, contact
the Technical Services Department).
e53531.1
62-44
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AIR CONDITIONING
62
FAULT CHART N 11 : Smells in passenger compartment
Check that the air extraction outlets are not

blocked.
no
Correct
yes
Check that the heating member is correctly

sealed (water box) and the bonnet is sealed
from the passenger compartment.
(Seals, plugs, bonnet, ...)
no
Correct
Is the smell present in

position
(max. heat)?
yes
Check the operation of the air recycling flap

which may be stuck in the recycled air position.
yes
no
Correct
Remove the heating assembly

and check the radiator
condition (dirty, leaking antifreeze, poor de-greasing...).
Repair or change the heating
radiator.
yes
Is the smell in position
(max. cold) ?
no
no
yes
Set the AC on MAX and the passenger

compartment fan on slow and use the
refrigerant detector in the central ventilator to
check that there is no refrigerant leak.
Is this correct?
no
yes
no
Correct
Change the
evaporator.
If the vehicle is new, the smell

may be caused by the
evaporation of solvents,
plastifiants ...
yes
Remove the evaporator unit and check that it is

not dirty (leaves, insects, ...), and check the
seals.
Clean or change the evaporator unit.
e53531.1
62-45
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AIR CONDITIONING
62
FAULT CHART N 12 : Water in the passenger compartment
Check that the leak is not coming from the

heating radiator.
Change the radiator if necessary.
no
Correct
no
Correct
no
Correct
yes
Check that the evaporator unit and the low

pressure pipe are thermally insulated (if they pass
inside the passenger compartment).
yes
Check the condensation drain tube.

Check that the water is running away to the
outside.
Set the AC on NORM. and check that water is
coming from under the vehicle.
Repair if necessary. Does the fault persist?
yes
If the customer is complaining of droplets of

water coming from the central ventilators or from
the front footwell vents, the evaporator may be
icing up.
Are water droplets coming from these vents ?
no
The leak is not from the air

conditioning system
yes
Test the air conditioning system : set the AC on

MAX, passenger compartment fan on max.,
windows and doors closed, measure the
temperature of the air blown from the central
ventilators; it should be 2C when the
compressor is operating. If it is lower, the
evaporator may ice up.
Change the evaporator sensor or the electronic
module.
e53531.1
62-46
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AIR CONDITIONING
Operating diagram
62
OPERATING DIAGRAM - AIR CONDITIONING CUT-OUT ( Diesel and Turbo Diesel Versions)
PRJ95707
171
Air conditioning clutch
257
Pre-heating unit
405
Pump load lever switch
412
Accelerated idle solenoid valve
421
Clutch pedal switch
584
AC compressor clutch relay
589
Injection pump
635
AC cut-out timer relay
661
AC cut-out timer control relay
+ after ignition
(on relay 584) fed by double threshold temperature switch
62-47
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AIR CONDITIONING
Consumables
62
COMPRESSOR OIL :
ELF RIMA 100
for circuit with refrigerant R12
SANDEM SP 20
for circuit with refrigerant R134a
REFRIGERANT FLUID :
R12
R134a
REFRIGERANT QUANTITY (in grammes) :
R12
Model Year
(up to 1 st July/ FRANCE)
Type
X533
F2N
X536
R134a :
1993
850
1050
850
850
X537
E6J
1050
1050
X53C
F3N
850
750
1050
X53H
1992
X53F
F3N
850
750
X53G
E6J
1050
1050
X534
F8Q
1050
1050
X53J
F8Q
1050
1050
X53A
E7J
1050
X53D
F7P
850
X53Y
F3P
750
X538
F3N
750
X53K
F8QT
850
X53T
F8QT
850
800 50 grammes
62-48
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AIR CONDITIONING
62
Following the ban on the production of R12 refrigerant from 31 December 1995 onwards, and in
order to assure the operation and maintenance of
vehicles which contain this refrigerant, the following recommendations apply to all vehicles in
the range.
NEW VEHICLES
USED VEHICLES
No conversion may be carried out on a new vehicle containing R12 before it is sold.
Foreword:
Vehicles whose refrigerant circuits operate using
R12 must only be converted to R134a if there is no
R12 available. Otherwise, filling the circuit with
the refrigerant for which it was designed is still
preferable.
Even if the "R12/R134a conversion" operation

does not affect its reliability, it will alter the performance and level of operating noise of the air
conditioning system.
These vehicles can only be made correct to specification by changing the entire system.
That is: the compressor, the condenser, the dehydrating bottle, the pressure relief valve, the evaporator, the pipes and the seals.
General information:
Before adapting the vehicle, it is advisable to
check the operation of the air conditioning
system.
Any component of the refrigerant circuit which is
found to be faulty must be changed.
Any O-ring seals which are removed at this point
must be changed.
For any work on the vehicles refrigerant circuit
following its conversion to R134a:
- only use refrigerant R134a and SANDEN SP 20
oil,
- fill in the information card accurately (refer to
the "Vehicle conversion procedure" section).
IMPORTANT: when ordering replacement parts

following conversion, retain the criterion "R12"
when making your selection.
NOTE: you may receive parts marked "R12" or
"R134a" until standardisation of the parts has
been completed.
62-49
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AIR CONDITIONING
62
VEHICLE CONVERSION PROCEDURE
2. Disconnect the R12 filling-retrieval point.
1. Retrieve the R12 refrigerant contained in the

vehicles refrigerant circuit then create a vacuum using the filling-retrieval point suitable
for this gas.
3. Change:
- the dehydrating bottle (the parts supplied
can now be used with R12 and R134a).
- the seals using kits:
77 01 204 314 .
IMPORTANT: it is advisable to take great care

during this operation in order to minimise the
quantities of R12 and mineral oil (ELF RIMA
100) remaining in the circuit.
4. Connect the R134a filling-retrieval point and

create a vacuum in the circuit.
In order to improve retrieval, start the vehicle

and operate the air conditioning system in recycling mode, with a low passenger compartment fan speed, until the compressor has cut
in twenty times (10 to 15 minutes of operation).
NOTE: as the vehicle circuit filling valves are
not compatible with the R134a point end

pieces, conversion and marking components
must be fitted to the vehicle (kit 77 01 204
882).
If DIAVIA AT 41 166 type filling equipment, or

equivalent, is available, retrieval of the oil and
separation of the refrigerant is automatic.
Otherwise, the compressor must be removed

and drained of its mineral oil, refer to the procedure in the "Compressor oil level" section.
62-50
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AIR CONDITIONING
62
5. Filling with oil: 135 cc of SANDEN SP 20 oil:

- if one of the filling-retrieval points mentioned is available, filling with oil is via the machine,
- if the equipment available is not suitable for
the filling procedure, the compressor must
be removed in order to fill it with oil.
CONVERSION
a) Remove the vehicle filling valve caps.

b) Remove the blanking pieces (1) from the vehicle valves using a conventional blanking piece
remover (for wheel valves).
6. Fill the circuit. Fill the refrigerant circuit with

800 50 g.
c) Fit the markers (2) around the filler valves.

d) Coat the thread of adaptors (3) and (4) with
LOCTITE FRENBLOC and screw them to the filler valves.
7. Check that the air conditioning system operates correctly.

8. To eliminate any risk of filling the circuit with
refrigerant R12 during subsequent operations,
affix a grid containing an information label
around the pipes, as close as possible to the
filler valves (date of conversion, type and
quantity of the new refrigerant and oil, etc...).
(Label : 77 11 178 677 (technical documentation part number).
Grid: 49 39 125 600 (stationary part number)).
High pressure:
small vehicle pipe,
16 mm diameter adaptor (3).
Low pressure:
large vehicle pipe,
13 mm diameter adaptor (4).
Tightening torque: 1 daN.m.
e) Replace the vehicle caps with those supplied

with the adaptors (5).
98880R
62-51
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AIR CONDITIONING
62
LABEL
Example of the information label to be ordered and to be affixed close to the filler valves:
AIR CONDITIONING
This vehicle has undergone the:
"R12 / R134a" Conversion
Date of conversion:
Quantity of R134a :
Quantity of SANDEN SP 20 oil:
Parts changed at time of conversion and subsequently:

Parts
Dates
Parts
Dehydrating bottle
Pipes:
Condenser
- Dehydrating bottle-pressure release valve
Evaporator
- Pressure relief valve-compressor
- Compressor-condenser
Compressor
- Condenser-dehydrating bottle
THIS VEHICLE CAN NO LONGER USE REFRIGERANT TYPE R12
Dates
77 11 178 677
REMINDER: Following R134a conversion, the cold circuit must be filled with 800 50 g of refrigerant.
62-52
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AIR CONDITIONING
Fan unit
62
REMOVAL
Drain the refrigerant circuit from the filling point.
Disconnect the refrigerant pipes from the

pressure relief valve (bolt D ).
Remove:
- the transverse bar between the shock absorber
housings,
- the AEI (integral electronic injection) (for
carburettor versions) or the MPA (ignition
power module) (for injection versions),
- the coolant reservoir cover (5 bolts A ).
92286R
Separate the air conditioning unit from the

ventilation body (3 bolts B ).
92287-1R
Disconnect the connector from the component

unit.
92285R
92284R2
62-53
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AIR CONDITIONING
Fan unit
62
Remove:
- the air conditioning unit mounting bolt (C) after removing the component unit.
92284R
- the air conditioning unit and the ventilation unit separately having removed the two ventilation unit
mounting bolts under the dashboard (left hand side).
92420S
REFITTING
There are no special notes for refitting. Check that all seals are in good condition.
62-54
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AIR CONDITIONING
Evaporator
62
REPLACEMENT
Remove the evaporator.
The fan unit must be removed before changing

the evaporator.
When refitting, check that the connection pipes

are not touching anything (noise).
Remove:
- the twelve clips (1) on the 1/2 housing and the
three bolts (2),

Torque tighten the bolts connecting the
evaporator to the pressure relief valve to
1 daNm (ensure that the seals are in good
condition).
Fill the refrigerant circuit at the filling point.
REMINDER: refer to the "Consumables" section
for the required amount of refrigerant.

IMPORTANT: When changing the evaporator, add
approximately 30 cm3 of ELF RIMA 100 oil to the
compressor (approximately.1/4 glass) (refer to
the "Consumables" section for the type of oil to
be used).
WARNING
AIR CONDITIONING
vehicles which contain this refrigerant, refer to
the "R12 / R134a conversion" section.
92391R
- the pressure relief valve (bolt L).
92392R
62-55
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E ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL

Drain the refrigerant circuit (See method in Air
Conditioning manual).
Undo the two bolts (A) and slacken the
compressor drive belt using bolt (B).
Remove the belt.
Disconnect the compressor feed (+ 12 V) (C).
96180R
- the oil filter,

- the nut and the spring on the exhaust flange
on the manifold (compressor side),
- the upper compressor mounting,
- the compressor.
IMPORTANT : The compressor pipes do not need
to be removed when removing the engine and
transmission assemblies.
Remove the upper and lower mountings and put
the assembly to one side.
96179R
Remove:
- the compressor refrigerant pipes,
- the front right hand wheel,
- the lower compressor mounting (D),
62-56
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F ENGINE
(petrol)
AIR CONDITIONING
Compressor
62
REMOVAL
Disconnect the + 12 Volts compressor feed.
Remove:
- the retaining bolt (C) holding the refrigerant
pipes on the compressor,

Remove:
- the alternator,
- the alternator mounting (A).
This operation may only be carried out after
removing the lower mounting nut and stud (B).
92282R
- the four compressor mounting bolts (D) and

remove the compressor (the 4th bolt is behind
the compressor).
96181R
96182R
96183R
62-57
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F8Q ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL

Remove the alternator belt.
Disconnect the alternator electrical connections.
Remove:
- the belt tensioner completely (1),
- the front right hand side headlight and
headlight embellisher, so that the alternator
mounting shaft may be removed (2),
- the alternator.
95734R
Remove:
- the engine undertray,
- the front right hand wheel,
- the mud guard in the front right hand wheel
arch,
- the lower compressor mountings.
95732R
Then remove :
- the power-assisted steering pump pulley,
- the belt guide wheel (3).
Loosen the alternator mounting.
95733R
62-58
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F8Q ENGINE
AIR CONDITIONING
Compressor
62
Tilt the compressor and remove the alternator

mounting.
Disconnect the + 12 Volts compressor feed.
Remove:
- the two refrigerant pipes from the compressor
(4),
- the compressor.
96176R
WARNING
AIR CONDITIONING
62-59
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F ENGINE
(petrol)
AIR CONDITIONING
Compressor
REFITTING
When refitting: if the compressor is changed, it is

supplied from the parts department filled with oil.
Before refitting, check the oil level.
Check that all the seals and pipes are in good
condition.
Torque tighten the bolts holding the refrigerant
pipes to the compressor to 3.5 + 0.5
daNm.
0
WARNING
AIR CONDITIONING
When the compressor is changed subsequent to

the R12 / R134a conversion, the oil must be
removed from the compressor supplied and it
must be filled with SANDEN SP 20 oil (for specific
use with R134a).
62-60
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62
AIR CONDITIONING
Compressor oil level
62
Top up the compressor by injecting 120 cm 3 (15

cm3 remains in the compressor body even after
draining, approximately 1 glass) of oil (example:
ELF RIMA 100 or other depending on the
refrigerant; refer to the "Consumables" section.
SD 508 COMPRESSOR
To check the oil level correctly, the testing gauge

must be made.
The oil level on the gauge should be 14 to 16 mm,
when the compressor is removed.
Refit the drain plug ensuring the seal and the

sealing surface are clean (torque tighten to
1 daN.m).
IMPORTANT: If a pipe bursts, the oil level must be

topped up.
Refit the compressor.

Fill the circuit with R12 or R134a refrigerant (refer
to the "Consumables" and "General" sections).
SD 709 COMPRESSOR
The compressor must be removed.

Unscrew and remove the oil plug (A).
WARNING
AIR CONDITIONING
95124R
Turn the compressor over and let the oil drain out
(to drain all the oil out, turn the compressor by
hand).
62-61
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AIR CONDITIONING
Condenser
62
Disconnect the engine cooling fan feed connectors.

Remove the upper engine coolant radiator mountings (J).
Remove the radiator and condenser assembly upwards.
Remove the condenser bolt (M).
WARNING
AIR CONDITIONING
92559R
There are no special notes for refitting except

when fitting the pipes on the condenser,
remember to oil them and support them using a
spanner.
WARNING
AIR CONDITIONING
Refit all components removed.
Top up the engine cooling circuit (see

IMPORTANT: when changing the condenser, add
approximately 30 cm3 of oil to the compressor
(example: ELF RIMA 100 or other depending on
the refrigerant; refer to the "Consumables"
section.
62-62
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AIR CONDITIONING
Condenser
62
REPLACEMENT
Drain the refrigerant circuit (see method in Air

Remove the refrigerant pipes (G) and (H) from
the condenser (hold on the condenser side with a
spanner as the pipes are delicate).
92279R
92280R
62-63
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AIR CONDITIONING
Pressure release valve
62
When refitting, ensure that the pipe seals are in

good condition.
REPLACEMENT
Drain the refrigerant circuit from the filling point

(see method in Air Conditioning manual).
Torque tighten the bolts to :

- bolt K 1 daN.m
- bolt L 1 daN.m
Remove:
- the pipe mounting bolt (K),
- the two bolts (L) holding the pressure relief
valve on the evaporator.
WARNING
AIR CONDITIONING
92286R1
62-64
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AIR CONDITIONING
Dehydrating bottle
62
REPLACEMENT
Drain the refrigerant circuit from the filling point

(see method in Air Conditioning manual).
Disconnect the pipes (N).
92280R1
When refitting, oil the threads using compressor

oil and check that the seals are in good condition.
WARNING
AIR CONDITIONING
62-65
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AIR CONDITIONING
Electrical controls
62
Use a screwdriver to push the three rubber

retaining pins back which hold the motor in the
housing.
PASSENGER COMPARTMENT FAN (320)
The fan unit must be removed in order to change

the fan.
Remove:
- the rubber cover over the engine connections
and remove the 2 feed wires (use a soldering
iron of at least 50 W),
- the 9 clips and separate the 2 half cowlings of

the ventilation unit (cut the foam seal).
92389S
Remove the motor by pulling out as shown below.
92388S
92390R
When refitting, remember to re-solder the motor

connections.
62-66
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AIR CONDITIONING
Electrical controls
62
ELECTRONIC MODULE (6)
RECYCLING MOTOR (475)
The fan control module is mounted on the body

of the air conditioning unit in the water box.
The fan unit must be removed to reach the

recycling motor.
Remove the coolant reservoir cover to reach the

module (5 bolts A ).
Remove the 2 mounting bolts on the recycling

unit.
The motor is not set in any particular position and
does not need to be adjusted when refitted.
92287-1R1
It is mounted with 2 bolts on the air conditioning

unit.
92395R1
92287R1
62-67
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AIR CONDITIONING
Electrical controls
62
COMPONENT UNIT (419)
EVAPORATOR SENSOR (408)
This is located in the water box, held by a strap

(P) on the body of the ventilation unit.
The evaporator sensor is mounted on the body of

the air conditioning unit in the water box.
Remove the water box cover to reach the sensor
(see method for removing the electronic module
page 62-67).
92393R
When removing, lift the indexing tab and turn the

unit 1/4 turn to the right having removed the
connector.
92284R1
ELECTRONIC THERMOSTAT (19)
Sensor testing values :

0C = 14 700 to 18 000
5C = 11 400 to 14 000
10C = 9 200 to 10 700
15C = 7 250 to 8 450
20C = 6 050 to 6 600
25C = 4 750 to 5 250
This is located in the component unit.
Testing should be carried out with the sensor in

place, passenger compartment fan on high speed,
AC on position 0, measuring the temperature at
the air inlet to the fan.
92394R
62-68
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AIR CONDITIONING
Electrical controls
62
TRI-FUNCTION PRESSOSTAT (411) or (206)
RELAYS:
The tri-function pressostat protecting the

refrigerant circuit has three settings:
Relay (234) for the passenger compartment fan

Relay (234) is mounted on the fan body, in the
water box.
- low pressure (2 bars)

- high pressure (27 bars)
The protective cover must be removed to reach

the relay (A).
- engine cooling fan high speed (19 bars).

It is located near to the dehydrating bottle.
The refrigerant circuit does not need to be
drained to work on the pressostat ; it is mounted
on a "SKRADER" valve.
96177R
92280R2
92285R1
62-69
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AIR CONDITIONING
Electrical controls
Relays:
- fuel pump (236)
- 1st fan speed (335)
- 2nd fan speed (336)
- AC compressor (petrol version) (474)
- AC compressor (diesel version) (584)
62
RELAYS:
Recycling motor relay (417)

Model Year 1989 and 1990
Relay (417) is located in the component unit near
the electronic thermostat (19).
These are in a protective unit under the left hand

side cowl side panel.
92394R1
From Model Year 1991 onwards

Relay (417) is no longer in the component unit .
96178R
It is now located in the recycling motor (475).

ATTENTION: location in the protective unit may
be different depending on version.
92395R
62-70
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AIR CONDITIONING
Electrical controls
62
Relay (690) for the electronic thermostat

From year of manufacture 1991, the electronic
thermostat is fed by a relay.
This is located in the component unit near the
electronic thermostat.
92394R2
0.28 RESISTANCE (321)

This is mounted on the engine cooling fan
mounting.
96175S
62-71
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Sealing and Soundproofing
BODY SEALS
WINDOW SEALS
77 11 190 886
NOVEMBER 1996
are constructed".
Edition Anglaise

Renault.
Rgie Nationale des Usines Renault 1988
http://vnx.su
EXPLODED VIEW
PRN6000
http://vnx.su
Sealing and
Soundproofing
Contents
Pages
64 BODY SEALS
A
Door pillar protective seal
64-1
"D53 CABRIOLET" windscreen

post seal
64-2
66 WINDOW SEALS
A
Front door frame seal
66-1
Front door outer rubbing strip
66-1
Front door inner rubbing strip
66-1
D Front door frame slide channel
66-2
66-3
Rear door outer rubbing strip
66-3
G Rear door inner rubbing strip
66-4
H Rear door frame slide channel
66-4
Quarter light outer rubbing

strip
66-5
Quarter light inner rubbing strip
66-5
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BODY SEALS
Door pillar protective seal
64
SPECIAL POINT
The protective seal on the door pillar is stuck in

place and held by three clips (1) which cannot be
recovered.
92251R
The seal is removed by destroying the clips, then

unsticking the seal using a hot air gun.
NOTE: see Workshop Repair Manual M.R. 501 for
fault-finding seals.
64-1
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D53
CABRIOLET
BODY SEALS
Windscreen post seal
64
PRN6400
94819R
Remove:
- the hood strikers,
- the seal.
Use sealing mastic when refitting.
(Using soapy water will make it easier to position
the seal in it slides).
64-2
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WINDOW SEALS
66
Lower the window to the open position.

Take care as the seal is fragile.
Remove the rear view mirror.
Free the front section then the rear section.
92252R
Front door outer rubbing strip
Lower the window to the open position.

ATTENTION: the rubbing strip is fragile. Using an
extra-flat chisel protected by a piece of cloth, raise

the rubbing strip every 10 cm.
92253S
Front door inner rubbing strip
Remove the internal trim.

Raise the rubbing strip a shown in the diagram.
92254S
66-1
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WINDOW SEALS
Front door frame slide channel
Remove the window.
Remove the frame slide channel, starting at the
vertical rear section (see diagram).
92255R
There are no particular points concerning the

removal of the inner section (1).
PRN6600
66-2
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66
WINDOW SEALS
Rear door frame seal
66
Remove the trim and the small fixed window

Remove:
the seal, which is very fragile, using an extra-flat
chisel. Free the rear section as shown in the
diagram.
92256G
Rear door outer rubbing strip
ATTENTION: the rubbing strip is fragile. Using an
extra-flat chisel protected with a piece of cloth,

raise the rubbing strip every 10 cm.
92257S
66-3
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WINDOW SEALS
Rear door inner rubbing strip
66
Remove the trim.

Raise the rubbing strip as shown in the diagram.
92258S
Rear door frame slide channel
Remove the window and the small fixed window.
There are no particular points concerning the

removal of the inner section (1).
Remove the frame slide channel, starting at the

rear section (see diagram).
92259S
PRN6601
66-4
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D53
CABRIOLET
WINDOW SEALS
Quarter light outer rubbing strip
66
94804R
Remove the two screws (A).
Quarter light inner rubbing strip
PRN6602
66-5
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Trim and Upholstery

GENERAL
BODY INTERIOR TRIM
SIDE OPENING ELEMENTS TRIM
TRIM FOR OPENING ELEMENTS (OTHER THAN SIDE)
REAR SHELVES
FRONT SEAT FRAMES AND SEAT RUNNERS
REAR SEAT FRAMES ANDSEAT RUNNERS
FRONT SEAT TRIM
REAR SEAT TRIM
SEAT FITTINGS
77 11 190 895
NOVEMBER 1996
are constructed".
Edition Anglaise

Renault.
Renault S.A. 1996
http://vnx.su
EXPLODED VIEW
PRC70.3
http://vnx.su
Trim
Contents
Pages
Pages
70 GENERAL
73 TRIM FOR OPENING ELEMENTS

(OTHER THAN SIDE)
Tooling and products
70-1
71 BODY INTERNAL TRIM

A
B
C
D
E
F
F
F
G
Front and rear door handles

Interior trim fastenings on body side
Centre pillar upper trim
Front, centre and rear pillar lower
trim
Front pillar upper trim
Rear quarter panel trim
Rear section lower trim (saloon)
Rear quarter panel trim (cabriolet)
Sill Panel - Seat belts
71-1
71-2
71-3
A
B
C
D
E
F
G
Bonnet trim
Tailgate trim
Hood exterior trim (cabriolet)
Padding (cabriolet)
Hood interior trim (cabriolet)
Changing the hood bonded rear
screen (cabriolet)
Changing the hood rear screen
secured by zip fastener (cabriolet)
73-1
73-1
73-2
73-7
73-9
73-13
73-20
71-4
71-5
71-5
71-6
71-7
71-8
74 REAR SHELVES
A
B
C
Side shelf
Side shelf (utility version)
Shelf trim (saloon)
74-1
74-2
74-3
72 SIDE OPENING ELEMENTS

TRIM
A
B
B
B
C
Door storage compartment

Front door trim
Front door trim (phase II)
Front door trim (cabriolet)
Rear door trim
75 FRONT SEAT FRAMES AND

72-1
72-2
72-3
72-5
72-6
SEAT RUNNERS
A
B
C
D
Complete seat
Seat frame
Seat runners
Seatback frame
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75-1
75-3
75-4
75-5
Contents (cont.)
Pages
76 REAR SEAT FRAMES AND

SEAT RUNNERS
A
B
Complete seatback
Seatback frame
76-1
76-1
77 FRONT SEAT TRIM

A
B
Seat trim
Seatback trim
77-1
77-3
78 REAR SEAT TRIM

A
B
B
C
C
Rear bench seat frame

Seat trim
Seat trim (cabriolet)
Seatback trim
Seatback trim (cabriolet)
78-1
78-2
78-3
78-4
78-5
79 SEAT FITTINGS
A
B
B
Head restraint trim

Ski flaps (cabriolet)
Rear head restraints (cabriolet)
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79-1
79-2
79-2
D 53
CABRIOLET
GENERAL
Tooling and products
70 A
94791S
1 - Stapler tool Type : NAUDER*

and stainless steel clips
2 - Rivets
Part number :
77 03 072 280
3 - Neoprene adhesive
4 - Brush
5 - Seal
Part number:
* NAUDER :
Please contact your local After Sales Head Office

for details.
70-1
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BODY INTERIOR TRIM

Front and rear door handles
92260R
REMOVAL
Insert a flat screwdriver in hole (2) in the upper

section, so that the first part of the handle can be
levered away and unhooked.
92261R
The handle is held by two screws (3).
71-1
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71 A
BODY INTERIOR TRIM

Interior trim fastenings on body side
71
PRF7101
90230R1
90231R
(A) Snap fastening
(C) Snap fastening
NOTE : If the dashboard is in place there is a risk of fastenings (A) ), (B), (C) and (D) breaking on removal. For
reasons of quality, it is preferable to change them, even if they can be re-used.
71-2
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BODY INTERNALIOR TRIM

Centre pillar upper trim
71
REMOVING THE UPPER TRIM (1)
Unpick the upper section then free the seals by

pulling it away.
92339G
Remove:
- the seat belt mounting from the centre pillar,
- the seat belt height adjustment pushrod
(component in two sections).
92340R
Remove the sliding cover from the adjustable

mounting.
71-3
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BODY INTERIOR TRIM

Front, centre and rear pillar lower trim
71 D
PRF7102
Remove:
- the upper trim from the centre pillar (1) see section 71 B
- the mounting screws,
- the lower seat belt mounting.
By hand, free the rear part of the trim from the surrounding seal and remove clips (B).
Proceed in the same way for the front part of the trim.
Take out the trim through the rear door aperture.
71-4
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BODY INTERIOR TRIM

Front pillar upper trim
71
Remove:
- the upper trim (1) from the centre pillar,
- the mounting screw,
- unpick the trim by pulling section (F) straight
downwards then backwards.
PRF7103
71
Remove (see exploded view in section 71 B) :

- trims (1), (2), (6) and (7) ,
- the seal from the luggage compartment aperture frame,
- the side shelf which is held by 5 screws,
- the two upper screws from the quarter panel
trim.
Unpick the trim (2 clips (C)) then remove the trim,
starting at the door seal end.
PRF7104
71-5
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L 53
SALOON
BODY INTERIOR TRIM

Rear section interior trim
71
PRF7105
Remove in the following order:

1-2-3
71-6
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D 53
CABRIOLET
BODY INTERNAL TRIM

71
PRF7106
REMOVAL
94810R
94811R
Open the hood and tilt the rear seat.

Remove the lower seat belt mounting and the
hood opening handle.
Remove nut (A) and unclip the fir tree type clips.
Detach the trim from the rubbing strip.
71-7
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S 53
UTILITY VERSION
BODY INTERIOR TRIM

Sill panel - Seat belts
71 G
PRJ4020
SILL PANEL
Fit the two lower sill panel trims (1) which serve as a storage compartment in the bottom of the side panel
trim.
REAR SEAT BELTS
Unclip:
- the trim between the left and right hand rear quarter panels,
- the rear quarter panel trims starting at the quarter light side and remove the seat belt blanking piece.
Fit the rear seat belt retractor in the rear quarter panel.
Route the belt and the guide through the opening in the rear quarter panel trim, then clip the guide to the
trim.
Reclip the panel trim and the centre trim.
Secure:
- The end of the seat belt to the sill panel trim at (4),
- the two seat belt stalks (5) to the floor panel after first removing the mastic from the mountings.
71-8
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Door storage compartment
HIGH SPECIFICATION MODEL TYPE STORAGE
COMPARTMENT
72 A
BASIC MODEL TYPE STORAGE COMPARTMENT
92262R
92263R
Remove:
- the speaker grille by unscrewing it 1/4 of a
turn,
- the speaker which is held by 4 screws,
- the 4 screws holding the speaker mounting,
- the mounting (6) and free the storage
compartment from the lower snap fastenings
(7), by pushing it upwards.
Remove the two screws (5) and free the storage

compartment from the lower snap fastenings (7),
by pushing it upwards.
Disconnect the electric switch feed (8).

There is a leaktight rivet (9) holding the lower
snap fastening in place (component stays on the
door).
72-1
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Front door trim
Remove:
- the internal opening control,
- the internal door handle,
- the rear view mirror base cover,
- the door storage compartment,
- the window winder.
92264R
(1) pressure stud

(2) clip on door
Remove the trim.
NOTE : the trim is clipped in place (1) and sealed
by mastic.
To remove it, the trim must be unpicked and unstuck gradually (use a saw blade to cut the mastic)
then free it from the upper rubbing strip.
NOTE: when changing a door or the trim, trim
sealing mastic part number 77 01 421 049 must be

reapplied (see Technical Note N.T. 219 "DOOR
TRIM SEALING MASTIC").
72-2
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72
X 53
PHASE II

Front door trim
72
95859-1S
REMOVAL
PRF7201
95859S
Unclip the rear view mirror mountings cover.
Remove the pulling handle cover.

Disconnect the various switches.
72-3
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X 53
PHASE II

Front door trim
PRF7202
Remove:
- the pulling handle,
- the loud speaker grille and storage compartment,
- the internal handle.
For all removal-refitting operations, the door trim
seal must be changed.
72-4
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72
D 53
CABRIOLET

Door trim
72
PRF7203
94792R
Remove:
- the rear view mirror internal cover (1),
- the internal handle (2),
- the internal opening handle (3),
- the speaker grille(4),
- the storage compartment(5).
Disconnect the rear view mirror harness (left hand
side).
72-5
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Rear door
Remove:
- the internal opening control,
- the internal door handle,
- the ashtray,
- the window winder.
92265R
(1) pressure stud

(2) clip on door
Remove the trim.
NOTE : the trim is clipped in place (1) and sealed
by mastic.
To remove it, the trim must be unpicked and unstuck gradually (use a saw blade to cut the mastic)
then free it from the upper rubbing strip.
NOTE: when changing a door or the trim, trim
sealing mastic part number 77 01 421 049 must be

reapplied (see "BODYWORK REPAIRS" poster).
72-6
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72
Bonnet trim
73 A
PRF7301
73
Tailgate trim
PRF7302
Remove the two screws (1) and two hooks (2).

Unclip the trim.
73-1
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D 53
CABRIOLET
Hood exterior trim
73
The operations described below must be carried out on both the left hand and right hand sides.
Any incorrect operation of the hood triggers an alarm. The order of operations must be followed.
PRF7303
Opening the hood
Fold the sun visors forwards.

Open the front locks without folding back the
hood.
Operate the unlocking handle (this opens the rear
hood locks and the hood compartment).
Lift the rear of the hood.

Remove the safety device and open the hood
compartment.
Fold the rear section of the hood back into the
compartment.
73-2
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D 53
CABRIOLET
Hood exterior trim
73
After opening the hood

Removal
94787S
Remove the front angle piece and the two corner

segments.
Remove the plastic clips.

Free the two sections of material which correspond to the front section.
Remove the seals from the front sections by sliding them.

Remove their slides (6 torx screws).
94762
Remove the rear seals and slides.

Remove the four plastic clips.
73-3
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D 53
CABRIOLET
Hood exterior trim
Free the two corresponding pieces of material.
73
At the front, remove the tensioning cable rivet

and remove the cable from the trim.
94971S
Undo the trim side mountings. (Quarter panels).
Lift the rear of the hood and remove the hood

frame rubber seal.
73-4
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D 53
CABRIOLET
Hood exterior trim
73
94788S
Free the rear screen tensioning material and remove the external hood trim.
Remove the rivets at the rear ends and at the

front of the rear pillar.
Remove the formed section of the rear part of the

hood.
73-5
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D 53
CABRIOLET
Hood exterior trim
73
Refitting
Start at the rear.

Clip the rear section taking care to centre the
hood (it is marked).
Route the tensioning cable and secure it.
94788S
Fold the hood forwards.

Stick the rear screen stiffener.
Refit the rubber seal.
Tilt the hood towards the rear and stick the front
section.
Drill the holes in the trim and refit the plastic clips.
Re-secure the front angle piece and the side segments.
Close the hood completely and stick the side sections. Ensure that there are no creases.
Refit the small side tensioning straps.
73-6
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D 53
Padding
CABRIOLET
73 D
PRF7304
Removal:
After removing the external trim, remove the rivets from the rear section and the stainless steel
clips.
Remove the adhesive tape from the front section.

Unstick the front section.
73-7
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D 53
CABRIOLET
Padding
73 D
Refitting:
Stick the front section of the padding.
Centre the padding on the hood.

Refit the two side rivets (on the roof arch).
Clip the padding using suitable equipment (page

70-1) ensuring that there are no creases.
94789R
Apply adhesive tape (Tsaband type).
NOTE : The clips must be stainless steel and pressed in completely to prevent the external trim
from being marked.
73-8
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D 53
Hood interior trim
CABRIOLET
73
PRF7305
Removal:
Remove the external trim and the padding.

Undo the velcro.
Remove the rear quarter panel padding clips.
Carefully unstick the front section of the trim.
73-9
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D 53
CABRIOLET
Hood interior trim
73
94790R
Carefully remove the tensioning strap rivets on the roof arches.
Remove the rear side rivets and the plastic pins,

then free the trim from the rear frame.
Carefully unstick the strips holding the trim on

the roof arches.
73-10
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D 53
CABRIOLET
Hood interior trim
73
Refitting:
With the hood open:

Start to stick the front section centring the trim.
Stick without forming any creases.
Temporarily fit the centre angle piece in order to
hold the front section.
Stick the trim to the roof arches and secure the

tensioning straps (rivets).
94789
Position the hood frame forwards.

Re-secure the rear sections of the tensioning
straps to the main roof arch (clips).
Tension and stick the rear section of the trim on
the roof roll-over bar and clip.
Check the tension of the trim.
Rivet the trim to the main roof arch (rear side).

Stick the trim to the rear hood frame and
resecure the velcro fasteners.
73-11
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D 53
CABRIOLET
Hood interior trim
Secure the side rivets to the internal surface.

Secure the plastic pins to the rear roof arch.
73-12
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73
D 53
CABRIOLET
Changing the hood bonded rear screen
73
98629R
Description of kit Part Number 77 01 204 801

1 - Fitting template, with double sided adhesive
strips
2 - Marking template
3 - Rear screen
4 - Brushes (large and small)
5 - Double sided adhesive tape
6 - Smoothing tool
7 - AGS adhesive Part Number 77 01 040 979 (to
be ordered separately) (Single use consumable. It is essential that only this type of adhesive is used).
98607S
Cut the centre section of the surround.

Clean the edge of the material with a brush.
73-13
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D 53
CABRIOLET
98608S
73
98610S
Stick the adhesive tape to the edge of the material.
Carefully cut (edge) the material along the edge

of the adhesive strip using scissors (FACOM type).
ATTENTION: the adhesive tape serves as a reference point for the dimensions of the new rear
screen.
Detach the remaining sections of the old rear

screen.
98609S
98611R
Make an initial cut of the rear screen leaving a

strip of 20 mm.
Open the hood compartment cover.

Remove rivet (A).
Undo the retaining strip mountings (B).
73-14
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D 53
CABRIOLET
98612R
73
98614R
Remove seal (C) and section (D) from the hood

frame.
Fit fitting template (1), to the top of the hood to

serve as a work plan.
Undo the adhesive strip protectors.
Turn the hood material over at the rear and fit
the rear screen cut-out onto the template starting
with the centre of the upper section and then the
lower section (marks, notches).
98613S
98615R
Unstick the rear screen tensioning band.
Distribute the material evenly and secure it using

the template adhesive strips.
73-15
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D 53
CABRIOLET
98616R
Fit the marking template (2) over fitting template

(1).
Using a ball point pen, mark the outline and external markers (notches) of template 2.
Remove template 2.
98617R
Apply an even layer of adhesive (using the large

brush) to the marked section of the hood material.
73-16
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73
D 53
CABRIOLET
73
98629-1R
NOTE: the strip of material has positioning
notches (B).
Also apply an even layer of adhesive to the strips
of material and the rear screen sealing strips
(using the small brush).
ATTENTION: It is essential to wait until the adhesive becomes transparent before carrying out any
work (wait 15 to 30 minutes depending on the
ambient temperature).
Any stains or excess adhesive can be removed

(scratched off by hand) once the adhesive is dry.
Free the hood material from template 1.
Turn the template over and refit it on the hood.
73-17
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D 53
CABRIOLET
98618R
73
94788S
Fit and stick the rear screen in line with the marks
(outline and notches) (two operators are required
to do this).
Stick the rear screen tensioning strip (Neoprene

adhesive 3 M 8150).
Fit seal (C).
Start at the centre of the upper section of the

hood.
Lock the hood.
Rub the rear screen strip of material using the

smoothing tool in order to prevent creases from
forming.
Fit section (D) and rivet it to the hood frame.
Fit the mountings for retaining strips (B).
73-18
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D 53
CABRIOLET
98606S
Protect the rear screen again (with cardboard and

lightweight felt to avoid damaging the rear
screen) and using the smoothing tool, lift the section and fold it back on the material.
Rub the material firmly along the formed section.
NOTE: A second operator is required to exert a
counter pressure from the inside.

Remove the protectors.
IMPORTANT: Wait 72 hours before folding the
hood.
73-19
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73
D 53
CABRIOLET
Changing the hood rear screen secured by zip fastener
73 G
99563
Parts required:
Description of operation :
REMOVAL
A kit Part Number: 77 01 041 838

1 - Clip and safety connection
2 - Slider
3 - Adhesive sealing strip
4 - Smoothing tool
Before carrying out any work, park the vehicle in

an area where there is an ambient temperature
of approximately 20C.
Lower the side windows.
Unlock the hood.
Protect the rear section of the vehicle.
99564
Using the smoothing tool, lift the formed section

bead (A). Over a length of approximately 100 mm
at the lower section and at the centre of the
screen, pull back the edge of the hood material
(B).
73-20
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D 53
CABRIOLET

99565
73 G
99567
From inside the vehicle, open the four claws of the

safety clip of the zip fastener by twisting them.
Exert a slight pressure to the edge of the rear

screen towards the inside to free it from the hood.
Take care not to damage the clip.
NOTE: remove any remnants of the sealing strip.
Remove the safety clip connection.

Remove the safety clip.
99566
From inside the vehicle and using the smoothing

tool, open the zip fastener.
73-21
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D 53
CABRIOLET

99617
73 G
99568
Protect the new rear screen.
Close the zip fastener slowly. The operator outside the vehicle must hold the start of the zip fastener to prevent it from opening.
First insert the slider on the rear screen transparent mounting (slider tab facing towards the inside of the vehicle).
Remove the slider.
From outside the vehicle, hold the rear screen in

position (a second person is required).
From inside the vehicle, insert the other part of
the zip fastener in the slider so that the two sides
are in line.
ATTENTION: the positioning operation is very important (risk of creasing the rear screen).
99569
Fit the safety clip and its connection.

Twist the claws (an external counter force is necessary to correctly twist the claws).
Close the hood without locking it.
73-22
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D 53
CABRIOLET

99570
73 G
98606S
Stick the sealing strip against the formed section

bead.
Using the smoothing tool, lift the formed section

and fold it back over the material.
Protect the rear screen with the cardboard on the

lightweight felt side.
Rub the material along the formed section firmly.

NOTE: Exert a counter force from inside.
Lock the hood.

Remove the protectors.
IMPORTANT: Wait 24 hours before folding the
hood.
73-23
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REAR SHELVES
Side shelf
74 A
92461R1
Remove the centre shelf.

Disconnect the speaker.
Remove the five mounting screws (1).
74-1
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S 53
UTILITY VERSION
REAR SHELVES
Side shelves
74
FITTING SIDE SHELVES
PRJ4021
Remove the rear wheel arch side trims.

Fit the side shelf lower mounting clips.
On the left hand side, cut the wheel arch side trim
at the wheelbrace clip locations.
Fit the 3 wheelbrace mounting clips (2).
Fit the two side shelves : 5 screws (1).
On the right hand side, fit the upper and lower
jack supports using pop rivets.
Fit the rear centre shelf in the location of the side
shelves and secure the retaining cords in the openings in the rear luggage compartment trim.
92461R
74-2
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L 53
SALOON
REAR SHELVES
Side shelves
74
Partially remove the two lower rear pillar trims.
PRF7401
REMOVAL
PRF7404
Remove the rear quarter panel trims.
PRF7402
Partially remove the two roof panel trims (A) (on

the rear door upper section).
93138S
PRF7403
74-3
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Complete seat
75 A
REMOVAL
93220
92464R
front mounting screw (3) and remove the

trim,
Remove:
- mounting screw (1) from the seat runner side
trim and remove the trim by pulling it forwards.
94262R
93219S
mounting screws (4) securing the seat frame

to the seat runner.
rear mounting screw (2) securing the centre

trim (on the handbrake side),
75-1
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Complete seat
92463R
On the opposite side, remove the three screws (5)

and the seat.
75-2
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75 A

Seat frame
75
92465
92466
The seat frame is secured to the subframe by four

Torx screws.
and by one screw on the opposite side.
92467
The seatback frame is secured to the seat squab

frame by three nuts, on the seat adjusting knob
side.
75-3
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Seat runners
REMOVAL
92460R
The seat runners are secured from underneath

the vehicle by means of four nuts (1).
75-4
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75

Seatback frame
75 D
LUMBAR ADJUSTING MECHANISM

REMOVAL
92475
To remove the plastic guide, open the two halfshells by unclipping them.
92473
After first stripping the seatback, adjust the mechanism to the released position.
Cut the rivet securing the control (indicated by the
arrow on the photograph).
REFITTING
92476
92474
Using a pair of pliers, remove the cable stop so

that the cable can be passed through the frame.
Refit the assembly, finishing with the assembly of

the two cables on the central spring.
75-5
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REAR SEAT FRAMES AND SEAT RUNNERS

Complete seatback
76 A
REMOVAL
92427S
Remove the seatback assemblies (2/3 - 1/3) by lifting the levers at the ends of the hinges.
Seatback frame
76
REMOVING THE CATCH
92483
92486
Using a screwdriver, remove the handle as shown.

Partially strip the seatback and remove the two
screws securing the catch.
76-1
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FRONT SEAT TRIM

Seat trim
77 A
92470
92468
Using a screwdriver, remove the centre clip from

the seatback adjusting knob and pull the knob to
remove it.
92469
93221
Turn the seat over and unclip the front and rear
plastic angle pieces from the trim.
Unclip the clips holding the two side sections of

the trim.
77-1
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FRONT SEAT TRIM

Seat trim
77 A
92471
From inside the frame, unclip the plastic hooks

holding the rear corner angle sections of the trim.
93222
To separate the trim from the foam, cut the clips

securing the trim to the linkage rods concealed in
the foam.
93221-1
Cut the clips which secure the trim linkage rods to

the frame.
Remove the foam - trim assembly.
77-2
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FRONT SEAT TRIM

Seatback trim
92477
77
92223
If the seat is fitted with seatback adjustment, remove the centre clip from the adjusting knob
using a screwdriver and pull the knob to remove
it.
Partially lift the trim and cut the clips securing the
back of it to the frame.
92478
92224
Behind the seat, cut the two clips securing the two
linkage rods together.
Lift the trim further and cut the clips located at

each end of the piece of card used to stretch the
material. Pass the card through the foam.
Unclip the rods from the frame at their ends.
77-3
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FRONT SEAT TRIM

Seatback trim
77
92480
Using a screwdriver, unclip the two guides from

the head restraint rods.
93225
Cut the two clips securing the upper rod linkage

to the frame and remove the trim.
77-4
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S 53
UTILITY VERSION
REAR SEAT TRIM

Rear bench seat frame
78 A
PRJ4022
PREPARING THE SEATBACK
Fit clip (1) and rod (2) connecting the two catches.
Fit the two catches (3) to the frame.
The handles (4) are fitted after fitting the trim to the seatback.
PREPARING THE SEAT
Fit:
- the handle guide (5),
- the manoeuvring handle (6),
- the two hinge supports (7) are fitted to the seat frame after fitting the trim.
PREPARATION ON THE VEHICLE
Fit:
to the wheel arch inner lining :
- the two seatback hinge pins (8),
- the two seatback locking pins (9).
to the floor panel :
- the two seat stops (10).
78-1
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REAR SEAT TRIM

Seat trim
92487
78
92489
After removing the bench seat, unpick the edge

of the trim from the metal frame.
92490
92488
Pass the two sheets of card used to stretch the fabric through the foam.
Turn the seat over.
Cut the clips securing the trim to the linkage rods
concealed in the foam.
92491
78-2
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D 53
CABRIOLET
REAR SEAT TRIM

Seat trim
78
PRF7801
94821
After removing the bench seat, carefully unpick

the edge of the trim.
94822
Remove the clips and pass the card through the

foam to separate the trim.
78-3
http://vnx.su
REAR SEAT TRIM

Seatback trim
78
REMOVAL
92482
92485
Unpick the lower corner of the trim held by three

fir tree type clips.
Pass the card used to stretch the fabric through

the foam.
92484
Unpick the edge of the trim secured to the metal

frame.
78-4
http://vnx.su
D 53
CABRIOLET
REAR SEAT TRIM

Seatback trim
78
PRF7802
94823
Carefully unpick the edge of the trim.

92427S
Remove the seatback.

Lift the levers located at the ends of the hinges.
78-5
http://vnx.su
D 53
CABRIOLET
REAR SEAT TRIM

Seatback trim
78
94824
94826
Separate the strips of velcro and unclip the trim

from around the ski flap.
Unclip the edge of the ski cover carefully.
Refitting:
For refitting, the ski flap must be removed

(4 rivets).
First refit:
The ski cover.
Re-secure the flap.
Clip the trim around the plate.
Finish off by hooking and clipping the other sections of the trim.
94825
Remove the clips and pass the pieces of card

through the foam.
Remove the circular clips retaining the seat belt
buckles.
Detach the trim from the foam.
78-6
http://vnx.su
SEAT FITTINGS
Head restraint trim
79 A
PRF7901
94827
94828
After removing the head restraint, unclip the trim

and detach the foam - trim assembly from the
frame.
79-1
http://vnx.su
SEAT FITTINGS
Ski flap
D 53
CABRIOLET
79
79
94812R
The ski flap is removed by removing rivets (A).
D 53
CABRIOLET
Rear head restraint
94827
REMOVAL:
Remove the screws and tilt the head restraint in

order to remove the retaining lugs.
94829
79-2
http://vnx.su
GENERAL
Paint identification
http://vnx.su
90
GENERAL
Bodywork colours
http://vnx.su
90
GENERAL
Paintwork products used
http://vnx.su
90
GENERAL
Paintwork products used
http://vnx.su
90
GENERAL
Sealing and anti-gravel products
http://vnx.su
90
GENERAL
Sealing and anti-gravel products
http://vnx.su
90
GENERAL
The concept of colour
http://vnx.su
90
GENERAL
http://vnx.su
90
GENERAL
http://vnx.su
90
GENERAL
Instructions to be followed
http://vnx.su
90
GENERAL
Protecting service exchange parts
http://vnx.su
90
GENERAL
Protecting service exchange parts
http://vnx.su
90
GENERAL
Paint application principle
http://vnx.su
90
GENERAL
Reminder of existing documents
http://vnx.su
90
PAINT APPLICATION SEQUENCE

Structure of replaced welded skin
http://vnx.su
94

Stylized arean
http://vnx.su
94

Replaced welded internal structure
http://vnx.su
94

Replaced welded internal structure
http://vnx.su
94

Replaced detachable components
http://vnx.su
94

Replaced detachable components
http://vnx.su
94

Blended-in colours and "lost-in" colours
http://vnx.su
94

Blended-in colours and "lost-in" colours
http://vnx.su
94
SEQUENCE FOR APPLYING PAINT TO PLASTIC PARTS

External fittings in grey
http://vnx.su
95

External fittings in body colour
http://vnx.su
95

Internal fittings to be painted
http://vnx.su
95

http://vnx.su
95

http://vnx.su
95
MASKING
Principle
http://vnx.su
99
MASKING
Special point
http://vnx.su
99
MASKING
Special point
http://vnx.su
99

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General

All copyrights reserved by Renault.

Rgie Nationale des Usines Renault S.A. 1996

07 VALUES AND SETTINGS

Trolley jack - Axle stands

Type of manual and automatic

B530 - C530 - L530

JB0 - JB1 - JB4 - JB5

B531 - C531 - L531

JB0 - JB1 - JB4 - JB5

JB0 - JB1 - JB4 - JB5

B532 - C532 - L532

B53G - B537 - C537

JB0 - JB1 - MB1

B53A - C53A - L53A

B535 - C535 - L535

B53W - C53W - L53W

JB0 - JB1 - JB3

B53E - B53M - B533

JB0 - JB1 - JB3 - AD4

B53B - B53C - B53F

AD4 - JB3 - MB3

B53V - B53Y - B538

AD4 - JB3 - JC5

B53D - B539 - C53D

B53I - B53J - B53K

B53H - B53P - C53P

200 CPV 4600

200 CPV 3500

IDENTIFICATION OF F3P ENGINES WITH REDUCED CUBIC CAPACITY

Definition of identification X and 0

Vehicle type code starting with a letter.

053A = 353 A, 453 A

Vehicle type code starting with a number.

The reduced cubic capacity can be identified using

the engine type

LOCATION OF THE VEHICLE IDENTIFICATION PLATE

Adhesive plate (D) is attached to the chassis on the

Plates (A) and (B) may be separate or on a single

Plate (C) is located on the front panel.

METAL PLATE (Position n 1)

DES USINES RENAULT

This consists of;

ting the EU approval

This consists of:

At A : the manufacturers name,

* NOTE: some of these items of information are

not required for certain export markets. The

* DEPENDING ON COUNTRY OR SPECIFICATION

METAL PLATE (Position n 2)

DES USINES RENAULT

This consists of:

At 1 : the vehicle type,

before that date, the manufacturing number is 7 numbers.

above are shown in their most complete form.

METAL PLATE (Position n 3)

REGIE NATIONALE DES

USINES RENAULT S.A.

This consists of:

above are shown in their most complete form.

ALLOCATION OF THE TECHNICAL EQUIPMENT CODES

Renault 19 all models

The engine letter"D" at A in both cases corresponds:

Renault 19 5 door hatchback with engine E7J 700

Safety symbol (special precautions to be taken when carrying out work).

ESSENTIAL SPECIAL TOOLS