notas técnicas_MR364MEGANE3

© Renault s.a.s. 2005

"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

77 11 318 062 MARCH 2003 Edition Anglaise

X84, and B84 or C84 or G84 or S84

3 Chassis

30A GENERAL VEHICLE INFORMATION

31A FRONT AXLE ASSEMBLIES

33A REAR AXLE ASSEMBLIES

35A WHEELS AND TYRES

35B TYRE PRESSURE MONITOR

36A STEERING ASSEMBLY

36B POWER ASSISTED STEERING

37A MECHANICAL COMPONENT CONTROLS

38C ANTI-LOCK BRAKING SYSTEM

Mégane II - Section 3

Contents

Page

Mégane II - Section 3ContentsPage

30A GENERAL VEHICLE INFORMATION

Schematic diagram of the brake circuit 30A-1

Brake circuit pipes and unions 30A-2

Brake fluid 30A-3

Brake: Specifications 30A-4

Brake circuit Bleeding 30A-5

Anti-roll bars: Specifications 30A-6

Rear anti-roll bar: Specifications 30A-7

Front axle: Tightening torque 30A-8

Rear axle: Tightening torque 30A-10

Brake circuit Tightening torque 30A-11

Steering: Tightening torque 30A-12

Underbody height 30A-13

Values and adjustments for the front axle assemblies 30A-14

Values and adjustments for the rear axle assemblies 30A-18


Front brake pads: Removal - Refitting 31A-1

Front brake calliper: Removal - Refitting 31A-3

Front brake calliper support: Removal - Refitting 31A-5

Front brake hose: Removal - Refitting 31A-7

Front brake disc: Removal - Refitting 31A-9

Front driveshaft hub carrier: Removal - Refitting 31A-10

Front hub carrier bearing: Removal - Refitting 31A-13

Spring and front shock absorber: Removal - Refitting 31A-17

Front driveshaft lower arm: Removal - Refitting 31A-22

Front anti-roll bar: Removal - Refitting 31A-25

Front axle sub-frame: Removal - Refitting 31A-26

33A REAR AXLE ASSEMBLIES

Rear brake pads: Removal - Refitting 33A-1

Rear brake caliper: Removal - Refitting 33A-2

Rear brake calliper mounting: Removal - Refitting 33A-4

Rear brake disc: Removal - Refitting 33A-6

Rear suspension spring: Removal - Refitting 33A-8

Shock absorber: Removal - Refitting 33A-10


Contents

Complete rear axle: Removal - Refitting 33A-11

Rear axle rubber bearing: Removal - Refitting 33A-17

35A WHEELS AND TYRES

Tyre inflation pressure: Identification 35A-1

Tyres: Identification 35A-3

Wheel rim: Identification 35A-4

Wheel: Balancing 35A-5

Wheel: Removal - Refitting 35A-9

Tyres: Removal - Refitting 35A-11

35B TYRE PRESSURE MONITOR

SSPP: List and location of components 35B-1

Pressure sensor: Operation 35B-2

Pressure sensor: Removal - Refitting 35B-3

Pressure sensor: Repair 35B-6

Tyres: Replacement 35B-7

Configuration 35B-8

36A STEERING ASSEMBLY

Axial ball joint linkage: Removal - Refitting 36A-1

33A REAR AXLE ASSEMBLIES 36B POWER ASSISTED STEERING

Description 36B-1

Steering rack: Removal - Refitting 36B-3

Intermediate shaft 36B-4

Bulkhead seal: Removal - Refitting 36B-5

Steering column: Removal - Refitting 36B-6

Steering wheel: Removal - Refitting 36B-13


Master cylinder: Removal - Refitting 37A-1

Brake servo: Removal - Refitting 37A-5

Brake servo non-return valve 37A-14

Vacuum pump: Removal - Refitting 37A-16

Accelerator pedal: Removal - Refitting 37A-21

Brake pedal: Removal - Refitting 37A-22

Brake pedal bell crank rod: Removal - Refitting 37A-27

Brake pedal position sensor 37A-28

Parking brake cables: Removal - Refitting 37A-29

Parking brake lever: Removal - Refitting 37A-31

Emergency brake assistance 37A-33

Clutch control: Description 37A-34

Clutch master cylinder: Removal - Refitting 37A-37

Clutch pedal: Removal - Refitting 37A-42

Contents

Clutch control pipes: Removal - Refitting 37A-47

Clutch circuit: Bleeding 37A-52

External gear control: Description 37A-55

External gear control: Removal - Refitting 37A-56

External gear control cable 37A-61

Gearbox lever unit Removal - Refitting 37A-62

38C ANTI-LOCK BRAKING SYSTEM

Introduction 38C-1

Hydraulic unit: Introduction 38C-2

Hydraulic unit 38C-3

ABS with ESP: Description 38C-22

Yaw speed and transversal acceleration sensor: Removal - Refitting 38C-23

Yaw speed and transverse acceleration sensors: Connection 38C-24

ABS computer: Removal - Refitting 38C-25


30A-1

GENERAL VEHICLE INFORMATIONSchematic diagram of the brake circuit 30A

« X- » shaped braking system

3877

IMPORTANT

This is a general system diagram, do not use it as areference for tapping or circuit allocation. Whenreplacing one of the brake circuit components on avehicle, always mark the pipes before removingthem as they must be reconnected in their originalpositions.

30A-2

GENERAL VEHICLE INFORMATIONBrake circuit pipes and unions 30A

Parts identification:

- shape of the steel or copper pipe end piece (A),

- shape of the threaded housings on components (B),

- shape of unions (C): 11 mm Allen key.

WARNING

- The pipes between the master cylinder, callipersand the hydraulic assembly are connected usingthreaded unions with a metric thread.

- Therefore, only parts specified in the Parts Catalo-gue for this vehicle should be used.

78491

30A-3

GENERAL VEHICLE INFORMATIONBrake fluid 30A

BRAKE FLUID REPLACEMENT INTERVALS

Our brake technology, in particular our disc brakes(hollow pistons which conduct little heat with a smallamount of fluid in the cylinder and sliding calipers avoi-ding the need for a fluid reservoir in the least cooledarea of the wheel), has allowed us to reduce the risksof « vapour-lock » as far as possible, even if the brakesare used intensively (in mountainous areas). However,current brake fluids are subject to a slight deteriorationduring the first months of use as a result of a smallamount of humidity intake. Reasons for it being recom-mended that you change the brake fluid: see warrantyand servicing booklet .

1 - Topping up the level

Brake pad wear will result in a gradual drop in the fluidlevel in the reservoir.

The fluid should not be topped up as the level will riseagain when the pads are changed. However, the brakefluid level should not drop below the minimum mark.

2 - Approved brake fluid

Mixing two incompatible brake fluids in the circuit couldlead to major leaks, mainly due to damage to the cups.

To avoid these risks, it is essential to only use brakefluids which have been checked and approved by ourlaboratories and which comply with the SAE J 1703-DOT4 standard.

For optimized braking, RENAULT recommends a bra-

ke fluid with low viscosity in cold conditions ( 750 mm2/s at 40˚C maximum).

30A-4

GENERAL VEHICLE INFORMATIONBrake: Specifications 30A

(1) Brake discs cannot be redressed. In the event ofexcessive scoring or wear they must be replaced.

Engine

K4J K9K, K4M, F9Q,F4R, M9R

Front brakes (mm)

Piston diameter 54 54

Disc diameter 260 280

Disc thickness 22 24

Minimum disc thickness (1) 19.8 21.8

Maximum disc run-out 0.07 0.07

Brake pad thickness (including backplate) 18 18

Minimum brake pad thickness (including backplate) 6 6

Rear brakes (mm)

Piston diameter 34

Disc diameter 240

Disc thickness 8

Minimum disc thickness (1) 6.5

Maximum disc run-out 0.07

Brake pad thickness (including backplate) 16

Minimum brake pad thickness (including backplate) 6

Master cylinder (mm)

Diameter 23.8

Stroke 36

30A-5

GENERAL VEHICLE INFORMATIONBrake circuit Bleeding 30A

Precautions to be taken during the braking circuit blee-ding operation:

- Check the brake fluid levels of the brake circuit andthe bleeding device.

- The braking regulation circuit must not have any hy-draulic or electrical faults.

I - BLEEDING THE BRAKE CIRCUIT OUTSIDE THE CONTROL CIRCUIT

This procedure should be used after one of the fol-lowing components has been removed or replaced:

- the master cylinder,

- the brake fluid,

- the hydraulic unit (new and pre-filled),

- a rigid pipe,

- a hose,

- the reservoir,

- a calliper.

Put the vehicle on a two-post lift.

Connect the bleeding device to the vehicle brakefluid reservoir (refer to the driver's handbook).

Fit the bleed reservoirs to the bleed screws.

Bleed the circuit by opening the bleed screws in the following order (remember to close them after the operation):

- the rear right-hand circuit,

- the front left-hand circuit,

- the rear left-hand circuit,

- the front right-hand circuit.

With the engine switched off, check the pedal travel;if it is not correct, start the bleeding procedure again.

Top up the brake fluid level in the reservoir once thebleeding device has been disconnected. Check thetightness of the bleed screws and ensure that thesealing caps are all present.

During a road test, trigger braking regulation to con-firm that the brake pedal travel is correct. If the pedaltravel becomes incorrect during the road test, followthe procedure for bleeding the braking regulation cir-cuit.

II - BLEEDING THE BRAKE CONTROL CIRCUIT

This procedure can be applied after a road test withbrake regulation during which the pedal travel beco-mes incorrect.


Referring to the equipment instructions, connect:

- tool brake circuit bleeding device (approved byRenault) to the vehicle brake circuit,

- the diagnostic tool .

Fit the bleed reservoirs to the bleed screws.

Bleed the regulation circuit using the diagnostictool .

Run command SC006 « hydraulic assembly andbrake circuits bleed » .

Follow the instructions on the diagnostic tool .

Disconnect the bleeding device.

Top up the brake fluid level in the reservoir.

Check the tightness of the bleed screws and ensurethat the sealing caps are all present.

During a road test, trigger braking regulation to con-firm that the brake pedal travel is correct. If the pedaltravel becomes incorrect during the road test, followthe procedure for bleeding the braking regulation cir-cuit.

It is therefore possible to use a larger quantity of bra-ke fluid than the capacity of the circuit.

Equipment required

brake circuit bleeding device (approved by Renault)

diagnostic tool

WARNING

Special precautions to be taken during the brakecircuit bleeding operation: the vehicle ignitionmust be switched off to ensure that the hydraulicunit solenoid valves do not operate.

Note:

Depress and release the brake pedal alternately(pumping action) throughout the bleed proce-dure.

30A-6

GENERAL VEHICLE INFORMATIONAnti-roll bars: Specifications 30A

FRONT AXLE

Bar diameter (mm) Marking

19 White

20 Yellow

30A-7

GENERAL VEHICLE INFORMATIONRear anti-roll bar: Specifications 30A

REAR AXLE

105839

F4R or F9Q or K9K, and DP0

Bar size (mm)

(X) : 15.7

(Y) : 41.3

K4J or K4M or K9K or M9R

Bar size (mm)

(X) : 15.9

(Y) : 38

30A-8

GENERAL VEHICLE INFORMATIONFront axle: Tightening torque 30A

101232

Mark Description Tightening torque(Nm)

(1) Bolt mounting the « spring - shock absorber » assembly on the body 21

(2) Lower arm bolt 70

(3) Sub-frame stud bolt 105

(4) Rear cross member bolt 62

(5) Bolt mounting the anti-roll bar on the sub-frame 21

(6) Radiator cross member front mounting bolt 105

(7) Calliper support bolt 105

Bolt mounting the steering rack on the sub-frame 105

(8) Radiator cross member rear mounting nuts 21

30A-9

GENERAL VEHICLE INFORMATIONFront axle: Tightening torque 30A

101231


(9) Shock absorber nut 62

(10) Anti-roll bar tie-rod ball joint nut 44

(11) Shock absorber base bolt 105

(12) Sub-frame tie-rod bolt 105

(13) Lower arm ball joint bolt 60

(14) Driveshaft nut 280

(15) Wheel bolts 110

(16) Track rod end nut 37

Bolt mounting the side stiffener on the radiator cross member 21

30A-10

GENERAL VEHICLE INFORMATIONRear axle: Tightening torque 30A

101900


(1) Stub-axle nut 175

(2) Calliper support bolt 105

(3) Guide pin bolt 36

(4) Bearing mounting bolt 62

(5) Shock absorber lower mounting bolt 105

Shock absorber upper mounting bolt 62

(6) Brake pipe nut 14

(7) Bearing - rear axle mounting bolt nut 125

Mounting bolt on guard beneath rear axle 8

30A-11

GENERAL VEHICLE INFORMATIONBrake circuit Tightening torque 30A

I - FRONT AND REAR BRAKES

II - BRAKE CONTROL

Description Tightening

torque

(Nm)

Front calliper bleed screw 6.5

Rear calliper bleed screw 10

Calliper inlet brake pipe 17

Front brake guide pin bolt 32

Calliper support bolt 105

Rear brake guide pin bolt 36

Disc mounting bolt 15


torques

(Nm)

Brake servo mounting nuts 21

Master cylinder mounting nuts 50

Master cylinder outlet pipe 17

Hydraulic unit mounting bolt 8

Hydraulic unit pipe unions 17

Parking brake control mountingnuts

8

Bolts mounting hydraulic unit sup-port on vehicle body

6.5

30A-12

GENERAL VEHICLE INFORMATIONSteering: Tightening torque 30A


torque

(Nm)

Steering wheel mounting bolt 44

Intermediate shaft mounting bolt onsteering column

44

Universal joint bolt 30

30A-13

GENERAL VEHICLE INFORMATIONUnderbody height 30A

MEASUREMENT POINTS

Measurement R1 is measured between the groundand the front wheel axle (R1) .

Measurement R2 is measured between the groundand the rear wheel axle (R2) .

Measurement W1 is measured between the groundand underneath the rear cross member mounting bolthead .

Measurement W2 is measured between the groundand the rubber bush mounting shaft on the bearing.

101937

102312

R1 R2

w1

102246

w2

30A-14

GENERAL VEHICLE INFORMATIONValues and adjustments for the front axle assemblies

F4R or F9Q or K4J or K4M or K9K or M9R, and RALU15 or RALU16 or RALU17 or RTOL15 or RTOL16 or 17"STEEL WHEELS

30A

I - PRELIMINARY OPERATIONS

Always check the following before placing the axle as-semblies on a test bench:

- the tyre size,

- the tyre pressure (see 35A, Wheels and tyres, Tyrepressure: Identification ),

- the degree of wear of the tyres,

- the play in the joints,

- the underbody height (see 30A, General informa-tion, Underbody height ).

II - CASTOR ANGLE

Not adjustable.

III - CAMBER

Not adjustable.

IV - PIVOT

Not adjustable.

Note:

Replace any faulty component before the test.

93012

Value Position of frontaxle (mm)

5˚ 00’ ± 30’

5˚ 20’ ± 30’

6˚ 06’ ± 30’

6˚ 30’ ± 30’

Maximum right/left difference= 0˚ 30’

W2 - W1 = 79

W2 - W1 = 71

W2 - W1 = 49

W2 - W1 = 40

93013


- 0˚ 02’ ± 30’

- 0˚ 12’ ± 30’

- 0˚ 15’ ± 30’

Maximum right/left diffe-rence = 0˚ 30’

R1 - W1 = 127

R1 - W1 = 146

R1 - W1 = 152

93014

30A-15


F4R or F9Q or K4J or K4M or K9K or M9R, and RALU15 or RALU16 or RALU17 or RTOL15 or RTOL16 or 17"STEEL WHEELS

30A

V - WHEEL ALIGNMENT: MEANING OF SYMBOLS

VI - WHEEL ALIGNMENT

Adjustable by rotating the track rod sleeves. After ad-justment, tighten to torque the wheel alignment ad-justment lock nuts (53 Nm)


10˚ 54’ ± 30’

11˚ 24’ ± 30’

11˚ 30’ ± 30’


R1 - W1 = 127

R1 - W1 = 146

R1 - W1 = 152

WARNING

Meaning of symbols used in this document,

-: toe-out,

+: toe-in.

WARNING

When adjusting the axle assemblies, program thesteering wheel angle and torque sensor using thediagnostic tool (see Workshop Repair Manual 366Fault finding, 36B, Electric power assisted stee-ring, Configuration and programming) .

93011

Value (for two wheels) Position offront axle(mm)

Toe-out: - 0˚ 10’ ± 10’ Vehicle inrunningorder

30A-16


BM0M or BM11 or CM0M or CM11 or CM1L

30AI - PREREQUISITES

Always check the following before placing the axle as-semblies on the test bench:

- the tyre size,

- the tyre inflation pressure (see 35A, Wheels and ty-res, Specifications ),


- the clearance of the joints,

- the underbody heights (see 30A, General vehicle in-formation, Underbody heights ).

II - CASTOR ANGLE

Not adjustable.

Sport version

III - CAMBER

Not adjustable.

Sport version

IV - PIVOT

Not adjustable.

Sport version

Note:

Replace all faulty components before checking.

93012


5˚ 16’ ± 30’

Maximum right/left difference= 0˚ 30’

W2 - W1 = 78.4

93013


- 0˚ 47’ ± 30’


R1 - W1 = 151.6

93014


9˚ 5’ ± 30’


R1 - W1 = 151.6

30A-17


BM0M or BM11 or CM0M or CM11 or CM1L

30AV - WHEEL ALIGNMENT: MEANING OF SYMBOLS

VI - WHEEL ALIGNMENT

Sport version

WARNINGMeaning of symbols used in this document,

-: toe-out,

+: toe-in.

WARNING

When adjusting the axle assemblies, programmethe steering wheel angle and torque sensor usingthe diagnostic tool (see Workshop Repair Manual366 Fault finding, 36B, Electric power assistedsteering, Configuration and programming) .

93011

Value (for two wheels) Position offront axle (mm)

Toe-out: - 0˚ 1’ ± 9’ Vehicle in runningorder (VODM)

30A-18

GENERAL VEHICLE INFORMATIONValues and adjustments for the rear axle assemblies

F4R or F9Q or K4J or K4M or K9K

30AI - PREREQUISITES

Always check the following before placing the axle as-semblies on a test bench:

- the tyre size,

- the tyre pressure (see 35A, Wheels and tyres, Tyrepressure: Identification ),


- the play in the joints,

- the underbody height (see 30A, General informa-tion, Underbody height ).

II - CAMBER

Not adjustable.

III - WHEEL ALIGNMENT: MEANING OF SYMBOLS

IV - WHEEL ALIGNMENT

Not adjustable.

Note:

Replace any faulty component before the test.

93013-1

Value Position of rear axle

- 1˚ 25’ ± 20’ Vehicle in running order

WARNING

Meaning of symbols used in this document,

-: toe-out,

+: toe-in.

93011-1

Value (for two wheels) Position offront axle(mm)

Toe-in: 0˚ 32’ ± 30’ Vehicle inrunningorder

31A-1

FRONT AXLE ASSEMBLIESFront brake pads: Removal - Refitting 31A

When replacing brake pads or a disc, it is essential toreplace the pads and disc on the opposite side.

REMOVAL


Remove:

- the front wheels,

- the lower pillar bolt (1) .

Unclip the brake hose (2) from the shock absorber.

Turn the calliper upwards.

Remove the pads.

Check the condition of the braking components.

Replace any faulty parts.

Special tooling required

Fre. 1190-01 Brake calliper pistonreturn tool.

Tightening torquesm

pillar bolts 3.2 daNm

wheel bolts 11 daNm

101214

101212

1

2

31A-2

FRONT AXLE ASSEMBLIESFront brake pads: Removal - Refitting 31A

REFITTING

Clean the calliper brackets and callipers.

Push back the pistons using tool (Fre. 1190-01) .

Fit the new pads, starting from the inside.

To refit, proceed in the reverse order of removal.

Tighten to torque:

- the pillar bolts ( 3.2 daNm ) ,

- the wheel bolts ( 11 daNm ) .

103115

WARNING

- Reattach the brake hose and wheel speed sen-sor wire if they have been detached.

- Do not twist the brake pipe.

IMPORTANT

Depress the brake pedal several times to bringthe pistons, the brake pads and discs into con-tact.

31A-3

FRONT AXLE ASSEMBLIESFront brake calliper: Removal - Refitting 31A

When replacing brake pads or a disc, it is essential tochange the pads and disc on the opposite side.

REMOVAL


Fit tool pedal press to the brake pedal to limit theflow of brake fluid.

Remove the front wheels.

Undo the brake hose from the brake calliper.

Remove:

- the pillar bolt (1) (brake calliper mountings),

- the brake calliper,

- the brake pads,






Equipment required

pedal press

Tightening torquesm

pillar bolt 3.2 daNm

brake hose 1.7 daNm

wheel bolts to torque 11 daNm

Note:

The callipers supplied as replacement parts arepre-filled.

101214

1

31A-4

FRONT AXLE ASSEMBLIESFront brake calliper: Removal - Refitting 31A

REFITTING

Push the piston back using the tool (Fre. 1190-01)until it is at the bottom of its bore.

Fit the pads, starting from the inside.

Refit:

- the calliper,

- the pillar bolt.

Tighten to torque:

- the pillar bolt ( 3.2 daNm ) ,

- the brake hose ( 1.7 daNm ) .

Refit the wheels.

Tighten the wheel bolts to torque ( 11 daNm ) .

Bleed the brake circuit partially if the compensationreservoir is not completely emptied during the proce-dure. If necessary, bleed the brake circuit comple-tely (see 30A, General Vehicle Information, Brakecircuit Bleeding, page 30A-5) .

Check the brake fluid level.

103115

WARNING



31A-5

FRONT AXLE ASSEMBLIESFront brake calliper support: Removal - Refitting 31A

When replacing brake pads or a disc, it is essential tochange the pads and disc on the opposite side.

REMOVAL


Remove:

- the front wheels,

- the pillar bolts (1) .

Suspend the brake calliper from the suspensionspring.

Remove:

- the brake pads,

- the two calliper bracket mounting bolts (2) ,

- the calliper bracket.






Tightening torquesm

calliper bracket bolts totorque

10.5 daNm


brake hose 1.7 daNm

wheel bolt to torque 11 daNm

101215

1

2

31A-6

FRONT AXLE ASSEMBLIESFront brake calliper support: Removal - Refitting 31A

REFITTING

Push back the piston using tool (Fre. 1190-01) untilit is at the bottom of its housing.

The calliper bracket bolts must be coated with a pro-duct such as FRENBLOC before they are fitted.

Refit:

- the calliper bracket,

- the calliper bracket mounting bolts.

Tighten the calliper bracket bolts to torque ( 10.5daNm ) .

Fit the pads, starting from the inside.

Refit:

- the calliper,

- the mounting bolts.


Tighten to torque:

- the pillar bolts ( 3.2 daNm ) ,

- the brake hose ( 1.7 daNm ) .

Refit the wheels.

Tighten the wheel bolt to torque ( 11 daNm ) .

103115

WARNING



IMPORTANT


31A-7

FRONT AXLE ASSEMBLIESFront brake hose: Removal - Refitting 31A

REMOVALFit the pedal press tool to the brake pedal to limitthe flow of brake fluid.

Undo:

- the pipe union (1) ,

- the calliper hose.

REFITTING

Refit the brake hose at the calliper end.

Tighten to torque:

- the brake hose on the calliper ( 1.7 daNm ) ,

- the brake hose on the union ( 1.7 daNm ) .

Place the female end of the brake hose on the retai-ning bracket without torsion stress.

Check that the end piece can move freely in thebracket splines.

Fit:

- the spring,

Equipment required

pedal press

Tightening torquesm

brake hose on the calli-per

1.7 daNm

brake hose on theunion

1.7 daNm

IMPORTANT

The order of operations for the procedure describedbelow must be observed.

101707

101709

WARNING

Do not twist the brake hose.

Make sure that there is no contact between thebrake hose and the surrounding components.

Note:

The hoses supplied as spare parts are encasedin a spring to prevent them from being twistedduring fitting.

1

31A-8

FRONT AXLE ASSEMBLIESFront brake hose: Removal - Refitting 31A

- the rigid pipe on the brake hose, making sure thatthe hose is not twisted when screwing on the rigidpipe.

Bleed the brake circuit (see 30A, General VehicleInformation, Brake circuit Bleeding, page 30A-5).

31A-9

FRONT AXLE ASSEMBLIESFront brake disc: Removal - Refitting 31A

When replacing the pads or disc, the pads and disk onthe opposite side must also be replaced.

REMOVAL


Remove:

- the front wheels,

- the two pillar bolts (1) .

Suspend the calliper from the suspension spring.

Remove:


- the two brake disc mounting bolts (2) ,

- the disc.

REFITTING



Tighten to torque:

- the disc mounting bolts ( 1.5 daNm ) ,

- the calliper bracket bolts ( 10.5 daNm ) .

Refit the wheels.

Tighten the wheel bolt to torque ( 11 daNm ) .

Tightening torquesm

disc mounting bolts 1.5 daNm

calliper bracket bolts 10.5 daNm

wheel bolt to torque 11 daNm

101212

2

1

WARNING



IMPORTANT


31A-10

FRONT AXLE ASSEMBLIESFront driveshaft hub carrier: Removal - Refitting 31A

REMOVAL


Disconnect the battery, starting with the negativeterminal.

Unclip:

- the wheel speed sensor from the hub carrier,

- the xenon bulb sensor (if fitted).

Remove:

- the front brake calliper mounting bolt (1) ,

- the track rod end mounting nut (2) ,

- the lower ball joint mounting nut (3) ,

- the shock absorber lower mounting bolt (4) .


Rou. 604-01 Hub locking tool.

Tav. 476 Ball joint extractor.

Sus. 1731 Front shock absorberremoval tool.

Equipment required

diagnostic tool

Tightening torquesm

shock absorber lowermounting bolt

105 Nm

lower ball joint nut 62 Nm

track rod end nut 37 Nm

brake disk mountingbolts

15 Nm

hub nut 280 Nm

brake calliper mountingbolts

105 Nm

wheel bolts 110 Nm

101215

31A-11


Hang the « front brake calliper mounting - calliper »assembly on the suspension spring.

Remove:

- the disc mounting bolts (5) ,

- the hub mounting nut (6) using tool (Rou. 604-01) ,

- the disc,

- the anti-roll bar upper linkage mounting nut (7) ,

- the anti-roll bar linkage.

Extract the ball joints using tool (Tav. 476) .

Separate the driveshaft from the hub carrier takingcare not to dislocate the driveshaft.

Fit tool (Sus. 1731) .

Tighten bolt (8) of tool (Sus. 1731) to remove thehub carrier while holding it.

REFITTINGTo refit, proceed in the reverse order to removal.

101212 112078

IMPORTANT

Take care not to drop the hub carrier.

WARNING

Check that part (9) of tool (Sus. 1731) is in con-tact with the shock absorber base.

Note:

The calliper mounting bolts must be coated witha product such as FRENBLOC before being refit-ted.

31A-12


Tighten to torque:

- the shock absorber lower mounting bolt ( 105Nm ) ,

- the lower ball joint nut ( 62 Nm ) ,

- the track rod end nut ( 37 Nm ) ,

- the brake disk mounting bolts ( 15 Nm ) ,

- the hub nut ( 280 Nm ) ,

- the brake calliper mounting bolts ( 105 Nm ) ,

- the wheel bolts ( 110 Nm ) .

Connect the battery, starting with the positive termi-nal.

IMPORTANT


WARNING

Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).

WARNING

Adjust the axle assemblies (see 30A, Generalinformation, Front axle assemblies valuesand adjustments ).

WARNING

Program the torque and angle sensor using thediagnostic tool .

Note:

Be sure to initialise the xenon bulb system (if fit-ted); see 80C, Xenon bulbs, Xenon headlights:Adjustment ).

31A-13

FRONT AXLE ASSEMBLIESFront hub carrier bearing: Removal - Refitting 31A

The following tools are required for this procedure:

- tool (Rou. 15-01) ,

- tool (Rou. 604-01) ,

- tool (Tav. 476) ,

- tool (Tav. 1050-02) .

REMOVAL

Remove the stub axle carrier (see 31A, Front axleassemblies, Front driveshaft hub carrier: Remo-val - Refitting, page 31A-10) .

Remove:

- the hub using a press with a 36 mm diameter tube,

- the stub axle carrier external bearing bush, grip-ping with a tube of the same diameter as the exter-nal bush,


Rou. 15-01 16 mm interior diame-ter shaft protector.

Rou. 604-01 Hub locking tool.


Tav. 1050-02 Tool for pushing dri-veshaft back

Tightening torquesm

lower ball joint bolt 6.2 daNm

track rod end nut 3.7 daNm

driveshaft nut 28 daNm

shock absorber basebolt

10.5 daNm

disc mounting bolt 1.5 daNm

calliper support bolt 10.5 daNm

wheel bolt 11 daNm

WARNING

The bearing has an active sensor, take care not tomark the wheel speed sensor target when refitting.

F4R or K4J or K4M

20786

31A-14


Remove the hub internal bush by gripping with atube of diameter 41 mm.

Remove:

- the hub using a press, gripping with a 41 mm dia-meter tube,

- the stub axle carrier external bearing bush by grip-ping with a tube of the same diameter as the exter-nal bush.

Remove the hub internal bush by gripping with atube of diameter 46 mm.

REFITTING

F4R or K4J or K4M

20787

F9Q or K9K

20786

20787

WARNING

- Be sure to check the condition of the hub sur-face and stub axle carrier bore before refittingthe bearing.

- Replace the stub axle carrier if it is faulty.

- Clean:

• the internal and external surfaces of the newbearing in contact with the stub axle carrierand the hub,

• the stub axle carrier surfaces in contact withthe new bearing,

• the hub surfaces in contact with the new bea-ring.

- Do not grip the inner bearing race, in order toavoid damaging the bearing (the fitting forcerequired is very high).

31A-15


Refit the sensor holder.

Position the sensor holder at (x) = 35˚ +/−−−− 5˚ fromvertical. This position corresponds to the centre ofthe housing.

Grip the external bush using a tube with an externaldiameter of 72 mm and a bore diameter of 65 mm .

Refit the circlip.

Check that the circlip is correctly positioned bymeasuring the internal diameter (X1) = 61.6 mm fora bearing with an external diameter of 72 mm .

Grip the external bush with a tube with an externaldiameter of 77 mm and an bore diameter of 70 mm .

101934

F4R or K4J or K4M

20788

x

101933

F9Q or K9K

20788

X1

31A-16


Refit the circlip.

Check that the circlip is correctly positioned bymeasuring the internal diameter (X1) = 67.6 mm fora bearing with an external diameter of 77 mm .

Refit:

- the hub,

- the « stub axle carrier / bearing / hub » assembly(see 31A, Front axle assemblies, Front drives-haft hub carrier: Removal - Refitting, page 31A-10) .

Tighten to torque:

- the lower ball joint bolt ( 6.2 daNm ) ,

- the track rod end nut ( 3.7 daNm ) ,

- the driveshaft nut ( 28 daNm ) ,

- the shock absorber base bolt ( 10.5 daNm ) ,

- the disc mounting bolt ( 1.5 daNm ) ,

- the calliper support bolt ( 10.5 daNm ) ,

- the wheel bolt ( 11 daNm ) .

101933

X1

20789

31A-17

FRONT AXLE ASSEMBLIESSpring and front shock absorber: Removal - Refitting 31A

REMOVAL

Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).

Remove the front wheels (see 35A, Wheels and ty-res, Wheel: Removal - Refitting ).

Unclip the brake hose from the shock absorber andthe wheel speed sensor cable.

Remove the seal (1) .

Cut the flap at (2) .

Remove:

- the flap plastic rivets,

- the anti-roll bar linkage upper nut.

Remove:

- the shock absorber base mounting bolts (3) ,

- the front brake calliper mounting bolt (4) .

Suspend the « front brake calliper mounting -calliper » assembly.


Sus. 1731 Front shock absorberremoval tool.

Equipment required

spring compressor

tool for removing the shock absorber rod nut

Tightening torquesm

shock absorber rod nut 62 Nm

shock absorber turretmounting bolts

21 Nm

shock absorber moun-ting bolt

105 Nm

anti-roll bar linkage balljoint mounting nut

44 Nm101210

101215

31A-18


Fit the (Sus. 1731) .

Tighten bolt (5) of the tool (Sus. 1731) and separatethe shock absorber base from the hub carrier.

Suspend the hub carrier.

Remove:

- the shock absorber turret mounting bolt (7) ,

- the « spring-shock absorber » assembly.

Mount the correct cups on the spring compressorand position the assembly on the spring.

Detach the spring from the cups by compressing thespring.

Remove the shock absorber rod nut using the toolfor removing the shock absorber rod nut .

Separate the various components of the « spring-shock absorber » assembly.

REFITTINGPlace the spring compressor tool in a vice.

112078

WARNING

Check that part (6) of the (Sus. 1731) is in con-tact with the shock absorber strut.

101211

96049

31A-19


95435

Note:

When replacing the spring for easier fitting,ensure that the positioning and orientation of thespring and the tool cups are correct.

31A-20


Position the spring in the cup groove, smooth sheathin the upper position, and grooved sheath the lower.

102201

31A-21


Respect the order and direction of fitting for theconstituent parts.

The shock absorber rod nut must be replaced.

Tighten to torque the shock absorber rod nut ( 62Nm ) .

Decompress the spring.

Remove the spring compressor.

Position the indexing (8) in its housing.

Proceed in the reverse order to removal.

Tighten to torque:

- the shock absorber turret mounting bolts ( 21Nm ) ,

- the shock absorber mounting bolt ( 105 Nm ) ,

- the anti-roll bar linkage ball joint mounting nut (44 Nm ) .

Refit the wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting ).

Adjust the xenon headlight system (if fitted to the ve-hicle), (see 80C, Xenon lights, Xenon headlight:Adjustment ).

101939

Note:

Make sure that the rotary stop is correctly orien-ted to facilitate refitting above and below.

96049

101211

WARNING

Refasten the brake hose and wheel speed sen-sor wiring, if they have been unclipped.

Do not twist the brake hose.

31A-22

FRONT AXLE ASSEMBLIESFront driveshaft lower arm: Removal - Refitting 31A

REMOVAL


Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).

Strap the radiator to the radiator grille.

Equipment required

component jack

Tightening torquesm

lower arm - sub-framemounting bolts

70 Nm


anti-roll bar return tie-rod ball joint nut

44 Nm

lower ball joint bolt 62 Nm

radiator cross memberfront mounting bolts

105 Nm

radiator cross memberrear mounting bolts

21 Nm

side reinforcementlower bolts

21 Nm

WARNING

Do not use the lower arm for support with a liftingsystem.

31A-23


Remove:

- the front wheel concerned (see 35A, Wheels andtyres, Wheel: Removal - Refitting ).

- the wheel arch protectors,

- the engine undertray,

- the lower bolts (1) from the side stiffener,

- the front mounting bolts (2) from the radiator crossmember,

- the radiator cross member rear mounting nuts,

- the radiator cross member.

Unclip the wheel sensor wiring.

Disconnect the wheel speed sensor connector fromthe wheel arch.

Remove:

- the lower ball joint bolt (3) ,

- the anti-roll bar linkage ball joint nut (4) ,

Extract the height sensor ball joint (if fitted to the ve-hicle).

Remove:

- the front and rear mounting bolts (5) from the lowerarm,

- the lower arm.

REFITTING


Fit the component jack to the sub-frame rearmounting bolt head (6) .

Lower the component jack by (H = 14 mm) .

Fit the lower arm ball joint (7) to the componentjack without changing the setting.

Torque tighten the lower arm - sub-frame moun-ting bolts ( 70 Nm ) in this position.

Remove the component jack .

101212

101213

1

3

2

4

55

103114

WARNING

When refitting, position the lower arm lower inheight than the sub-frame rear mounting bolthead (H = 14 mm) in order to tighten the rubberbushes without compressing them.

H = 14 mm

67

31A-24


Refit the lower ball joint into the hub carrier.

Refit and tighten to torque:

- the track rod end nut ( 37 Nm ) ,

- the anti-roll bar return tie-rod ball joint nut ( 44Nm ) .

- the lower ball joint bolt ( 62 Nm ) .

- the radiator cross member and the radiator crossmember front mounting bolts ( 105 Nm ) ,

- the radiator cross member rear mounting bolts( 21 Nm ) ,

- the side reinforcement lower bolts ( 21 Nm ) ,

- the front wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting ).

Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).

Adjust the axle assemblies (see 30A, General infor-mation, Front axle assemblies adjustments andvalues ).

Adjust the xenon headlight system (see 80C, Xenonbulbs, Xenon headlights: Adjustment ).

WARNING

- The sub-frame and arm mountings must bereplaced with new mountings.

- Be sure to place a 10 mm thick shim betweenthe radiator cross member and the sub-frame totorque tighten the radiator cross member moun-tings.

31A-25

FRONT AXLE ASSEMBLIESFront anti-roll bar: Removal - Refitting 31A

REMOVAL


Remove:

- the front axle sub-frame (see 31A, Front axle as-semblies, Front axle sub-frame: Removal - Re-fitting, page 31A-26) ,

- the steering rack mounting bolts on the sub-frame,

- the steering rack,

- the anti-roll bar mounting bolts on the sub-frame,

- the anti-roll bar.

REFITTING


Tighten to torque:

- the anti-roll bar mounting bolts on the sub-fra-me ( 2.1 daNm ) ,

- the steering rack mounting bolts on the sub-fra-me ( 10.5 daNm ) .

Tightening torquesm

anti-roll bar mountingbolts on the sub-frame

2.1 daNm

steering rack mountingbolts on the sub-frame

10.5 daNm

WARNING

Correctly position the anti-roll bar mounting lugpins in the sub-frame openings.

31A-26

FRONT AXLE ASSEMBLIESFront axle sub-frame: Removal - Refitting 31A

REMOVAL


Set the wheels straight ahead.

Centre the steering wheel.

Lift the floor carpet to access the universal joint bolt.

Discard the cover (do not keep it).

Remove the universal joint bolt and nut.

Position the steering wheel lock .


Strap the radiator to the radiator grille.

Equipment required

steering wheel lock

component jack

Tightening torquesm

sub-frame stud bolts 105 Nm

rear cross member bolton the sub-frame

62 Nm

lower ball joint bolts 62 Nm

sub-frame tie-rod bolts 105 Nm

engine tie-bar bolts onthe engine mountings (For M engines)

180 Nm

engine tie-bar bolts tothe engine (K engines)

105 Nm

engine tie-bar bolts onthe sub-frame

105 Nm

anti-roll bar tie-rod balljoint nuts

44 Nm

track rod end nuts 37 Nm

radiator cross memberfront mountings

105 Nm

side reinforcement bolts 21 Nm

universal joint bolts 30 Nm

WARNING

Do not use the lower arm for support with a liftingsystem.

104020

31A-27


Remove:

- the front wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting ).

- the wheel arch liners,


- the lower bolts (1) from the side stiffeners,

- the front mounting bolts (2) from the radiator crossmember,

- the radiator cross member rear mounting nuts,

- the radiator cross member.

Unclip the wheel speed sensors wiring.

Disconnect the wheel speed sensor connector fromthe wheel arch.

Remove:

- the steering ball joint nuts (3) ,

- the lower ball joint bolts (4) ,

- the upper ball joint nuts (5) from the anti-roll bar tiebars.

Take out the ball joints.

Remove the mounting bolt (6) from the engine tie-bar.

101212

101213

1

2

3

4

5

K4J or K4M or K9K

101208

6

31A-28


Remove the mounting bolt (7) from the engine tie-bar.

Remove the engine tie-bar mounting bolt (8) fromthe engine.

Position the component jack under the sub-frame.

Strap the sub-frame to the component jack .

Remove the lower arm ball joints.

Remove the wheel speed sensor wiring support.

Remove:

- the rear cross member mounting bolts,

- the sub-frame - body mounting bolts,

- the rear cross member,

- the sub-frame.

F4R or F9Q

102313

7

M9R

114650

31A-29


Remove the equipment from the sub-frame.

REFITTING

Be sure to replace the sub-frame and arm moun-tings.


Tighten to torque:

- the sub-frame stud bolts ( 105 Nm ) ,

- the rear cross member bolt on the sub-frame (62 Nm ) ,

- the lower ball joint bolts ( 62 Nm ) ,

- the sub-frame tie-rod bolts ( 105 Nm ) ,

- the engine tie-bar bolts on the engine moun-tings (F or M engines) ( 180 Nm ) ,

- the engine tie-bar bolts to the engine (K engi-nes) ( 105 Nm ) ,

- the engine tie-bar bolts on the sub-frame ( 105Nm ) ,

- the anti-roll bar tie-rod ball joint nuts ( 44 Nm ) ,

- the track rod end nuts ( 37 Nm ) ,

- the radiator cross member front mountings (105 Nm ) ,

- the side reinforcement bolts ( 21 Nm ) ,

- the universal joint bolts ( 30 Nm ) .

101209

WARNING

- A shim 10 mm thick must be placed betweenthe radiator cross member and the sub-frame.

- Set the wheels straight, centre the steeringwheel.

31A-30


Check that the universal joint is in the correct posi-tion.


Refit the floor carpet.

Adjust the axle assemblies (see 30A, General infor-mation, Front axle assemblies adjustments andvalues ).


Initialise the xenon bulb system (if fitted to the vehi-cle) (see MR 366 Fault finding, 80C, Xenon bulbs,Configuration and programming ).

116021

116022

Note:

Check that the floor carpet reaches under theaccelerator pedal end-stop.

33A-1

REAR AXLE ASSEMBLIESRear brake pads: Removal - Refitting 33A

When replacing brake pads or a disc, it is essential toreplace the pads and disc on the opposite side as well.

REMOVAL


Release the parking brake.

Remove the rear wheels.

Unclip the parking brake cables.

Remove the lower mounting bolts from the calliperpillars.

Turn the callipers upwards.

Remove the brake pads.




REFITTING

Push the calliper piston back using tool (Fre. 1190-01) until it is at the bottom of its bore.

Refit:

- the new brake pads,

- the column bolts.

Torque tighten the calliper mounting pillar lowerbolts to ( 0.7 daNm ) .

Refit the parking brake cables.

Operate the parking brake control several times toactivate the locking and unlocking function and thecalliper self-adjustment.

Refit the wheels.

Torque tighten the wheel bolts to ( 11 daNm ) .



Tightening torquesm

calliper mounting pillarlower bolts to

0.7 daNm

wheel bolts to 11 daNm

101702

18931

Note:

Coat the mounting bolts in a FRENBLOC typeproduct before fitting.

IMPORTANT


33A-2

REAR AXLE ASSEMBLIESRear brake caliper: Removal - Refitting 33A

When replacing brake pads or a disc, it is essential tochange the pads and disc on the opposite side as well.

REMOVAL



Remove the rear wheel.

Unclip the parking brake cable.

Memorise the parking brake cable routing for refit-ting.

Undo the brake hose.

Remove:

- the pillar mounting bolts,

- the calliper.

Place a plug on the hose.



Clean the calliper and the calliper mounting.

REFITTING


Refit:

- the brake pads,

- the calliper,

- the column mounting bolts.

Tighten the pillar bolts to ( 3.6 daNm ) .

Tighten the brake hose to ( 1.7 daNm ) .



Tightening torquesm

pillar bolts to 3.6 daNm

brake hose to 1.7 daNm

wheel bolt to 11 daNm

Note:

The callipers supplied as replacement parts aresupplied pre-filled.

18931

Note:

Coat the mounting bolts in a FRENBLOC typeproduct before fitting.

33A-3

REAR AXLE ASSEMBLIESRear brake caliper: Removal - Refitting 33A

Refit the parking brake cable.

Check that the parking brake cable stop is properlyfitted in its housing.



Operate the parking brake application control seve-ral times to activate the locking and unlocking func-tion and to activate the calliper automatic playcompensation.

Refit the wheel.

Tighten the wheel bolt to ( 11 daNm ) .

101306

33A-4

REAR AXLE ASSEMBLIESRear brake calliper mounting: Removal - Refitting 33A

REMOVAL



Remove the rear wheel.

Release the parking brake cable.

Remember the parking brake cable routing for refit-ting.

Remove:

- the pillar bolts,

- the calliper.

Hang up the calliper.

Remove:

- the brake pads,

- the calliper bracket mounting bolts,

- the calliper bracket.



Clean the calliper bracket and the calliper.

REFITTING

Refit:


- the calliper bracket mounting bolts.

Torque-tighten the calliper mounting bolts ( 10.5daNm ) .


Refit:

- the brake pads,

- the calliper,

- the post bolts.

Torque-tighten the pillar bolts ( 3.6 daNm ) .




Tightening torquesm

calliper mounting bolts 10.5 daNm


wheel bolts 11 daNm

Note:

Coat the calliper and pillar mounting bolts withFRENBLOC or a similar product before fittingthem.

18931

33A-5

REAR AXLE ASSEMBLIESRear brake calliper mounting: Removal - Refitting 33A

Check that the parking brake cable stop is properlyengaged in its housing.

Operate the parking brake application control seve-ral times to activate the locking and unlocking func-tion and to activate the calliper automatic playcompensation.

Refit the wheel.

Torque-tighten the wheel bolts ( 11 daNm ) .

101301

33A-6

REAR AXLE ASSEMBLIESRear brake disc: Removal - Refitting 33A

Brake discs cannot be reground. If the brake discs aresignificantly worn or scratched, they must be replaced(see 30A, General information, Brakes: Specifica-tions ).

When replacing a brake disc, be sure to replace thedisc on the opposite side.

When replacing a brake disc, you must replace the bra-ke pads.

The discs are supplied with fitted bearings.

REMOVAL


Remove the rear wheels (see 35A, Wheels and ty-res, Wheel: Removal - Refitting ).

Release the parking brake cables (1) .

Note the routing for refitting.

Remove:

- the guide pin bolts (2) ,

- the calliper.

Hang up the calliper.

Remove:

- the brake pads,

- the calliper mounting bolts (3) ,

- the calliper supports,

- the hub caps,

- the stub-axle nuts,

- the « disc - bearing » assemblies.



REFITTING

Clean the callipers and calliper supports.



Tightening torquesm

stub-axle nuts 175 Nm

calliper support bolts 105 Nm

guide pin bolts 36 Nm

101301

1

101306

Note:

Coat the calliper support and guide pin bolts withFRENBLOC or similar product before fittingthem.

2

3

33A-7

REAR AXLE ASSEMBLIESRear brake disc: Removal - Refitting 33A

Push the calliper piston back using the (Fre. 1190-01) until it is at the end of its bore.

Proceed in the reverse order to removal

Tighten to torque:

- the stub-axle nuts ( 175 Nm ) ,

- the calliper support bolts ( 105 Nm ) ,

- the guide pin bolts ( 36 Nm ) .


Check that the parking brake cable stops are proper-ly engaged in their housing.


Operate the parking brake control several times toactivate the locking and unlocking function and toactivate the calliper automatic play compensation.


18931

101306

4

Note:


33A-8

REAR AXLE ASSEMBLIESRear suspension spring: Removal - Refitting 33A

During removal, note the colours of the shock absor-bers and springs, to ensure the parts match when refit-ting.

REMOVAL

Mount the vehicle on a two post lift.


Remove:

- the clips from the rear axle protective fairing usingunclipping pliers,

- the rear axle protective cowling.

I - LEFT SIDE

Mount the component jack tool, with a shim, underthe left spring cup.

Mark the position where the left spring is fitted.

Remove the left shock absorber lower mounting (1)using a long socket.

Release the left shock absorber lower mounting.

Remove the component jack tool.

Equipment required

component jack

Tightening torquesm

wheel bolts 11 daNm

shock absorber lowermounting bolts

10.5 daNm

rear axle under-protec-tor mounting bolts

0.8 daNm

WARNING

Never grip the rear axle with a lifting system. 101304

1

33A-9

REAR AXLE ASSEMBLIESRear suspension spring: Removal - Refitting 33A

Remove the left spring with its lower support.

II - RIGHT SIDE

Repeat these operations on the right side of the ve-hicle.

Hang up the rear axle.

REFITTING

Refit both spring supports.

Refit the springs in their housing.

Mount the bump stops on the axle assembly, withthe marking towards the rear and in the longitudinalaxis of the vehicle.

I - LEFT SIDE

Mount the component jack tool, with a shim, underthe spring cup.

Compress the rear axle.

Refit the shock absorber lower mounting.

Pre-tighten the shock absorber lower mounting.


II - RIGHT SIDE


Refit the rear wheels.

Tighten to torque the wheel bolts ( 11 daNm ) .

Lower the lift until the wheels touch the ground.

Tighten to torque the shock absorber lower moun-ting bolts ( 10.5 daNm ) .

Raise the lift again.

Refit the rear axle under-protector, replacing any da-maged plastic clips.

Tighten to torque the rear axle under-protectormounting bolts ( 0.8 daNm ) .

101307

WARNING

If the upper support is unclipped, replace it.

WARNING

The shock absorber mountings are only to betightened with the vehicle wheels on the ground.

33A-10

REAR AXLE ASSEMBLIESShock absorber: Removal - Refitting 33A

During removal, note the colours of the shock absor-bers and springs in order to ensure the conformity ofthe parts ordered for refitting.

REMOVAL


Lift the carpet in the boot.

Remove the shock absorber head upper mountingbolt (1) .

Raise the lift.

Remove:

- the clip from the protective fairing cover,

- the shock absorber lower mounting nut,

- the shock absorber.

REFITTING

Refit:

- the shock absorber,

- the shock absorber lower mounting.

Pretighten the shock absorber lower mountings.

Cut the retaining cord.

Position the shock absorber head in its housing.

Lower the lift until the wheels touch the ground.

Align the shock absorber head with the drilling holein the luggage compartment.

Refit the shock absorber upper mounting bolt.

Pretighten the shock absorber upper mounting bolt.

Repeat the operation on the opposite side.

Tighten to torque:

- the shock absorber upper mounting bolts ( 6.2daNm ) ,

- the shock absorber lower mounting bolts ( 10.5daNm ) whilst holding the bolt head.

Refit the protection beneath the rear axle, replacingthe damaged plastic clips.

Torque-tighten the mounting bolts on the protec-tion beneath the rear axle ( 0.8 daNm ) .

Tightening torquesm

shock absorber uppermounting bolts

6.2 daNm

shock absorber lowermounting bolts

10.5 daNm

mounting bolts on theprotection beneath therear axle

0.8 daNm

WARNING

- Never use the rear axle as support for a lifting sys-tem.

- When replacing a shock absorber, the shockabsorber on the opposite side must be replaced.

101302

1

WARNING


33A-11

REAR AXLE ASSEMBLIESComplete rear axle: Removal - Refitting 33A

REMOVAL

Mount the vehicle on a two post lift.

Fit the pedal press tool to the brake pedal to limitthe outflow of brake fluid.


Unclip the parking brake cables.

Note the parking brake cable routing for refitting.

Undo the brake hose nuts (1) .

Disconnect the wheel speed sensor connectors oneach side member.

Remove:

- the clips from the rear axle protective fairing usingunclipping pliers,

- the rear axle protector.


Mot. 1390 Support for removing/refitting the engine -gearbox assembly.

Equipment required

pedal press

component jack

Tightening torquesm

bearing mounting bolts 6.2 daNm

brake hose mountingbolts

1.4 daNm

shock absorber lowermountings

10.5 daNm

rear axle under-protec-tor mounting bolts

0.8 daNm

wheel bolts 11 da Nm

WARNING

Never grip the rear axle with a lifting system.

Note:

- During this operation, secure the vehicle to thelift with a strap to prevent it from becomingunbalanced.

- For the strap fitting procedure ( (see 02A, Lif-ting) ).

101303

11

33A-12


1 - Left side


Mark the position where the left spring is fitted.

Remove the left shock absorber lower mounting (2)using a long socket.

Release the left shock absorber lower mounting.


Remove the left spring with its lower support.

2 - Right side


Fit tool (Mot. 1390) on the rear axle jacking points.

101304

2

101307

WARNING

If the upper spr ing support is unclipped, replaceit.

101300

33A-13


Adjust the height of the pads to obtain a centre-to-centre distance between the shock absorber moun-ting points (body mounting - (4) axle mounting (5) )corresponding to a length of 402 mm .

Loosen the bearing bolts (3) .

Press the pads of tool (Mot. 1390) onto the rearaxle.

Strap the rear axle.

Remove the bearing bolts (3) .

raise the vehicle.

106178

101303

4

402 mm

5

33

33A-14


Remove the rear axle equipment.

REFITTINGRefit the rear axle equipment.

Strap the rear axle onto tool (Mot. 1390) ;.

Position the axle underneath the vehicle.

101305

33A-15


Lower the lift.

Position the bearing locators opposite the centringholes.

Refit the mountings, starting with the left bearing.

Insert the brake pipes into their housing.

Remove the strap.

Raise the lift.

Remove tool (Mot. 1390) ;.

Tighten to torque:

- the bearing mounting bolts ( 6.2 daNm ) ,

- the brake hose mounting bolts ( 1.4 daNm ) .

Reconnect the ABS system connectors.


Check that the parking brake cable stops are proper-ly engaged in their housing.

Refit the spring supports.

Refit the springs into their housing.

Position the bump stops on the axle assembly, withthe marking at the rear and in the longitudinal axis ofthe vehicle.

1 - Left side





2 - Right side


Check the position of the bump stop on the axle as-sembly.



101300 101706

WARNING


33A-16



Lower the lift.

Tighten to torque the shock absorber lower moun-tings ( 10.5 daNm ) .

Raise the lift again.

Refit the rear axle under-protector, replacing any da-maged plastic clips.

Tighten to torque the rear axle under-protectormounting bolts ( 0.8 daNm ) .

Refit the rear wheels.

Tighten to torque the wheel bolts ( 11 da Nm ) .

33A-17

REAR AXLE ASSEMBLIESRear axle rubber bearing: Removal - Refitting 33A

Never use the rear axle as support for a lifting system.


The operation is carried out with the shock absorberlower mounting bolt removed.

Fit tool pedal press .

Position using the component jack tool, to obtain acentre-to-centre measurement between the shockabsorber mounting attachment points (body moun-ting (1) , axle mounting (2) ) equal in length to 402mm .

Tighten the joint mounting bolts to a torque of (12.5 daNm ) .

Equipment required

safety belt

pedal press

component jack

Tightening torquesm

joint mounting bolts to atorque of

12.5 daNm

Note:

- During this operation, strap the vehicle to the liftusing tool safety belt , to prevent it from beco-ming unbalanced.

- For how to position the tool safety belt , refer to(see 02A, Lifting) .

102521

106178

402 mm

2

1

35A-1

WHEELS AND TYRESTyre inflation pressure: Identification 35A

I - INFLATION

* Alloy wheel rim

The pressure values given are « motorway » values.

WARNING

If checking the tyre pressure when hot, increase thepressure by 0.2 to 0.3 bar above the recommendedpressure.

Engine Wheel Tyre Tyre pressure when cold (bar)

Front Rear

K4J

6.5 J 15 195/65 R15 T 2.2 2

6.5 J 16* 205/55 R16H 2.2 2

6.5 J 16* 205/55 R16 V 2.2 2

6.5 J 17* 205/50 R17V 2.2 2

K4M

6.5 J 15 195/65 R15 T 2.3 2

6.5 J 15 195/65R15H 2.3 2

6.5 J 16* 205/55 R16H 2.3 2

6.5 J 16* 205/55 R16 V 2.3 2

6.5 J 17* 205/50 R17V 2.4 2

K9K

6.5 J 15 195/65 R15T 2.3 2

6.5 J 16* 205/55 R16H 2.3 2

6.5 J 16* 205/55 R16 V 2.3 2

6.5 J 17* 205/50 R17V 2.4 2

F4R

6.5 J 16* 205/55 R16H 2.4 2

6.5 J 16* 205/55 R16 V 2.4 2

6.5 J 17* 205/50 R17V 2.5 2

F9Q

6.5 J 15 195/65R15H 2.4 2

6.5 J 16* 205/55 R16H 2.4 2

6.5 J 16* 205/55 R16 V 2.4 2

6.5 J 17* 205/50 R17V 2.5 2

M9R6.5 J 16* 205/55 R16 V 2.6 2

6.5 J 17* 205/50 R17V 2.8 2.1

35A-2

WHEELS AND TYRESTyre inflation pressure: Identification 35A

II - CONFORMITY CHECK AND ADJUSTMENT

Wheel bolt tightening torque ( 110 Nm )

Maximum wheel rim run-out checked on the external diameter of the rim:

- steel wheel: 0.8 mm ,

- alloy wheel: 0.3 mm .

Maximum run-out checked on the face of the wheel:0.7 mm .

Wheel offset:

- steel wheel rim: 45 mm ,

- alloy wheel rim: 49 mm .

For fitting chains, see « Owner's Manual » .

WARNING

If the tyre size is changed, calibrate the ElectricPower Assisted Steering system computer and thetyre pressure monitor (see MR 366, Fault finding,36B, Electric Power Assisted Steering, Configu-ration and programming ).

35A-3

WHEELS AND TYRESTyres: Identification 35A

Example of tyre identification marking: 205/55 R 16 91S.

Speed suffix table:

101008

205 Tyre width in mm (l)

55 Ratio h/w

R Radial structure

16 Internal diameter in inches

91 Load suffix

V Speed suffix

Maximum speed mph

R 170

S 180

T 190

U 200

H 210

V 240

ZR greater than240

l

h

c

35A-4

WHEELS AND TYRESWheel rim: Identification 35A

I - IDENTIFICATION

The wheel rims are marked in one of two ways:

- engraved marking for steel wheel rims,

- cast marking for alloy wheel rims.

The marking gives the main dimensional specificationsof the wheel rim.

This marking may be:

- complete, for example 5 1/2 J 144 CH 36;

- simplified, for example 5 1/2 J14.

The wheel bolts are positioned with a pitch circle dia-meter of 100 mm for wheels with four mounting boltsand 108 mm for wheels with five mounting bolts.

The maximum run-out is measured at the rim edge (7) .

II - SPECIAL NOTES FOR WHEEL BOLTS

Alloy wheel rim bolts (8) .

Steel rim bolts (9) .

III - SPECIAL NOTES ON VEHICLES FITTED WITH TYRE PRESSURE MONITORING SYSTEM

Each set of four tyres is programmed into the compu-ter.

When fitting a « winter » set of tyres, if the program-ming has already been carried out, the set of tyres fit-ted on the vehicle is automatically recognised: you donot need to do anything with the diagnostic tool .

Equipment required

diagnostic tool

Wheel type 5.5 J 14

1 Width (in inches) 5.5

2 Rim edge profile J

3 Nominal diameter (in inches) 14

4 Number of holes 4

5 Tyre bead profile CH

6 Offset (in mm) 36

100988

110809

WARNING

The wheel bolts for the steel wheel rim and the alloywheel rim are different. Check that the bolts matchthe wheel rims.

35A-5

WHEELS AND TYRESWheel: Balancing 35A

60 mm ring

Order the ring from your hardware manufacturer.

I - PREREQUISITES FOR WHEEL BALANCING

Wheel balancing is a measuring operation.

Several conditions must be met to achieve a reliableresult in a single operation.

The wheel balancer must be installed in accordancewith the manufacturer's instructions.

It is essential that the machine is recalibrated at theintervals specified by the manufacturer.

Never grease the threaded shaft.

Check the condition of the supports, centring com-ponents and mountings.

Replace any faulty parts (see manufacturer's ins-tructions).

The wheel and the wheel balancer must be clean.

Driver's observation

If the wheels are not correctly balanced this causesthe steering wheel and/or the vehicle floor to vibrate.

The vibrations occur at between 54 mph (90 km/h)and 90 mph (150 km/h) .

Adjust the tyre pressures (see 35 A, Wheels and ty-res, Tyre pressure: Identification ).

Always drive for a minimum distance of 1.2 miles (2km) before balancing the wheels, in order to preventa flat spot from developing on the tread after the ve-hicle has stopped.

After the drive:

- raise the vehicle immediately,

- leave the four wheels hanging free,

- release the parking brake.

Equipment required

pedal press

MAKE MACHINE TYPE SHAFT DIAMETER RING PART NO.(SUPPLIER)

RING PART NO.(HAWEKA)

BALCO BALCO 995 28 mm 160 280 012 160 280 012

MULLER BEM 1605-1610-1620-1625-1630-1460-1650

30 mm 160 300 012 160 300 012

MULLER BEM 4605-5604-5605 35 mm No 160 350 012

RAVAGLIOLI G120-G121-G122 36 mm GAR 147 160 360 012

CORGHI All types 38 mm No 160 380 012

MULLER BEM 1611-1626-1627-1636-1638-1639-1690

40 mm 102857 160 400 012

FACOM All types 40 mm UA.SU16 160 400 012

HOFMANN All types 40 mm 160 400 012 160 400 012

BEISSBARTH All types 40 mm 000075546 160 400 012

35A-6


To reproduce the exact vehicle wheel assembly, it isessential to fit a ring (1) with a diameter of 60 mm onthe wheel balancer.

There are three types of weight:

In certain countries it is prohibited to use lead wei-ghts. Instead, ZAMAK weights are recommended.

Only use weights provided by the Parts Department.

II - WHEEL REMOVAL AND WHEEL BALANCING

Place the vehicle on a two-post lift immediately afterthe road test (see 02A, Lifting equipment, Under-body lift ).

Loosen the wheel bolts.

Raise the vehicle.


Check that the wheels are not damaged due to acci-dental impacts (if they are, replace the damagedcomponents),

Position the wheel so that the valve is at the top.

Fit the pedal press .

Remove:

- the wheel bolts,

- the wheel.

Always clean the bearing surfaces of the wheel anddisc (or drum).

Make sure that the wheel balancer bearing surfaceand all the centring equipment (ring, thrust plate,etc.) are kept clean.

Try not to scratch the (alloy) wheel rim with thewheel tightening device.

The wheel is fitted on the wheel balancer as follows:

- (5) wheel balancer back-plate,

- (6) ring, diameter 60 mm ,

- (7) wheel,

105870

113742

(2) Alloy wheel rim with flange

(3) Alloy wheel rim without flange

(4) Steel wheel rim with flange

105871

35A-7


- (8) wheel tightening device (certain alloy wheelrims need a device 200 mm in diameter to ensurecorrect tightening),

- (9) outer wheel plane.

Place the valve at the top of the wheel balancer,then carry out the tightening procedure.

Remove any grit which may be jammed in the tyretreads.

Enter the specific wheel parameters when startingthe wheel balancer.

Operate the wheel balancer and check the wheelbalance, which should be 0 g on each plane of thewheel.

If this is not the case, remove the old balancing wei-ghts and repeat the wheel balancer procedure,checking that the wheel balance equals 0 on eachwheel plane.

III - REFITTING THE VEHICLE WHEELS

Refit the wheel onto the vehicle in the same positionit was removed with the valve at the top.

Pretighten the wheel bolts (30 Nm) with the wheelhanging freely, starting with the lower bolts (10) andfinishing with the upper bolts (11) .

Remove the pedal press .

100681

WARNING

To avoid detachment of the balancing weights,use only weights which correspond to the vehiclewheel rims.

113180

100682

35A-8


Rotate the wheel through 180˚ to bring the valve intothe bottom position.

Place the vehicle on its wheels.

Torque tighten the wheel bolts (see 35A, Wheelsand tyres, Wheel: Removal - Refitting ).

Carry out these operations on the other wheels ofthe vehicle.

Carry out a road test to confirm the customer com-plaint is resolved.

100683

35A-9

WHEELS AND TYRESWheel: Removal - Refitting 35A

The removal - refitting procedure is the same for allwheels.

REMOVAL

Position the vehicle on a lift (see 02A, Lifting equi-pment, Underbody lift ).

Remove the trim (if fitted to the vehicle).

Loosen the wheel bolts with the wheels on theground.

Raise the lift.

Position the wheel so that the valve is at the top.

Remove:

- the wheel bolts,

- the wheel.

REFITTING

Clean the hub carrier using a wire brush.

there are two types of wheel bolts for aluminium (A)and steel wheel rims (B) ; do not swap them.

Check the condition of the tyre.

Do not move or remove the balancing weights.

Refit the wheel to the vehicle, positioning the valveat the top.

Fit the wheel bolts.

Pretighten the wheel bolts (30 Nm) with the wheelhanging freely, starting with the lower bolts (6) andfinishing with the upper bolts (7) .

Rotate the wheel 180˚ to bring the valve into the lowposition.

Place the vehicle on its wheels.

Tightening torquesm

wheel bolts 110 Nm

110809

113180

100682

35A-10

WHEELS AND TYRESWheel: Removal - Refitting 35A

Tighten to torque and in order the wheel bolts ( 110Nm ) .

Refit the trim (if fitted to the vehicle).

100683

113180

Note:

Use sockets with protective sheaths in order toavoid scratching the aluminium wheel rims.

35A-11

WHEELS AND TYRESTyres: Removal - Refitting

B84 or C84 or S84

35AREMOVAL

I - DETACHING THE BEAD FROM THE OUTSIDE OF THE TYRE

Begin on the opposite side to the valve when deta-ching the bead from the wheel rim.

II - DETACHING THE BEAD FROM THE INSIDE OF THE TYRE

III - REMOVING THE BEAD FROM THE OUTSIDE OF THE TYRE

Position the tyre lever approximately 15 cm from thevalve.

Remove the bead finishing at the valve.

IV - REMOVING THE BEAD FROM THE INSIDE OF THE TYRE

This method is exactly the same as the method forremoving the bead from the outside described in thepreceding paragraph

REFITTING

Soap the tyre beads.

Engage the inside bead at approximately 15 cm af-ter the valve.

Refit the tyre finishing at the valve.

Fit the bead on the outside using the same methodas for the bead on the inside.

Inflate the tyre to the recommended pressure.

18884

WARNING

Make sure that the tyre bead does not pull on thesensor at any point.

WARNING

- Detaching the bead from the inside does notpresent any particular difficulties.

- Make sure that the tyre bead does not pull onthe sensor at any point.

18885

WARNINGMake sure that the tyre bead does not pull on thesensor at any point.

WARNING


35A-12


TYRE PRESSURE SENS.

35ABecause a tyre pressure monitoring sensor is fitted inthe wheel, precautions must be taken when removing/refitting tyres. Not following these recommendationscan lead to damage to the sensor and result in tyrepressure monitoring system operational faults.

REMOVAL


Remove the wheels concerned (see 35A, Wheelsand tyres, Wheel: Removal - Refitting ).

Remove the valve mechanism.

Lift off the bead from the outside of the tyre, startingwith the side opposite the valve.

Detach the bead from the inside of the tyre.

Position the tyre lever approximately 15 cm from thevalve on the outside of the wheel rim.

Remove the tyre bead, finishing at the valve.

Position the tyre lever approximately 15 cm from thevalve on the outside of the wheel rim in order to re-move the bead from inside the tyre.

Remove the tyre bead, finishing at the valve.

REFITTING

Apply soap to the two tyre beads.

Insert the lower tyre bead approximately 15 cm afterthe valve.

Finish fitting the tyre at the valve.

Fit the exterior bead approximately 15 cm after thevalve using the tyre lever.

Inflate the tyre.

Refit the valve mechanism.

Inflate the tyre to the recommended pressure (see35A, Wheels and tyres, Tyre pressure: Identifica-tion ).

Balance the wheel (see 35A, Wheels and tyres,Wheel: Balancing ).

18884

WARNING


Note:

Detaching the tyre bead from the inside does notpresent any particular difficulties.

18885

Note:

The tyre pressure monitoring system sensordoes not need to be removed when removing atyre.

35A-13


TYRE PRESSURE SENS.

35ARefit the wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting ).

35A-14


WITHOUT TYRE PRESSURE SENS.

35AREMOVAL


Remove the wheels concerned (see 35A, Wheelsand tyres, Wheel: Removal - Refitting ).

Remove the valve mechanism.

Detach:

- the bead from the outside of the tyre,

- the bead from the inside of the tyre.

Position the tyre lever on the outside of the wheelrim in order to remove the bead on the outside of thetyre.

Remove the exterior bead.

Position the tyre lever on the outside of the wheelrim in order to remove the bead on the inside of thetyre.

Remove the interior bead.

REFITTING

Always replace the valve.

Apply soap to the two tyre beads.

Fit the lower bead.

Fit the tyre.

Fit the exterior bead using the tyre lever.

Inflate the tyre.

Refit the valve mechanism.

Inflate the tyre to the recommended pressure (see35A, Wheels and tyres, Tyre pressure: Identifica-tion ).

Balance the wheel (see 35A, Wheels and tyres,Wheel: Balancing ).


18885

35B-1

TYRE PRESSURE MONITORSSPP: List and location of components 35B

The system consists of:

- four pressure sensors (1) built into the valves (one perwheel); the sensors transmit a radio signal,

- a computer (2) which collects, decodes and proces-ses sensor signals, and then determines which mes-sage to display,

- a display (3) built into the instrument panel.

102413

Note:

Each sensor is identified by a coloured marking around the valve:

- green = front left-hand,

- yellow = front right-hand,

- red = rear left-hand,

- black = rear right-hand.

35B-2

TYRE PRESSURE MONITORPressure sensor: Operation 35B

The pressure sensor comprises:

- a conventional valve,

- a pressure sensor,

- a temperature sensor,

- an acceleration sensor,

- a specific radiofrequency transmitter,

- a non-removable battery.

OPERATION

The sensors (supplied by an integrated battery) regu-larly measure the internal pressure, temperature andacceleration of the tyres. They transmit these signalsand their code to the receiver (integrated into the UCH)via radio waves.

Programming the four sensors into the UCH

If replacing valves, carry out sensor programmingusing the diagnostic tool .

Do not swap the wheels if they have been removed.

When replacing the UCH:

- configure the recommended pressures,

- program the sensors using the (Ms. 1607) and thediagnostic tool .


Ms. 1607 SSPP wheel valveactivation tool.

Equipment required

diagnostic tool

102415

Note:

Each sensor is identified by a coloured marking round the valve:

- green = front left-hand,

- yellow = front right-hand,

- red = rear left-hand,

- black = rear right-hand.

WARNING

Be sure to follow the colour coding, so that the sys-tem displays the signals correctly. Each sensor hasits own unique computer code.

Note:

A second set of two or four-wheel sensors can beidentified by the UCH. It is important to keep thecolours in their correct positions.

Note:

In order that the UCH can recognise two or fouradditional wheels fitted with sensors, it must be pro-grammed when the wheels are first fitted. The sys-tem subsequently automatically recognises thewheel set which is fitted to the vehicle.

35B-3

TYRE PRESSURE MONITORPressure sensor: Removal - Refitting 35B

REMOVAL


Remove:

- the wheels (see 35A, Wheels and tyres, Wheel:Removal - Refitting ).

- the tyres (see 35A, Wheels and tyres, Tyres: Re-moval - Refitting ).

Remove:

- the retaining nut (1) , holding the pressure sensor(2) on the rim,

- the pressure sensor (2) .

I - RIGID TYRE PRESSURE MONITOR VALVE

The following parts must be replaced:

- the seal (3) ,

- the mechanism (4) ,

- the cap (5) ,

- the retaining nut (6) .

If necessary, replace:

- the coloured marker (7) .

Equipment required

diagnostic tool

Tightening torquesm

tyre pressure monitorrigid sensor retainingnut

7.5 Nm

tyre pressure monitorhinged sensor retainingnut

8.5 Nm

112627

18887

35B-4


II - HINGED TYRE PRESSURE MONITOR VALVE


- the seal with the metal ring (8) ,


- the retaining nut (10) ,

- the cap (11) .


- the coloured marker (12) .

III - ALL TYPES

Make sure that the sensor is correctly positioned on the wheel rim:

- figure 1 = fitted incorrectly,

- figure 2 = fitted correctly.

Position the sensor in the valve opening, checkingthat the seal is attached all around the edge of theopening.

Manually tighten the retaining nut, holding the pres-sure sensor in contact with the rim.

For hinged tyre pressure monitor valves, gentlypress the cap towards the centre of the wheel, kee-ping the sensor support on the rim to modify the val-ve/sensor angle to the rim profile.

Tighten the nut manually.

Tighten to the corresponding torque:

- the tyre pressure monitor rigid sensor retainingnut ( 7.5 Nm ) ,

- the tyre pressure monitor hinged sensor retai-ning nut ( 8.5 Nm ) .

Refit the tyres (see 35A, Wheels and tyres, Tyres:Removal - Refitting ).

Balance the wheels (see 35A, Wheels and tyres,Wheel: Balancing )

115168 102242

Note:

After using a tyre repair aerosol, remove the pro-duct residue from the valve with a dry cloth or airgun before refitting it on the wheel rim.

35B-5



If replacing a pressure sensor, carry out the neces-sary operations using the diagnostic tool (see MR366 Fault finding, 35B, Tyre pressure monitor,Replacement of components ).

35B-6

TYRE PRESSURE MONITORPressure sensor: Repair 35B

REPLACEMENT


- the seal (1) ,


- the cap (3) .


- the retaining nut (4) ,

- the colour marking (5) .

Position the sensor in the valve opening, checkingthat the seal is attached around the entire edge ofthe opening.

Tighten to torque the tyre pressure monitor sen-sor retaining nut ( 0.8 daNm ) .

Tightening torquesm

tyre pressure monitorsensor retaining nut

0.8 daNm

18887

5

4

3

2

1102242

WARNING

Make sure that the sensor is in the correct posi-tion on the wheel rim:

- figure 1 = incorrect refit,

- figure 2 = correct refit.

Note:

After a tyre repair aerosol has been used, cleanthe valve before refitting it to the rim.

2

1

35B-7

TYRE PRESSURE MONITORTyres: Replacement 35B

REMOVAL

I - DETACHING THE BEAD FROM THE OUTSIDE OF THE TYRE

When detaching the bead from the wheel rim, beginon the opposite side to the valve.

II - DETACHING THE BEAD FROM THE INSIDE OF THE TYRE

III - REMOVING THE BEAD FROM THE OUTSIDE OF THE TYRE

Position the tyre lever approximately 15 cm from thevalve.

Remove the bead finishing at the valve.

IV - REMOVING THE BEAD FROM THE INSIDE OF THE TYRE

This procedure is exactly the same as the methodfor removing the bead from the outside described inthe preceding paragraph

REFITTING

Soap the tyre bead correctly.

Engage the inside bead at approximately 15 cm af-ter the valve.

Refit the tyre finishing at the valve.

Fit the bead on the outside using the same procedu-re as for the bead on the inside.

Inflate the tyre to the recommended pressure.

18884

WARNING


WARNING

- Detaching the bead from the inside does notpresent any particular difficulties.

- Make sure that the tyre bead does not pull onthe sensor at any point.

18885

WARNING


WARNING


35B-8

TYRE PRESSURE MONITORConfiguration 35B

I - VALVE IDENTIFICATION CODE

Programming the four valve codes

Establish dialogue with the UCH using the diagnos-tic tool .

Select the « Repair mode menu » .

Select the « Programming menu » .

Select the « SC002: Programming the four valvecodes » line in the « tyres function » .

A table of stored codes and valve sets detected isdisplayed.

By default, the diagnostic tool displays the« summer » set when the UCH is replaced.

Confirm by selecting « next » .

Select the « Valve set selection menu » and then« summer » or « winter » .

Validate to obtain the « Valve programmingconditions » table.

Confirm by selecting « next » to access the« search for valve codes menu. »

Follow the procedure displayed in the « Help » win-dow.

Confirm to save the codes.

Adjust the tyres to the recommended pressure.

II - READING THE CODES FOR THE DIFFERENT TYRES (SUMMER / WINTER)

Select the « Repair mode menu » .


Select the « SC001: Reading the valve set andstored valve codes » line in the « Tyresfunction » .

III - RECOMMENDED PRESSURES FOR THE VEHICLE

Depending on the tyres actually fitted to the vehicle,check the recommended pressures given on the la-bel on the driver's door rabbet ( (see 30A, GeneralVehicle Information) ) or in the driver's handbookfor the vehicle( (see Specifications) .

1 - Procedure for writing or modifying recommended pressures

Select the « repair mode menu » .


Select in the « tyres sub-function » line « SC007:entering the recommended tyre pressures » .

2 - Reading recommended pressures

The maximum and minimum recommended pressu-res for the vehicle can be displayed by selecting:

- the « tyres function » .

- the « tyre management sub-function » .

- Select the lines:

• « PR009: recommended pressure low-speedfront axle » ,

• « PR010: Recommended pressure low-speedrear axle » ,

• « PR011: Recommended pressure high-speed front axle » ,

• « PR012: Recommended pressure high-speed rear axle » ,

IV - TYRE PRESSURE MONITOR

The pressures can be displayed by selecting:

- the « tyres function »

- the « fault finding mode menu »

- the « reading statuses and parametersfunction »

- the « tyre reception sub-function »

Equipment required

diagnostic tool

WARNING

It is essential to follow the instructions displayedon the diagnostic tool screen.

WARNING

It is essential to follow the order of confirmationgiven in the table.

WARNINGThe time between programming the two valvesmust be limited to two minutes, otherwise theprocedure will be interrupted.

35B-9

TYRE PRESSURE MONITORConfiguration 35B

- Select the lines:

• « PR003 : front left-hand tyre pressure » ,

• « PR004: Front right-hand tyre pressure » ,

• « PR005: Rear right-hand tyre pressure » ,

• « PR006: Rear left-hand tyre pressure » ,

Note:

If the battery has been disconnected, the fourparameter readings are 3.5 bar for as long as thevehicle speed does not exceed 12 mph (20 km/h) .

36A-1

STEERING ASSEMBLYAxial ball joint linkage: Removal - Refitting 36A

REMOVAL


Remove:

- the front wheel on the side concerned (see 35A,Wheels and tyres, Wheel: Removal - Refitting ),

- the track rod end nut.

Extract the track rod end using the (Tav. 476) .

Loosen the wheel alignment adjusting lock nut.

Remember the number of thread turns captured, forpresetting the wheel alignment when refitting.

Remove:

- the ball joint housing,

- the lock nut,

- the gaiter retaining clips,

- the gaiter.

Position the (Dir. 1306-04) (1) on the steering rodon the pinion side.

Unlock the axial ball joint using the (Dir. 1305-01)(2) .

Remove the axial ball joint.

REFITTING

Always fit a new washer (3) .

Refit:

- the washer (3) ,

- the axial ball joint (4) .

Tighten to torque the axial ball joint ( 80 Nm ) usingthe (Dir. 1305-01) .

Coat the following parts with lithium grease:

- the steering rack,

- the axial ball joint.

Refit:

- the gaiter,

- the metal clip,



Dir. 1306-04 Tool for locking stee-ring rack.

Dir. 1305-01 Tool for removing/refit-ting 35 mm to 41 mmdiameter axial balljoints.

Tightening torquesm

axial ball joint 80 Nm

wheel alignment adjust-ment lock nut

53 Nm


Note:

During this operation, the steering box must be inplace on the vehicle.

WARNING

Take care not to deform the gaiters: they couldbe irreparably damaged.

102206

101355

1

2

34

36A-2

STEERING ASSEMBLYAxial ball joint linkage: Removal - Refitting 36A

- the new plastic clip, the same as the original fitting,

- the lock nut,

- the ball joint housing.

Retighten the track rod end housing by the numberof rotations noted during removal.

Reposition the track rod end.

Tighten to torque:

- the wheel alignment adjustment lock nut ( 53Nm ) ,

- the track rod end nut ( 37 Nm ) .

Refit the wheel (see 35A, Wheels and tyres,Wheel: Removal - Refitting ).

Adjust the axle assemblies (see 30A, General infor-mation, Front axle assemblies values and set-tings ).

Adjust the xenon headlight system (see 80C, Dis-charge bulbs, Xenon headlights: Adjustment ).

36B-1

POWER ASSISTED STEERINGDescription 36B

The assistance varies according to the speed.

Electric power assisted steering computer101938

2

1

5

4

3

(1) Electrical power assisted stee-ring computer fitted with a tor-que and angle sensor

(2) Electric stepper motor withworm screw

(3) Reducer pinion

(4) Intermediate shaft

(5) Universal joint in the passengercompartment

IMPORTANT

- Never carry out work on the constituent parts ofthe electric power assisted steering columnassembly.

- If a mechanical fault finding procedure on thefunction requires two people, the battery must bedisconnected.

103746

3

11

2

10

71

69

5

84

36B-2

POWER ASSISTED STEERINGDescription 36B

Mark Description

Inputs

1 Vehicle speed signal (communicated by the Anti-lock Braking System computer)

2 Engine status signal (in operation, idle, being actuated by the starter or stalled)

3 CAN bus status signal

4 Diagnostic socket

5 + after ignition feed

6 Power supply (permanent +)

Outputs

7 Angle sensor signal (Electronic Stability Program signal)

8 Instrument panel signals

9 Diagnostic socket

Mark Description

10 CAN connection

11 Wire connection

WARNING

In the event of a malfunction, the trip computer dis-plays the warning messages:

- message « Check steering » accompanied by the« Service » warning light coming on,

- message « Faulty steering » accompanied by the« Stop » warning light coming on,

- flashing (at a frequency of 8 Hz ) of the« Service » warning light indicates that the stee-ring angle is not calibrated (blank computer).

Note:

- On starting, the « Service » warning light switcheson for 3 seconds .

- During fault finding, the « Service » warning lightflashes at a frequency of 2 Hz .

36B-3

POWER ASSISTED STEERINGSteering rack: Removal - Refitting 36B

REMOVAL

Centre the vehicle over a two-post lift.



In the passenger compartment, remove:

- the bolt,

- the cam nut from the universal joint.



Disconnect the battery, starting with the negativeterminal (see 80A, Battery, Battery: Removal - Re-fitting ).

Remove:

- the sub-frame (see 31A, Front axle assemblies,Front axle sub-frame: Removal - Refitting, page31A-26) ,

- the two steering box mounting bolts,

- the steering box.

REFITTING

The steering box arm, universal joint and sub-framemountings must be replaced.

Tighten to torque the steering box mounting boltson the sub-frame ( 105 Nm ) .





Adjust the axle assemblies (see 30A, General infor-mation, Front axle assemblies values and set-tings ).

Initialise the discharge bulb system (if fitted to thevehicle); (see MR Fault finding, 80C, Dischargebulbs, Configuration and programming ).

Equipment required

steering wheel lock

Tightening torquesm

steering box mountingbolts on the sub-frame

105 Nm

WARNING

- A 10 mm thick shim must be placed betweenthe radiator cross member and the sub-frame totighten the radiator cross member mountings tothe recommended torque.

- The wheels must be set straight ahead; centrethe steering wheel.

116021

116022

Note:


36B-4

POWER ASSISTED STEERINGIntermediate shaft 36B

CHECKING

These vehicles are fitted with a non-removable« intermediate shaft / steering wheel shaft / steeringcolumn » assembly. If it is not possible to fit the uni-versal joint eccentric bolt, or after an impact, checkthat the length of the shaft is correct.

If the length of the intermediate shaft is incorrect, re-place the steering column assembly, (see 36B,Power assisted steering, Steering column: Re-moval - Refitting, page 36B-6) .

Check that: L = 269.35 +/- 1 mm

WARNING

Never pull the intermediate shaft (after animpact).

92218

36B-5

POWER ASSISTED STEERINGBulkhead seal: Removal - Refitting 36B

REMOVAL

Centre the vehicle over a two-post lift.

Straighten the wheels.


In the passenger compartment, remove:

- the bolt,

- the cam nut from the universal joint.



Remove the battery cover.

Disconnect the battery starting with the negative ter-minal.

Remove the sub-frame (see 31A, Front axle as-semblies, Front axle sub-frame: Removal - Refit-ting, page 31A-26) .

Unclip the bulkhead seal using a screwdriver.

REFITTING

To refit, proceed in the reverse order to removal.

Equipment required

steering wheel lock

101352

36B-6

POWER ASSISTED STEERINGSteering column: Removal - Refitting 36B

These operations do not require a lift.

REMOVAL

Lock the airbag computer (see MR 366 Fault fin-ding, 88C, Airbag - Seat belt pretensioners, Con-figuration and programming ).


Unclip:

- the sump access flap,

- the side panel,

- the headlight adjustment control.

Remove the bolts (1) .

Disconnect the remote adjustment control connec-tors.

Tightening torquesm

electric lock mountingbolt

8 Nm

steering column moun-ting nuts

21 Nm

universal joint bolt 30 Nm

casing bolts 2 Nm

steering wheel bolt 44 Nm

IMPORTANT

Never handle the pyrotechnic systems (airbag andpretensioners) near a heat or flame source; there isa risk of triggering.

IMPORTANT

It is essential to lock the airbag computer using thediagnostic tool before removing it. When this func-tion is activated, all the trigger lines are inhibitedand the airbag warning light on the instrumentpanel is lit continuously (ignition on). Locking theairbag computer also allows the electric steeringcolumn lock to be released.

101194

101196

101197

111

36B-7


Unclip the air duct (3) at (4) .

Fold the air duct (3) down at (5) .

Lift the air duct at (6) .

Remove the air distribution duct (3) .

Insert a screwdriver in the opening behind the stee-ring wheel.

Unlock the system (7) .

Remove the driver's front airbag.

Disconnect the airbag connector.


Disconnect the connectors in the steering wheel.

Remove:

- the steering wheel bolt,

- the steering wheel.

102211

6

3

54

2

18455

7

36B-8


Remove:

- the three lower bolts (8) ,

- the upper and lower casing.

Mark the position of steering column switch assem-bly.

Check that the « 0 » mark on the rotary switch (9) iscorrectly positioned opposite the index.

Remove the steering column switch assembly.

Loosen the bolt (10) .

Unclip the steering column assembly.

Disconnect:

- the various connectors (wiper, radio and lightingcontrol),

- the rotary switch connector.

101202

88

101203

9

10

36B-9


Remove both bolts (11) .

Unclip both upper clips (12) .

Partially remove the second lower casing.

Remove the instrument panel visor.

Remove the upper bolt (13) .

Press the two clips (14) .

Remove the instrument panel.

Disconnect the instrument panel connector.

Partially remove the carpet on the driver's side.

101204

101205

12

11

101206

101282

13

14

36B-10


Discard the cover (15) (do not keep it).

Remove the steering column universal joint bolt.

Disconnect:

- the steering column lock connector,

- the power-assisted steering computer power con-nector using a screwdriver 4 mm wide and 0.5 mmthick,

- the power-assisted steering computer signal con-nector using a screwdriver 4 mm wide and 0.5 mmthick.

Unclip the rotary switch wiring harness from thesteering column.

Access the mounting nuts (16) from behind the stee-ring column, between the steering column interme-diate shaft and the brake pedal.

Remove the nuts.

Remove both steering column mounting nuts (17) .

Special note for right-hand drive

Access the steering column front mounting nuts viathe dashboard openings (18) .

Unclip the locator.

104020

101350

15

16

101353

102202

17

18

36B-11


Remove the steering column.

Remove the adjustment handle.

Remove the two steering column front mountingnuts.

Unclip the locator.

Remove the steering column.

REFITTING

Tighten to torque the electric lock mounting bolt (8 Nm ) .

The universal joint cam nut and bolt and the steeringwheel bolt must be replaced.


Ensure that the universal joint cam nut and bolt arefitted the right way round.

Refit the universal joint.

Refit the cam nut and the joint bolt.

Finger tighten the cam nut and the joint bolt.

Immobilise the cam nut in its housing (on the univer-sal joint).

Pretighten the universal joint nut and bolt.

Note:

- If the steering column is being replaced,remove the column lock.

- The column lock is attached by a bolt with a left-handed thread.

Note:

Remove the locator if it is damaged when thesteering column is removed.

Note:

- If replacing the electric lock (see MR 366 Faultfinding, 36B, Electric power-assisted stee-ring, Replacement of components ).

- Remove the locator if it is damaged when thesteering column is removed. Do not replace itwhen refitting the steering column.

- Do not refit the cover (19) .

- The universal joint cam nut is pre-fitted on anew steering column.

WARNING

Push and pull on the electric power-assistedsteering computer power and signal connectorsto check that they are properly secured (risk ofloss of assistance).

104020

36B-12




Tighten to torque:

- the steering column mounting nuts ( 21 Nm ) ,

- the universal joint bolt ( 30 Nm ) ,

- the casing bolts ( 2 Nm ) ,

- the steering wheel bolt ( 44 Nm ) .

Lock the steering column in the high position.



Refit the lower section of the dashboard and the ca-sing.

Unlock the airbag computer (see MR 366 Fault fin-ding, 88C, Airbag - Seat belt pretensioners, Con-figuration and programming ).

116021

116022

Note:

Take care to route the remote adjustment controlwiring harness above the air duct.

Note:


36B-13

POWER ASSISTED STEERINGSteering wheel: Removal - Refitting

B84 or C84

36B

REMOVAL

Lock the airbag computer (see 88C, Airbags - Pre-tensioners, Airbag computer locking procedure).


Remove the driver's frontal airbag (see 88C, Air-bags - Pretensioners, Driver's frontal airbag: Re-moval - Refitting ).


Disconnect the connectors (depending on equip-ment level).

Remove the steering wheel mounting bolt (1) .

Remove the steering wheel carefully to avoid dis-connecting the rotary switch connectors.

REFITTING

The steering wheel bolt must be replaced with a newone whenever it is removed.


Tighten to torque the steering wheel mountingbolt ( 44 Nm ) .

Refit the driver's frontal airbag (see 88C, Airbags -Pretensioners, Driver's frontal airbag: Removal -Refitting ).


Equipment required

diagnostic tool

Tightening torquesm

steering wheel moun-ting bolt

44 Nm

IMPORTANT

It is essential to lock the airbag computer using thediagnostic tool before starting the removal. Whenthis function is activated, all the trigger lines areinhibited and the airbag warning light on the instru-ment panel is lit continuously (ignition on). Lockingthe airbag computer also allows the electric stee-ring column lock to be released.

IMPORTANT

Handling pyrotechnic systems (airbags or preten-sioners) near to a source of heat or flame is forbid-den: there is a risk of triggering the airbags orpretensioners.

101201

WARNING

- Push and pull on the electric power assistedsteering computer power and signal connec-tors to check that they are properly secured(risk of loss of assistance).

- The steering wheel should enter the splinesfreely (the splines have foolproofing devices).

- Do not damage the foolproofing splines.

36B-14

POWER ASSISTED STEERINGSteering wheel: Removal - Refitting

B84 or C84

36BIf all is correct, unlock the airbag computer (see 88C,Airbags - Pretensioners, Airbag computer loc-king procedure ).

37A-1

MECHANICAL COMPONENT CONTROLSMaster cylinder: Removal - Refitting

F9Q or K4J or K4M or K9K or M9R, and DG

37A

REMOVALPosition the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).

Remove:

- the battery (see 80A, Battery, Battery: Removal -Refitting ),

- the battery tray mounting bolts,

- the battery tray - injection computer assembly.

Unclip the turbocharger regulation solenoid valve (1).

Disconnect the air flowmeter connector.

Tightening torquesm

master cylinder reser-voir mounting bolt

8.5 Nm

master cylinder moun-ting nuts

50 Nm

brake pipe nuts 17 Nm

WARNING

Prepare for brake fluid outflow, to prevent damageto the mechanical parts and bodywork around thebraking system.

F9Q or M9R

101889

1

37A-2



37A

Remove the air resonator.

Remove:

- the front left-hand wheel (see 35A, Wheels and ty-res, Wheel: Removal - Refitting ).

- the wheel arch liner.

Remove both air resonators (2) .

Remove:

- the air inlet sleeve (3) ,

- the air sleeve (4) ,

- the air sleeve after the air filter unit,

- the air filter unit (5) (see 12A, Fuel mixture, Air fil-ter unit: Removal - Refitting (in particular forM9R)).

K4J

101103

K4J or K4M or K9K

101955

2

101808

5

4

3

37A-3



37A

Disconnect the electrical connector (6) from themaster cylinder reservoir.

Drain the master cylinder reservoir with a syringe.

Remove:

- the heat shield retaining clip,

- the clutch master cylinder pipe (7) ,

- the brake pipes (8) from the master cylinder,

- the nuts (9) securing the master cylinder on thebrake servo,

- the master cylinder assembly and the master cylin-der reservoir,

- the master cylinder reservoir mounting bolts (10) ,

- the master cylinder reservoir.

REFITTING

Clip the master cylinder reservoir onto the mastercylinder correctly.

Refit the bolt securing the master cylinder reservoirto the master cylinder.

Tighten to torque the master cylinder reservoirmounting bolt ( 8.5 Nm ) .

101700

10

76

9

8

101704

WARNING

Be sure to replace the master cylinder seals (11).

37A-4



37A

Line up the master cylinder with the brake servo sothat the pushrod goes into the master cylinder hou-sing.

Refit the nuts securing the master cylinder to thebrake servo.

Tighten to torque the master cylinder mountingnuts ( 50 Nm ) on the brake servo.


Tighten to torque the brake pipe nuts ( 17 Nm ) onthe master cylinder.



101711

WARNING

When refitting the master cylinder, be sure thecup is centred in the brake servo.

37A-5

MECHANICAL COMPONENT CONTROLSBrake servo: Removal - Refitting

F4R or K4J or K4M or K9K

37A



Remove the engine cover.

Remove the master cylinder (see 37A, Mechanicalcomponent controls, Master cylinder: Removal -Refitting, page 37A-1) .

Tightening torquesm

brake servo mountingnuts

21 Nm

Note:

It is impossible to remove the brake servo pushrod.

WARNING


37A-6



37A

Remove:

- the gear lever upper ball joint (1) (see 37A, Mecha-nical element controls, External gear control:Removal - Refitting ),

- the gearbox control cable sleeve stop (2) .

101698

101743

12

1

2

103113

WARNING

Do not touch the system of adjustment on theND gearbox selector cables, as this would alterthe length of the cable and consequently themovement of the gear lever.

37A-7



37A

Remove the brake pedal clevis pin (3) from the bra-ke servo pushrod in the passenger compartment.

Remove:

- the plenum chamber partition mounting clips (4) ,

- the brake servo mounting bolts (5) .

REFITTING

Check the following dimension before refitting:

- for left-hand drive vehicles: (X1) = 163.7 mm ,

- for right-hand drive vehicles: (X1) = 133.2 mm .


Tighten to torque the brake servo mounting nuts (21 Nm ) .

Refit the master cylinder (see 37A, Mechanicalcomponent controls, Master cylinder: Removal -Refitting, page 37A-1) .



Adjust the brake pedal position switch( (see Brakelight switch: Removal - Refitting) .

102245

101698

3

5

4

91101

IMPORTANT

Check that the brake servo pushrod-brake pedalconnecting shaft is locked in place.

37A-8


F9Q

37A



Remove the engine covers.

Remove the master cylinder (see 37A, Mechanicalcomponent controls, Master cylinder: Removal -Refitting, page 37A-1) .

Remove:

- the exhaust gas recirculation valve mounting bolts(1) ,

- the exhaust gas recirculation valve (2) ,

- the gearbox control ball joints .

Tightening torquesm

brake servo mountingbolts

21 Nm

gear lever sheath sup-port mounting bolts

21 Nm

exhaust gas recircula-tion valve mountingbolts

9 Nm

WARNING

Drain the brake fluid to prevent damage to themechanical parts and bodywork around the bra-king system.

102244

2

111

37A-9


F9Q

37A

Remove:

- the gear lever ball joints (5) (see 37A, Mechanicalelement controls, External gear control: Remo-val - Refitting ).

- the sheath stop support mounting bolts (4) ,

- the sheath stop support.

103494

101743

5

4

103113

WARNING

Do not touch the system of adjustment on theND gearbox selector cables, as this would alterthe length of the cable and consequently themovement of the gear lever.

37A-10


F9Q

37A

Remove the brake pedal clevis pin from the brakeservo pushrod at the passenger compartment side.

Remove:

- the scuttle panel partition mounting clips (6) ,

- the brake servo mounting bolts (7) , at the enginecompartment side.

REFITTING

Check the following dimension before refitting:

- for left-hand drive vehicles: (X1) = 163.7 mm ,

- for right-hand drive vehicles: (X1) = 133.2 mm .


Tighten to torque:

- the brake servo mounting bolts ( 21 Nm ) ,

- the gear lever sheath support mounting bolts (21 Nm ) ,

- the exhaust gas recirculation valve mountingbolts ( 9 Nm ) .

Refit the master cylinder (see 37A, Mechanicalcomponent controls, Master cylinder: Removal -Refitting, page 37A-1) .




102245

101698

7

6

91101

IMPORTANT


37A-11


M9R, and DG

37A



Remove:

- the engine cover,

- the scuttle panel grille (see MR 365, 55A, Exteriorprotection, Scuttle panel grille: Removal - Refit-ting ).

- the soundproofing underneath the scuttle panelgrille,

- the battery (see 80A, Battery, Battery: Removal -Refitting ).

- the air filter unit with the injection computer (see12A, Fuel mixture, Air filter unit: Removal - Re-fitting ).

- the master cylinder (see 37A, Mechanical compo-nent controls, Master cylinder: Removal - Refit-ting, page 37A-1) .

Unclip the vacuum pipe (1) from the air inlet duct.

Disconnect the oil vapour rebreathing pipe (2) .

Undo the air inlet duct retaining clip (3) on the turbo-charger.

Remove:

- the air inlet duct,

- the clip (4) .

On the passenger compartment side, remove theshaft connecting the brake servo pushrod and thebrake pedal, after removing the circlip from the endof the connecting shaft.

Tightening torquesm

servo support mountingnuts

21 Nm

brake servo mountingbolts

21 Nm

WARNING


115165

102245

37A-12


M9R, and DG

37A

Remove:

- the non-return valve,

- the brake servo mounting bolts (5) , on the enginecompartment side.

Move the servo forwards.

Remove the nuts (6) from the servo support.

Position the servo support on the servo.

Compress the servo pushrod using a screwdriver inorder to remove the pushrod from its opening.

Remove:

- the servo with its support,

- the servo support.

101698

115162

115163

37A-13


M9R, and DG

37AREFITTING

Check the following dimension before refitting: (X1)= 163.7 mm .


Tighten to torque:

- the servo support mounting nuts ( 21 Nm ) ,

- the brake servo mounting bolts ( 21 Nm ) .

Refit:

- the master cylinder (see 37A, Mechanical compo-nent controls, Master cylinder: Removal - Refit-ting, page 37A-1) .

- the air filter unit with the injection computer (see12A, Fuel mixture, Air filter unit: Removal - Re-fitting ),

- the battery (see 80A, Battery, Battery: Removal -Refitting ),

- the soundproofing underneath the scuttle panelgrille,

- the scuttle panel grille (see MR 365, 55A, Exteriorprotection, Scuttle panel grille: Removal - Refit-ting ),

- the engine cover.




91101

IMPORTANT


37A-14

MECHANICAL COMPONENT CONTROLSBrake servo non-return valve

F4R or K4J

37AREMOVAL


Loosen the clips (1) from the air duct.

Remove the air duct (2) .

Disconnect the vacuum pipe on the brake servo side(3) .

Pull and turn the non-return valve to release it fromthe rubber sealing washer.

Disconnect the vacuum pipe on the inlet manifoldside (4) .

REFITTING

Check the condition of the sealing washer and thenon-return valve.



101807

103492

Note:

Do not damage the vacuum tube on the plenumchamber. If it is damaged, the plenum chamberwill have to be replaced.

1

2

34

37A-15

MECHANICAL COMPONENT CONTROLSBrake servo non-return valve

F9Q or K9K

37AREMOVAL


Remove the air unit duct.



Disconnect the vacuum pipe on the vacuum pumpside (2) .



Disconnect the vacuum pipe at the vacuum pumpend (2) .

REFITTING

Check the condition of:

- the sealing washer,

- the return valve.



K9K

103564

1

2

F9Q

103567

2 1

37A-16

MECHANICAL COMPONENT CONTROLSVacuum pump: Removal - Refitting

K9K

37A

REMOVAL


Remove:

- the hose connected to the brake servo,

- the vacuum pump mounting bolts (1) ,

- the vacuum pump.

REFITTING


Tighten the vacuum pump mounting bolts to a tor-que of ( 2.1 daNm ) .

Tightening torquesm

to a torque of 2.1 daNm

103565

1

37A-17


F9Q

37A

REMOVAL


Remove:

- the inlet manifold mounting bolts,

- the inlet manifold,

- the hose connected to the brake servo,


- the vacuum pump.

REFITTING


Tighten to torque:

- the vacuum pump mounting bolts ( 2.1 daNm ) ,

- the inlet manifold mounting bolts ( 0.8 daNm ) .

Tightening torquesm

vacuum pump moun-ting bolts

2.1 daNm

inlet manifold mountingbolts

0.8 daNm

103566

111

37A-18


M9R

37A

REMOVAL

Remove:

- the engine cover,


Disconnect:

- the computer connectors (1) ,

- the air flowmeter connector.

Unclip:

- the wiring harness (2) from the computer connec-tor,

- the battery negative terminal connector wiring har-ness,

- the turbocharging regulation solenoid valve fromthe air filter unit,

- the wiring harness.

Remove:

- the battery tray mounting bolts (3) ,

- the mounting nut (4) from the wiring harness.

Move the electric wiring harness to one side.

Remove the battery tray with the injection computersupport.

Tightening torquesm

vacuum pump moun-ting bolts

21 Nm

diesel pipe retainingbracket mounting bolt

14 Nm

battery tray mountingbolts

21 Nm

112659

37A-19


M9R

37A

Disconnect:

- the vacuum pipe (5) ,

- the non-return valve (6) .

Remove:

- the mounting bolt (7) from the diesel pipe retainingbracket,

- the diesel pipe retaining bracket,

- the mounting bolt (8) from the vacuum pump.

Unclip the harness at (9) .

Remove:


- the vacuum pump.

REFITTINGBe sure to replace the vacuum pump seal.


Tighten to torque:

- the vacuum pump mounting bolts ( 21 Nm ) ,

- the diesel pipe retaining bracket mounting bolt( 14 Nm ) .

Refit the battery tray with the injection computer sup-port.

Fit the wiring harness.

Refit:

- the wiring harness mounting nut,

- the battery tray mounting bolts.

Tighten to torque the battery tray mounting bolts (21 Nm ) .

Fit the wiring harness.

Refit the turbocharging regulation solenoid valve onthe air filter unit,

Fit:

- the battery negative terminal connector wiring har-ness,

115167 115166

37A-20


M9R

37A- the wiring harness to the computer connector,

Connect the injection computer connectors.

Refit:


- the engine cover.

37A-21

MECHANICAL COMPONENT CONTROLSAccelerator pedal: Removal - Refitting 37A

REMOVALSwitch off the ignition.

Disconnect connector (1) from the accelerator pedalpotentiometer.

Remove:

- the accelerator pedal mounting nuts (2) ,

- the accelerator pedal.

REFITTINGProceed in the reverse order to removal.

Tighten to torque the accelerator pedal mountingnuts ( 8 Nm ) .

Tightening torquesm

accelerator pedalmounting nuts

8 Nm

116018

37A-22

MECHANICAL COMPONENT CONTROLSBrake pedal: Removal - Refitting

DG

37A

REMOVAL

Pull back the carpet on the driver's side.

Disconnect the accelerator pedal sensor (1) .

Turn the brake pedal position sensor (1) a quarter ofa turn anti-clockwise.

Remove:

- the brake pedal position sensor,

- the brake pedal clevis from the brake servo pushrod,

- the brake pedal clevis securing nuts (2) ,

- the brake pedal,

- the accelerator pedal securing nuts,


REFITTING


Tighten to torque the securing nuts on the brakepedal clevis ( 2.1 daNm ) .

Tightening torquesm

securing nuts on thebrake pedal clevis

2.1 daNm

102203

22

1

37A-23


DD

37A

REMOVAL


Remove:

- the dashboard (see 83A, Instrument panel, Dash-board ),

- the steering column (see 36B, Power AssistedSteering, Steering column ).

Disconnect connector (1) from the accelerator pedalposition potentiometer.

Remove:

- mounting bolts (2) from the accelerator pedal,



Fre. 1752 Safety pin

Equipment required

diagnostic tool

Tightening torquesm

brake pedal yokemounting nuts

21 Nm

battery cover bolts 4 Nm

IMPORTANT

- Before carrying out any work on the airbag sys-tem, lock the airbag computer using the diagnos-tic tool (see 88C, Airbags and pretensioners,Airbag computer locking procedure ).

- Do not carry out work on pyrotechnic systems(pretensioner or airbag) near a source of heat or anaked flame; there is a risk of triggering.

WARNING

When the brake pedal is replaced, the pedal is sup-plied fitted with a pin (Fre. 1752)

If removing or refitting (without replacing the brakepedal), it is essential to fit the pin (Fre. 1752) duringthe removal and refitting procedure.

103831

22

1

37A-24


DD

37A

Disconnect the clutch pedal switch.

Remove clutch pedal assembly mounting bolts (3) .

Remove the clutch pedal mounting from its housingwithout removing the master cylinder pipes.

Remove shaft (4) connecting the « brake pedal -idler bar » assembly.

Remove:

- the brake pedal switch,

- brake pedal assembly mounting bolts (5) ,

- the brake pedal mounting, by turning it until it is re-leased from the idler bar.

Cut pin (6) .

Insert pin (Fre. 1752) from left to right (if the pedal isnot replaced).

103829

WARNING

Do not damage the clutch master cylinder pipes.

333

103830

104823

5

4

5555

6

37A-25


DD

37AREFITTING

Cut the pin according to the dotted line (do not remo-ve the pedal pin).

104824

IMPORTANT

The pedal is fitted with an unlocking system inthe event an impact. Do not strike pedal system(7 ) (there is a risk of the pedal being fullydepressed erratically.

Note:

Do not remove the pin before refitting and tighte-ning the pedal assembly.

7

104825

37A-26


DD

37A


Tighten to torque the brake pedal yoke mountingnuts ( 21 Nm ) .

Remove the pin.

Connect the battery, starting with the positive termi-nal.

Tighten to torque the battery cover bolts ( 4 Nm ) .

103858

WARNING

Before refitting, check that fuse board (8) is notdeformed. If there is any deformation on the fuseboard, the brake pedal assembly must be repla-ced.

IMPORTANT

Unlock the computer using the diagnostic tool(see 88C, Airbags and pretensioners, Airbagcomputer locking procedure ).

WARNING

Carry out the necessary programming (see 80A,Battery: Remove and Refit ).

8

37A-27

MECHANICAL COMPONENT CONTROLSBrake pedal bell crank rod: Removal - Refitting

DD

37AREMOVAL

Remove the brake pedal (see 37A, Mechanicalcomponent controls, Brake pedal: Removal - Re-fitting, page 37A-22) .

Turn the brake switch (1) one quarter of a turn anti-clockwise.

Remove:

- the brake switch (1) ,

- the two nuts from the idler bar retaining ring (2) ,

- idler bar retaining ring,

- the shaft (3) connecting the « idler bar - brake ser-vo pushrod » assembly.

Remove the idler bar to the driver's side.

REFITTING


103828

WARNING

Do not damage the clutch master cylinder pipes.

3

2

1

37A-28

MECHANICAL COMPONENT CONTROLSBrake pedal position sensor 37A

REMOVAL

Disconnect the brake pedal position sensor.

Rotate the brake pedal position sensor a quarter of aturn anti-clockwise.

Remove the position sensor from the brake pedal.

REFITTING

It is essential to pull on the end of the sensor to bringit to the minimum position.

The brake pedal position sensor has an automaticadjustment function and adapts according to the pe-dal's position.


102205

37A-29

MECHANICAL COMPONENT CONTROLSParking brake cables: Removal - Refitting 37A

REMOVAL

Place the vehicle on a two-post lift.

Remove the centre console ( (see 57A, Interior ac-cessories) ).

Remove the nut (1) .

Remove the parking brake cables:

- at the parking brake lever end (see 37A, Mechani-cal component controls, Parking brake lever:Removal - Refitting, page 37A-31) ,

- at the brake calliper end ( (see 33A, Rear axle as-semblies) ).

Remove the parking brake cables from their hou-sing.

REFITTING

Refit the parking brake cables into their housing.

Check the handbrake cable stops are correctly posi-tioned at the body end.

Refit the parking brake cables:

- at the brake calliper end ( (see 33A, Rear axle as-semblies) ),

- at the parking brake lever end (see 37A, Mechani-cal component controls, Parking brake lever:Removal - Refitting, page 37A-31) .

Refit the nut.

Ensure that the handbrake cable stops are fully in-serted in their housing.

Tighten the nut so that (X) = 21 mm if the cable slee-ve stop bracket is black, and (X) = 16 mm if the ca-ble sleeve stop bracket is gold.

Operate the parking brake to activate the compen-sation.

101927

1

X

Note:

Always replace the nut (1) .

Note:

When replacing the parking brake cable sleeves,pull the parking brake lever several times beforeadjusting so that (X) = 21 mm if the cable sleevestop bracket is black, and the (X) = 16 mm if thecable sleeve stop bracket is gold.

37A-30

MECHANICAL COMPONENT CONTROLSParking brake cables: Removal - Refitting 37A

Check the detachment of the control lever (2) fromits stop (the clearance must be 1 mm ).

Check the lever stroke.

With the handbrake released, check that the wheelsrotate freely.

Refit the centre console ( (see 57A, Interior acces-sories) ).

24316

2

37A-31

MECHANICAL COMPONENT CONTROLSParking brake lever: Removal - Refitting 37A

REMOVALRemove the centre console (see (see 57A, Interioraccessories) ).

Remove the nut (3) .

Remove the parking brake cables from their housing(1) .

Remove:

- the parking brake lever mounting nuts (2) .

- the parking brake lever.

Disconnect the switch.

REFITTING

Refit:

- the parking brake lever,

- the parking brake lever mounting nuts.

Tighten to torque the parking brake lever moun-ting nuts ( 8 daNm ) .

Refit the parking brake wiring harness clip.

Reconnect the parking brake connector.

Refit the parking brake cables at the parking brakelever end.

Refit the nut.

Ensure that the handbrake cable stops are fully in-serted in their housing.

Tighten the nut so that (X) = 21 mm if the cable slee-ve stop bracket is black, and (X) = 16 mm if the ca-ble sleeve stop bracket is gold in colour.

Operate the parking brake to activate the compen-sation.

Check the detachment of the control lever (4) fromits stop (the clearance must be 1 mm ).

Tightening torquesm

parking brake levermounting nuts

8 daNm

101927

2

2

1

X

3

Note:

Always replace the nut (3) .

24316

4

37A-32

MECHANICAL COMPONENT CONTROLSParking brake lever: Removal - Refitting 37A

Check the lever stroke.

With the handbrake released, check that the wheelsrotate freely.

Refit the centre console ( (see 57A, Interior acces-sories) ).

37A-33

MECHANICAL COMPONENT CONTROLSEmergency brake assistance 37A

Emergency brake assist is a system which supple-ments ABS.

OPERATING PRINCIPLE

Emergency brake assist enables the system to reco-gnise the situation and act immediately to provide thebest possible stopping distance.

Emergency braking is calculated according how quic-kly the brake pedal is depressed; in this situation, bra-king assistance immediately reaches its maximumlevel of output.

The system works conditionally for current braking sys-tems.

The emergency brake assist is a mechanical systembuilt into the brake servo and completely independentof any electronic component.

The brake servo is fitted with a magnet which reacts bylocking the control unit when the pedal is depressedsharply.

102886

1

2

(1) Without emergency brake assist

(2) With emergency brake assist

37A-34

MECHANICAL COMPONENT CONTROLSClutch control: Description 37A

DG

102207

3

2

1

(1) Master cylinder supply pipe(engine compartment)

(2) Master cylinder (engine com-partment - passenger compart-ment connection)

(3) Slave cylinder supply pipe(engine compartment)

37A-35


DD

102208

3

2

1

6

5

4

37A-36


(1) Master cylinder supply pipe(engine compartment)

(2) Master cylinder return (enginecompartment - passenger com-partment connection)

(3) Master cylinder supply pipe(passenger compartment)

(4) Master cylinder (passengercompartment)

(5) Slave cylinder supply pipe (pas-senger compartment)

(6) Slave cylinder supply pipe(engine compartment)

37A-37

MECHANICAL COMPONENT CONTROLSClutch master cylinder: Removal - Refitting 37A

REMOVAL



Remove:

- the engine cover,


- the air filter unit (see 12A, Fuel mixture, Air filterunit), Removal - Refitting ).

Drain the brake fluid reservoir using a syringe untilthe level is below the master cylinder supply orifice.

Remove the bleed plug.

Place a cloth under the bleed hole.

Remove the clip (1) .

Pull out the master cylinder control pipe by one posi-tion.


Emb. 1797 24mm socket forremoving and refittingclutch master cylinder

Tightening torquesm

clutch pedal assemblyplate nuts

21 Nm

M9R

F4R or F9Q or K4M or K9K or M9R

JH3 or JR5

101701

37A-38




Press clip (2) with your hand while pulling the pipe.

Pull out the master cylinder control pipe by one posi-tion.

Remove:


- the bleed plug (3) .

Turn the end (4) of the slave cylinder anti-clockwiseas far as it will go.

Connect a transparent pipe to the bleed hole, andposition it so that it runs into an empty container pla-ced under the bleed hole.

Depress the pedal using your hand (to drain themaster cylinder and the pipe).

ND0

102513

WARNING

Do not pull the clip. If it is incorrectly handled inany way, the pipe will need to be replaced.

PK4

115170

37A-39


Place a cloth under the master cylinder.

Disconnect the brake fluid reservoir pipe.

Fit plugs into the openings.


Remove the union clip on the master cylinder (5) .

Disconnect the pipes.

Place plugs in each opening.

Disconnect the master cylinder ball joint from theclutch pedal in the passenger compartment.

Remove the master cylinder from the bulkhead inthe engine compartment by turning it a quarter turnclockwise (bayonet type mounting) using the (Emb.1797) .

DG

101740

19399

DD

Note:

The clutch master cylinder is mounted on theclutch pedal assembly. Remove the pedal - mas-ter cylinder assembly to extract the pedal and themaster cylinder.

37A-40


Remove the grey switch (6) from the top of travel byturning it through 90 degrees (see 37A, Mechanicalelement controls, Clutch pedal position sensor:Removal - Refitting ).

Disconnect the connector from the switch (6) .

Remove the green switch (7) from the bottom of thetravel by turning it through 90 degrees (see 37A,Mechanical element controls, Brake light switch:Removal - Refitting ).



Remove the union clips on the master cylinder (8) .



Extract the clutch master cylinder ball joint from thepedal.

Remove the four nuts from the « pedal assembly » .

Extract the « pedal assembly - master cylinder » as-sembly.

Remove the master cylinder from the bulkhead byturning it a quarter turn clockwise (bayonet typemounting) using the (Emb. 1797) .

REFITTING

Check the condition of the seals.


Connect the master cylinder ball joint to the clutchpedal.

101741

DG

19148

Note:

- Lubricate both ends of the supply pipe withbrake fluid to facilitate fitting on the brake fluidreservoir take-off pipe.

- The master cylinder has a foolproofing device, itonly fits in one position.

WARNING

Do not use the take-off points as a support whenfitting.

37A-41



Refit the « pedal - master cylinder » assembly.

Tighten to torque the clutch pedal assembly platenuts ( 21 Nm ) .


Bleed the clutch control (see 37A, Mechanicalcomponent controls, Clutch circuit: Bleeding,page 37A-52) .

Check that the clutch system is operating correctly.

Adjust and refit:

- the brake light switch (see 37A, Mechanical ele-ment controls, Brake light switch: Removal -Refitting ).

- the clutch switch (see 37A, Mechanical elementcontrols, Clutch pedal position sensor: Remo-val - Refitting ).


DD

37A-42

MECHANICAL COMPONENT CONTROLSClutch pedal: Removal - Refitting

DG

37A

REMOVALDisconnect the battery, starting with the negativeterminal.

Remove:

- the lower left-hand cover (see (see 5, Mecha-nisms and accessories) ),

- the UCH (1) (see (see 87B, Passenger compart-ment connection unit) ),

- the left-hand air duct (2) .

Remove the grey start-of-travel switch (3) by turningit a quarter of a turn.


Remove the green end-of-travel switch (4) by tur-ning it a quarter of a turn.


Extract the clutch master cylinder ball joint from thepedal (5) .

Remove the three nuts (6) from the clutch pedal as-sembly.

Withdraw the clutch pedal assembly.

REFITTINGTo refit, proceed in the reverse order to removal.

Torque tighten the clutch pedal assembly platenuts ( 2.1 daNm ) .

It is essential that the sensors are pulled to the endstop so that they are in the minimum position.

The clutch pedal position sensors have an automaticadjustment function which adjusts in accordancewith the position of the pedal.

Tightening torquesm


2.1 daNm

battery cover bolts 0.4 daNm

101193

1

2

101899

6

5

4

3

6

37A-43


DG

37A

Position the switches in their housing.

Move them one quarter of a turn clockwise.

Reconnect the two clutch pedal switches.

Tighten to torque the battery cover bolts ( 0.4daNm ) .

102205

WARNING

Connect the battery; carry out the necessary pro-gramming (see (see 80A, Battery) ).

37A-44


DD

37A

REMOVALDisconnect the battery, starting with the negativeterminal.

Drain the brake fluid reservoir until the level is belowthe master cylinder supply orifice.

Remove:

- the engine covers,

- the battery,

- the battery tray.

Disconnect the injection computer.

Remove the injection computer.

Loosen the inlet sleeve clip (1) .

Remove:

- the inlet sleeves (2) ,

- the air filter unit.

Drain the brake fluid reservoir until the level is belowthe master cylinder supply orifice.

Tightening torquesm


2.1 daNm


Note:

The clutch master cylinder is mounted on theclutch pedal assembly. Remove the « pedalassembly - master cylinder » unit to withdraw thepedals or the master cylinder.

101737

1 2

37A-45


DD

37A

Remove clip (3) .

Pull out the clutch control pipe by one position.


Operate the pedal by hand to empty the master cy-linder and the pipe.

Remove clip (4) .

Disconnect the pipes from the slave cylinder.



Pull out the pipes on the clutch control by one posi-tion.


Operate the pedal by hand to empty the master cy-linder and the pipe.

Remove clip (5) .



JH3 or JR5

101701

4

3

ND0

102513

WARNING


5

37A-46


DD

37AIn the passenger compartment

Remove the grey start-of-travel switch (6) by turningit a quarter of a turn.


Remove the green end-of-travel switch (7) by tur-ning it a quarter of a turn.



Remove the union clips on the master cylinder (8) .



Extract the clutch master cylinder ball joint from thepedal.

Remove the four clutch plate nuts.

Extract the « pedal assembly - master cylinder » as-sembly.

Remove the master cylinder from the pedal assem-bly by turning it clockwise a quarter of a turn (bayo-net type mounting).

REFITTING



Torque tighten the clutch pedal assembly platenuts ( 2.1 daNm ) .

It is essential that the sensors are pulled to the endstop so that they are in the minimum position.

The clutch pedal position sensors have an automaticadjustment function which adjusts in accordancewith the position of the pedal.

Position the switches in their housing.

Turn them one quarter turn clockwise.

Reconnect the two clutch pedal switches.



101741

8

7

6

8

102205

WARNINGConnect the battery; carry out the necessary pro-gramming (see (see 80A, Battery) ).

37A-47

MECHANICAL COMPONENT CONTROLSClutch control pipes: Removal - Refitting 37A

REMOVAL



Remove:

- the engine cover,


- the battery tray with the injection computer,

- the air filter unit (see 12A, Fuel mixture, Air filterunit), Removal - Refitting ).

Drain the brake fluid reservoir using a syringe untilthe level is below the master cylinder supply orifice.





Operate the pedal by hand to empty the master cy-linder and the pipes.




M9R

F4R or F9Q or K4M or K9K or M9R

JH3 or JR5

101701

37A-48







Press the clip (3) .



Remove:






ND0

102513

WARNING

Do not pull the clip. If there are any errors whenhandling the pipe it will need to be replaced.

PK4

115170

37A-49





Unclip the pipe at (7) .


Remove the clip (8) from the union on the master cy-linder return.



Withdraw the slave cylinder supply pipes.

Remove:

- the left-hand glove compartment,

- the left-hand air duct.

PK4

115169

DG

101739

DD

37A-50


Place a cloth under the pipe unions.

Remove the clip (9) from the master cylinder unionon the master cylinder return



Remove the clip (10) from the slave cylinder unionon the master cylinder return.




Remove the clip (11) from the master cylinder unionon the master cylinder return



Withdraw the master cylinder supply pipe from theleft-hand side.

Remove the clip (12) from the slave cylinder unionon the master cylinder return.



Withdraw the slave cylinder supply pipe from theleft-hand side.

102212 101741

37A-51


Place a cloth under the hole (13) .

Remove the brake fluid reservoir pipe.


Remove the master cylinder return (14) from thebulkhead by turning it a quarter of a turn clockwise(bayonet type mounting)

REFITTINGCheck the condition of the seals.





101739

37A-52

MECHANICAL COMPONENT CONTROLSClutch circuit: Bleeding 37A

PROCEDURE



I - BLEEDING BETWEEN THE RESERVOIR AND THE BLEED HOLE

Keep the clutch pedal in the raised position.

Fill the hydraulic circuit reservoir with the approvedfluid.

Connect the brake circuit bleeding device (appro-ved by Renault) to the hydraulic circuit reservoir.


Connect a transparent pipe to bleed hole (1) and po-sition it so that it runs into an empty container placedabove the bleed hole

Remove clip (2) .


Equipment required

brake circuit bleeding device (approved by Renault)

PK4

Note:

- Even the tiniest air bubble in the circuit cancause faulty operation (pedal failing to returnproperly, crunching sound when changing gear,etc.).

- Incorrect bleeding can lead to incorrect fault fin-ding and unnecessary part replacements.

During every operation on the hydraulic clutch system, it is essential to bleed:

- between the reservoir and the bleed hole,

- between the bleed hole and the hydraulic tap-pet.

JH3 or JR5

101701

37A-53



Connect a transparent pipe to bleed hole (3) and po-sition it so that it runs into an empty container placedabove the bleed hole.

Press clip (4) .

Pull out the clutch control pipe by one position to freethe bleed hole.

Remove:



Connect a transparent pipe to the bleed hole , andposition it so that it runs into an empty container pla-ced under the bleed hole.


Activate the brake circuit bleeding device (appro-ved by Renault) .

Let the liquid flow until there are no more air bub-bles.

Push the clutch control pipe (or turn the end of theslave cylinder clockwise as far as it will go, if the ve-hicle is fitted with a PK4 gearbox) in order to blockthe bleed hole as soon as the liquid flows out.

ND0

102513

WARNING


34

B84 or C84 or G84 or S84, and PK4

115170

WARNING

Check that the level is still above the hydrauliccontrol union.

WARNING

A safety click should be heard when the clutchcontrol pipe on J or N gearboxes is locked.

37A-54


Disengage and engage the clutch rapidly about tentimes.

Remove the brake circuit bleeding device (appro-ved by Renault) .

II - BLEEDING BETWEEN THE HYDRAULIC TAPPET AND THE BLEED HOLE.

Connect a syringe containing 60 cc of approved li-quid to the end of the transparent pipe.

Open the bleed hole.

Slowly inject the entire contents of the syringe intothe circuit, without injecting any air from the top partof the syringe.

Close the bleed hole.

Remove the syringe and its transparent pipe fromthe bleed hole.

Disengage and engage the clutch rapidly about tentimes.


Repeat the operation if necessary.

Top up the fluid level so that it reaches the maximummark on the reservoir.

III - APPLY THE FOLLOWING PROCEDURE IN THE EVENT OF A SPONGY PEDAL (ONLY FOR RIGHT-HAND DRIVE VEHICLES)

If necessary, remove:



Remove the air filter unit with the injection computerif necessary (see 12A, Fuel mixture, Air filter unit:Removal - Refitting ).

Disconnect the supply pipe between the reservoirand the clutch master cylinder.

Block off the tank outlet so that no fluid can flow out.

Add a small amount of approved fluid to the syringe.

Insert the syringe into the supply pipe between thereservoir and the clutch master cylinder.

Draw out all the air trapped at the top of the mastercylinder with the syringe.

Disconnect the syringe.

Connect the supply pipe to the reservoir.

Depress the clutch pedal five times.


Refit:



WARNING

A safety click should be heard when the clutchcontrol pipe on J or N gearboxes is locked.

112306

37A-55

MECHANICAL COMPONENT CONTROLSExternal gear control: Description 37A

JH3 or JR5

102326

(1) Gear selection cable

(2) Gear change cable

ND0 or PK4

102325

Note:

The ND - PK4 external control is the same as theJH-JR except for the adjustment system (3) on theselection cable.

1

2

3

37A-56

MECHANICAL COMPONENT CONTROLSExternal gear control: Removal - Refitting

JH3 or JR5 or ND0 or PK4

37A

REMOVAL


Remove the battery (see 80A, Battery, Battery: Re-moval - Refitting ).

Remove:

- the battery tray with the injection computer,

- the air filter unit, if necessary (see 12A, Fuel mix-ture, Air filter unit: Removal - Refitting ).

Select third gear.

Unclip the two cables from the levers on the gear-box:

- at the two anchoring ball joints (1) ,

- at the sheath stops (2) .

Remove:

- the gear lever knob by lifting it,

- the gear lever gaiter.

Unclip the centre console upper trims.

Remove the centre console bolts (3) .

Remove the centre console.

Tightening torquesm

control unit mountingbolts

21 Nm

101742

101743

101320

2

1

3

3

37A-57



37A

Cut the carpet between the airbag computer and thegear lever unit.

Remove the soundproofing covering the airbagcomputer and the gear lever unit.

Remove the four control unit mounting bolts (4) .

Press the four tabs (5) to release the control unit.

Remove the engine undertray.

Remove the exhaust bracket mounting nuts (6) .

101328

101898

4

45

101793

37A-58



37A

Remove the exhaust pipe rubber mounting bushmounting bolts (7) .

Let the exhaust pipe rest on the rear axle.

Remove:

- the heat shield mountings

- the heat shield (8) .

Remove the gear lever unit.

REFITTING

Refit:

- the control unit,

- the heat shield,

- the heat shield mountings.

Tighten to torque the control unit mounting bolts (21 Nm ) .

102116

102117

109405

101897

37A-59



37A

Press the clip tabs together.

Press the insert to fit the clip.

Adjust the gearbox cables.

Check that all the gears engage correctly.


Refit the battery (see 80A, Battery, Battery: Remo-val - Refitting ).

I - ADJUSTING THE GEARBOX CABLES

Refit the cables in their respective sleeve stops.

Fit the cables into their respective ball joints.

Check that all the gears engage correctly beforestarting the engine.

II - ADJUSTING THE GEARBOX CABLES

Refit the control unit.

1 - Passenger compartment

Refit the reverse gear trigger in the right direction.

Fit a shim (9) between the trigger and the stop:

- 4 mm in thickness, if the vehicle is fitted with aPK4 gearbox,

- 5 mm in thickness, if the vehicle is fitted with anND0 gearbox.

Immobilise the lever against the shim in 3rd gear en-gaged position using a strap.

2 - Engine compartment

Position the gear lever on the gearbox in 3rd gearengaged position.

Refit the cables into their respective sleeve stops.

Fit the selector cable on the lever ball joint.

Loosen the clip (using a screwdriver) on the selec-tion cable.

Adjust the length of the cable accordingly.

Fit the selector cable on the gear lever ball joint.

103113

JH3 or JR5

Note:

- There is no cable adjustment system.

- The external control unit and the control leverson the gearbox must be in third gear when thecables are attached to the levers.

ND0 or PK4

116019

37A-60



37A

Lock the clip by pressing down on (10) and stop itsmovement by sliding the catch (11) .

102429

WARNING

The permanent shim must be removed from thegear lever after the cables have been adjustedand fitted.

37A-61

MECHANICAL COMPONENT CONTROLSExternal gear control cable


37AREMOVAL



Remove the complete external control (see 37A,Mechanical component controls, External gearcontrol: Removal - Refitting, page 37A-56) .

Detach the flat seal.

Remove the four mounting bolts.

Open the control unit.

Unclip the cable from the ball joint concerned (1) .

Remove the clip from the cable sleeve stop concer-ned (2) .

Remove the cable concerned.

REFITTING


Affix a new flat seal on the control unit.

Refit the complete external control (see 37A, Me-chanical component controls, External gear con-trol: Removal - Refitting, page 37A-56) .

Check that all the gears engage correctly beforestarting the engine.


102324

102428

37A-62

MECHANICAL COMPONENT CONTROLSGearbox lever unit Removal - Refitting

DP0

37A

REMOVAL

Position the vehicle on a two-post lift.



Remove:

- the multifunction switch cable ball joint (1) ,

- the control cable from the sleeve stop (2) on themodular connector mounting.

Remove the diagnostic socket access cover (3) .

Turn the part (4) a quarter of a turn.

Remove the part.

Remove the gear lever knob (5) by lifting it.

Tightening torquesm


WARNING

Mark the position of the selector lever clearly beforestarting the operation: if not, position the gearselector and the multifunction switch in neutral« N » .

103408

1

2

103424

103425

3

4

5

37A-63


DP0

37A

Unclip the console trim (6) .

Disconnect the connector (7) .

Open the glove compartment.

Unclip the handbrake lining trim (8) and (9) .

Unclip the lower cover (10) .

Unclip the cigarette lighter holder.

Disconnect the cigarette lighter connector.

103426

103427

6

7

101322

101319

101321

8

9

10

37A-64


DP0

37A

Disconnect the heated seat connectors (if fitted tothe vehicle).

Remove the two front seats ( (see 75A, Front seatframes and runners) ).

Remove the screws (11) .

Remove:

- the console carefully (12) ,

- the gear lever console.

Disconnect the connector (13) .

Remove the sensor (14) .

Remove the three exhaust bracket mounting nuts(15)

Remove the two mounting bolts (16) .

101320

101504

12

111111

1314

101793

101818

151515

16

37A-65


DP0

37A

Remove:

- the mounting bolts (17) ,

- the front section of the heat shield.

Pull back the carpet.

Remove cover (18) .

Remove the protector (19) .

Remove the four mounting bolts (20) from the con-trol unit.

Hold the gear lever rod and release the control unitretaining clips.

Remove the unit-control cable assembly.

102117

103428

17

18

103429

103431

19

2020

37A-66


DP0

37AREFITTING


Adjust the control cable.

Check that the system is operating correctly.

ADJUSTING THE CONTROL CABLE

Press the slide valve (21) to release the cable.

Clip the control cable into the sheath stop.

Clip the cable end piece to the multifunction switchball joint.

Apply the clip (22) to lock the cable end piece.

Check that the system and gear selection are opera-ting correctly.


WARNING

Mark the position of the gear lever clearly beforestarting the operation: if not, position the gearlever and the multifunction switch in neutral « N ».

23334

21

23335

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

22

38C-1

ANTI-LOCK BRAKING SYSTEMIntroduction 38C

Mégane II is equipped with a BOSCH 8.0. ABS system

Depending on the equipment level, the BOSCH 8.0system has a ABS function only, or it is linked to anelectronic stability programme function (ESP).

I - DESCRIPTION OF THE ABS SYSTEM WITH ESP

The anti-lock braking system / electronic stability pro-gram consist of:

- a brake servo assembly,

- a pump assembly consisting of:

• a hydraulic pump,

• a pressure modulation unit (twelve solenoid valves),

• a computer,

• a pressure sensor.

- a steering wheel angle sensor integrated into thepower assisted steering,

- a combined yaw speed and lateral acceleration sen-sor,

- four wheel speed sensors,

- an electronic stability program deactivation button.

II - OPERATING PRINCIPLE OF THE ABS SYSTEM WITH ESP

The reference status is calculated continuously fromwheel speed and steering wheel angle measurements.The reference status represents the desired correctbehaviour.

This reference status is compared to the actual statusof the vehicle from the yaw speed and transverse acce-leration measurements.

Where there is a difference between the desired trajec-tory and the actual trajectory, the appropriate wheel isbraked. In certain cases, the under-steer control bra-kes both wheels at the same time. The torque genera-ted sets the vehicle on the desired trajectory.

In some cases, the anti-skid control modifies the engi-ne torque.

III - SPECIAL FEATURES OF THE ESP FUNCTION

The function can be disconnected using the switch lo-cated on the dashboard.

This function can not be deactivated above a thresholdof approximately 30 mph (50 km/h) .

This function is automatically reactivated when the ve-hicle is switched on, or at speeds above approximately30 mph (50 km/h) .

Equipment required

diagnostic tool

IMPORTANT

After any operation on the ESP system, it is essen-tial to confirm the repair with a road test and acheck with the diagnostic tool. diagnostic tool

38C-2

ANTI-LOCK BRAKING SYSTEMHydraulic unit: Introduction 38C

The Anti-lock Braking System pump assembly isequipped with a 26-track computer.

The Anti-lock Braking System and Electronic StabilityProgram pump assembly is equipped with a 46-trackcomputer.

102311

102384

Note:

The computer cannot be separated from the pumpassembly.

38C-3

ANTI-LOCK BRAKING SYSTEMHydraulic unit

K4J, and 730 or 732

38C

REMOVAL



Remove:

- the front right-hand wheel (see 35A, Wheels andtyres, Wheel: Removal - Refitting ).

- the front right-hand wheel arch liner,

- the bumper.

Drain the refrigerant circuit using the filling station .

Fit a pedal press to the brake pedal to limit the out-flow of brake fluid.

Remove:


- the wiper arm nuts (1) ,

Equipment required

filling station

pedal press

diagnostic tool

Tightening torquesm

bolts securing thehydraulic unit onto itssupport

8 Nm

bolts securing the pipeson the hydraulic unit

17 Nm

bolts supporting thehydraulic unit on thebody

6.5 Nm

plenum chamber moun-ting bolts

9 Nm

air conditioning pipebolts

8 Nm

CA or CAREG

102105

102101

102100

1

32

38C-4


K4J, and 730 or 732

38C- the wiper arms,

- the left and right-hand side pillars,

- the bulkhead seal (2) ,

- the plastic rivets (3) ,

- the scuttle panel grille,

- the scuttle panel partition.

Remove:

- the air resonator unit mounting bolt (4) ,

- the air resonator unit (5) .

Disconnect:

- the brake servo vacuum pipe from the plenumchamber end,

- the ignition coil connectors,

- the throttle valve connector.

Disconnect the air temperature sensor (6) .

Unclip the engine wiring harness (7) .

Unclip the petrol vapour recirculation pipe (8) .

Loosen the air filter unit mountings without removingit from the engine compartment.

101103

WARNING

Do not damage the vacuum outlet on the plenumchamber. If it is damaged, the plenum chamberwill have to be replaced.

5

4101100

101488

7

6

8

38C-5


K4J, and 730 or 732

38C

Remove:

- the filter element (9) ,

- the air filter unit (10) ,

- the throttle valve mounting bolts (11) ,

- the throttle valve.

Remove:

- the plenum chamber mounting bolts (12) ,

- the plenum chamber,

- the soundproofing screen mountings.

Remove the soundproofing screen.

Remove:

- the lifting eye (13) ,

- the air conditioning pipe flange mounting bolt onthe bulkhead side,

- the air conditioning pipe flange mounting bolt onthe dehydration canister side,

- the air conditioning pipe (14) between the bulkheadflange and the dehydration canister (if fitted).

101104

101800

910

11

101794

102124

121212121212

14

13

38C-6


K4J, and 730 or 732

38C

Remove:

- the condensation drain channel (15) ,

- the ABS computer earth terminal mounting bolt(17) .

Disconnect the computer connector.

Unscrew the pipes from the hydraulic unit.

Unclip the pipes from the hydraulic unit.

Remove:

- the hydraulic unit support mounting bolts (16) ,

- the « hydraulic unit - support » assembly,

- the bolts securing the hydraulic unit on the support,

- the hydraulic unit.

REFITTING


Tighten to torque:

- the bolts securing the hydraulic unit onto itssupport ( 8 Nm ) ,

- the bolts securing the pipes on the hydraulicunit ( 17 Nm ) ,

- the bolts supporting the hydraulic unit on thebody ( 6.5 Nm ) ,

- the plenum chamber mounting bolts ( 9 Nm ) .

Tighten to torque the air conditioning pipe bolts (8 Nm ) .


101935

17

1616

15

106032

WARNING

Set up the ear th terminal wires facingdownwards, to optimise the hydraulic unit compu-ter connector sealing.

CA or CAREG

38C-7


K4J, and 730 or 732

38C

Bleed the brake circuit using the diagnostic tool(see 30A, General Vehicle Information, Brake cir-cuit Bleeding, page 30A-5) .

Fill the coolant circuit using the filling station .

WARNING

- Replace the throttle valve seal each time it isremoved. When the ignition is switched on, thethrottle valve must run a minimum and maxi-mum stop programming cycle. Using the dia-gnostic tool , check that this programming hasbeen carried out correctly.

- The seals at the ends of the air conditioningpipe must be replaced.

CA or CAREG

Note:

- Make sure the air conditioning is working pro-perly with the fan assembly at top speed.

- If there is no cold air, check for any leaks (see62A, Air conditioning, Checking for leaks ).

38C-8


K4M, and 760 or 761

38C

REMOVAL



Remove:


- the wheel arch liner,

- the bumper.



Remove:



Equipment required

filling station

pedal press

diagnostic tool

Tightening torquesm

bolts securing thehydraulic unit on its sup-port

8 Nm


17 Nm


6.5 Nm


9 Nm

air conditioning pipemounting bolts

8 Nm

CA or CAREG

102105

102101

102100

1

32

38C-9


K4M, and 760 or 761







Loosen the air duct clips (4) .


Disconnect:




Unclip the petrol vapour recirculation pipe (8) .

Remove:

- the throttle valve mounting bolts (6) ,

- the throttle valve.

Disconnect the air temperature sensor.

Remove the engine wiring harness (7) .

101807

Note:


5

4

101813

101795

66

8

7

38C-10


K4M, and 760 or 761

38C

Remove:





Remove the hydraulic unit end lifting eye.

Remove the air conditioning pipe (11) between thebulkhead flange and the dehydration canister.

Remove:






Remove:




REFITTING


102304

CA or CAREG

102124

101010

11

101935

14

1313

12

38C-11


K4M, and 760 or 761

38C

Tighten to torque:

- the bolts securing the hydraulic unit on its sup-port ( 8 Nm ) ,




Tighten to torque the air conditioning pipe moun-ting bolts ( 8 Nm ) .




106032

WARNING

Set up the earth terminal with the wires facingdownwards to optimise the hydraulic unit compu-ter connector sealing.

CA or CAREG

WARNING

- Replace the throttle valve seal each time it isremoved. When the ignition is switched on, thethrottle valve must run a minimum and maxi-mum stop programming cycle. Using the dia-gnostic tool , check that this programming hasbeen carried out correctly.


CA or CAREG

Note:

- Make sure that the air conditioning is workingproperly with the fan assembly at maximumspeed.

- If there is no cold air, check for any leaks (see62A, Air conditioning, Searching for leaks ).

38C-12


F9Q or K9K

38C




Remove:


- the wheel arch liners,

- the bumper,

- the air conditioning pipe flange mounting bolt onthe bulkhead side,

- the air conditioning pipe flange mounting bolt onthe dehydration canister side.

Remove the air conditioning pipe (1) between thebulkhead flange and the dehydration canister.


Remove:


- the lifting eye,


Remove the soundproofing.

Equipment required

filling station

pedal press

diagnostic tool

Tightening torquesm

bolts securing thehydraulic unit on its sup-port

8 Nm


17 Nm


6.5 Nm


8 Nm

CA or CAREG

101886

1

38C-13


F9Q or K9K

38C

Remove:


- the ABS computer earth terminal mounting bolt (4).




Remove:



- the bolts securing the hydraulic unit on the support,


REFITTING


Tighten to torque:

- the bolts securing the hydraulic unit on its sup-port ( 8 Nm ) ,


- the bolts supporting the hydraulic unit on thebody ( 6.5 Nm ) .



Bleed the hydraulic unit using the diagnostic tool(see 30A, General Vehicle Information, Brake cir-cuit Bleeding, page 30A-5) .

101935

2

33

4

106032

WARNING


CA or CAREG

WARNING

The seals at the ends of the air conditioning pipemust be replaced.

38C-14


F9Q or K9K

38C


CA or CAREG

Note:


- If there is no cold air, check for any leaks (see62A, Air conditioning, Searching for leaks ).

38C-15


F4R

38C

REMOVAL



Remove:


- the wheel arch liner,

- the bumper.



Remove:



Equipment required

filling station

pedal press

diagnostic tool

Tightening torquesm


8 Nm


17 Nm


6.5 Nm


9 Nm


8 Nm

CA or CAREG

102105

102101

102100

1

32

38C-16


F4R







Loosen the air duct clips (4) .


Disconnect:




Unclip the petrol vapour recirculation pipe at the so-lenoid valve end (9) .

Disconnect:

- the air pressure sensor (10) ,

- the air temperature sensor (8) .

Remove the engine wiring harness (11) .

101807

Note:


5

4

102735

102725

7

6

10

9

11

8

38C-17


F4R

38C

Remove:





Remove the hydraulic unit end lifting eye.

Remove:

- the air conditioning pipe (14) between the bulkheadflange and the dehydration canister,

- the screen washer reservoir filler neck (13) .

Remove:




102726

12121212

CA or CAREG

102124

101935

13

14

16

1717

15

38C-18


F4R

38CUnscrew the pipes from the hydraulic unit.


Remove:



- the hydraulic unit support mounting bolts,


REFITTING


Tighten to torque:









106032

WARNING


CA or CAREG

Note:


- If there is no cold air, check for any leaks (see62A, Air conditioning, Checking for leaks ).

WARNING

- Replace the throttle valve seal each time it isremoved.

- When the ignition is switched on, the throttlevalve must run a minimum and maximum stopprogramming cycle. Using the diagnostic tool ,check that this programming has been carriedout correctly.


38C-19


M9R, and DG

38C

REMOVAL




Remove:

- the engine cover,

- the scuttle panel grille (see MR 365, 55A, Exteriorprotection, Scuttle panel grille: Removal - Refit-ting ).

- the soundproofing under the scuttle panel grille,

- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).

- the bulkhead heat shield clips,

- the bulkhead heat shield central bolt,

- the lifting eye mounting bolts,

- the lifting eye.

Remove the heat shield.

Equipment required

pedal press

Tightening torquesm


8 Nm


17 Nm


6.5 Nm

WARNING

Drain the brake fluid to prevent damage to themechanical parts and bodywork around the bra-king system.

38C-20


M9R, and DG

38C

Remove:


- the ABS computer earth terminal mounting bolt (2).

Disconnect the computer connector by lifting bracket(3) .

Loosen the brake pipe unions (4) .

Remove the hydraulic unit support mounting bolts(5) .

Unpick the harness at (6) from the hydraulic unit onits support.

Loosen the brake pipe union (7) by moving the hy-draulic unit forward.

Remove:

- the hydraulic unit and support assembly,

- the bolts securing the support onto the hydraulicunit,


REFITTING


Tighten to torque:



- the bolts supporting the hydraulic unit on thebody ( 6.5 Nm ) .

101935

106032

Note:

To remove the hydraulic unit computer, see 38C,Anti-lock braking system, Computer: Remo-val - Refitting ).

106032

WARNING


38C-21


M9R, and DG

38CBleed the brake circuit (see 30A, General VehicleInformation, Brake circuit Bleeding, page 30A-5).


38C-22

ANTI-LOCK BRAKING SYSTEMABS with ESP: Description 38C

Pump unit

The steering wheel angle sensor is integrated into theelectric power assisted steering. This sensor cannot beremoved.

103798

121110

9

8

7

6

5

4

3

2

1Mark Type of connection

10 CAN network

11 Wire connection

12 Hydraulic connection

Mark Description

Inputs

1 Braking pressure from the master cylinder

2 Combined yaw speed and transverse acceleration sensor signal

3 Wheel speed sensor signals

4 Steering wheel angle sensor signal

5 Diagnostic socket

6 Supply (+ after ignition)

Outputs

7 Brake pressure adjusted on one or more of the wheels concerned

8 Diagnostic socket

9 Anti-skid and Electronic Stability Program deactivation push-button

Note:

Two types of pump assembly are fitted, either ABSor ABS / ESP. The ABS computer comprises 26tracks . The ABS - ESP computer comprises 46tracks .

38C-23

ANTI-LOCK BRAKING SYSTEMYaw speed and transversal acceleration sensor: Removal - Refitting 38C

REMOVAL


Remove:

- the driver's seat,

- the carpet on the driver's side (see MR 365 Bo-dywork, 71A, Body internal trim, Floor carpet:Removal - Refitting ).

Disconnect the lateral acceleration and yaw sensorconnector.

Remove:

- the sensor mounting nuts,

- the sensor.

REFITTING

Refit the sensor in its correct direction of fitting.

Tighten to torque the lateral acceleration and yawsensor mounting nuts ( 8 Nm ) .



If replacing a lateral acceleration and yaw sensor,carry out the necessary operations using the dia-gnostic tool (see MR 366 Fault finding, 38C, Anti-lock braking system, Replacement of compo-nents ).

Equipment required

diagnostic tool

Tightening torquesm

lateral acceleration andyaw sensor mountingnuts

8 Nm

WARNING

Handle the lateral acceleration and yaw sensorwith care.

20912

WARNING

- The sensor must be fitted facing the vehicle'sdirection of travel (as shown by the arrow).

- Be sure to replace any sensor which has suffe-red an impact.

Note:


38C-24

ANTI-LOCK BRAKING SYSTEMYaw speed and transverse acceleration sensors: Connection 38C

This sensor is located under the driver's seat.

102310

1

6

Track Description

1 Yaw speed sensor reference signal

2 Yaw sensor test signal

3 Accessories + feed

4 Yaw speed signal

5 Transverse acceleration signal

6 Earth

20912

38C-25

ANTI-LOCK BRAKING SYSTEMABS computer: Removal - Refitting 38C

Removal of the ESP or ABS computer is allowed.

REMOVAL


Remove the entire hydraulic unit (see 38C, Anti-lock braking system, Hydraulic unit: Removal -Refitting ).

Remove:

- the computer mounting bolts (1) on the pressuremodulation unit,

- the computer (2) .

REFITTING

Do not clean the pressure modulation unit (4) .

Always replace the computer mounting bolts.

Refit the computer, holding it by its edge.

The hydraulic pump (3) must be pressed against thepressure modulation unit (4) .

When a new computer is being fitted, remember toattach the interconnection fork (5) between the pres-sure modulation unit and the computer.

Refit the bolts securing the computer on the pressu-re modulation unit.

Tighten to torque the computer mounting bolts ( 3Nm ) using the (Mot. 1608) .

Refit the entire hydraulic unit (see 38C, Anti-lockbraking system, Hydraulic unit: Removal - Refit-ting ).

Configure the speedometer index using the dia-gnostic tool (see MR 366 Fault finding, 38C, Anti-lock braking system, Replacement of compo-nents ).

Clear any faults that have been stored in the compu-ter.

Carry out a road test to confirm the repair.


Mot. 1608 Torque screwdriver.

Equipment required

diagnostic tool

Tightening torquesm

computer mountingbolts

3 Nm

115161

Note:

Do not try to force the computer into place whenrefitting, it should fit in without any resistance.

19113

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