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"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 11 322 062 MARCH 2009 Edition Anglaise
X84, and J84
3 Chassis
30A GENERAL INFORMATION
31A FRONT AXLE COMPONENTS
33A REAR AXLE COMPONENTS
35A WHEELS AND TYRES
35B TYRE PRESSURE MONITOR
36A STEERING ASSEMBLY
37A MECHANICAL COMPONENT CONTROLS
37B ELECTRONIC PARKING BRAKE
38C ANTI-LOCK BRAKING SYSTEM
Scénic II - Section 3
Contents
Page
Scénic II - Section 3ContentsPage
30A GENERAL INFORMATION
Brake circuit Operating diagram 30A-1
Brake circuit Bleeding 30A-2
Brake circuit Tightening torque 30A-4
Brake fluid: Specifications 30A-5
Brake: Specifications 30A-6
Steering: Tightening torque 30A-7
Axle assemblies: Check 30A-8
Underbody height: Adjustment values 30A-9
Front axle: Tightening torque 30A-12
Front axle: Adjustment values 30A-14
Front axle: Adjusting 30A-16
Rear axle: Tightening torque 30A-17
Rear axle: Adjustment values 30A-18
Rear axle: Adjusting 30A-20
31A FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting 31A-1
Front brake hose: Removal - Refitting 31A-3
Front brake calliper: Removal - Refitting 31A-5
Front brake calliper: Repair 31A-7
Front brake calliper support: Removal - Refitting 31A-9
Front brake disc: Description 31A-10
Front brake disc: Removal - Refitting 31A-11
Front driveshaft hub carrier: Removal - Refitting 31A-12
Front hub carrier bearing: Removal - Refitting 31A-15
Spring and front shock absorber: Removal - Refitting 31A-18
Front driveshaft lower arm: Removal - Refitting 31A-22
Front driveshaft lower arm ball joint: Check 31A-25
Yaw speed and transversal acceleration sensor: Removal - Refitting 38C-23
Braking computer: Removal - Refitting 38C-25
30A-1
GENERAL INFORMATIONBrake circuit Operating diagram 30A
« X » braking system with ABS
3877
IMPORTANTThis is a diagram of the general principle, do notuse it as a reference for take-off points or circuitallocation. When replacing components in a vehi-cle's braking circuit, always mark the pipes beforeremoving them.
30A-2
GENERAL INFORMATIONBrake circuit Bleeding 30A
This procedure must be applied after one of the fol-lowing components has been removed or replaced:
- the master cylinder,
- the brake fluid,
- the hydraulic unit,
- a rigid pipe,
- a hose,
- the reservoir,
- a calliper.
a Use locally produced containers to collect the usedbrake fluid.
Front and rear callipers:
- 2 washer fluid containers (1) (1 litre),
- 4 mm diameter transparent pipes (2) ,
- 4 pipettes (3) (part no: 00 00 081 501),
- 2 T-unions (4) .
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Switch off the vehicle ignition.
Essential equipment
pedal press
brake circuit bleeding device
IMPORTANT
To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Brake circuit Precautions for repair) .
WARNING
Switch off the vehicle ignition so as not to activatethe hydraulic unit solenoid valves when bleeding thebrake circuit.
WARNING
The level must be between the « MIN » and« MAX » markings on the reservoir.
115993
Note:
The new hydraulic unit is pre-filled.
When working on one of the following compo-nents, position a pedal press to limit the outflow of brake fluid and prevent any air from entering the master cylinder and the circuits downstream of the master cylinder:
- hydraulic unit,
- pipes between the hydraulic unit and brake cal-lipers,
- brake hoses,
- brake calliper.
Remove the pedal press before carrying out thebraking system bleeding procedure.
30A-3
GENERAL INFORMATIONBrake circuit Bleeding 30A
a Connect the brake circuit bleeding device (afterhaving received Renault approval) to the master cy-linder reservoir (see the instructions for the equip-ment).
a Pressurise the brake circuit.
a Adjust the pressure to between 1.5 bar < P < 2 barfor 3 minutes to stabilise it in the braking circuit.
a Close the circuit between the bleed screw and brakefluid reservoir without dumping the pressure.
a Fit the bleed containers to the four bleed screws ofthe callipers.
a Undo the calliper bleed screws:
- front left-hand,
- front right-hand,
- rear left-hand,
- rear right-hand.
a Open the circuit between the bleed screw and brakefluid reservoir and allow the liquid to run until all theair bubbles have been released.
a Tighten the bleed screws in the following order:
- front left-hand,
- front right-hand,
- rear left-hand,
- rear right-hand.
a Undo the calliper bleed screw:
- front left-hand,
- allow the fluid to run until all the air bubbles havebeen released,
- tighten the bleed screw on the calliper.
a Carry out the previous operation on the callipers:
- front right-hand,
- rear left-hand,
- rear right-hand.
a Close the bleed screw to dump the pressure in thebrake circuit.
a Remove the brake circuit bleeding device fromthe master cylinder reservoir.
a Check pedal travel and resistance. If it is not correct, finish bleeding the brake circuit with the help of a se-cond operator. Start the bleed operation by bleeding the calliper that is the furthest away from the master cylinder:
- hold down the brake pedal,
- open the circuit bleed screw to release the air fromthe brake circuit,
- close the circuit bleed screw,
- release the brake pedal.
a Top up the brake fluid level in the reservoir, if neces-sary. Check the sealing of the front and rear bleedscrews and ensure that the sealing covers are in pla-ce (see 30A, General information, Brake circuitTightening torque, page 30A-4) .
a During a road test, trigger braking regulation to con-firm that the brake pedal travel is correct.
a Clean off any traces of brake fluid on the vehicleusing BRAKE CLEANING PRODUCT (see Vehi-cle: Parts and ingredients for the repairwork)
Note:
The circuit between the bleed screw and brake fluid reservoir is closed in different ways depen-ding on the type of equipment used:
- valve,
- switch.
30A-4
GENERAL INFORMATIONBrake circuit Tightening torque 30A
I - FRONT AND REAR BRAKES
II - BRAKE CONTROL
Description Tightening
torque
(N.m)
Front calliper bleed screw 6.5
Rear calliper bleed screw 14
Front calliper inlet brake hose 17
Rear calliper inlet brake hose 14
Brake hose on brake pipe 14
Front brake guide pin bolt 32
Calliper support bolt 105
Rear brake guide pin bolt 36
Disc mounting bolt 15
Description Tightening
torque
(N.m)
Brake servo mounting bolts 21
Master cylinder mounting nuts 50
Master cylinder outlet pipe 14
Hydraulic unit mounting bolt 8
Hydraulic unit pipe unions 14
Parking brake control mountingnuts
8
Bolts mounting hydraulic unit sup-port on vehicle body
6.5
30A-5
GENERAL INFORMATIONBrake fluid: Specifications 30A
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc bra-kes (hollow pistons which conduct little heat, have alow volume of fluid in the cylinder, sliding callipers avoi-ding the need for a fluid reserve in the least cooledarea of the wheel), has allowed us to prevent the risk of« vapour lock » as far as possible, even with heavybraking (mountainous area). However, current brakefluids are subject to minor deterioration during the firstmonths of use due to slight humidity intake. This is whyit is recommended that you change the brake fluid: seemaintenance booklet for the vehicle.
1 - Topping up the level
Wear of the brake pads will result in a gradual drop inthe fluid level in the reservoir.
Do not top up the fluid, as the level will rise again whenthe pads are next changed. The brake fluid level mustnot fall below the minimum mark.
2 - Approved brake fluid
Mixing two incompatible brake fluids in the brake circuit may lead to:
- serious risk of leakage due mainly to deterioration ofthe cups,
- deterioration in the operation of the ESP system.
To prevent such risks, it is essential to use only brakefluids that comply with the RENAULT standard (seeVehicle: Parts and ingredients for the repairwork) .
30A-6
GENERAL INFORMATIONBrake: Specifications 30A
(1) Scenic.
(2) Long Scenic.
(3) Brake discs cannot be reground. If they are too hea-vily worn or scratched they must be replaced.
Engine
K4J, K4M, K9K F9Q, F4R, M9R
Front brakes (mm)
Piston diameter 54 54
Disc diameter 280 (1)
300 (2)
300
Disc thickness 24 24
Minimum disc thickness (3) 21.8 21.8
Maximum disc run-out 0.07 0.07
Brake pad thickness (including backplate) 18 18
Minimum pad thickness (including backplate) 6 6
Rear brakes (mm)
Piston diameter 34
Disc diameter 270 (1)
274 (2)
Disc thickness 10
Minimum disc thickness (3) 9 (1)
9.5 (2)
Maximum disc run-out 0.07
Brake pad thickness (including backplate) 16
Minimum pad thickness (including backplate) 6
Master cylinder (mm)
Diameter 23.8
Stroke 36
30A-7
GENERAL INFORMATIONSteering: Tightening torque 30A
I -
II -
DOCUMENT PHASE 2 – M9R, and DOCUMENTPHASE 1
Description Tightening
torque
(Nm)
Steering wheel bolt 44
Intermediate shaft bolt on steeringcolumn
44
Universal joint bolt 44
F4R or F9Q or K4J or K4M or K9K, and DOCU-MENT PHASE 1
Description Tightening
torque
(Nm)
Steering wheel bolt 44
Intermediate shaft bolt on steeringcolumn
44
Universal joint bolt 26
30A-8
GENERAL INFORMATIONAxle assemblies: Check 30A
a Lock the slip plates of the lift.
a Position the vehicle on a lift (see Vehicle: Towingand lifting) .
a Check the condition of the following components:
- track rods,
- axial ball joint linkages,
- subframe,
- lower arm rubber bushes,
- lower arm ball joints (see 31A, Front axle compo-nents, Front driveshaft lower arm ball joint:Check, page 31A-25) ,
- shock absorbers,
- tyres,
a Check:
- the tyre size (see 35A, Wheels and tyres, Tyres:Identification, page 35A-7) ,
- the tyre inflation pressure (see 35A, Wheels andtyres, Tyre inflation pressure: Identification,page 35A-10) .
a Put the vehicle in the VODM position (vehicle in run-ning order) (see 30A, General information, Under-body height: Adjustment values, page 30A-9) :
- tank full,
- vehicle empty (without luggage, etc.).
a Consult:
- the front axle geometry values (see 30A, Generalinformation, Front axle: Adjustment values,page 30A-14) ,
- the rear axle geometry values (see 30A, Generalinformation, Rear axle: Adjustment values,page 30A-18) .
a Refer to the user manual for the geometry tester.
a Check the geometry using the geometry tester.
a If there is an inconsistency between the manufactu-rer's values and the measured values:
a Adjust the front axle (see 30A, General informa-tion, Front axle: Adjusting, page 30A-16)
30A-9
GENERAL INFORMATIONUnderbody height: Adjustment values 30A
I - MEASURING POINTS
Radius under load:
- (R1) : Distance between the ground and the frontwheel centre line
- (R2) : Height between the ground and the rear wheelcentre line
1 - Front height (W1)
(W1) : Height between the ground and the rear crossmember bolt head.
2 - Rear height (W2)
101937
102312
139129
102246
30A-10
GENERAL INFORMATIONUnderbody height: Adjustment values 30A
(W2) : Height between the ground and the shaft of therubber bush on the bearing.
II - MEASURING METHODS
Measure the heights:
- R1,
- R2,
- W1 right-hand and left-hand,
- W2 right-hand and left-hand.
Special cases:
Fit a bar across the lift.
1 - Plate higher than the lift:
Measure the heights (1) , (2) and (3) .
Example: (1) = 13 cm, (2) = 8 cm, (3) = 10 cm
Calculate the height Wx:
Wx = height (1) + height (3) - height (2)
Wx = 15 cm
2 - Plate lower than the lift:
Measure the heights (1) , (2) and (3) .
Example: (1) = 8 cm, (2) = 10 cm, (3) = 4 cm
Calculate the height Wx:
Wx = height (1) + height (2) + height (3)
Wx = 22 cm
III - VEHICLE IN RUNNING ORDER POSITION
VODM (Vehicle in working order) position:
- tank full,
- vehicle empty (without luggage, etc.).
139128
Note:
For measurements (W1) and (W2) , take intoaccount the height difference between the platesand the lift.
Note:
The value of Wx to be entered into the geometrybench is the average of the W1 heights, right-handand left-hand and of the W2 heights, right-hand andleft-hand.
Note:
If the measuring points are located in empty space(between the rails of the lift), use a bar.
126087
126088
30A-11
GENERAL INFORMATIONUnderbody height: Adjustment values 30A
Note:
The position of the vehicle varies according to:
- the weight of the engine,
- the springs and shock absorbers,
- the tyres,
- the amount of fuel in the tank.
30A-12
GENERAL INFORMATIONFront axle: Tightening torque 30A
101232
Mark Description Tightening torque(Nm)
(1) « spring - shock absorber » assembly bolt on the body 17
(2) Lower arm rear bolt 105
(2*) Lower arm front bolt 70
(3) Sub-frame stud bolt 105
(4) Rear cross member bolt 62
(5) Anti-roll bar bolt on the subframe 21
(6) Radiator cross member front bolt 105
(7) Calliper support bolt 105
(8) Radiator cross member rear nut 21
Steering box bolt on the subframe 105
30A-13
GENERAL INFORMATIONFront axle: Tightening torque 30A
101231
Mark Description Tightening torque(Nm)
(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 (except M9R) 130
Wheel bolts (M9R) 110
(16) Track rod end nut 37
Side stiffener bolt on the radiator cross member 21
30A-14
GENERAL INFORMATIONFront axle: Adjustment values 30A
I - CHECK
Check the settings of the axle assemblies (see 30A,General information, Axle assemblies: Check, page30A-8)
II - CASTOR ANGLE
Not adjustable.
III - CAMBER
Not adjustable.
IV - PIVOT
Not adjustable.
93012
Value Position of frontaxle (mm)
+ 4˚ 54’ ± 30’
+ 5˚ 12’ ± 30’
+ 6˚ 00’ ± 30’
+ 6˚ 12’ ± 30’
Maximum left - right diffe-rence = 30’
W2 - W1 = 84
W2 - W1 = 74
W2 - W1 = 50
W2 - W1 = 47
93013
Value Position of frontaxle (mm)
0˚ 00’ ± 30’
- 0˚ 02’ ± 30’
- 0˚ 10’ ± 30’
- 0˚ 13’ ± 30’
Maximum left - right diffe-rence = 30’
R1 - W1 = 124
R1 - W1 = 130
R1 - W1 = 149
R1 - W1 = 155
93014
30A-15
GENERAL INFORMATIONFront axle: Adjustment values 30A
V - WHEEL ALIGNMENT
Value Position of frontaxle (mm)
+ 10˚ 52’ ± 30’
+ 11˚ 00’ ± 30’
+ 11˚ 18’ ± 30’
+ 11˚ 28’ ± 30’
Maximum left - right diffe-rence = 30’
R1 - W1 = 124
R1 - W1 = 130
R1 - W1 = 149
R1 - W1 = 155
WARNING
Symbols used by RENAULT:
- toe-out: -
- toe-in: +
93011
Value (for two wheels) Position ofvehicle
- 0˚ 10’ ± 10’ Vehicle inrunningorder
30A-16
GENERAL INFORMATIONFront axle: Adjusting 30A
I - ADJUSTMENT PREPARATION STAGE
a
a Check the geometry (see 30A, General informa-tion, Axle assemblies: Check, page 30A-8) .
II - ADJUSTMENT OPERATION
1 - Wheel alignment
a Set the wheels straight ahead.
a Lock the steering wheel using a steering wheellock.
a Adjust the wheel alignment by rotating the track rodsleeves.
a Loosen the wheel alignment adjustment lock nut (1).
a Turn the track rod sleeve (2) to the required value.
a After adjustment, torque tighten the wheel align-ment adjustment lock nuts (53 N.m).
2 - Castor angle
a Not adjustable.
3 - Camber
a Not adjustable.
4 - Pivot
a Not adjustable.
Essential equipment
steering wheel lock
Tightening torquesm
wheel alignment adjust-ment lock nuts
53 N.m
Note:
Throughout the axle assembly checking and adjustment process:
- the Renault Card must remain in the reader,
- do not press the « START » button. 121364
30A-17
GENERAL INFORMATIONRear axle: Tightening torque 30A
101900
Mark Description Tightening torque(Nm)
(1) Stub-axle nut (standard chassis) 220
(1) Stub-axle nut (long chassis) 280
(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-18
GENERAL INFORMATIONRear axle: Adjustment values 30A
I - CHECK
Check the settings of the axle assemblies (see 30A,General information, Axle assemblies: Check, page30A-8)
II - CAMBER
Not adjustable.
III - WHEEL ALIGNMENT
Not adjustable.
93013-1
Value Position of vehicle
- 1˚ 25’ ± 20’ Vehicle in running order
WARNINGMeaning of symbols used in this document,
-: toe-out
+: toe-in
93011-1
A x l e p a rtnumber
Value Position ofvehicle
77 01 475 149
77 01 475 150
77 01 475 706
Toe-in:
+0˚40’ ± 25’
Vehicle in run-ning order77 01 476 341
77 01 476 344
77 01 476 345
Toe-in:
+0˚35’ ± 25’
STANDARD CHASSIS, and ADJUSTED SUSPEN-SION
A x l e p a rtnumber
Value Position ofvehicle
77 01 476 509
77 01 476 512
77 01 477 073
77 01 477 077
Toe-in:
-0˚29’ ± 25’
Vehicle in run-ning order
LONG CHASSIS, and ADJUSTED SUSPENSION
A x l e p a rtnumber
Value Position ofvehicle
77 01 476 513
77 01 477 079
Toe-in:
-0˚25’ ± 20’
Vehicle in run-ning order
30A-19
GENERAL INFORMATIONRear axle: Adjustment values 30A
EQT LEVEL EA6
A x l e p a rtnumber
Value Position ofvehicle
77 01 476 509
77 01 476 512
77 01 477 073
77 01 477 077
Toe-in:
-0˚29’ ± 25’
Vehicle in run-ning order
STANDARD CHASSIS, and NORMAL SUSPEN-SION – EQT LEVEL E3 PLUS or EQT LEVEL EA1or EQT LEVEL EA2 or EQT LEVEL EA3 or EQTLEVEL EA4, and STANDARD CHASSIS, andDOCUMENT PHASE 2
A x l e p a rtnumber
Value Position ofvehicle
77 01 476 509
77 01 476 512
77 01 477 073
77 01 477 077
Toe-in:
-0˚32’ ± 30’
Vehicle in run-ning order
LONG CHASSIS, and NORMAL SUSPENSION –EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQTLEVEL EA2 or EQT LEVEL EA3 or EQT LEVELEA4, and LONG CHASSIS, and DOCUMENTPHASE 2
A x l e p a rtnumber
Value Position ofvehicle
77 01 476 513
77 01 477 079
Toe-in:
-0˚31’ ± 20’
Vehicle in run-ning order
30A-20
GENERAL INFORMATIONRear axle: Adjusting 30A
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
The operation is carried out with the shock absorberlower mounting removed.
a Adjust the height of the pads to obtain a centre-to-centre distance between the shock absorber moun-ting points (body mounting (1) , axle mounting (2) )corresponding to a length of 402 mm.
a Torque tighten the mounting bolt joints (12.5daNm).
Essential equipment
safety strap(s)
Tightening torquesm
mounting bolt joints 12.5 daNm
WARNING
Never use the rear axle as support for a lifting sys-tem.
Note:
- During this operation, strap the vehicle to the liftusing a safety strap(s), to avoid any imba-lance.
- For the procedure to fit the safety strap(s)(see Vehicle: Towing and lifting) (MR 370,02A, Lifting equipment).
102521
106178
31A-1
FRONT AXLE COMPONENTSFront brake pads: Removal - Refitting 31A
This procedure concerns TEVES type brake pads.
When replacing brake pads, it is essential to replacethe pads on the opposite side.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Remove the front wheel (see 35A, Wheels and ty-res, Wheel: Removal - Refitting, page 35A-1) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Unclip the brake hose from the shock absorber.
a Remove the retaining spring (1) from the brake calli-per using a flat-blade screwdriver.
a Remove:
- the caps (2) from the guide pin bolts,
- the calliper guide pin bolts (2) ,
- the calliper (3) from its support.
a Attach the calliper (3) to the shock absorber spring.
a Remove the brake pads.
Essential special tooling
Fre. 1190-01 Brake calliper piston returntool.
Tightening torquesm
bolts of the calliperguide pins
27 N.m
WARNING
In order not to damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surroundingcomponents.
127487
127486
31A-2
FRONT AXLE COMPONENTSFront brake pads: Removal - Refitting 31A
REFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Front brake calliperguide pin bolt (13,03,03,07).
a Measure the thickness of the pads and then compa-re them to the minimum values (see 30A, Generalinformation, Brake: Specifications, page 30A-6) .
a Do not allow friction materials to come into contactwith grease, oil or other lubricants and cleaning pro-ducts which are mineral oil based.
a Clean using a wire brush and BRAKE CLEANER (see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products):
- the calliper supports,
- the callipers.
a Push the piston with the tool (Fre. 1190-01).
II - REFITTING OPERATION FOR PART CONCERNED
a Refit:
- the brake pads,
- the brake calliper,
- the calliper retaining spring.
a Torque tighten the bolts of the calliper guide pins(27 N.m).
a Refit the guide pin bolt caps.
a Attach the brake hose to the shock absorber.
III - FINAL OPERATION
a Refit the front wheel (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
IMPORTANT
To avoid any accident, bring the pistons, brakepads and brake discs into contact by depressingthe brake pad several times.
31A-3
FRONT AXLE COMPONENTSFront brake hose: Removal - Refitting 31A
REMOVALa
a Fit the pedal press to the brake pedal to limit theoutflow of brake fluid.
a Unscrew:
- the pipe union (1) ,
- the calliper hose.
REFITTING
a
a Refit the brake hose at the calliper end.
a Torque tighten:
- the brake hose on the calliper (1.7 daNm),
- the brake hose on the union (1.4 daNm).
a Position the female end of the brake pipe on the re-taining bracket without straining it by twisting.
a Make sure that the end piece engages freely into thebracket splines.
Essential equipment
pedal press
Tightening torquesm
brake hose on the calli-per
1.7 daNm
brake hose on the union 1.4 daNm
bleed screw 0.65 daNm
IMPORTANT
Be sure to follow the order of operations in the pro-cedure described below.
101707
WARNING
Drain the brake fluid to prevent damage to themechanical parts and bodywork around the bra-king system.
101709
WARNING
Do not twist the brake pipe, and straighten thewheels as steering lock makes it easier for theunit to become twisted.
Make sure that there is no contact between thebrake pipe and the surrounding components.
Note:
The pipe supplied as spare parts are encased ina spr ing to prevent them from being twistedduring fitting.
31A-4
FRONT AXLE COMPONENTSFront brake hose: Removal - Refitting 31A
a Fit:
- the spring,
- the rigid pipe on the brake hose, making sure thatthe hose does not twist when screwing on the rigidpipe.
a Bleed the brake circuit ( (see 30A, General infor-mation) ).
a Torque tighten the bleed screw (0.65 daNm).
31A-5
FRONT AXLE COMPONENTSFront brake calliper: Removal - Refitting 31A
a When replacing brake pads or a disc, be sure to re-place the pads or disc on the opposite side.
REMOVAL
a Position the vehicle on a two-post lift.
a Fit the pedal press to the brake pedal to limit theoutflow of brake fluid.
a Unlock the steering wheel.
a Remove the front wheels.
a Release the brake hose from the brake calliper.
a Remove:
- the two guide pin bolts (1) ,
- the brake calliper,
- the brake pads.
a Check the condition of the braking components (re-place defective parts).
a Clean the calliper supports and callipers.
REFITTING
a Push the piston back using the (Fre. 1190-01) until itis at the end of its bore.
a Fit the pads, starting from the inside.
a Refit:
- the calliper,
- the guide pin bolt.
a Torque tighten:
- the guide pin bolts (3.2 daNm),
- the brake hose (1.7 daNm).
Essential special tooling
Fre. 1190-01 Brake calliper piston returntool.
Essential equipment
pedal press
Tightening torquesm
guide pin bolts 3.2 daNm
brake hose 1.7 daNm
bleed screw 0.65 daNm
wheel bolts 13 daNm
Note:
The callipers supplied as replacement parts arepre-filled.
WARNING
Prepare for brake fluid outflow, to preventdamage to the mechanical parts and bodyworkaround the braking system.
101214
WARNING- Refasten the brake hose and wheel speed sen-
sor wiring, if they have been unclipped.
- Do not twist the brake hose.
31A-6
FRONT AXLE COMPONENTSFront brake calliper: Removal - Refitting 31A
a Refit the wheels.
a Torque tighten:
- the bleed screw (0.65 daNm),
- the wheel bolts (13 daNm).
a Bleed the brake circuit partially if the compensationreservoir is not completely emptied during the proce-dure. Otherwise, carry out a full bleed ( (see 30A,General information) ).
a Check the brake fluid level.
31A-7
FRONT AXLE COMPONENTSFront brake calliper: Repair 31A
REPAIR
I - REPAIR PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Position the pedal press on the brake pedal to limitthe outflow of brake fluid.
a Remove:
- the front wheel (see 35A , Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) ,
- the front brake calliper (see 31A, Front axle com-ponents, Front brake calliper: Removal - Refit-ting, page 31A-5) .
II - REPAIR OPERATION FOR PART CONCERNED
a Remove the piston using compressed air, makingsure to insert a wooden block between the calliperand the piston to avoid damaging it. Any trace of im-pact on the end panel will render the piston unfit foruse.
a Remove the dust seal.
a Remove the rectangular section seal from the calli-per groove with a round edged spring blade (feelergauge).
a Clean the parts using methylated spirit.
Essential special tooling
Fre. 1190-01 Brake calliper piston returntool.
Essential equipment
pedal press
IMPORTANT
Consult the safety and cleanliness advice and ope-ration recommendations before carrying out anyrepair (see Front axle assemblies: Precautionsfor repair) .
WARNING
Prepare for the flow of fluid, and protect the sur-rounding components.
81546
81545
WARNING
The whole calliper must systematically be repla-ced if there are any scratches in the calliper bore.
31A-8
FRONT AXLE COMPONENTSFront brake calliper: Repair 31A
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Refit:
- the new rectangular section seal in the callipergroove,
- the piston (after having smeared it with the greasesupplied in the repair kit) using the (Fre. 1190-01),
- the dust seal.
II - FINAL OPERATION.
a Refit:
- the brake calliper (see 31A, Front axle compo-nents, Front brake calliper: Removal - Refitting,page 31A-5) ,
- the front wheel (see 35A , Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a Remove the pedal press.
a Bleed the brake circuit (see 30A, General informa-tion, Brake circuit Bleeding, page 30A-2) .
IMPORTANT
To avoid any accident, bring the pistons, brakepads and brake discs into contact by depressingthe brake pad several times.
31A-9
FRONT AXLE COMPONENTSFront brake calliper support: Removal - Refitting 31A
a When replacing brake pads or a disc, it is essentialto change the pads and disc on the opposite side.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Remove the front wheels (see 35A, Wheels and ty-res, Wheel: Removal - Refitting, page 35A-1) .
a Remove the guide pin bolts (1) .
a Hang the brake calliper from the suspension spring.
a Remove:
- the brake pads,
- the two calliper mounting bolts (2) ,
- the calliper mounting.
a Check the condition of the braking components (re-place defective parts).
a Clean the calliper supports and callipers.
REFITTING
a Push the piston back using the (Fre. 1190-01) until itis at the end of its housing.
The calliper mounting bolts and the guide pin boltsmust be coated with FRENBLOC type product befo-re being fitted.
a Refit:
- the calliper mounting,
- the calliper mounting bolts.
a Torque tighten the calliper mounting bolts (10.5daNm).
a Fit the pads, starting from the inside.
a Refit:
- the calliper,
- the guide pin bolts.
a Check the brake fluid level.
a Torque tighten the guide pin bolts (3.2 daNm).
a Refit the wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a
a Check the brake fluid level.
Essential special tooling
Fre. 1190-01 Brake calliper piston returntool.
Tightening torquesm
calliper mounting bolts 10.5 daNm
guide pin bolts 3.2 daNm
101215
WARNING
- Reattach the brake hose and wheel speed sen-sor wire if they have been detached.
- Do not twist the brake hose.
IMPORTANT
Depress the brake pedal several times to bringthe pistons, brake pads and discs into contact.
31A-10
FRONT AXLE COMPONENTSFront brake disc: Description 31A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
Remove the wheel (see 35A , Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
II - CHECKING OPERATION FOR PART CONCERNED
Position the Palmer tool (1) to measure the disc thic-kness.
Measure the thickness of the disc at 4 points in order(90˚ apart).
Compare the values with those recommended by themanufacturer (see 30A, General information, Brake:Specifications, page 30A-6) .
III - FINAL OPERATION
Replace the discs if necessary (see 31A, Front axlecomponents, Front brake disc: Removal - Refitting,page 31A-11) .
Refit the wheel (see 35A, Wheels and tyres, Wheel:Removal - Refitting, page 35A-1) .
Note:
Use a Palmer type tool to check the thickness of thedisc.
117057
88310
31A-11
FRONT AXLE COMPONENTSFront brake disc: Removal - Refitting 31A
REMOVALa Brake discs cannot be reground. If there is excessi-
ve scoring or wear, they will need to be replaced.
a When replacing a brake disc, be sure to replace thedisc on the opposite side.
a Be sure to replace the brake pads if the brake discsare being replaced.
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Unlock the steering wheel.
a Remove the front wheels (see 35A, Wheels and ty-res, Wheel: Removal - Refitting, page 35A-1) .
a Remove both calliper bracket bolts (1) .
a Suspend the calliper-calliper support assembly.
a Remove
- the calliper mounting,
- the two disc bolts (2) ,
- the disc.
REFITTINGa
a Clean the calliper mountings and callipers.
a Proceed in the reverse order to removal.
a Torque tighten:
- the disc bolts (15 Nm),
- the calliper bracket bolts (105 Nm).
a The calliper bracket bolts must be coated with a pro-duct such as FRENBLOC before they are fitted.
a Refit the wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
Tightening torquesm
disc bolts 15 Nm
calliper bracket bolts 105 Nm
101215
101212
WARNING
- Attach the wheel speed sensor wiring and hoseif they were detached.
- Do not twist the brake hose.
31A-12
FRONT AXLE COMPONENTSFront driveshaft hub carrier: Removal - Refitting 31A
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Disconnect the battery (see Battery : Removal -Refitting) (MR 370, 80A, Battery).
a Remove the front wheel (see 35A, Wheels and ty-res, Wheel: Removal - Refitting, page 35A-1) .
a Unclip:
- the wheel speed sensor from the hub carrier,
- the xenon bulb sensor (if fitted to the vehicle).
a Remove:
- the front brake calliper mounting bolts (1) .
- the track rod end nut (2) ,
- the lower ball joint nut (3) ,
- the lower bolt (4) from the shock absorber.
Essential special tooling
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
Sus. 1731 Front shock absorber removaltool.
Essential equipment
diagnostic tool
Tightening torquesm
shock absorber lowerbolt
105 Nm
lower ball joint nut 62 Nm
track rod end nut 37 Nm
front brake disc bolts 15 Nm
front wheel driveshaftnut
280 Nm
front brake callipermounting bolts
105 Nm
wheel bolts 130 Nm
101215
31A-13
FRONT AXLE COMPONENTSFront driveshaft hub carrier: Removal - Refitting 31A
a Hang the « front brake calliper - front brake callipermounting » assembly on the suspension spring.
a Remove:
- the front brake disc bolts (5) ,
- the nut (6) from the front wheel driveshaft using the(Rou. 604-01),
- the front brake disc,
- the anti-roll bar tie rod upper nut (7) ,
- the anti-roll bar tie-rod.
a Extract the ball joints using the (Tav. 476).
a Remove the front wheel driveshaft from the front dri-veshaft hub carrier, taking care not to extract the dri-veshaft from the front wheel.
a Position the (Sus. 1731).
a Tighten the bolt (8) of the (Sus. 1731) to remove thehub carrier from the front driveshaft while holding it.
a Check that section (9) of the (Sus. 1731) is pressedfirmly against the shock absorber base.
REFITTINGa Proceed in the reverse order to removal.
101212
WARNING
In order to prevent irreversible damage to the front hub bearing:
- Do not loosen or tighten the driveshaft nut whenthe wheels are on the ground.
- Do not place the vehicle with its wheels on theground when the driveshaft has been loosenedor removed.
112078
Note:
Take care not to drop the hub carrier.
Note:
The calliper mounting bolts must be coated witha product such as HIGH RESISTANCE THREADLOCK before being refitted.
31A-14
FRONT AXLE COMPONENTSFront driveshaft hub carrier: Removal - Refitting 31A
a Torque tighten:
- the shock absorber lower bolt (105 Nm),
- the lower ball joint nut (62 Nm),
- the track rod end nut (37 Nm),
- the front brake disc bolts (15 Nm),
- the front wheel driveshaft nut (280 Nm),
- the front brake calliper mounting bolts (105Nm),
- the wheel bolts (130 Nm).
a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).
a Adjust the axle assemblies (see 30A, General infor-mation, Front axle: Adjustment values, page30A-14) .
a When adjusting the axle assemblies, program thesteering wheel torque and angle sensor diagnostictool (see Fault finding - Replacement of compo-nents) (MR 372, 36B, Power-assisted steering).
a Adjust the xenon headlights, if fitted to the vehicle(see Xenon headlights: Adjustment) (MR 370,80C, Xenon bulbs).
IMPORTANT
To avoid any accident, bring the pistons, brakepads and brake discs into contact by depressingthe brake pad several times.
31A-15
FRONT AXLE COMPONENTSFront hub carrier bearing: Removal - Refitting 31A
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Remove the front driveshaft hub carrier (see 31A,Front axle components, Front driveshaft hubcarrier: Removal - Refitting, page 31A-12) .
a Remove:
- the hub, with the press, applying pressure with a 41mm diameter tube,
- the circlip.
a Remove the bearing, applying pressure to the innerbearing bush with a 46 mm diameter tube.
REFITTING
a
a It is essential to check the condition of the hub surfa-ce and the hub carrier bore before refitting the bea-ring.
a Replace the front driveshaft hub carrier if it is faulty.
a Clean:
- the inner and outer surfaces of the new bearing incontact with the front driveshaft hub carrier and thehub,
- the surfaces of the front driveshaft hub carrier incontact with the new bearing,
- the hub surfaces in contact with the new bearing.
a
20786
20787
WARNING
To ensure that the wheel speed sensor worksproperly, do not mark the sensor target on thebearing.
WARNINGDo not press the bearing's internal bush so as toavoid damaging the bearing (very high shrink-fit-ting force).
31A-16
FRONT AXLE COMPONENTSFront hub carrier bearing: Removal - Refitting 31A
a Refit the sensor holder.
a Position the sensor holder at (x) = 35˚ ±±±± 5˚ from ver-tical. This position corresponds to the centre of thehousing.
a Apply force to the external bearing bush using a pipewith an outer diameter of 77 mm and bore diameterof 70 mm.
a Refit the circlip.
a Check that the circlips are correctly positioned bymeasuring the inner diameter (Z = 67.6 mm) for abearing with an outer diameter of 77 mm.
101934
20788
101933
31A-17
FRONT AXLE COMPONENTSFront hub carrier bearing: Removal - Refitting 31A
a
a Refit:
- the hub,
- the front driveshaft hub carrier (see 31A, Frontaxle components, Front driveshaft hub carrier:Removal - Refitting, page 31A-12) .
20789
WARNING
In order to prevent irreversible damage to the front hub bearing:
- Do not loosen or tighten the driveshaft nut whenthe wheels are on the ground.
- Do not place the vehicle with its wheels on theground when the driveshaft has been loosenedor removed.
31A-18
FRONT AXLE COMPONENTSSpring and front shock absorber: Removal - Refitting 31A
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Disconnect the battery (see Battery : Removal -Refitting) (MR 370, 80A, Battery).
a Remove the front wheels (see 35A, Wheels and ty-res, Wheel: Removal - Refitting, page 35A-1) .
a Unclip the brake hose from the shock absorber andthe wheel speed sensor cable.
a Remove:
- the anti-roll bar tie-rod ball joint,
- the windscreen wiper mechanism (see Winds-creen wiper mechanism: Removal - Refitting)(MR 370, 85A, Wiping - Washing).
a Remove:
- the shock absorber base mounting bolt (1) ,
- the front brake calliper mounting bolt (2) .
a Suspend the « front brake calliper mounting -calliper » assembly.
a Position the (Sus. 1731).
a Tighten the bolt (3) of the (Sus. 1731) to separatethe shock absorber base from the hub carrier.
a Ensure that the section (4) of the (Sus. 1731) ispressed firmly against the shock absorber base.
a Suspend the hub carrier
Essential special tooling
Sus. 1731 Front shock absorber removaltool.
Essential equipment
spring compressor
spanner for shock absorber rod nut
Tightening torquesm
shock absorber rod nut 62 Nm
shock absorber turretmounting bolts
17 Nm
shock absorber basemounting bolt
105 Nm
anti-roll bar tie-rod balljoint mounting nut
44 Nm101215
112078
31A-19
FRONT AXLE COMPONENTSSpring and front shock absorber: Removal - Refitting 31A
a Remove:
- the shock absorber turret mounting bolts (5) ,
- the « spring/shock absorber » assembly.
a Place the appropriate cups on the spring compres-sor and position the assembly on the spring.
a Detach the spring from the cups by compressing thespring.
a Remove the shock absorber rod nut using the span-ner for shock absorber rod nut.
a Separate the various components of the spring-shock absorber assembly.
REFITTING
a Fit the spring compressor in a vice.
a
104428
96049
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
FRONT AXLE COMPONENTSSpring and front shock absorber: Removal - Refitting 31A
a Position the spring in the cup groove, smooth sheathabove, and grooved sheath below.
102201
31A-21
FRONT AXLE COMPONENTSSpring and front shock absorber: Removal - Refitting 31A
a Respect the order and direction of fitting for theconstituent parts.
a The shock absorber rod nut must be replaced.
a Torque tighten the shock absorber rod nut (62Nm).
a Decompress the spring.
a Remove the spring compressor.
a Fit the index bolt (6) in its housing.
a Proceed in the reverse order to removal.
a Torque tighten:
- the shock absorber turret mounting bolts (17Nm),
- the shock absorber base mounting bolt (105Nm),
- the anti-roll bar tie-rod ball joint mounting nut(44 Nm).
a Refit:
- the anti-roll bar tie-rod ball joint,
- the windscreen wiper mechanism (see Winds-creen wiper mechanism: Removal - Refitting)(MR 370, 85A, Wiping - Washing).
a Refit the front wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).
101939
Note:
Make sure that the rotary stop is correctly orien-ted to facilitate refitting above and below.
96049
104428
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 COMPONENTSFront driveshaft lower arm: Removal - Refitting 31A
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Unlock the steering wheel.
a Strap the radiator to the radiator grille.
Essential equipment
component jack
Tightening torquesm
rear bolt mounting thelower arm on the sub-frame
105 Nm
front bolts mounting thelower arm on the sub-frame
70 Nm
track rod end nut 37 Nm
anti-roll bar linkage balljoint nuts
44 Nm
lower ball joint nut 110 Nm
radiator cross memberfront mounting bolts
105 Nm
radiator cross memberrear bolts
21 Nm
side stiffener lower bolts 21 Nm
WARNING
Do not use the lower arm for support with a liftingsystem.
31A-23
FRONT AXLE COMPONENTSFront driveshaft lower arm: Removal - Refitting 31A
a Remove:
- the front wheel concerned (see 35A, Wheels andtyres, Wheel: Removal - Refitting, page 35A-1) ,
- the wheel arch protectors,
- the engine undertray,
- the side stiffener lower bolts (1) ,
- the radiator cross member rear nuts,
- the radiator cross member front bolts (2) ,
- the radiator cross member.
a Unpick the wheel speed sensor harness.
a Disconnect the wheel sensor connector in the wheelarch.
a Remove the lower ball joint bolt (3) .
a Remove:
- the lower ball joint,
- the height sensor ball joint (if fitted to the vehicle).
a Remove:
- the lower arm front and rear bolts (4) ,
- the lower arm.
REFITTINGa Be sure to replace the sub-frame and arm moun-
tings.
a Proceed in the reverse order to removal.
101212
101213
31A-24
FRONT AXLE COMPONENTSFront driveshaft lower arm: Removal - Refitting 31A
a Place the component jack against the subframerear bolt head (5) .
a Lower the component jack by (H) = 10 mm.
a Rest the lower arm ball joint (6) on the componentjack without adjusting the settings.
a In this position, tighten to torque:
- the rear bolt mounting the lower arm on thesubframe (105 Nm),
- the front bolts mounting the lower arm on thesubframe (70 Nm).
a Remove the component jack.
a Refit the lower ball joint into the hub carrier.
a Refit and tighten to torque:
- the track rod end nut (37 Nm),
- the anti-roll bar linkage ball joint nuts (44 Nm),
- the lower ball joint nut (110 Nm),
- the radiator cross member and the radiator crossmember front mounting bolts (105 Nm),
- the radiator cross member rear bolts (21 Nm),
- the side stiffener lower bolts (21 Nm),
- the front wheel concerned (see 35A, Wheels andtyres, Wheel: Removal - Refitting, page 35A-1) .
a Adjust the axle assemblies (see 30A, General infor-mation, Front axle: Adjustment values, page30A-14) .
a Initialise the xenon bulb system (see Fault finding -Configurations and programming) (MR 372, 80C,Xenon bulbs).
103114
107304
WARNING
When refitting, position the lower arm below thesubframe rear bolt head (H) = 10 mm to tightenthe rubber bushes freely.
WARNING
A 10mm shim must be placed between the radia-tor cross member and the subframe to tightenthe radiator cross member mountings to torque.
WARNING
Refasten the brake hose and wheel speed sen-sor wiring if they have been unclipped.
Do not twist the brake hose.
31A-25
FRONT AXLE COMPONENTSFront driveshaft lower arm ball joint: Check 31A
CHECKING
CHECKING THE FRONT DRIVESHAFT LOWER ARM BALL JOINT
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
1 - Checking the condition
a Check:
- the crimping of the gaiter on the lower ball joint,
- that the gaiter is not torn.
a If the front driveshaft lower arm ball joint gaiter is inpoor condition or not crimped, replace the front dri-veshaft lower arm (see 31A, Front axle compo-nents, Front driveshaft lower arm: Removal -Refitting, page 31A-22) .
2 - Check the fitting of the lower arm ball joint
a Check:
- the "front driveshaft lower arm ball joint - front dri-veshaft lower arm bolt" assembly is correctly posi-tioned,
- the tightening torque of the stud (1) on the front dri-veshaft lower arm ball joint (see 31A, Front axlecomponents, Front driveshaft lower arm: Re-moval - Refitting, page 31A-22) .
3 - Checking the play of the lower arm ball joint
a Check that there is no play in the front driveshaft lower arm ball joint:
- from a position underneath the vehicle,
- using both hands, hold the front driveshaft lowerarm as close as possible to the wheel,
- push downwards several times.
a If there is play in the front driveshaft lower arm balljoint, replace the front driveshaft lower arm (see31A, Front axle components, Front driveshaftlower arm: Removal - Refitting, page 31A-22) .
101213
117494
31A-26
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting 31A
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Set the wheels straight ahead.
a Centre the steering wheel.
a Lift the floor carpet to access the universal joint.
a Discard the cover (do not keep it).
a Remove:
- the universal joint bolt (do not keep),
- the universal joint cam nut (do not keep).
a Position the steering wheel lock.
a Strap the radiator to the radiator grille.
Essential equipment
steering wheel lock
component jack
Tightening torquesm
sub-frame linkage bolt 105 Nm
rear cross member boltson the subframe
62 Nm
bolts to the sub-frametie-rod
105 Nm
radiator cross memberrear bolts
21 Nm
front mountings of theradiator cross member
105 Nm
lower ball joint bolts 60 Nm
engine tie-bar bolts onthe subframe
105 Nm
anti-roll bar tie rod balljoint nuts
44 Nm
track rod end nuts 37 Nm
side stiffener bolts 21 Nm
universal joint bolt (TRWcolumn)
30 Nm
universal joint bolt (NSKcolumn)
44 Nm
engine tie-bar bolts onthe F or M engine sup-port
180Nm
engine tie-bar bolts onthe K engine
105Nm
WARNING
Do not use the lower arm for support with a liftingsystem.
104020
31A-27
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting 31A
a Remove:
- the front wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) ,
- the wheel arch liners,
- the engine undertray,
- the side stiffener lower bolts (8) ,
- the radiator cross member front bolt (9) ,
- the radiator cross member rear nuts,
- the radiator cross member.
a Unpick the wheel speed sensor harness.
a Disconnect the wheel speed sensor connector fromthe wheel arch.
a Remove:
- the track rod end nuts (11) ,
- the lower ball joint bolts (12) ,
- the anti-roll bar tie-rod upper ball joint nuts (13) .
a Remove:
- the track rod ends,
- the anti-roll bar tie-rod upper ball joints.
a Remove the engine tie-bar bolt (14) on the engine.
101212
101213
K4J or K4M or K9K
101208
31A-28
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting 31A
a Remove the engine tie-bar bolt (15) on the engine.
a Remove the engine tie-bar bolt (16) on the enginemounting.
a Fit the component jack underneath the sub-frame.
a Strap the sub-frame to the component jack.
a Remove the lower arm ball joints.
a Remove the wheel speed sensor wiring support.
a Remove:
- the rear cross member bolts,
- the subframe bolts on the body,
- the rear cross member,
- the sub-frame.
F4R or F9Q
102313
M9R
114650
31A-29
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting 31A
a Remove the sub-frame fittings.
REFITTING
a Be sure to replace the sub-frame and arm moun-tings.
a Degrease the surfaces on the body that make con-tact with the subframe and cross member usingsome SURFACE CLEANER.
a Torque tighten and in order:
- the sub-frame linkage bolt (105 Nm),
- the rear cross member bolts on the subframe(62 Nm),
- the bolts to the sub-frame tie-rod (105 Nm).
a Torque tighten the lower arm bolts (see 31A, Frontaxle components, Front driveshaft lower arm:Removal - Refitting, page 31A-22) .
a Proceed in the reverse order to removal.
a Torque tighten:
- the radiator cross member rear bolts (21 Nm),
- the front mountings of the radiator cross mem-ber (105 Nm).
- the lower ball joint bolts (60 Nm),
- the engine tie-bar bolts on the subframe (105Nm),
- the anti-roll bar tie rod ball joint nuts (44 Nm),
- the track rod end nuts (37 Nm),
- the side stiffener bolts (21 Nm).
101209
WARNING
Be sure to follow the sub-frame tightening order.
WARNING
A shim of 10 mm in thickness must be placedbetween the radiator cross member and the sub-frame. Centre the radiator cross member pin inthe subframe hole at the level of the lower armfront mounting, to torque tighten the radiatorcross member mountings.
31A-30
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting 31A
a Observe the direction of fitting for the universal jointcam nut and bolt.
a Refit the universal joint.
a Refit the universal joint cam nut and bolt.
a Position the universal joint cam nut and bolt.
a Lock the cam nut in its housing (on the universaljoint).
a Pretighten the universal joint cam nut and bolt.
a Identify the make of the steering column (see 36A,Steering assembly, Steering column: Removal -Refitting, page 36A-8) .
a Torque tighten:
- the universal joint bolt (TRW column) (30 Nm),
- the universal joint bolt (NSK column) (44 Nm)
a Check that the universal joint is in the correct posi-tion.
101354
116021
116022
WARNINGRefasten the brake hose and wheel speed sen-sor wiring if they have been unclipped.
Do not twist the brake hose.
31A-31
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting 31A
a Torque tighten the engine tie-bar bolts on the F orM engine support (180Nm).
a Torque tighten the engine tie-bar bolts on the Kengine (105Nm).
a Refit the wheels (see 35A , Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a Refit the floor carpet.
a Adjust the axle assemblies (see 30A, General infor-mation, Front axle: Adjustment values, page30A-14) .
a Initialise the xenon bulb system (if fitted to the vehi-cle) (see Fault finding - Configurations and pro-gramming) (MR 372, 80C, Xenon bulbs).
F4R or F9Q or M9R
K4J or K4M or K9K
Note:
Check that the floor carpet reaches under theaccelerator pedal end-stop.
31A-32
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting
EQT LEVEL SPORT
31A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Set the wheels straight ahead.
a Centre the steering wheel.
a Position the steering wheel lock.
a In the passenger compartment, remove the steeringcolumn universal joint bolt and nut.
a Strap the radiator to the radiator grille.
a Remove:
- the front wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) ,
- the front wheel arch liners (see Front wheel archliner: Removal - Refitting) (55A, Exterior protec-tion),
- the engine undertray.
a Remove:
- the side panels (1) ,
- the radiator cross member front bolts (2) ,
- the radiator cross member rear nuts (3) ,
- the radiator cross member.
a Extract the height sensor ball joint.
a Unclip the wheel speed sensors wiring.
a Disconnect the wheel speed sensor connector fromthe wheel arch.
Essential special tooling
Tav. 476 Ball joint extractor.
Essential equipment
steering wheel lock
component jack
safety strap(s)
Tightening torquesm
subframe bracket bolts 62 Nm
subframe tie-rod bolts 105 Nm
engine tie-bar bolts onthe engine
180 Nm
engine tie-bar bolts onthe subframe
105 Nm
pivot bolts 72 Nm
subframe stiffener strutbolts
62 Nm
anti-roll bar tie bar nuts 44 Nm
track rod end nuts 37 Nm
lower ball joint nuts 100 Nm
radiator cross memberfront bolts
105 Nm
radiator cross memberrear nuts
21 Nm
side panel bolts 21 Nm
universal joint bolt 24 Nm
106077
31A-33
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting
EQT LEVEL SPORT
31A
a Remove:
- the track rod end nuts (4) ,
- the upper ball joint nuts (5) from the anti-roll bar tie-rods.
a Remove the lower tie-bar nuts (6) .
a Extract the ball joints using the (Tav. 476).
a Compress the driveshaft by approximately 10 cm.
a Remove the three bolts (7) from the pivot support.
a Relax the driveshaft by raising the lift by 50 cm.
a Remove the sub-frame stiffener strut (8) .
105891
105893
106114
106085
31A-34
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting
EQT LEVEL SPORT
31A
a Remove the pivots (9) from their support (10) usinga hammer.
II - OPERATION FOR REMOVAL OF PART CONCERNED:
a Remove the engine tie-bar (11) .
a Fit the component jack underneath the subframe.
a Strap the subframe to the component jack.
a Remove:
- the bolts (12) from the subframe bracket,
- the bracket.
107161
106245
102313
106085
31A-35
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting
EQT LEVEL SPORT
31A
a Remove:
- the subframe tie rod bolts (13) ,
- the sub-frame.
a Remove the subframe fittings.
REFITTING
I - REFITTING PREPARATION OPERATION
a Degrease the body surfaces that make contact withthe sub-frame and cross member using SURFACECLEANER (see Vehicle: Parts and ingredientsfor the repairwork) (04B, Consumables - Pro-ducts).
a Always replace the subframe and arm mountings.
a A shim 10 mm thick must be placed between the ra-diator cross member and the sub-frame.
a Set the wheels straight ahead; centre the steeringwheel.
106086
102313
31A-36
FRONT AXLE COMPONENTSFront axle sub-frame: Removal - Refitting
EQT LEVEL SPORT
31AII - REFITTING OPERATION FOR PART CONCERNED
a Refit the subframe equipment.
a Strap the sub-frame onto the component jack.
a Refit:
- the sub-frame,
- the bracket,
- the engine tie-bar .
a Tighten to torque:
- the subframe bracket bolts (62 Nm),
- the subframe tie-rod bolts (105 Nm),
- the engine tie-bar bolts on the engine (180 Nm),
- the engine tie-bar bolts on the subframe (105Nm).
III - FINAL OPERATION.
a Refit:
- the pivots on their support,
- the subframe stiffener strut,
- the anti-roll bar tie bars,
- the ball joints.
a Tighten to torque:
- the pivot bolts (72 Nm),
- the subframe stiffener strut bolts (62 Nm),
- the anti-roll bar tie bar nuts (44 Nm).
- the track rod end nuts (37 Nm),
- the lower ball joint nuts (100 Nm).
a Connect the wheel speed sensor connector.
a Clip the wheel speed sensor wiring.
a Refit:
- the height sensor ball joint,
- the radiator cross member,
- the side panels.
a Tighten to torque:
- the radiator cross member front bolts (105 Nm),
- the radiator cross member rear nuts (21 Nm),
- the side panel bolts (21 Nm).
a Refit:
- the engine undertray,
- the front wheel arch liners (see Front wheel archliner: Removal - Refitting) (55A, Exterior protec-tion),
- the front wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) ,
- the universal joint.
a Torque tighten the universal joint bolt (24 Nm).
a Remove the safety strap(s) from the radiator.
a Adjust the axle assemblies (see 30A, General infor-mation, Axle assemblies: Check, page 30A-8) .
31A-37
FRONT AXLE COMPONENTSFront anti-roll bar: Removal - Refitting 31A
REMOVAL
a Mount the vehicle on a two post lift.
a Remove:
- the front axle sub-frame (see 31A, Front axlecomponents, Front axle sub-frame: Removal -Refitting, page 31A-26) ,
- the steering rack - sub-frame mounting bolts,
- the steering rack,
- the anti-roll bar - sub-frame mounting bolts,
- the anti-roll bar.
REFITTING
a Proceed in the reverse order to removal.
a Torque tighten:
- the anti-roll bar - sub-frame mounting bolts (2.1daNm),
- the steering rack - sub-frame mounting bolts(10.5 daNm).
Tightening torquesm
anti-roll bar - sub-framemounting bolts
2.1 daNm
steering rack - sub-frame mounting bolts
10.5 daNm
WARNING
Make sure the anti-roll bar mounting bracket lugsare correctly positioned in the sub-frame apertu-res.
When replacing brake pads, be sure to replace thepads on the opposite side.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Release the parking brake.
a Remove the rear wheels (see 35A, Wheels and ty-res, Wheel: Removal - Refitting, page 35A-1) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Unclip the parking brake cable.
a Remove the calliper guide pin lower bolt (discard it).
a Rotate the calliper upwards.
a Remove the brake pads.
REFITTING
I - REFITTING PREPARATION OPERATION
a Measure the thickness of the brake pads and com-pare them with the minimum values (see 30A, Ge-neral information, Brake: Specifications, page30A-6) .
a Clean using a wire brush and BRAKE CLEANER (see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products):
- the calliper supports,
- the callipers.
a parts always to be replaced: Rear brake calliperguide pin bolt (13,03,04,10).
Essential special tooling
Fre. 1190-01 Brake calliper piston returntool.
Tightening torquesm
calliper guide pin lowerbolt
36 N.m
WARNING
To avoid damaging the parking brake cable protec-tors and causing premature wear of the system, donot handle the cables with a tool.
a Push the calliper piston back using the (Fre. 1190-01) until it reaches the end of its bore.
a Refit:
- the brake pads,
- the calliper,
- the guide pin bolts.
a Torque tighten the guide pin bolts (36 Nm).
a Refit the parking brake cables.
a Check that the parking brake cable stop is properlyengaged in its housing.
a Apply the parking brake control several times to ac-tivate the locking and unlocking function and to acti-vate the calliper automatic play compensation.
a Refit the wheel (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
Brake discs cannot be reground. If there is excessivewear or scoring, the brake discs must be replaced (see30A, General information, Brake: Specifications,page 30A-6) .
When replacing a brake disc, be sure to replace thedisc on the opposite side.
When replacing a brake disc, be sure to replace thebrake pads.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02A, Lifting equip-ment).
a Remove the wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a Check the condition of the braking components (re-place the faulty parts), (see 30A, General informa-tion, Brake: Specifications, page 30A-6) .
a Clean the callipers and calliper mountings using thecleaning station.
REFITTINGa
a Torque tighten:
- the stub-axle nuts (standard chassis) (220 Nm),
- the stub-axle nuts (long chassis) (280 Nm),
- the calliper mounting bolts (105 Nm),
- the guide pin bolts (36 Nm).
a Refit the parking brake cables (5) .
a Check that the parking brake cable stops are proper-ly engaged in their housing.
a Check the brake fluid level.
a Apply the parking brake control several times to ac-tivate the locking and unlocking function and to acti-vate the calliper automatic play compensation.
a Refit the wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
117348
Note:
Coat the calliper mounting and guide pin boltswith HIGH RESISTANCE THREAD LOCK pro-duct before fitting them.
101306
Note:
Depress the brake pedal several times to bringthe pistons, brake pads and discs into contact.
a To refit, proceed in the reverse order of removal.
a Torque tighten:
- the rigid brake pipe on the rear axle (1.4 daNm),
- the rigid brake pipe on the calliper (1.4 daNm).
a Bleed the brake circuit (see 30A, General informa-tion, Brake circuit Bleeding, page 30A-2) .
106768
IMPORTANT
Make sure that the underbody brake pipes arenot under any strain at all the clips, and that theyare not crossed. If the brake pipes are crossed,the ABS and ESP systems will not work properly.
a Remove the brake disc (see 33A, Rear axle com-ponents, Rear brake disc: Removal - Refitting,page 33A-8) .
a Remove the circlip (1)
a Remove the bearing with a press, applying pressurewith a 49 mm diameter tube.
REFITTING
a
104528
104396
WARNING
Take care not to mark the wheel speed sensortarget on the bearing fitted with it when refitting.
WARNING
Clean:
- the internal and external surfaces of the newbearing in contact with the hub carrier and thestub-axle,
- the hub carrier surfaces in contact with the newbearing,
- the stub-axle surfaces in contact with the newbearing,
WARNING
Before refitting the bearing, the condition of thestub-axle surface and the bore of the hub carriermust be checked. Replace the hub carrier if it isfaulty.
WARNING
Do not apply pressure to the inner bearing bush,to avoid damaging the bearing (significant forceis required for fitting).
a Fit the (Mot. 1390) on the rear axle jacking points.
a Adjust the height of the pads to obtain a centre-to-centre distance between the shock absorber moun-ting points (body mounting (5) , axle mounting (6) )corresponding to a length of 402 mm.
a Loosen the bearing bolts.
a Position the pads of the (Mot. 1390) in contact withthe rear axle.
a Fit the component jack with a shim, under thespring cup.
a Check the position of the bump stop on the axle as-sembly.
a Compress the rear axle.
a Refit the shock absorber lower mounting.
a Remove the component jack.
a Lower the lift.
a Torque tighten the shock absorber lower moun-tings (10.5 daNm).
a Raise the lift again.
a Refit the rear axle protective cowling, replacing thedamaged plastic clips.
a Refit the rear wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a Torque tighten the wheel bolts (13 daNm).
35A-1
WHEELS AND TYRESWheel: Removal - Refitting 35A
The removal - refitting procedure is the same for alloyand steel wheels.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Release the parking brake.
a Remove the trim.
a Position the wheel so that the valve is at the top.
a Mark the position of the wheel on the hub.
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Loosen the wheel bolts with the wheel on theground.
a Raise the lift.
a Remove:
- the wheel bolts,
- the wheel.
If the wheel cannot be removed after the bolt has been undone:
a Position all the wheel bolts.
a Tighten the wheel bolts to bring all the bolt headsinto contact with the wheel.
a Undo the wheel bolts by one turn.
a Strike around the edge of the tyre walls (1) severaltimes using a mallet on the inner and outer surfacesof the wheel to detach the wheel.
a Remove:
- the wheel bolts,
- the wheel.
Tightening torquesm
wheel bolts 130 N.m
Note:
This mark is necessary for:
- marking the initial position of the wheel rim onthe hub,
- perform the balancing operation.
Note:
Use sockets with protective sheaths in order toavoid scratching the alloy wheel rims.
100682
35A-2
WHEELS AND TYRESWheel: Removal - Refitting 35A
If this procedure does not work:
a Strike the inner surface of the wheel (2) using a mal-let and a wooden block to detach it.
a Remove:
- the wheel bolts,
- the wheel.
REFITTING
I - REFITTING PREPARATION OPERATION
a Clean the hub carrier using a wire brush.
a Check the condition of the tyre.
a Do not move or remove the balance weights.
II - REFITTING OPERATION FOR PART CONCERNED
a Clean the "wheel - hub carrier" contact surfacesusing a wire brush.
a Coat the wheel-mating face (3) with COPPER ANTI-SEIZE AGENT (see Vehicle: Parts and ingre-dients for the repairwork) (04B, Consumables -Products).
a Align the mark on the wheel with the mark made onthe hub when it was removed.
a Fit the wheel to the vehicle, positioning the valve atthe top.
a Insert the wheel bolts.
106089
Note:
Do not strike the surface of the wheel usingexcessive force as this may damage it.
Note:
There are two types of wheel bolts for aluminiumand steel wheel rims; do not swap them.
124750
35A-3
WHEELS AND TYRESWheel: Removal - Refitting 35A
a Tighten the wheel bolts to bring all the bolt headsinto contact with the wheel. a Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.
a Pre-tighten the wheel bolts to 30 N.m, with the wheelhanging, starting with the bottom bolts.
a Rotate the wheel through 180˚ to bring the valve intothe bottom position.
a Position the vehicle on its wheels.
a Tighten in order and to torque the wheel bolts (130N.m).
a Refit the trim piece.
M9R, and STANDARD CHASSIS
100682
F4R or F9Q or K4J or K4M or K9K, and STAN-DARD CHASSIS
113180
35A-4
WHEELS AND TYRESWheel: Balancing 35A
I - PREREQUISITES FOR WHEEL BALANCING
a Wheel balancing is a measurement 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 to calibrate the balancer according tothe frequency recommended by the manufacturer.
Do not grease the threaded shaft.
Check the condition of the supports, centring com-ponents and mountings.
Replace any faulty parts (see manufacturer's ins-tructions).
The wheel and the wheel balancer must be clean.
Driver's perception
a If the wheels are not correctly balanced this causesthe steering wheel and/or the vehicle floor to vibrate.
These vibrations appear between 54 mph (90 km/h)and 90 mph (150 km/h).
II - BALANCING PREPARATION OPERATION
a Adjust the tyre pressure (see 35A, Wheels and ty-res, Tyre inflation pressure: Identification, page35A-10) .
a Always carry out a road test for a minimum distanceof 1 mile (2 km) before balancing the wheels, in or-der to remove any flat spots on the tread caused bythe vehicle being immobilised.
a Actions to be carried out immediately after the test drive:
- Position the vehicle on a two-post vehicle lift (seeVehicle: Towing and lifting) ,
- raise the vehicle,
- leave the four wheels hanging free,
- release the parking brake.
a
To reproduce the exact vehicle wheel assembly, usea ring (1) of diameter:
a 60 mm
a There are three types of weight:
105870
Note:
The ring is available from the supplier of theequipment used.
35A-5
WHEELS AND TYRESWheel: Balancing 35A
a In some countries, the use of lead weights is forbid-den; in this case it is recommended to use ZAMAKweights instead.
Only use weights provided by the Parts Department.
a Remove the wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a Always clean the wheel, disc, and hub bearing surfa-ces.
III - PROCEDURE FOR BALANCING THE WHEEL IN QUESTION
a Make sure that the wheel balancer bearing surfaceand all the centring equipment (ring, thrust plate,etc.) are kept clean.
a Try not to scratch the (alloy) wheel rim with thewheel tightening device.
a The wheel is fitted on the wheel balancer as follows:
- (5) ring,
- (6) wheel balancer back-plate,
- (7) wheel tightening device (certain alloy wheelsrequire a device 200 mm in diameter to ensure thatthe wheel has been correctly tightened),
- (8) outer wheel plane,
- (9) wheel.
a Place the wheel on the wheel balancer, with the val-ve at the top, then lock the wheel in place.
a Remove any stones trapped in the tyre tread.
113742
(2) Steel wheel with flange
(3) Alloy wheel with flange
(4) Alloy wheel without flange
105871
100681
35A-6
WHEELS AND TYRESWheel: Balancing 35A
a Enter the specific wheel parameters when startingthe wheel balancer.
a Start the wheel balancer and check the wheel balan-ce, which should be 0 g on each plane of the wheel.
a If this is not the case, remove the old wheel balan-cing weights and repeat the wheel balancing proce-dure, checking that the wheel balance equals 0 oneach wheel plane.
IV - FINAL OPERATION
a Refit the wheel (see 3 5 A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
WARNING
To avoid detachment of the balance weights, useonly weights which correspond to the vehiclewheel rims.
35A-7
WHEELS AND TYRESTyres: Identification 35A
Example of a tyre identification mark: 205/65 R 15 91V.
Speed code table:
101008
123448
205 Tyre width in mm (L)
65 Height/width ratio
R Radial structure
15 Internal diameter in inches (c)
91 Load index
V Speed code
Code Maximumspeed inmph (km/h)
R 170
S 180
T 190
U 200
H 210
V 240
ZR above 240
W 270
Y 300
35A-8
WHEELS AND TYRESTyres: Removal - Refitting 35A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Remove:
- the wheel in question (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) ,
- the balance weights,
- the valve mechanism.
II - OPERATION FOR REMOVAL OF PART CONCERNED
a
a Detach:
- the bead from the outside of the tyre, starting withthe side opposite the valve,
- the bead from the inside of the tyre.
a Position the tyre lever approximately 15 cm from thevalve on the outside of the wheel rim in order to re-move the exterior bead from the tyre.
a Remove the exterior bead of the tyre, finishing at thevalve.
a 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.
a Remove the interior bead of the tyre, finishing at thevalve.
REFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Tyre valve (13,05,02,02)
a Lubricate the two tyre beads correctly using theTYRE PASTE (see Vehicle: Parts and ingre-dients for the repairwork) (04B, Consumables -Products).
II - REFITTING OPERATION FOR PART CONCERNED
a Engage the lower tyre bead approximately 15 cm af-ter the valve.
TYRE PRESSURE SENS.
WARNING
To avoid any damage to the sensor, make surethe tyre bead never presses on the sensor.
18884
18885
WITHOUT TYRE PRESSURE SENS.
35A-9
WHEELS AND TYRESTyres: Removal - Refitting 35A
a Finish fitting the tyre at the valve.
a Fit the exterior bead approximately 15 cm after thevalve using the tyre lever.
a Inflate the tyre to 3.5 bar to press the tyre beadsagainst the wheel rim.
III - FINAL OPERATION
a Refit the valve mechanism.
a Inflate the tyre to the recommended pressure (see35A, Wheels and tyres, Tyre inflation pressure:Identification, page 35A-10) .
a Balance the wheel (see 35A, Wheels and tyres,Wheel: Balancing, page 35A-4) .
a Refit the wheel in question (see 35A, Wheels andtyres, Wheel: Removal - Refitting, page 35A-1) .
Note:
It is not necessary to drive the vehicle before andafter a new wheel is balanced.
35A-10
WHEELS AND TYRESTyre inflation pressure: Identification 35A
I - INFLATION
Tyre pressure when cold (bar), for the tyre pressure monitoring system (SSPP)
WARNING
If checking the tyre pressure when hot, increase thetyre inflation pressure by 0.2 to 0.3 bar above therecommended pressure.
STANDARD CHASSIS
Engine Wheel rim Tyre
Tyre inflation pressure when cold (bar)
Front Rear Emer-gencysparewheel
Normal Motorway Normal Motorway
K4J
6.5 J 15 195/65 R 15 T 2.4 2.4 2.2 2.2 2.4
6.5 J 16* 205/55 R16H
205/55 R16 V
2.2 2.4 2 2.1 2.4
195/440(49)
205-650 R440(1)
2.3 2.3 2.1 2.1 2.3
K4M
6.5 J 15 195/65 R 15 T 2.4 2.4 2.2 2.2 2.4
6.5 J 16* 205/55 R16H
205/55 R16 V
2.2 2.4 2 2.1 2.4
195/440(49)
205/650 R440(1)
2.3 2.3 2.1 2.1 2.3
K9K
6.5 J 15 195/65 R 15 T 2.4 2.4 2.2 2.2 2.4
6.5 J 16* 205/55 R16 V 2.2 2.4 2 2.1 2.4
6.5 J 16* 205/55 R16H 2.2 2.4 2 2.1 2.4
6.5 J 16 205/60 R16H 2.3 2.5 2.1 2.3 2.5
195/440(49)
205/650 R440(1)
2.3 2.3 2.1 2.1 2.3
35A-11
WHEELS AND TYRESTyre inflation pressure: Identification 35A
F4R
6.5 J 17* 205/55 R17V 2.4 2.5 2.2 2.3 2.5
6.5 J 16* 205/60 R16H 2.3 2.5 2.1 2.3 2.5
6.5 J 17 205/55 R17V(2)
2.4 2.6 2.2 2.4 2.6
6.5 J 17 205/55 R17V 2.4 2.5 2.2 2.3 2.5
6.5 J 16 205/60 R16H(2)
2.3 2.5 2.1 2.3 2.5
6.5 J 16 205/60 R16V 2.3 2.5 2.1 2.3 2.5
195/440(49)
205-650 R440(1)
2.3 2.3 2.1 2.1 2.3
195/440(49)
205-650 R440(1) (2)
2.4 2.4 2.2 2.2 2.4
F9Q
6.5 J 17* 205/65 R17V 2.4 2.5 2.2 2.3 2.5
6.5 J 16* 205/60 R16V 2.3 2.5 2.1 2.3 2.5
6.5 J 17 205/55 R17V 2.4 2.5 2.2 2.3 2.5
6.5 J 16 205/60 R16H 2.3 2.5 2.1 2.3 2.5
195/440(49)
205-650 R440(1)
2.3 2.3 2.1 2.1 2.3
M9R6.5 J 16 205/60 R16V 2.5 2.7 2.2 2.2 2.7
6.5 J 17 205/55 R17V 2.6 2.7 2.2 2.2 2.7
Engine Wheel rim Tyre
Tyre inflation pressure when cold (bar)
Front Rear Emer-gencysparewheel
Normal Motorway Normal Motorway
LONG CHASSIS
Engine Wheel rims Tyre
Load condition 5 persons maximum
Load condition 5 to 7 persons
Roads and motorways Roads and motorways Emer-gencysparewheel
Front Rear Front Rear
K4M6.5 J 17 205/55 R17V 2.4 2.2 2.6 2.5 2.6
6.5 J 16 205/60 R16H 2.2 2.2 2.4 2.5 2.5
35A-12
WHEELS AND TYRESTyre inflation pressure: Identification 35A
* Alloy wheel rim
The tyre pressure values given are the recommendedpressures for the tyres when cold.
(1) Run-flat tyre
(2) Turbocharged engine
II - CONFORMITY CHECK AND ADJUSTMENT
Wheel rim offset:
- steel wheel rim: 45 mm,
- alloy wheel rim: 49 mm.
For information on fitting chains, see « Driver'shandbook » .
Roads and motorways Roads and motorways Emer-gencysparewheel
Front Rear Front Rear
WARNING
If the size of the tyres is changed, calibrate theElectric Power-assisted Steering computer and thetyre pressure monitoring system (see MR 372 Faultfinding, 36B, Electric power-assisted steering,Configuration and programming).
35A-13
WHEELS AND TYRESWheel rim: Identification 35A
IDENTIFICATION
1 - Marking
There are two types of identification marking on thewheel rims:
- 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 6 J 15 5 CH 36,
- simplified, for example 6 J 15.
There are 3 types of wheel rim edges (2) :
- those with two flat edges,
- those with two raised edges,
- those with one flat edge and one raised edge.
2 - Installation diameter for the wheel bolts
The wheel bolts are positioned with a pitch circle dia-meter of:
- 5 holes: 108 mm,
- 4 holes: 100 mm.
3 - Rim run-out
The maximum run-out is measured at the wheel rimedge (7) .
Steel wheel rims: 0.8 mm
Alloy wheel rims: 0.3 mm
4 - Out-of-roundness
The maximum out-of-round value is measured on thetyre bead bearing surface.
0.7 mm
Wheel type 6 J 15
1 Width (in inches) 6
2 Rim edge profile J
3 Nominal diameter (in inches) 15
4 Number of holes 5
5 Anchorage profile of the tyre CH
6 Offset (in mm) 36
100988
35A-14
WHEELS AND TYRESSpare wheel winch: Removal - Refitting 35A
REMOVAL
a Lower the luggage cover (if necessary).
a Remove the floor carpet.
a Tilt the rear right-hand seat to base position (if ne-cessary).
a Remove the blanking cover.
a Loosen the bolt (1) .
a Press the emergency spare wheel lock.
a Rotate the emergency spare wheel lock a quarter ofa turn.
a Remove the emergency wheel.
a Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift).
Tightening torquesm
emergency spare wheelwinch bolts
21 Nm
WARNING
Take care not to insert the tool between the unloc-king mechanism and the screw head.
This could lead to the destruction of the emergencyspare wheel winch mechanism.
IMPORTANT
To remove the emergency wheel:
- do not work on an inspection pit,
- do not lift the vehicle.
111120
WARNING
Do not use an air tool.
35A-15
WHEELS AND TYRESSpare wheel winch: Removal - Refitting 35A
a Remove:
- the emergency spare wheel winch mounting nuts(2) ,
- the emergency spare wheel winch.
REFITTINGa Proceed in the reverse order to removal.
a Tighten to torque the emergency spare wheelwinch bolts (21 Nm).
111111
35A-16
WHEELS AND TYRESRun flat tyres: Identification 35A
I - TYRE IDENTIFICATIONS The marking on these tyres differs from that on con-ventional product ranges.
Example of marking read on sidewall: 195-620 R 420 A90 H
21576
Illustrationreference
Example Meaning
(L) 195 Width in mm
(D) 620 External diameter in mm
R T y p e o f s t ructure(R = radial)
420 Nominal diameter on seatin mm
A Asymmetric
90 Load index (90 = 600 kg)
H Speed code (H = 130 mph[210 km/h] maximum)
Note:
The internal diameter (di) is always greater than theexternal diameter (de) .
35A-17
WHEELS AND TYRESRun flat tyres: Identification 35A
II - SUPPORT IDENTIFICATIONS Example of markings read: 195-440 (49)
21577
Illustrationreference
Example Meaning
(L) 195 Nominal width in mm
(D) 440 Nominal diameter on seatin mm
(h) 49 Support height in mm
35A-18
WHEELS AND TYRESRun flat wheel rim: Identification 35A
WHEEL RIM IDENTIFICATIONS Example of markings read: 185-420 A-4-43
21578
Illustrationreference
Example Meaning
(L) 185 Nominal width in mm
(D) 420 Nominal diameter on seatin mm
A Asymmetric
4 Number of mounting holes
43 Offset in mm
35A-19
WHEELS AND TYRESRun flat tyres: Repair 35A
REPAIR AFTER PUNCTURE OR FLAT RUNNING
a
a Remove the tyre and the support (consulting the cor-responding method).
a With a rag, remove most of the gel present in thetyre and the support.
a Inspect the inside of the tyre to detect any sign of the following possible types of damage:
- chafing or overheating marks on the inner rubbercharacteristic of prolonged running at an inadequa-te pressure,
- detachment of rubber or plies,
- visible or deformed bead wires,
- damage to the bead laying bare the plies.
a Inspect the support to detect any sign of the fol-lowing possible types of damage:
- missing pieces;
- cracks in the partitions or the crown,
- visible blistering.
If the tyre is not damaged in any of the specified ways, it may be repaired by a PRP (tyre repair patch) on condition that the perforations or holes meet the following conditions:
- on the sidewalls, the perforation must be less than3 mm, up to speed code T inclusive (codes H, V,W, Y and Z with a perforated sidewall must be re-placed),
- in the crown region for perforations below 6 mm forall speed codes.
a Refit the tyre and support (consult the correspondingmethod).
a Inflate the tyre. The pressure values given in the ma-nuals and Technical Notes are values for a fully la-den vehicle or for motorway travel.
The tyre inflation pressure must be checked whencold.
WARNING
No repair can be carried out without removingthe tyre and support.
21593
WARNING
Be sure to replace any components damaged inany of the specified ways.
WARNING
Hot repair is strictly prohibited.
Note:
Always use a source of dry compressed air.
35A-20
WHEELS AND TYRESRun flat tyres: Specifications 35A
WHEEL COMPOSITION
A wheel comprises four components:
- a tyre (A) (also known as the cover),
- a support (B) ,
- a wheel rim (C) ,
- a pressure detector (D) with a built-in valve.
The tyre, the support and the wheel rim are asymme-tric.
The pressure detector has a coloured marking determi-ning the wheel's position on the vehicle.
The spare wheel (depending on equipment level) doesnot have an active pressure detector.
It should be used only in case of emergency.
The wheels should be refitted in their respective posi-tions on the vehicle after a servicing operation. Accor-dingly, operations such as swapping wheels over arestrictly prohibited.
21575
Marking colour Wheel position
Green Front left
Yellow Front right
Red Rear left
Black Rear right
35A-21
WHEELS AND TYRESRun flat tyres 35A
REMOVAL
a Remove:
- the valve cap;
- the valve insert.
a Empty the air from the tyre.
a Push the bead slightly inside the wheel rim with theroller to lubricate the inner edge of the wheel rim andbead.
a Gradually push the tyre bead towards the inside ofthe tyre, the wheel rim groove using the roller andturning the assembly.
a Push the bead slightly towards the outside of thewheel rim with the roller to lubricate the outer edgeof the wheel rim and bead.
a Rotate the assembly to insert the rule into the spacecreated by the roller between the tyre and the wheelrim. Make sure the rule is fitted the right way round,with the badge facing the tyre sidewall.
21579
21580
21581
21582
35A-22
WHEELS AND TYRESRun flat tyres 35A
a Insert the lever in the rule slot and remove the outerbead. Do not forget the rule in the tyre.
a Pull off the tyre and support by pushing the roller androtating the assembly, without damaging the pressu-re detector.
a Extract the support by hand or with a lever.
21583
21584
21585
35A-23
WHEELS AND TYRESRun flat tyres 35A
REFITTING
a For a new tyre, empty out the dose of gel inside thetyre and spread with the scraper. Never apply thedose of gel on the tyre beads.
a For a tyre previously removed for repair or checking,remove the gel from the tyre.
a Empty out the corresponding quantity of recommen-ded gel (consult the manuals or Technical Notesin section 35 for details) inside the tyre and spreadwith the scraper. Never apply the dose of gel on thetyre beads.
a Lubricate the tyre beads with a lubricant solution forpassenger car tyres.
a Remove the size label from the support, if present.Insert the support, clean and free of gel, into the tyremaking sure to fit it the right way round.
a Lubricate the wheel rim over its entire width.
21587
21586
21585
21588
35A-24
WHEELS AND TYRESRun flat tyres 35A
a Mount the support up to the wheel stop by pushingthe roller and rotating the assembly. Make sure thesupport is properly positioned against the wheelstop, without damaging the pressure detector.
a Remove the tyre's inner bead from the wheel rimgroove using the lever.
a Position the roller to bear against the wheel rim.
a Mount the tyre's outer bead on the wheel rim seat.
a Fit the tyre's inner bead in the same way as before.
a Make sure that the tyre is correctly fitted when infla-ting, and then screw on the valve cap.
21589
21590
21592
21591
Note:
Always use a source of dry compressed air.
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) integrated to the instrument panel.
102413
Note:
Each sensor is identified by a coloured marking around the valve:
- green = front left,
- yellow = front right,
- red = rear left-hand,
- black = rear right-hand.
35B-2
TYRE PRESSURE MONITORPressure sensor: Removal - Refitting 35B
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 364, 02A, Lifting equip-ment).
a Remove:
- the wheels (see 35A, Wheels and tyres, Wheel:Removal - Refitting, page 35A-1) ,
- the tyres (see 35A, Wheels and tyres, Tyres: Re-moval - Refitting, page 35A-8) .
a Remove:
- the retaining nut (1) , holding the pressure sensor(2) on the wheel,
- the pressure sensor (2) .
I - RIGID TYRE PRESSURE MONITOR VALVE
a The following parts must be replaced:
- the seal (3) ,
- the mechanism (4) ,
- the cap (5) ,
- the retaining nut (6) .
a If necessary, replace:
- the coloured marker (7) .
Essential equipment
diagnostic tool
Tightening torquesm
tyre pressure monitorrigid sensor retainingnut
7.5 Nm
tyre pressure monitorhinged sensor retainingnut
8.5 Nm
112627
18887
35B-3
TYRE PRESSURE MONITORPressure sensor: Removal - Refitting 35B
II - HINGED TYRE PRESSURE MONITOR VALVE
a The following parts must be replaced:
- the seal with the metal ring (8) ,
- the mechanism (9) ,
- the retaining nut (10) ,
- the cap (11) .
a If necessary, replace:
- the coloured marker (12) .
III - ALL TYPES
a Make sure that the sensor is correctly positioned on the wheel rim:
- figure 1 = fitted incorrectly,
- figure 2 = fitted correctly.
a Position the sensor in the valve opening, checkingthat the seal is attached all around the edge of theopening.
a Manually tighten the retaining nut, holding the pres-sure sensor in contact with the rim.
a 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.
a Tighten to the following torques:
- the tyre pressure monitor rigid sensor retainingnut (7.5 Nm),
- the tyre pressure monitor hinged sensor retai-ning nut (8.5 Nm).
a Refit the tyres (see 35A, Wheels and tyres, Tyres:Removal - Refitting, page 35A-8) .
a Balance the wheels (see 35A, Wheels and tyres,Wheel: Balancing, page 35A-4) .
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-4
TYRE PRESSURE MONITORPressure sensor: Removal - Refitting 35B
a Refit the wheels (see 35A , Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a If replacing a pressure sensor, carry out the neces-sary operations using the diagnostic tool (see MR372 Fault finding, 35B, Tyre pressure monitor,Replacement of components).
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Remove:
- the front wheels (see 35A, Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) ,
- the engine undertray bolts,
- the engine undertray,
- the front axle subframe (see 31A, Front axle com-ponents, Front axle sub-frame: Removal - Refit-ting, page 31A-26) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Remove:
- the steering box bolts (1) ,
- the steering box (2) .
REFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Steering rack bolt(13,04,03,05).
II - REFITTING OPERATION FOR PART CONCERNED
a Refit the steering box.
a Torque tighten the steering box bolts (105 N.m).
III - FINAL OPERATION
a Refit the front axle subframe (see 31A, Front axlecomponents, Front axle sub-frame: Removal -Refitting, page 31A-26) .
Tightening torquesm
steering box bolts 105 N.m
IMPORTANT
To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Steering: Precautions for repair) .
132716
WARNING
- A 10 mm thick shim must be placed betweenthe radiator cross member and the sub-frame totorque tighten the radiator cross member moun-tings to the recommended torque.
- The wheels must be set straight ahead; centrethe steering wheel.
a Lock the airbag computer (see Fault finding - Re-placement of components) (88C, Airbags and pre-tensioners).
a Disconnect the battery (see Battery : Removal -Refitting) (80A, Battery).
a Move the steering column to low position and pull itout as far as possible.
Tightening torquesm
steering column nuts 21 N.m
steering column lockbolt
8 N.m
steering column nuts 21 N.m
electric steering columnlock bolt
8 N.m
universal joint bolt (TRWcolumn)
30 N.m
universal joint bolt (NSKcolumn)
44 N.m
118660
(A) Black intermediate shaft
118661
(B) Silver intermediate shaft
IMPORTANT
Never handle the pyrotechnic systems (pretensio-ners or airbags) near to a source of heat or nakedflame - they may be triggered.
IMPORTANT
To avoid any risk of triggering when working on ornear a pyrotechnic component (airbags or preten-sioners), lock the airbag computer using the dia-gnostic tool.
When this function is activated, all the trigger linesare inhibited and the airbag warning light on the ins-trument panel lights up continuously (ignition on).
a parts always to be replaced: Steering shaft yokebolt (13,04,01,07).
parts always to be replaced: Steering shaft yokenut (13,04,01,08).
parts always to be replaced: Steering wheel bolt(13,04,01,09).
a
a When refitting, the steering column must stay in pla-ce using the retainers (11) ,
a Push and pull on the electric power-assisted stee-ring computer power and signal connectors to checkthat they are properly secured (risk of loss of assis-tance).
Note:
When replacing an NSK type steering column onvehicles not equipped with ESP, do not removethe steering wheel angle sensor located on thenew steering column.
115385
Note:
The steering wheel should enter the splinesfreely (the splines have foolproofing devices).
Do not damage the foolproofing splines.
Note:
- Do not refit the housing.
- On a new steering column, the universal jointcam nut is pre-fitted.
a Torque tighten the steering column nuts (21 N.m).
a Clip the steering column rotary switch wiring har-ness.
a Refit the column lock.
a Connect the column lock connector.
a Refit the column lock bolt.
a Torque tighten the steering column lock bolt (8N.m).
2 - TRW column
a Refit the steering column.
a Connect the connectors.
a Refit the steering column nuts, starting with thelower threaded stud the furthest away and finishingwith the upper threaded stud.
a Torque tighten the steering column nuts (21 N.m).
a Clip the steering column rotary switch wiring har-ness.
a Connect:
- the electric power-assisted steering computerpower connector using a 4 mm wide and 0.5 mmthick screwdriver,
- the electric power-assisted steering computer si-gnal connector using a 4 mm wide and 0.5 mmthick screwdriver.
a Refit the column lock.
a Connect the column lock connector.
a Refit the electric steering column lock bolt.
a Torque tighten the electric steering column lockbolt (8 N.m).
a Clip on:
- the instrument panel lower trim piece,
- the instrument panel upper trim piece.
a Respect the direction of fitting for the universal jointcam bolt and nut.
a Refit the universal joint.
a Refit the cam nut and the fork bolt.
a Finger tighten the cam nut and the yoke bolt.
a Immobilise the cam nut in its housing (on the univer-sal joint).
a Pretighten the universal joint nut and bolt.
Note:
When replacing an NSK type steering column onvehicles not equipped with ESP, do not removethe steering wheel angle sensor located on thenew steering column.
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Remove:
- the front wheel (see 35A , Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) ,
- the track rod, (see 3 6 A, Steering assembly,Track rod: Removal - Refitting, page 36A-3)
- the wheel alignment adjusting lock nut.
II - OPERATION FOR REMOVAL OF PART CONCERNED
a
a Remove the gaiter retaining clip (1)
a Cut the gaiter retaining clip (2) .
a Remove the gaiter (3) .
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace:
- the steering box gaiter,
- the retaining clips.
a Clean the contact surfaces between the steering boxand the gaiter using SURFACE CLEANER (see Ve-hicle: Parts and ingredients for the repairwork) .
a Coat the gaiter bearing face on the axial ball jointwith SILICONE LUBRICANT (see Vehicle: Partsand ingredients for the repairwork) to prevent thegaiter from twisting.
II - REFITTING OPERATION FOR PART CONCERNED
a Refit:
- a new steering box gaiter,
- new retaining clips.
III - FINAL OPERATION.
a Refit:
- the wheel alignment adjustment lock nut,
- the track rod, (see 3 6 A, Steering assembly,Track rod: Removal - Refitting, page 36A-3)
- the front wheel (see 35A , Wheels and tyres,Wheel: Removal - Refitting, page 35A-1) .
a Check the axle geometry (see 30A, General infor-mation, Axle assemblies: Check, page 30A-8) .
a If necessary, adjust the axle assemblies' geometry(see 30A, General information, Front axle: Adjus-ting, page 30A-16) .
105678
Note:
When removing the steering gaiter, blast the gai-ter surfaces with compressed air to eliminate anyimpurities that could enter the steering box.
Note:
Be sure to centre the steering to ensure the air inthe gaiters is equalised.
Note:
Be careful not to damage the gaiters: risk of irre-versible damage.
a Lock the airbag computer (see Fault finding - Re-placement of components) (MR 372, 88C, Airbagand pretensioners).
a Disconnect the battery (see Battery : Removal -Refitting) (MR 370, 80A, Battery).
a Remove the driver's front airbag (see Driver's frontairbag: Removal - Refitting) (MR 370, 88C, Air-bags and seat belt pretensioners).
a Set the wheels straight ahead.
a Disconnect the connectors (depending on equip-ment level).
a Remove the steering wheel mounting bolt (1) .
a Remove the steering wheel carefully to avoid dis-connecting the rotary switch connectors.
REFITTING
a The steering wheel bolt must be replaced each timeit is removed.
a Proceed in the reverse order to removal.
a Torque tighten the steering wheel mounting bolt(44 Nm).
a Refit the driver's front airbag (see Driver's front air-bag: Removal - Refitting) (MR 370, 88C, Airbagsand seat belt pretensioners).
a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).
Essential equipment
diagnostic tool
Tightening torquesm
steering wheel mountingbolt
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 continuously lit (with the ignition on).Locking the airbag computer also unlocks the elec-tric steering column lock.
IMPORTANT
It is not permitted to handle the pyrotechnic sys-tems (airbags and pretensioners) near a source ofheat or flame since there is a risk of these beingtriggered.
103799
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 column switch should enter the splinesfreely (the splines have location notches).
a 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.
a Remove:
- the brake servo valve (8) ,
- the brake servo mounting bolts (9) , on the enginecompartment side.
- the « brake pedal - accelerator pedal » assembly,
- the accelerator pedal securing nuts,
- the accelerator pedal.
REFITTING
a
104824
104824
IMPORTANT
The pedal is fitted with an unlocking system inthe event an impact. Do not strike the pedal sys-tem (6) (this could fully depress the pedal inad-vertently).
Note:
- Do not remove the pin before refitting and loc-king the pedal assembly.
a Disconnect the battery, starting with the negativeterminal.
a Remove:
- the dashboard (see 83A, Instrument Panel, Das-hboard),
- the steering column (see 36B, Power-assistedsteering, Steering column),
- the dashboard cross member (see MR 371 Bo-dywork, 42A, Upper front structure, Dashboardcross member).
a Disconnect the connector from the accelerator pedalposition potentiometer.
a Remove:
- the mounting bolts (1) from the accelerator pedal,
- the accelerator pedal.
Essential special tooling
Fre. 1752 Safety pin
Essential equipment
diagnostic tool
Tightening torquesm
brake pedal yoke moun-ting nuts
21 Nm
IMPORTANT
- Before carrying out any work on a safety systemcomponent, lock the airbag computer using dia-gnostic tool (see 88C, Airbags and pretensio-ners, Airbag computer locking procedure).
- When this function is activated, all the trigger linesare inhibited and the airbag warning light on theinstrument panel is continuously lit (with the igni-tion on).
- 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.
WARNING
When the brake pedal is replaced, the pedal is sup-plied fitted with a pin. (Fre. 1752).
When removing and refitting (without replacing thebrake pedal), always fit the pin (Fre. 1752) duringremoval.
- the brake pedal assembly by rotating it to release itfrom the idler bar.
REFITTING
a
104755
104756
104754
WARNING
Before refitting the brake pedal, the fuse plate (7)must be checked for deformation. If there is anydeformation to the fuse board, the brake pedalmust be replaced.
Note
- Do not remove the pin before refitting and loc-king the pedal assembly.
a Disconnect the brake light switch connector (1) .
a Turn the brake light switch (2) a quarter of a turnanti-clockwise.
a Remove the brake light switch.
REFITTING
WHEN REMOVING AND REFITTING OR REPLACING THE BRAKE LIGHT SWITCH
a
a Measure dimension (X) of the piston (4) . If dimen-sion (X) is less than 17 mm, carefully pull on the endof the piston to adjust the dimension (X) between thevalues: minimum 17 mm and maximum 18 mm.
a Depress the brake pedal by hand.
a Position the brake light switch on the pedal assem-bly.
a Lock the brake light switch by turning it a quarter ofa turn clockwise.
a Carefully follow the return of the brake pedal.
a Connect the connector.
WARNING
The switch must be replaced if the brake pedalposition switch piston is extracted completely.
WARNING
The switch must be replaced if handling of the pis-ton results in three adjustments being made.
109201
108436
WARNING
Handle the switch (3) with care.
Only operate the piston (4) to adjust the dimen-sion (X) .
The switch must be replaced:
- if the piston (4) is separated from the switch (3),
- if more than three adjustments to dimension (X)are necessary during the operation.
Note:
The brake pedal switch has an automatic adjust-ment which adapts to the pedal position.
The automatic adjustment makes a clicking noisewhen in operation.
This procedure only deals with removing - refitting thesecondary brake cables.
The primary brake cable cannot be removed. It is soldcomplete with the automatic parking brake control unit(see 37B, Electronic parking brake, Control unit:Removal - Refitting, page 37B-3) .
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Switch on the + after ignition feed.
a Release the parking brake using the handle.
a Switch off the ignition.
a Disconnect the battery (see Battery : Removal -Refitting) (80A, Battery).
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Note the brake cable routing for refitting.
a Remove the bolts (1) from the brake cable anchora-ge support.
a Unclip the anchorage guard.
a Remove the primary cable (2) from the anchorage.
a Remove the secondary cables (3) from the anchora-ge.
a Turn the end (7) of the slave cylinder anticlockwiseas far as it will go.
a Connect a transparent pipe to the bleed hole runningto an empty container placed under the bleed hole.
a Place a cloth under the bleed hole.
a Depress the pedal using your hand (to drain themaster cylinder and the pipe).
a
a Remove the grey start of travel switch (8) by turningit a quarter of a turn (see 37A, Mechanical compo-nent controls, Clutch pedal position sensor: Re-moval - Refitting, page 37A-64) .
a Disconnect the switch connector (8) .
a Remove the green end of travel switch (9) by turningit a quarter of a turn (see 37A, Mechanical compo-nent controls, Brake pedal switch: Removal - Re-fitting, page 37A-31) .
a Disconnect the switch connector (9) .
a Place a cloth under the master cylinder.
a Remove the union clips from the master cylinder(10) .
a Disconnect the pipes.
a Fit plugs into the openings.
a Remove the clutch master cylinder ball joint from thepedal.
a Remove the four nuts from the « pedal » assembly.
a Extract the « pedal - master cylinder » assembly.
a Remove the master cylinder from the bulkhead byturning it a quarter turn clockwise (bayonet typemounting) using the (Emb. 1797).
REFITTING
a Visually check the condition of the seals.
PK4
115170
Note:
The clutch master cylinder is mounted on theclutch pedal assembly. Remove the « pedal -master cylinder » assembly to remove the pedaland master cylinder.
a Turn the end (7) of the slave cylinder anticlockwiseas far as it will go.
a Connect a transparent pipe to the bleed hole runningto an empty container placed under the bleed hole.
a Place a cloth under the bleed hole.
a Depress the pedal using your hand (to drain themaster cylinder and the pipe).
a Place a cloth under the hole (8) .
a Disconnect the brake fluid reservoir pipe.
a Fit plugs into the openings.
a Place a cloth under the master cylinder.
a Remove the union clip from the master cylinder (9) .
a Disconnect the pipes.
a Fit plugs into the openings.
a Disconnect the master cylinder ball joint from theclutch pedal in the passenger compartment.
a Remove the master cylinder from the bulkhead inthe engine compartment by turning it a quarter turnclockwise (bayonet type mounting) using the (Emb.1797).
I - WHEN REMOVING AND REFITTING OR WHEN REPLACING A CLUTCH PEDAL SWITCH
a
a Measure dimension (X) of the piston (4) . If the di-mension (X) is less than 17 mm, carefully pull on theend of the piston (4) to adjust the dimension (X)between the values 17 mm minimum and 18 mmmaximum.
II - REFITTING THE CLUTCH PEDAL SWITCHES
a Depress the clutch pedal by hand.
a Position the start of travel switch on the pedal as-sembly.
a Lock the start of travel switch by turning it one quar-ter of a turn clockwise.
a Support the return of the clutch pedal.
a Connect clutch switch connector.
a Position the end of travel switch on the pedal assem-bly.
a Lock the end of travel switch by turning it one quarterof a turn clockwise.
a Depress the clutch pedal by hand.
a Support the return of the clutch pedal.
a Connect clutch switch connector.
III - FINAL OPERATION
a Be sure to carry out a repair check using diagnostictool.
108434
WARNING
Handle the switch (3) with care.
Only operate the piston (4) to adjust the dimen-sion (X) .
The switch must be replaced:
- if the piston (4) is separated from the switch (3),
- if more than three adjustments to the dimension(X) are necessary during the operation.
CRUISE CONTROL
Note:
The clutch pedal switch has an automatic adjust-ment feature, adapting to the pedal position.
The automatic adjustment makes a clicking noisewhen in operation.
DOOR OPEN SYST. 433 NML
Note:
The clutch pedal switch has an automatic adjust-ment feature, adapting to the pedal position.
The automatic adjustment makes a clicking noisewhen in operation.
a Precautions to be taken when removing and refittingthe gear cable end pieces to avoid tearing the plasticguide tube and damaging the ball joints.
a To remove the gear control cables from their balljoints, use an open-ended spanner as shown above.This prevents the control cables from being dama-ged.
II - REFITTING
a To refit, use pliers to clip the gear control cables tothe ball joints.
a Perform rapid gearchanges for all gears for 20 se-conds.
Check that the cables are not unclipped.
121257
121258
121259
37A-55
MECHANICAL COMPONENT CONTROLSGear control unit: Removal - Refitting
AJ0
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Move the gear lever to position D.
a Switch off the ignition.
a Remove:
- the central console (see Centre console: Remo-val - Refitting) (57A, Interior equipment),
- the engine cover,
- the engine undertray bolts,
- the engine undertray.
- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (55A, Exterior protection).
a Remove:
- the air filter access panel bolts (1) ,
- the air filter access panel (2) ,
- the bolts (3) from the scoop under the scuttle panelgrille,
- the scoop under the scuttle panel grille (4) .
- the battery (see Battery : Removal - Refitting)(80A, Battery)
- the battery tray (see Battery tray: Removal - Re-fitting) (80A, Battery),
- the injection computer (see Diesel injection com-puter: Removal - Refitting) (13B, Diesel injec-tion),
- the air pipe at the air filter box outlet.
Tightening torquesm
automatic gearbox con-trol unit nuts
21 Nm
Note:
It is essential that the passenger compartmentgear lever and the multifunction switch lever onthe gearbox are in D.
104343
104246
37A-56
MECHANICAL COMPONENT CONTROLSGear control unit: Removal - Refitting
AJ0
37A
a Remove the bolts (5) from the exhaust bracket.
a Move the exhaust pipe to one side.
a Disconnect the oxygen sensor connector.
a Remove the bolts from the heat shield.
a Move the heat shield towards the back of the vehi-cle.
II - OPERATION FOR REMOVAL OF PART CONCERNED
a Unclip the control cable on the gearbox at:
- the anchoring ball joint (6) using an open-jawedspanner,
- from the cable sleeve stop (7) .
114991
105107
37A-57
MECHANICAL COMPONENT CONTROLSGear control unit: Removal - Refitting
AJ0
37A
a Disconnect the automatic gearbox control unit con-nector (8) .
a Remove:
- the automatic gearbox control unit nuts (9) .
- the bulkhead seal bolts.
a Remove the "unit - automatic gearbox control cable"assembly through the passenger compartment.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Refit:
- the « unit - automatic gearbox control cable » as-sembly,
- the bulkhead seal bolts.
a Torque tighten the automatic gearbox control unitnuts (21 Nm).
a Connect the automatic gearbox control unit connec-tor.
a Clip the control cable on the gearbox at the sleevestop level.
a Compress the spring of the automatic gearbox con-trol cable at (10) .
a Unlock the adjustment mechanism by pressing onthe catch (11) .
a Adjust the length of the automatic gearbox controlcable.
a Clip the automatic gearbox control cable anchoringball joint on the automatic gearbox.
a Lock the adjustment mechanism while pushing backthe catch to its initial position.
105108
Note:
Do not open the automatic gearbox control unit, itcould cause damage (infrared system).
104733
104736
37A-58
MECHANICAL COMPONENT CONTROLSGear control unit: Removal - Refitting
AJ0
37AII - FINAL OPERATION.
a Refit the heat shield.
a Connect the oxygen sensor connector.
a Refit:
- the exhaust pipe,
- the air pipe at the air filter box outlet,
- the injection computer (see Diesel injection com-puter: Removal - Refitting) (13B, Diesel injec-tion),
- the battery tray (see Battery tray: Removal - Re-fitting) (80A, Battery),
- the battery (see Battery : Removal - Refitting)(80A, Battery)
- the scuttle panel grille scoop,
- the air filter access panel,
- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (55A, Exterior protection),
- the engine undertray,
- the engine cover,
- the central console (see Centre console: Remo-val - Refitting) (57A, Interior equipment).
a Check that the system and gear selection are wor-king correctly.
a Disconnect the battery, starting with the negativeterminal.
a Drain the brake fluid reservoir until the level is belowthe master cylinder supply port.
a Remove:
- the engine covers,
- the scuttle panel grill ( (see 85A , Wiping -Washing) ).
a Remove:
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the mounting bolt (2) from the scuttle panel parti-tion.
a Remove:
- the radiator tank partition mounting bolts (3) ,
- the scuttle panel partition.
a Remove:
- the battery,
- the battery tray,
- the computer with its mounting,
- the air filter outlet duct.
a Drain the brake fluid reservoir until the level is belowthe master cylinder supply port.
Tightening torquesm
clutch pedal plate nuts 2.1 daNm
Note:
The clutch master cylinder is mounted on theclutch pedal assembly. Remove the « pedal -master cylinder » assembly to extract the pedalor master cylinder.
a The hydraulic clutch system is very sensitive to con-tamination. The risks caused by contamination are:
- impossible to change gears,
- damage to or destruction of the clutch system,
- leaks on the hydraulic circuit.
All the operations on the hydraulic clutch circuit sys-tem must be carried out under excellent cleanlinessconditions. This ensures that no impurities enter thehydraulic circuit during the operation.
The cleanliness principles apply to all componentsof the hydraulic clutch circuit.
Items causing contamination are:
- metal or plastic swarf,
- fibres:
• cardboard,
• brushes,
• paper,
• clothing,
• cloth,
• dust and particles in the air,
• etc.
Cleaning cloths.
a Use lint-free cleaning cloths (see Recommendedproducts for repairwork) (04B, Consumables -Products).
Each cloth must only be used once.
There are two types of equipment used to bleed the clutch circuit:
a ARC50 via the brake fluid reservoir.
a Syringe via the bleed hole located on the clutch sla-ve cylinder.
There are two procedures used to bleed the clutch circuit:
a If no parts of the clutch hydraulic circuit are remo-ved:
- Carry out the bleed operation using the ARC50 viathe brake fluid reservoir or using a new syringe viathe bleed hole located on the clutch slave cylinder.
a If no parts of the clutch hydraulic circuit are remo-ved:
- Only carry out the bleed operation using a new sy-ringe by injecting the brake fluid via the bleed holeon the clutch slave cylinder.
Consumables required for the repair:
a Bleed the clutch circuit using approved (see Vehi-cle: Parts and ingredients for the repairwork)brake fluid (04B, consumables - products).
II - PREPARATION STAGE
a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).
a Remove the engine undertray.
Essential equipment
brake circuit bleeding device
hydraulic circuit bleed syringe
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 detec-tion of faults and unnecessary part replace-ments.
a To open the bleed screw, lower the clip (6) and liftthe clip (7) while pulling by one notch.
III - BLEED PROCEDURE IF NO PARTS OF THE HYDRAULIC CIRCUIT ARE REMOVED
1 - Bleed using the ARC50.
a Keep the clutch pedal in the upper position using astrap attached to the steering wheel to ensure conti-nuity of the hydraulic circuit during the bleed opera-tion.
a Connect the brake circuit bleeding device (afterhaving received Renault approval) to the master cy-linder reservoir (see the instructions for the equip-ment).
a Remove the bleed plug from the clutch slave cylin-der.
a Connect a transparent pipe to the bleed hole runningto an empty container placed under the bleed hole.
a Open the bleed screw.
a Open the circuit between the bleeding device andthe brake fluid reservoir.
a Let the brake fluid run until all air bubbles have beenreleased.
a Stop the bleeding device to dump the pressure in theclutch circuit.
a Close the bleed screw.
a Remove the transparent pipe from the bleed hole.
a Refit the bleed plug.
a Top up the brake fluid level in the master cylinder re-servoir after disconnecting the bleed device.
a Disengage and engage the clutch quickly aroundtwenty times.
a Check that the clutch system is operating correctly.
a Repeat the bleed operation if necessary.
a Check the adjustment of the switch. (see 37A, Me-chanical component controls, Clutch pedalswitch: Removal - Refitting, page 37A-51) (37A,mechanical control elements).
113732
Note:
Take care not to disrupt the adjustment of theclutch start of travel switch.
a Keep the clutch pedal in the upper position using astrap attached to the steering wheel to ensure conti-nuity of the hydraulic circuit during the bleed opera-tion.
a Remove the bleed plug from the clutch slave cylin-der.
a Connect a transparent pipe of sufficient length to thebleed hole (at least thirty centimeters) in order to pla-ce it at the same height as the reservoir.
a Open the bleed screw.
a Fill the brake fluid master cylinder reservoir until bra-ke fluid flows out of the bleed screw.
a Connect a new hydraulic circuit bleed syringefilled with a useful volume of 60 ml of approved bra-ke fluid to the end of the transparent pipe.
a Slowly inject the entire contents of the syringe intothe hydraulic clutch circuit without injecting any ofthe air from the top section of the syringe.
a Close the bleed screw.
a Remove the transparent pipe from the bleed hole.
a Refit the bleed plug.
a Top up the brake fluid level in the master cylinder re-servoir.
a Disengage and engage the clutch quickly aroundtwenty times.
a Check that the clutch system is operating correctly.
a Repeat the bleed operation if necessary.
a Check the adjustment of the switch. (see 37A, Me-chanical component controls, Clutch pedalswitch: Removal - Refitting, page 37A-51) (37A,mechanical control elements).
IV - BLEED PROCEDURE IF PARTS OF THE HYDRAULIC CIRCUIT ARE REMOVED.
a
Note:
Take care not to disrupt the adjustment of theclutch start of travel switch.
Note:
The transparent pipe must remain at the sameheight as the master cylinder reservoir to preventair from entering inside the clutch circuit.
WARNING
The master cylinder pipe must be disconnectedfrom its take-off point on the brake fluid reservoir,to avoid any foreign matter penetrating inside thebrake system hydraulic circuit.
WARNING
Prepare for the flow of fluid and protect the sur-rounding components.
Note:
Prefill the hydraulic circuit pipe equipped with afilter.
Position the filter head facing downwards toensure that it fills.
a Prefill the hydraulic tappet using the new syringe (bygravity).
a Refit the part(s) concerned.
V - BLEED PROCEDURE AFTER A REMOVING A COMPONENT OF THE HYDRAULIC CIRCUIT.
a Keep the clutch pedal in the upper position using astrap attached to the steering wheel to ensure conti-nuity of the hydraulic circuit during the bleed opera-tion.
a Remove the bleed plug from the clutch slave cylin-der.
a Connect a transparent pipe of sufficient length to thebleed hole (at least thirty centimeters) in order to pla-ce it at the same height as the reservoir.
a Open the bleed screw.
a Fill the brake fluid master cylinder reservoir until bra-ke fluid flows out of the bleed screw.
a Connect a new syringe containing 60 ml of appro-ved brake fluid to the end of the transparent pipe.
a Slowly inject the entire contents of the syringe intothe hydraulic clutch circuit without injecting any ofthe air from the top section of the syringe.
a Close the bleed screw.
a Remove the transparent pipe from the bleed hole.
a Refit the bleed plug.
a Top up the brake fluid level in the master cylinder re-servoir.
a Disengage and engage the clutch quickly aroundtwenty times.
a Check that the clutch system is operating correctly.
a Repeat the bleed operation if necessary.
a Check the adjustment of the switch. (see 37A, Me-chanical component controls, Clutch pedalswitch: Removal - Refitting, page 37A-51) (37A,mechanical control elements).
141809
Note:
Take care not to disrupt the adjustment of theclutch start of travel switch.
Note:
The transparent pipe must remain at the sameheight as the master cylinder reservoir to preventair from entering inside the clutch circuit.
a Disconnect the battery (see Battery : Removal -Refitting) (80A, Battery).
a Remove:
- the glove compartment, driver's side,
- the remote adjustment control mounting.
II - REMOVAL OPERATION FOR PART CONCERNED
a Remove the bolts (1) from the lever.
a Remove the lever.
a Disconnect the connector from the lever.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
a Connect the lever connector.
a Refit the lever.
II - FINAL OPERATION.
a Refit:
- the remote adjustment control mounting.
- the glove compartment, driver's side,
a Connect the battery (see Battery : Removal - Refit-ting) (80A, Battery).
a Switch on the + after ignition feed.
a Clear the faults using the diagnostic tool.
Essential equipment
diagnostic tool
104411
104410
38C-1
ANTI-LOCK BRAKING SYSTEMIntroduction 38C
The vehicle is fitted with a BOSCH 8.0. ABS system.
Depending on the vehicle equipment, the BOSCH 8.0system consists of the ABS system only or the Anti-lock Braking System in conjunction with the ElectronicStability Program (ESP).
I - DESCRIPTION OF THE ABS SYSTEM WITH ELECTRONIC STABILITY PROGRAM
The ABS system / Electronic Stability Program compri-ses:
- a brake servo assembly,
- a pump assembly comprising:
• a hydraulic pump,
• a pressure modulation unit (twelve solenoid valves),
• a computer,
• a pressure sensor,
- a steering wheel angle sensor built into the electricpower assisted steering,
- a combined yaw speed and transverse accelerationsensor,
- four wheel speed sensors,
- aneElectronic stability program deactivation pressurebutton.
II - PRINCIPLE OF OPERATION OF THE ABS SYSTEM WITH ELECTRONIC STABILITY PROGRAM
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 understeer monitoringbrakes two wheels at the same time. The torque gene-rated sets the vehicle on the desired trajectory.
In some cases, the anti-skid control modifies the engi-ne torque.
III - ELECTRONIC STABILITY PROGRAM OPERATION SPECIAL FEATURES
The ESP function can be disconnected via the switchlocated on the dashboard.
This function can not be deactivated above a thresholdof approximately 50 km per hour.
This function is automatically reactivated when the ve-hicle is switched on, or at speeds above approximately50 km/h.
Essential equipment
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 (CLIP).
- the throttle valve (see Throttle valve: Removal -Refitting) (MR 370, 12A, Fuel mixture),
- the air filter box (10) (see Air filter unit: Removal- Refitting) (MR 370, 12A, Fuel mixture).
a Remove:
- the plenum chamber unit mounting bolts (12) ,
- the plenum chamber unit,
- the soundproofing screen mountings.
a Remove the soundproofing screen.
a Remove the lifting eye (13) .
a Remove the air-conditioning hose between the bulk-head bracket and the dehydrator reservoir (see De-hydration canister - evaporator connecting pipe:Removal - Refitting) (MR 370, 62A, Air conditio-ning).
- the air distribution unit (see Inlet manifold: Remo-val - Refitting) (MR 370, 12A, Fuel mixture),
- the soundproofing screen mountings.
a Remove the soundproofing screen.
a Remove the lifting eye (10) .
a Remove the air-conditioning hose between the bulk-head bracket and the dehydrator reservoir (see De-hydration canister - evaporator connecting pipe:Removal - Refitting) (MR 370, 62A, Air conditio-ning).
a Remove the ABS computer earth terminal mountingbolt.
a Disconnect the computer connector.
a Unscrew the pipes from the hydraulic unit.
a Unclip the pipes from the hydraulic unit.
a Remove:
- the mounting bolts (11) from the hydraulic unit sup-port,
a Remove the air-conditioning hose between the bulk-head bracket and the dehydrator reservoir (see De-hydration canister - evaporator connecting pipe:Removal - Refitting) (MR 370, 62A, Air conditio-ning).
a Remove the ABS computer earth terminal mountingbolt.
a Disconnect the computer connector.
a Unscrew the six pipes on the hydraulic unit.
a Unclip the six pipes on the hydraulic unit.
a Remove:
- the mounting bolts (5) from the hydraulic unit sup-port,
- the « hydraulic unit - support » assembly,
- the bolts securing the hydraulic unit on the support,
- the hydraulic unit.
REFITTING
a
Proceed in the reverse order to removal.
104324
AIR CONDITIONING or CLIMATE CONTROL
104341
WARNING
Ensure the hydraulic unit earth terminal wire isfacing downwards to optimise the computer con-nector sealing.
- the air distribution unit (see Inlet manifold: Remo-val - Refitting) (MR 370, 12A, Fuel mixture),
- the soundproofing screen mountings.
a Remove the soundproofing screen.
a Remove the lifting eye (13) .
a Remove the air-conditioning hose between the bulk-head bracket and the dehydrator reservoir (see De-hydration canister - evaporator connecting pipe:Removal - Refitting) (MR 370, 62A, Air conditio-ning).
a Remove the ABS computer earth terminal mountingbolt.
a Disconnect the computer connector.
a Unscrew the six pipes from the hydraulic unit.
a Unclip the six pipes from the hydraulic unit.
a Remove:
- the mounting bolts (14) from the hydraulic unit sup-port,
- the « hydraulic unit - support » assembly,
- the bolts securing the hydraulic unit on the support,
a The sensor must be fitted facing the vehicle's direc-tion of travel (as shown by the arrow).
a Proceed in the reverse order to removal.
a Torque tighten the lateral acceleration and yawsensor mounting nuts (8 Nm).
a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).
a If replacing the lateral acceleration and yaw sensor,carry out the necessary operations using the dia-gnostic tool (see Fault finding - Replacement ofcomponents) (MR 372, 38C, ABS).
20912
Note:
Be sure to replace any sensor which has suffe-red an impact.