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Renault Laguna III, Manual

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Renault Laguna III Manual Download Page 3188

41A

-

14

FRONT LOWER STRUCTURE

Front side member: General description

41A

II - AREA TO BE CUT FOR PARTIAL 
REPLACEMENT

Cut 1:

This line marks the place in which it is possible to make
a partial replacement.

This operation allows you to access the inside of the
hollow section of the structural element to straighten it.

In this case, the side member weld line must be stag-
gered from that of its closure panel.

III - ASSEMBLY METHOD FOR A PARTIAL 
REPLACEMENT

Only the connections which are specific to the partial
replacement by cutting are indicated.

If  there  are  other  issues  regarding  access  to  mating
faces, the various replacement options are described
in the basic instructions for structural bodywork repair
(see

 MR 400

).

Line (

3

) on the drawing shows a butt weld by continu-

ous EGW welding.

110549

Note:

For  the  partial  replacement  of  parts  constituting  a
single structural component, it is essential to stag-
ger the welds of each of the components.

WARNING

If the mating faces of the parts to be welded are not
accessible,  make  EGW  plug  welds  to  replace  the
original resistance welds (see

 MR 400

).

110550

Summary of Contents for Laguna III

Page 1: ...s and accessories from which the vehicles are constructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering syste...

Page 2: ...CTION Vehicle Precautions for the repair 01D 1 Tightening torques General information 01D 3 02A LIFTING EQUIPMENT Vehicle Towing and lifting 02A 1 03B COLLISION Vehicle involved in an impact Impact fa...

Page 3: ...01A 1 VEHICLE MECHANICAL SPECIFICATIONS Vehicle Specifications B91 01A Dimensions in metres 123275 A 1 014 B 2 756 C 0 925 D 4 695 E 1 557 F unladen 1 445 G 1 512 H 1 811...

Page 4: ...Euro 4 813 Euro 3 4 and 5 K4M 824 1598 TL4 016 019 Euro 3 and 4 K9K 780 1461 013 Euro 1 3 and 4 782 013 022 Euro 5 M4R 704 1997 017 020 Euro 3 and 4 726 Euro 5 M9R 742 1995 PK4 007 Euro 4 744 746 007...

Page 5: ...01A 3 VEHICLE MECHANICAL SPECIFICATIONS Vehicle Specifications K91 01A Dimensions in metres 123276 A 1 014 B 2 758 C 1 031 D 4 776 E 1 557 F unladen 1 455 G 1 512 H 1 811...

Page 6: ...018 Euro 4 813 Euro 3 and 4 K4M 824 1598 TL4 016 019 Euro 3 and 4 K9K 780 1461 013 Euro 4 782 013 022 Euro 5 M4R 704 1997 017 020 Euro 3 and 4 726 Euro 5 M9R 742 1995 PK4 007 Euro 4 744 746 007 009 7...

Page 7: ...01A 5 VEHICLE MECHANICAL SPECIFICATIONS Vehicle Specifications D91 01A Dimensions in metres 141547 A 1 019 B 2 693 C 0 931 D 4 643 E 1 547 F unladen 1 401 G 1 542 H 2 082...

Page 8: ...rbox suffix F4R 800 1998 PK4 008 Euro 4 802 Euro 5 811 AJ0 007 018 Euro 4 813 Euro 3 and 4 M9R 742 1995 PK4 007 Euro 4 744 748 007 009 Euro 3 and 4 754 800 012 Euro 4 802 007 009 Euro 4 and 5 803 AJ0...

Page 9: ...1 Vehicle type mine and type num ber this information also appears on marking B 2 MGVW Maximum Gross Vehi cle Weight 3 GTW Gross train weight vehi cle under load with trailer 4 Maximum permissible fr...

Page 10: ...EHICLE BODYWORK SPECIFICATIONS Vehicle Identification 01C IV COLD MARKING OF THE BODY Marking C 123656 Note If the complete body is being replaced it must be marked in compliance with the current regu...

Page 11: ...ion 1 X1 1 5 mm 1 B91 or K91 124288 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respect to the o...

Page 12: ...01C 4 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 2 X2 5 mm 2 Section 3 X3 4 mm 1 5 Section 4 X4 1 mm Section 5 X5 0 4 mm 0 4 124254 124256 124257 124253...

Page 13: ...01C 5 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 6 X6 3 5 mm 1 2 Section 7 X7 4 5 mm 1 2 Section 8 X8 Plating Section 9 X9 4 mm 0 8 124258 124285 124287 124279...

Page 14: ...01C 6 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 10 X10 4 5 mm 1 2 Section 11 X11 4 2 mm 1 2 Section 12 X12 4 7 mm 1 2 124286 124280 124282...

Page 15: ...ction 13 X13 6 mm 0 2 B91 124289 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respect to the oppo...

Page 16: ...C 8 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 14 X14 4 mm 1 9 Section 15 X15 4 mm 1 7 Section 16 X16 3 7 mm 1 25 Section 17 X17 1 mm 0 9 124277 124273 124278 1242...

Page 17: ...01C 9 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 18 X18 1 mm Section 19 X19 2 mm 1 Section 20 X20 4 mm 0 8 Section 21 X21 4 5 mm 2 124276 124252 124281 124271...

Page 18: ...01C 10 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 22 X22 4 mm 2 Section 23 X23 4 mm 1 6 Section 24 X24 2 mm 0 6 124270 124274 124283...

Page 19: ...Section 25 X25 1 6 mm K91 124290 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respect to the oppo...

Page 20: ...1C 12 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 26 X26 2 mm 1 Section 27 X27 4 2 mm 1 75 Section 28 X28 2 2 mm Section 29 X29 4 mm 1 7 124260 124259 124267 124265...

Page 21: ...C 13 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 30 X30 1 mm 1 2 Section 31 X31 0 4 mm 0 4 Section 32 X32 1 mm 1 7 Section 33 X33 1 mm 1 7 124261 124264 124263 1242...

Page 22: ...01C 14 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 34 X34 6 5 mm 2 4 124268 D91 134840...

Page 23: ...ion 36 X36 4 mm 1 5 Section 37 X37 0 5 mm 0 5 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respec...

Page 24: ...16 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 38 X38 0 4 mm 0 4 Section 39 X39 3 5 mm 1 2 Section 40 X40 1 mm 0 9 Section 41 X41 4 5 mm 1 5 133295 133293 133300 13...

Page 25: ...17 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 42 X42 4 mm 1 Section 43 X43 1 5 mm 0 9 Section 44 X44 4 5 mm 1 5 Section 45 X45 1 3 mm 1 2 133301 133292 133297 133...

Page 26: ...01C 18 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 47 X47 4 mm 2 133307 134839...

Page 27: ...LE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 48 X48 5 4 mm 1 5 Section 49 X49 a 1 mm 0 8 X49 b 1 mm 0 8 Section 50 X50 4 mm 1 5 Section 51 X51 0 4 mm 0 4 133313 133316 13...

Page 28: ...01C 20 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 52 X52 4 mm 1 2 Section 53 X53 2 mm 0 7 Section 54 X54 4 mm 1 5 Section 55 X55 4 mm 1 133312 133310 133311 133302...

Page 29: ...01C 21 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 56 X56 4 mm 2 Section 57 X57 4 mm 1 Section 58 X58 0 mm Section 59 X59 4 mm 1 133309 133303 133304 133305...

Page 30: ...01C 22 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 60 X60 5 mm 0 5 133306...

Page 31: ...be bonded threads stub axle splines to ensure proper adher ence protect the accessories and timing belts the electrical accessories starter blanking cover electric power assisted steering pump and th...

Page 32: ...moke when working on vehicles use smoke extractors welding exhaust gases etc do not use harmful products in unventilated rooms do not overstrain yourself or attempt inappropriate work operations use a...

Page 33: ...bly to prevent their separation or sliding when submitted to exterior forces Exterior forces The assembly is submitted to forces that are static and or dynamic simple e g simple traction multiple trac...

Page 34: ...he friction coefficients from one assem bly to another and the uncertainty of the tightening pro cedures and methods 2 Angle tightening The principle consists of putting the parts of the assem bly in...

Page 35: ...when using a click type torque wrench is 15 The instructions to be observed are Place the hand in the centre of the handle An incor rectly positioned hand on the handle will alter the trig ger thresh...

Page 36: ...ening Using a universal joint will result in a difference between the set torque of the wrench and the actual torque applied Before storing the wrench loosen the adjustment spring completely A wrench...

Page 37: ...ways pull in the direction of the rod s length in order to avoid breaking it Vehicles fitted with automatic transmission The vehicle should preferably be transported on a platform or towed by lifting...

Page 38: ...he vehicle under the rear axle mechanism bearing at 6 and place the axle stand under the jacking point at 7 122657 IMPORTANT To prevent any accidents the trolley jack must only be used to lift and or...

Page 39: ...Fitting the straps Fitting the safety strap s For safety reasons the safety strap s must always be in perfect condition replace them if they show signs of wear When fitting the safety strap s check th...

Page 40: ...the jacking points 10 at the rear IMPORTANT Only the jacking points described in this section allow the vehicle to be raised in complete safety Do not raise the vehicle using points other than those...

Page 41: ...1 COLLISION Vehicle involved in an impact Impact fault finding 03B I CHECKING THE SUBFRAME a Chronological order of checks Front impact Gd Ng Gg Nd Nd Hg Ng Hd Rear impact Gd Bg Gg Bd Bd Jg Bg Jd 124...

Page 42: ...ct Impact fault finding 03B II DETAILED VIEW OF INSPECTION POINTS Points Ad Ag Points Bd Bg Rear axle guide Points Gd Gg Front side member rear guide Points Hg Hd Radiator cross member mounting on fro...

Page 43: ...03B 3 COLLISION Vehicle involved in an impact Impact fault finding 03B Points Jd Jg Rear side member rear leader pin a 124333...

Page 44: ...al impact Description 03B COMBINATIONS FOR REPLACING WELDED STRUCTURAL PARTS IN ACCORDANCE WITH IMPACT SUSTAINED 1st Degree 1 front end cross member mounting stiffener 2 front panel mounting bracket 3...

Page 45: ...scription 03B 2nd Degree 4 front section of front right hand side member 5 scuttle side panel 6 battery tray bracket 7 front section of front left hand side member 8 front side member closure panel fr...

Page 46: ...03B 6 COLLISION Vehicle involved in a frontal impact Description 03B 3rd Degree 10 front right hand half unit 11 upper linkage mounting 12 front left hand half unit 125028...

Page 47: ...03B 7 COLLISION Vehicle involved in a side impact Description 03B 1st Degree B91 or K91 125037 B91 or K91 125038...

Page 48: ...pper body 2 sill panel 3 body side closure panel 4 body side front section 2nd Degree 5 scuttle side panel 6 A pillar reinforcement 7 B pillar reinforcement 8 sill panel closure panel 9 sill panel rei...

Page 49: ...reen aperture lower cross member 18 front wheel arch front section 19 front wheel arch rear section 20 centre floor front cross member 21 front cross member under front seat 22 rear cross member under...

Page 50: ...03B 10 COLLISION Vehicle involved in a side impact Description 03B 1st Degree D91 134770 D91 134771...

Page 51: ...n 03B 29 body side front section 30 body side closure panel front section 31 sill panel 2nd Degree 32 scuttle side panel reinforcement 33 A pillar reinforcement 34 windscreen pillar reinforcement 35 B...

Page 52: ...involved in a side impact Description 03B 3rd Degree 37 roof 38 roof rear cross member 39 roof middle cross member 40 roof front cross member 41 A pillar lining 42 side floor 43 A pillar lining 44 sil...

Page 53: ...03B 13 COLLISION Vehicle involved in a rear impact Description 03B B91 125034...

Page 54: ...03B 14 COLLISION Vehicle involved in a rear impact Description 03B 1st Degree K91 125033 B91 128233...

Page 55: ...COLLISION Vehicle involved in a rear impact Description 03B 1 rear end panel 2 rear wing panel 1st Degree 3 rear wing panel 4 cross member closure panel component 5 absorber mounting cross member K91...

Page 56: ...16 COLLISION Vehicle involved in a rear impact Description 03B 2nd Degree 6 rear wheel arch 7 rear wing panel rain channel 8 rear side member 9 light mounting lining 10 rear floor rear section B91 125...

Page 57: ...a rear impact Description 03B 2nd Degree 11 rear wheel arch 12 rear end pillar closure panel 13 rear side member 14 rear end panel 15 rear cross member rear section 16 rear floor rear section 17 rear...

Page 58: ...impact Description 03B 3rd Degree 18 quarter panel reinforcement 19 shoulder harness reinforcement 20 rear wheel arch 21 side roof rail lining 22 grab handle fixed bridge piece 23 rear subframe assem...

Page 59: ...scription 03B 3rd Degree 25 rear wheel arch 26 rear side member assembly 27 side roof rail lining rear section 28 rear subframe assembly 29 side roof rail lining front section 30 roof bar mounting rei...

Page 60: ...03B 20 COLLISION Vehicle involved in a rear impact Description 03B 1st Degree D91 134769 D91 134774...

Page 61: ...3B 21 COLLISION Vehicle involved in a rear impact Description 03B 32 body side rear section 33 rear end panel 2nd Degree 34 quarter panel lining 35 rear light mounting element upper section D91 134768...

Page 62: ...2 COLLISION Vehicle involved in a rear impact Description 03B 3rd Degree 36 rear side parcel shelf 37 rear inner wheel arch 38 rear side rain channel 39 rear parcel shelf 40 body side extension D91 13...

Page 63: ...23 369 SILICOJOINT 90 g tube 77 11 236 469 LOCTITE ADHESIVE 597 Sealing paste for PXX gearboxes Cartridge 77 11 219 705 RESIN ADHESIVE or SEALING RESIN Sealing resin for engine and gear box covers 25...

Page 64: ...EANER 600 ml aerosol 77 11 422 413 150 ml aerosol 77 11 422 414 BIO BRAKE CLEANER 750 ml spray bottle 77 11 427 217 AIR CONDITIONING CLEANER 250 ml aerosol 77 11 230 498 CARBURETTOR CLEANER Aerosol 77...

Page 65: ...ENAULT STANDARD 03 50 005 Authorised for vehicles without ESP 0 5 L container 77 11 172 381 5 L container 77 01 395 503 25 L container 77 11 171 926 DOT 4 Authorised for vehicles without ESP without c...

Page 66: ...na III 1 L container PLANETELF PAG 488 250 ml container 77 11 172 668 SANDEN SP 10 Oil for air conditioning compressor 77 01 419 313 TYRES TYRE PASTE 1 kg pack 77 11 223 052 5 kg pack 77 11 223 053 TY...

Page 67: ...BIPAC EVOLUTION ADHESIVE KIT 2 225 ml cartridges 77 11 421 434 LINT FREE CLOTH Box of 340 cloths 77 11 237 262 METAL PRIMER Bottle 77 11 419 599 WINDOW SEALING MASTIC 310 ml cartridge 77 11 170 222 SP...

Page 68: ...container 77 11 420 288 FINISHING LIQUID 1 L container 77 11 420 289 MASTIC Universal mastic GALAXI 2 5 kg pack 77 11 172 238 OPTIMAX 1 23 l cartridge 77 11 172 239 EXCELLENCE For finishing plastic re...

Page 69: ...rtridge 77 11 423 519 PLASTIC REPAIR CLOTH 90 m roller 77 11 423 520 PLASTIC REPAIR NOZZLES 12 nozzles 77 11 423 522 COMPOSITE MATERIAL REP AIR BY WELDING PLASTIC WELD REPAIR SET 77 11 425 742 PROTECT...

Page 70: ...adhesion pro moter for thermoplastics 400 ml aerosol 77 11 423 734 PRIMARA BLACK adhesion pro moter primer for thermoplastics 1 L container 77 11 423 735 77 11 171 514 Activator PRIMARA adhesion prom...

Page 71: ...he vehicles are constructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering system is forbidden without the pri...

Page 72: ...ed by the manufacturer in the production of the various component units and accessories from which the vehicles are constructed All rights reserved by Renault Copying or translating in part or in full...

Page 73: ...227 Oil level sensor Removal Refitting 10A 237 Oil pump Removal Refitting 10A 245 Oil pressure Check 10A 262 Multifunction support Removal Refitting 10A 265 Flywheel Removal Refitting 10A 277 Drive p...

Page 74: ...manifold Removal Refitting 12A 122 Rear exhaust manifold Removal Refitting 12A 129 11A TOP AND FRONT OF ENGINE 12B TURBOCHARGING Turbocharging Precautions for the repair 12B 1 Turbocharger Removal Re...

Page 75: ...C 3 14A ANTIPOLLUTION Oil vapour rebreathing circuit Description 14A 1 Oil vapour rebreathing circuit Operating diagram 14A 3 13B DIESEL INJECTION Exhaust gas recirculation Operating diagram 14A 6 Fue...

Page 76: ...ng fan assembly Removal Refitting 19A 121 Thermoplunger unit Removal Refitting 19A 135 Coolant pump inlet pipe Removal Refitting 19A 139 Expansion bottle Removal Refitting 19A 152 Electric coolant pum...

Page 77: ...135 19C TANK Sender Removal Refitting 19C 1 Pump sender filter Removal Refitting 19C 4 Fuel tank Draining 19C 7 Fuel tank Removal Refitting 19C 11 Filler neck Removal Refitting 19C 31 19D ENGINE MOUNT...

Page 78: ...e mounting rubber pad 62 N m engine tie bar bolt on the subframe 115 N m engine tie bar bolt on the engine tie bar mounting 190 N m IMPORTANT To avoid all risk of damage to the systems apply the safet...

Page 79: ...air outlet pipe on the tur bocharger side a Drain the cooling system see 19A Cooling Cooling system Draining Refilling page 19A 16 the engine if necessary see 10A Engine and cylinder block assembly E...

Page 80: ...ne tie bar bolt 7 from the subframe the front wheels see Wheel Removal Refitting 35A Wheels and tyres the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts...

Page 81: ...10 from the Protection and Switching Unit a Disconnect the connector 11 from the electric cool ant pump a Remove the bolt 12 from the electric coolant pump on the body a Remove the bolt 13 from the ma...

Page 82: ...the upper radiator cover the front end panel see Front end panel Remov al Refitting 42A Upper front structure a Use a flat blade screwdriver 17 to unclip the pow er assisted steering fluid reservoir a...

Page 83: ...e sensor connector 20 from the condenser expansion valve connecting pipe a Disconnect the pressure sensor wiring from the condenser expansion valve connecting pipe a Disconnect the engine cooling fan...

Page 84: ...air inlet pipe a Pull the clip 24 on the intercooler air outlet pipe a Disconnect the intercooler air outlet pipe a Remove the condenser expansion valve connecting pipe bolt 25 the compressor condense...

Page 85: ...of the upper cooling pipe on the cooling radiator side using the tool Mot 1448 a Disconnect the upper cooling pipe on the cooling ra diator side a Remove the bolt 28 of the air conditioning pipe on t...

Page 86: ...oss member Removal Refitting 41A Front upper structure a Remove the earth wiring nuts 30 from the front left hand side member a Disconnect the earth wiring from the front left hand side member a Disco...

Page 87: ...ring from the engine the engine harness channel a a Disconnect the inlet distributor fuel supply union 35 the inlet distributor oil vapour rebreather pipe union 36 the inlet distributor vacuum pipe un...

Page 88: ...matrix pipes 38 by pressing each side of the quick release union a Separate the clip 39 on the pipe of the power as sisted steering pump using the tool Mot 1448 a Disconnect the pipe from the power as...

Page 89: ...pipe bracket on the steering box a Remove the lower power assisted steering pipe a Insert the blanking plugs a Remove the gearbox control cable by unclipping it at 42 using an open jawed span ner by u...

Page 90: ...and on the slave cylinder a Unclip the clutch rigid pipe from the gearbox a Disconnect the reversing connector a Unclip the gearbox control cables from the ball joints 45 the gearbox control cables fr...

Page 91: ...rts always to be replaced exhaust downpipe hose stud on the catalytic converter if loos ened 10 08 02 15 parts always to be replaced turbocharger air cooler air inlet pipe seal 10 09 04 04 parts alway...

Page 92: ...ach the engine harness to the engine harness channel a Clip the petrol injection computer wiring the feed wiring on the battery disconnection unit a Refit the earth cable on the gearbox a Connect the...

Page 93: ...box cover the max fuse box the electric coolant pump a Connect the electric coolant pump connector the Protection and Switching Unit connectors a Clip on the Protection and Switching Unit cover a Ref...

Page 94: ...rform the following operations fill the refrigerant circuit using a refrigerant charg ing station see Refrigerant circuit Draining Filling 62A Air conditioning refill the engine if necessary see 10A E...

Page 95: ...refitting of engine gearbox assembly Equipment required refrigerant charging station Tightening torquesm left hand suspended engine mounting rubber pad central nut 62 N m left hand suspended engine m...

Page 96: ...al Refitting 55A Exterior protec tion the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the front left hand driveshaft see Front left hand driveshaft Re...

Page 97: ...ansion bottle at Y a Remove the expansion bottle a Remove the bolts 6 from the expansion valve compressor and condenser compressor con necting pipe unions on the compressor a Disconnect the unions 7 f...

Page 98: ...ol cables from the manual gearbox from the anchoring ball joints at 10 from the cable sleeve stops at 11 a Move the gearbox control cables aside a Disconnect the following from the inlet distributor t...

Page 99: ...etrol vapour rebreathing solenoid valve connector 15 a Disconnect the connector 16 from the throttle valve a Disconnect the connector from the coil wiring 17 the injector wiring 18 the camshaft sensor...

Page 100: ...nector 27 a Remove the nut 28 from the alternator a Move aside the alternator wiring a Remove the bolt 29 from the wiring bracket on the gearbox a Move aside the wiring bracket on the gearbox a Remove...

Page 101: ...y protector the nut 36 from the right hand side underbody protector a Remove the right hand side underbody protector the heat shield behind the right hand side under body protector a Unclip the downst...

Page 102: ...lant pipe between the water chamber and the cooling radiator using the tool Mot 1448 a Disconnect the coolant pipe between the water chamber and the cooling radiator a Separate the clip 43 on the cool...

Page 103: ...the clip 45 on the coolant pipe of the multifunction support a Disconnect the coolant pipe between the thermostat unit and the thermostat unit cooling radiator the coolant pipe from the multifunction...

Page 104: ...engine and gearbox assembly on Mot 1390 a Remove the right hand suspended engine mounting see 19D Engine mounting Right hand sus pended engine mounting Removal Refitting page 19D 51 a Remove the centr...

Page 105: ...ed steering pump on the gearbox a Refit the new exhaust flange seal the exhaust flange springs a Torque tighten the exhaust flange bolts 21 N m a Connect the coolant pipe between the thermostat unit a...

Page 106: ...10A a Refit the bolt on the underbody protector on the right hand side the nut on the underbody protector on the right hand side a Clip the wiring onto the gearbox bracket a Refit the earth strap bol...

Page 107: ...r the brake servo pipe union the fuel return pipe union a Fit the gearbox control cables a Clip the manual gearbox control cables onto the anchoring ball joints the cable sleeve stops a Remove the bla...

Page 108: ...he air filter unit the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 a Connect the air filter unit air outlet pipe to the rocker cover the air filter unit air outl...

Page 109: ...l Refitting 29A Driveshafts the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts a Remove the differential output seals see Differen tial output seal...

Page 110: ...engine cooling fan wir ing a Remove the cooling radiator bottom hose clip 1 us ing the tool Mot 1448 a Disconnect the bottom hose from the cooling radia tor a Remove the clip 2 from the hose between t...

Page 111: ...he air air intercooler end a Pull the clip 5 from the intercooler air outlet pipe at the intercooler end a Disconnect the intercooler air outlet pipe at the inter cooler end a Release the clips 6 on t...

Page 112: ...blanking plugs a Remove the nut 9 from the air conditioning hose on the compressor a Disconnect the air conditioning hose on the com pressor a Insert the blanking plugs a Remove the cooling assembly 1...

Page 113: ...lder cover 10 the strut nuts 11 the strut from the left hand suspended engine mounting a Remove the fuse holder bolt 12 the fuse holder clip 13 a Remove the main supply fuses 14 a Cut the fuse holder...

Page 114: ...e reverse gear sensor connector a Fit the tool Ms 583 on the clutch pipe a Unclip the clutch rigid pipe from the gearbox a Disconnect the clutch rigid pipe from the clutch thrust bearing a Fit blankin...

Page 115: ...ntrol cable from the multifunction switch 21 the control cable from its support 22 a Disconnect the connector 23 from the automatic transmission computer a Unclip the computer wiring 24 from the engin...

Page 116: ...moval Refitting M9R 10A a Remove the nuts 26 from the earth wires on the side members a Move aside the earth wires a Attach the engine wiring mounting 27 onto the en gine a Disconnect the fuel heater...

Page 117: ...release union the fuel return pipe quick release union from the tank return pipe the fuel supply pipe quick release union from the fuel filter unit a Insert the blanking plugs a Remove the radiator m...

Page 118: ...ssisted steer ing pipes on the power assisted steering box a Remove the lower power assisted steering pipe a Insert the blanking plugs a Position the engine and the gearbox against the rub ber pads of...

Page 119: ...r air outlet pipe seal 10 09 04 05 a Remove the intercooler air outlet pipe seal at the intercooler end using a tweezers the intercooler air inlet pipe seal at the intercooler end using a tweezers a a...

Page 120: ...tic transmission computer con nector a Clip the automatic transmission control cable onto its mounting the automatic transmission control cable onto the multifunction switch a Fit the rigid clutch pip...

Page 121: ...ip using the tool Mot 1448 the cooling radiator bottom hose clip using the tool Mot 1448 a Connect the hose between the cooling radiator and the expansion bottle on the cooling radiator side a Fit the...

Page 122: ...Draining Filling 62A Air conditioning a Fill and bleed the cooling system see 19A Cool ing Cooling system Draining Refilling page 19A 16 a Fill the pump assembly reservoir with power assist ed steeri...

Page 123: ...els and tyres the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the engine undertray a Drain the gearbox see Manual gearbox oils Draining Filling 21A Ma...

Page 124: ...from the max fuse box a Remove the max fuse box 3 from its housing a Remove the max fuse box cover by pressing on the clips 4 a Remove the fuses 5 from the max fuse box a Unclip the max fuse box fuse...

Page 125: ...channel by pressing on the clip 7 a Unpick 8 the engine wiring channel body wiring a Remove the nut 9 from the left hand side member earth a a Unpick the injector wiring 10 from the engine wiring cha...

Page 126: ...n the clutch pipe hose on the brake fluid reservoir outlet a Disconnect the clutch control pipe 11 a Insert the blanking plugs a Unclip the control cables from the manual gearbox from the anchoring ba...

Page 127: ...the compres sor a Insert the blanking plugs a a Disconnect 15 the high pressure pump supply pipes 16 the pipes from the diesel injector fuel return rail 122876 WARNING T o prevent moisture from enteri...

Page 128: ...pes 40 the pipes from the diesel injector fuel return rail a Insert the correct blanking plugs a Detach the fuel pipes a Disconnect the engine cooling hoses 17 from the heater matrix by pressing each...

Page 129: ...10A a Disconnect the brake servo pipe from the vacuum pump 18 a Move the cooling radiator top hose clip 19 to one side using the Mot 1448 a Disconnect the cooling radiator top hose a Unclip the fuel...

Page 130: ...r the diesel heater on the diesel filter mounting a Move aside the fan assembly wiring a Remove the front left hand wheel driveshaft see Front left hand driveshaft Removal Refitting 29A Driveshafts th...

Page 131: ...pipe a Disconnect the intercooler air inlet pipe from the in tercooler a Pull the clip 27 of the intercooler air outlet pipe a Disconnect the intercooler air outlet pipe from the in tercooler a Remov...

Page 132: ...the exhaust flange seal a Disconnect the particle filter temperature sensor connector 37 the particle filter pressure sensor connector 38 a Disconnect the power assisted steering pump as sembly connec...

Page 133: ...of the left hand suspended engine mounting rubber pad on the left hand suspended engine mounting support using a indelible pencil a Remove the nuts 35 from the left hand suspended engine mounting rub...

Page 134: ...he exhaust pipe a Refit the exhaust bracket bolts a Connect the particle filter pressure sensor connector the particle filter temperature sensor connector a Refit a new exhaust flange seal a Fit the e...

Page 135: ...Tighten the earth nut on the left hand side member a Clip the body wiring onto the engine wiring channel a Clip the feed wiring onto the engine harness chan nel a Refit a new clip to the max fuse box...

Page 136: ...448 Remote operation pliers for hose clips Mot 1390 Support for removal refitting of engine gearbox assembly Equipment required refrigerant charging station Tightening torquesm nut on the left hand su...

Page 137: ...ay bolts the engine undertray the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the front left hand driveshaft see Front left hand driveshaft Removal Re...

Page 138: ...compressor connecting pipe union a Move aside the following from the compressor the expansion valve compressor connecting pipe the condenser compressor connecting pipe a Fit the Ms 583 4 on the low p...

Page 139: ...teering high pressure pipe on the gear box a Remove the power assisted steering high pressure pipe a Unclip the clutch control pipe from the left hand sus pended engine mounting shaft of the manual ge...

Page 140: ...stops at 15 a Move the gearbox control cables to one side a Disconnect the air pressure sensor connector 16 the brake servo pipe union 17 on the intake dis tributor a Disconnect the fuel rebreathing p...

Page 141: ...mshaft position sensor a Disconnect the injector wiring connector 23 the connector of each coil 25 the air temperature sensor connector 24 a Unclip the coil wiring 26 a Move aside the coil wiring a Di...

Page 142: ...connector 30 a Disconnect the connector 31 from the oil level sen sor a Disconnect the alternator connector 32 a Remove the nut 33 from the alternator positive ter minal a Move aside the alternator wi...

Page 143: ...body pro tector the nut 39 on the right hand side underbody pro tector a Remove the right hand side underbody protector the heat shield behind the right hand side under body protector 122879 Note Befo...

Page 144: ...ubframe at 41 a Move the engine wiringaside a Remove the clip 42 from the cooling hose between the coolant outlet unit and the cooling radiator using the Mot 1448 a Disconnect the cooling hose between...

Page 145: ...cket ring II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the rear suspended engine mounting bolts 45 the rear suspended engine mounting 46 a Support the engine and gearbox assembly on Mot 1390 a...

Page 146: ...ON a For standard replacements see standard replace ment Technical Note 6020A 10A Engine and pe ripherals II REFITTING OPERATION FOR PART CONCERNED a Fit the engine gearbox assembly into the body a Re...

Page 147: ...new exhaust bracket ring a Torque tighten the exhaust bracket nuts 21 Nm a Connect the coolant hose between the coolant outlet unit and the cooling radiator to the coolant outlet unit the cooling hos...

Page 148: ...openings a Connect the reversing sensor connector the hydraulic clutch control pipe a Clip the clutch control pipe on to the left hand sus pended engine mounting shaft of the gearbox a Fit the high p...

Page 149: ...5A Wheels and tyres the battery tray see Battery tray Removal Re fitting 80A Battery the air outlet pipe to the air filter box the air filter box see 12A Fuel mixture Air filter unit Removal Refitting...

Page 150: ...cial tooling required Mot 1448 Remote operation pliers for hose clips Mot 1390 Support for removal refitting of engine gearbox assembly Equipment required refrigerant charging station safety strap s T...

Page 151: ...ction Petrol injection computer Removal Refitting page 17B 30 the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 a Remove the air scoops 4 from the cooling radiator...

Page 152: ...emove the earth wire nut 6 a Move the earth wire away from the left hand scuttle reinforcement a Remove the max fuse box cover all of the fuses 7 all of the fuse holders from the max fuse box the bolt...

Page 153: ...t 12 from the power assisted steer ing pipe support a Move aside the power assisted steering pipe sup port a Move aside the clip of the power assisted steering lower hose using the Mot 1448 a Drain th...

Page 154: ...V4Y 10A a Move aside the clips 14 of the power assisted steering fluid reservoir hoses using the Mot 1448 a Disconnect the hoses from the power assisted steering fluid reservoir a Remove the power as...

Page 155: ...see Front catalyt ic pre converter Removal Refitting the rear catalytic pre converter see Rear catalytic pre converter Removal Refitting a Move aside the clips 18 of the heater matrix hoses at the ou...

Page 156: ...e automatic transmission a Move aside the automatic transmission wiring a Remove the bolts 22 from the lower engine tie bar the lower engine tie bar II OPERATION FOR REMOVAL OF PART CONCERNED a Suppor...

Page 157: ...ngine tie bar a Torque tighten the lower engine tie bar bolts 180 N m a Fit the automatic transmission wiring a Refit the bolts of the wiring protective sheath on the automatic transmission a Connect...

Page 158: ...compartment connection unit the battery disconnection unit see Battery dis connection unit Removal Refitting the front left hand driveshaft see Front left hand driveshaft Removal Refitting the front...

Page 159: ...charg ing station see Refrigerant circuit Draining Filling 62A Air conditioning a leak test see Refrigerant circuit Check 62A Air conditioning fill and bleed the power assisted steering circuit see P...

Page 160: ...Horn the bonnet catch see Bonnet lock Removal Refitting 52A Non side opening element mecha nisms the front end panel see Front end panel Remov al Refitting 42A Upper front structure the engine coolin...

Page 161: ...rcooler see 19A Cooling Cooling radiator Removal Refitting page 19A 28 assembly the front impact cross member see Front impact cross member Removal Refitting 41A Front lower structure a Rotate the cli...

Page 162: ...c coolant pump of the exhaust cooler see 19A Cooling Electric coolant pump Re moval Refitting page 19A 159 the additional radiator see Additional radiator Removal Refitting the radiator mounting cross...

Page 163: ...e the power assisted steering hose a Move aside the clip 9 of the power assisted steer ing hose using the Mot 1448 a Disconnect the power assisted steering hose a Remove the power assisted steering fl...

Page 164: ...e max fuse box support a Remove the fuse assembly 13 a Unclip the fuse holder assembly 14 a Move the max fuse box to one side a Remove the electric coolant pump of the turbocharg er see 19A Cooling El...

Page 165: ...efitting page 12A 28 a Disconnect the xenon bulb computer connector 18 a Unclip the xenon bulb computer wiring a Unclip the engine wiring connector 19 from the front left hand wing panel a Disconnect...

Page 166: ...he gearbox wiring a Disconnect the connector 24 from the air conditioning pres sure sensor the connector from the water detection sensor on the diesel filter a Disconnect the connector 25 from the ele...

Page 167: ...battery discon nection unit a Remove the supply wiring of the battery disconnection unit the protective sheath of the gearbox wiring a Disconnect the turbocharger control solenoid valve connector 29...

Page 168: ...e quick release unions 36 of the fuel supply and return pipes a Disconnect the fuel temperature sensor connector 37 a Unclip 38 the fuel return pipes from their supports a Move the fuel pipesto one si...

Page 169: ...cooling hose of the heater matrix using the Mot 1448 a Disconnect the outlet cooling hose of the heater ma trix a Disconnect the inlet cooling hose 42 of the exhaust cooler a Move aside the inlet coo...

Page 170: ...e the seal between the connecting hose and the particle filter a Disconnect the fuel supply pipe union 46 of the ex haust fuel injector a Move aside the fuel pipe of the exhaust fuel injector a Unclip...

Page 171: ...temperature sensor connector 48 a Unclip the particle filter temperature sensor wiring from the heat shield a Move aside the particle filter temperature sensor wir ing a Unclip the gearbox control fro...

Page 172: ...gine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 a Lift the vehicle to remove the engine gearbox assembly REFITTING I REFITTING PREPARATION OPERATION a parts always to...

Page 173: ...et cooling hose of the coolant outlet unit a Fit the gearbox control a Clip on the gearbox control a Fasten the gearbox control onto its support a Fit the particle filter temperature sensor wiring a C...

Page 174: ...Clip on the supply wiring of the battery disconnection unit a Refit the nut of the protective sheath of the gearbox wir ing the bolt of the protective sheath of the gearbox wir ing a Position the elec...

Page 175: ...e oil vapour rebreathing pipe to the air fil ter box air outlet pipe a Clip on the vacuum pipes of the turbocharger control solenoid valve a Torque tighten the clip of the air filter unit air out let...

Page 176: ...leed the power assisted steering circuit see Power assisted steering circuit Bleeding 36B Power assisted steering a Refit the front bumper see Front bumper Removal Refitting 55A Exterior protection th...

Page 177: ...ing 02A Lifting equipment a Remove the engine undertray Equipment required oil recovery tray oil change wrench oil change end piece with an 8 mm square drive Tightening torquesm drain plug with a roll...

Page 178: ...a a Fit the new seal on the drain plug 3 if the seal is rolled orient the groove 4 towards the plug the drain plug on the engine oil sump a Using a oil change end piece with an 8 mm squa re drive tor...

Page 179: ...k a Refit the oil filler cap dipstick assembly WARNING Always check the oil level using the dipstick Do not exceed the maximum level on the dipstick could destroy the engine Correct the engine oil lev...

Page 180: ...undertray bolts the engine undertray Equipment required oil recovery tray Tightening torquesm drain plug 34 Nm Engine Average oil capacity test with dipstick l Oil change with o u t fi l t e r replace...

Page 181: ...n to torque the drain plug 34 Nm a Clean the traces of oil around the drain plug so that any possible leaks can be detected II FILLING a Consumable Engine oil see Engine oil Specifications Tech nical...

Page 182: ...ace the oil recovery tray under the engine a Remove the drain plug 3 from the engine oil sump using a oil change wrench the engine oil sump drain plug seal a Let the engine oil run into the oil recove...

Page 183: ...oil recommended by the manufacturer see Engine oil Specifications Technical Note 6013A 04A Lubricants a Adjust the engine oil level if necessary a Refit the filler cap the dipstick 113765 WARNING Alwa...

Page 184: ...oil recovery tray under the engine a Remove the drain plug 3 from the engine oil sump using a oil change wrench the engine oil sump drain plug seal a Allow the engine oil to flow into the oil recover...

Page 185: ...funnel to fill the engine with oil recommended by the manufacturer see Engine oil Specifica tions Technical Note 6013A 04 Lubricants a Check the engine oil level if necessary a Refit the filler cap t...

Page 186: ...g and lifting 02A Lifting equipment a Remove the engine cover the filler cap 1 the dipstick 2 the engine undertray Equipment required oil recovery tray oil change wrench oil change end piece with an 8...

Page 187: ...plug on the sump a Torque tighten the drain plug 20 N m using a oil change end piece with an 8 mm square drive a Clean the traces of oil around the drain plug so that any possible leaks can be detect...

Page 188: ...recom mended by the manufacturer see Engine oil Specifications Technical Note 6013 04A Lubri cants a Check the engine oil level if necessary a Refit the filler cap the dipstick the engine cover Note W...

Page 189: ...equired oil recovery tray Tightening torquesm drain plug 35 N m Engine Average oil capacity adjust with dipstick l Oil change without oil fil ter replace ment O i l change plus oil filter replacement...

Page 190: ...w seal on the drain plug the drain plug a Torque tighten the drain plug 35 N m a Clean the traces of oil around the drain plug so that any possible leaks can be detected a Remove the oil recovery tray...

Page 191: ...10A 114 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil Draining Refilling V4Y 10A the engine cover...

Page 192: ...il recovery tray oil change wrench torque wrench oil change end piece with an 8 mm square drive Tightening torquesm engine oil sump drain plug 44 N m Engine Average oil capacity adjust with dipstick l...

Page 193: ...Remove the drain plug seal a Fit a new seal onto the engine oil drain plug a Torque tighten the engine oil sump drain plug 44 N m using a torque wrench and a oil change end piece with an 8 mm square d...

Page 194: ...hrough the opening 2 a Allow the oil contained in the oil filter unit to flow a Remove the cover 3 oil filter 4 assembly the cover seal 5 Equipment required oil recovery tray Tightening torquesm oil f...

Page 195: ...ter unit cover a Fit a new cover seal 5 a new filter element in the cover II REFITTING OPERATION a Manually tighten the cover oil filter assembly a Torque tighten the oil filter unit cover 25 Nm III F...

Page 196: ...new engine oil II REFITTING OPERATION FOR PART CONCERNED a Tighten the oil filter until it makes contact a Tighten the oil filter by 3 4 of a turn by hand III FINAL OPERATION a Remove the oil recover...

Page 197: ...with new engine oil II REFITTING OPERATION FOR PART CONCERNED a Fit the new oil filter a Tighten the oil filter until it makes contact a Tighten the oil filter by 3 4 of a turn III FINAL OPERATION a W...

Page 198: ...R 415 04B Consumables Products a Start the engine and wait until the oil pressure warn ing light goes out on the instrument panel a Check for leaks from the oil filter a Remove the oil recovery tray a...

Page 199: ...ter 10 05 05 03 a Lubricate the new oil filter seal with engine oil II REFITTING OPERATION FOR PART CONCERNED a Refit the new oil filter by hand until the seal makes contact with the mounting Special...

Page 200: ...ommended by the manufacturer see Engine oil Specifications MR 415 04A Lubricants a Start the engine and leave it running for 30 seconds a Check there are no leaks from the oil filter a Remove the oil...

Page 201: ...RT CONCERNED a Fit a new oil filter a Tighten the oil filter until it makes contact a Tighten the oil filter by 3 4 of a turn III FINAL OPERATION a Remove the oil recovery tray a Wipe any oil run off...

Page 202: ...e Engine oil Specifications Technical Note 6013A 04A Lubricants a Start the engine until the oil pressure warning light goes out on the instrument panel a Check that there are no leaks around the oil...

Page 203: ...ITTING PREPARATION OPERATION a parts always to be replaced Oil filter 10 05 05 03 a Check that the used oil filter seal does not remain at tached to the engine a Lubricate the new oil filter seal with...

Page 204: ...rt the engine and wait until the oil pressure warn ing light goes out on the instrument panel a Check for leaks from the oil filter a Refit the front right hand wheel see Wheel Removal Refitting 35A W...

Page 205: ...R PART CONCERNED a Fit a new oil filter a Tighten the oil filter until it makes contact a Tighten the oil filter three quarters of a turn using the Mot 1280 01 III FINAL OPERATION a Remove the oil rec...

Page 206: ...n ing light goes out on the instrument panel a Check for leaks from the oil filter a Refit the engine undertray a Wait at least 10 minutes a Check the oil level using the dipstick a Adjust the engine...

Page 207: ...t pipe on the damper valve a Disconnect the intercooler air outlet pipe on the side of the damper valve a Remove the pin from the intercooler air outlet pipe at the intercooler end a Disconnect the in...

Page 208: ...rom the positive terminal on the alterna tor 5 the oil pressure sensor connector 6 a Move aside the alternator wiring a Remove the oil filter unit coolant outlet union bolts 6 a Remove the clip 7 from...

Page 209: ...oil filter unit coolant outlet union gasket face 1 If reusing the oil filter unit a parts always to be replaced Oil filter cartridge 10 05 05 04 2 If replacing the oil filter unit a Remove the oil pre...

Page 210: ...ooler air outlet pipe a Connect the intercooler air outlet pipe at the inter cooler end a Connect the intercooler air outlet pipe on the side of the damper valve a Torque tighten the intercooler air o...

Page 211: ...r Removal Refitting MR 416 55A Exterior protection the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and...

Page 212: ...block gasket face II REFITTING OPERATION FOR PART CONCERNED a Refit the new crankshaft seal on the timing end us ing the Mot 990 03 III FINAL OPERATION a Refit the crankshaft timing sprocket the timin...

Page 213: ...ne Accessories belt Removal Refitting page 11A 13 the front right hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front right hand wheel see Wheel...

Page 214: ...Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove...

Page 215: ...comes into con tact with the timing cover a Remove the crankshaft accessories pulley bolt the Mot 1790 a Check that the crankshaft seal on the timing end is correctly fitted III FINAL OPERATION a Ref...

Page 216: ...10A 139 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end Removal Refitting M4R 10A the front right hand wheel see Wheel Removal Refitting MR 415 35A Wheels and tyres...

Page 217: ...l Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 II REMOVAL OPERATION FOR PART CONCERNED a Remove t...

Page 218: ...ite the timing cover notches 3 a Engage the new crankshaft seal lugs in the timing cover notches a Manually tighten the crankshaft seal using the tool supplied in the spare parts kit for the new crank...

Page 219: ...d front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the front right hand w...

Page 220: ...Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the right hand suspended en...

Page 221: ...ting Right hand suspended engine mounting Removal Refitting page 19D 51 the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the engine undertray the fro...

Page 222: ...he crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the timing end cranksha...

Page 223: ...is correctly posi tioned III FINAL OPERATION a Refit the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the accessories belts...

Page 224: ...wer engine tie bar 2 the right hand lower engine tie bar 3 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the acces...

Page 225: ...10A II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the end piece 4 of the tool Mot 1577 from the extractor a Remove the circlips Mot 1577 from the tool 5 us ing circlip pliers a Remove the shaft...

Page 226: ...al Refitting V9X 10A a Fit the cup 8 of the tool Mot 1912 on the tool Mot 1577 a Fit the shaft 9 of the tool Mot 1577 on the tool Mot 1577 a Fit the circlips 10 on the tool Mot 1577 using cir clip pli...

Page 227: ...the tool III REFITTING PREPARATION OPERATION a parts always to be replaced Crankshaft seal on timing end 10 03 03 04 a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consum a...

Page 228: ...d IV FINAL OPERATION a Refit the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the crankshaft accessories belt see 11A Top a...

Page 229: ...ght hand engine tie bar bolts 180 N m 1 the left hand engine tie bar bolts 105 N m 2 a Refit the engine undertray the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A...

Page 230: ...see Front right hand driveshaft Removal Refitting MR 415 29A Driveshafts the differential output seals see Differential out put seal Removal Refitting MR 415 21A Manual gearbox the radiator mounting c...

Page 231: ...vice of the Mot 1791 the centring device of the Mot 1791 a Check that the crankshaft seal on the gearbox side is correctly fitted III FINAL OPERATION a Refit the flywheel see 10A Engine and cylinder b...

Page 232: ...ee Manual gearbox oils Draining Filling MR 415 21A Manual gearbox a Refit the front wheel arch liners see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front wheels see W...

Page 233: ...l driveshaft see Front left hand driveshaft Removal Refitting 29A Driveshafts the differential output seals see Differential out put seal Removal Refitting 21A Manual gear box the radiator mounting cr...

Page 234: ...ING OPERATION FOR PART CONCERNED a a Fit the new seal protector seal cover assembly on the crankshaft the bolts 1 M6 90 mm long to guide the crank shaft seal cover assembly a Move the seal cover assem...

Page 235: ...moval Refitting 41A Front lower structure the differential output seals see Differential out put seal Removal Refitting 21A Manual gear box the front left hand wheel driveshaft see Front left hand dri...

Page 236: ...415 80B Headlights the radiator upper cover the front end panel see Front end panel Remov al Refitting MR 416 42A Upper front struc ture the engine cooling assembly see 19A Cooling Cooling radiator R...

Page 237: ...clamp the exhaust harness seal a Remove the bolt 3 from the catalytic converter bracket on the catalytic converter the bolt 4 from the upstream strut of the catalytic converter on the catalytic conver...

Page 238: ...talytic converter downstream strut a Remove the nut 9 from the starter excitation terminal the nut 10 from the starter supply terminal a Move the starter electrical wiring aside a Remove the starter b...

Page 239: ...tic converter and the turbocharger the exhaust bracket gasket the studs if they have become loose a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products...

Page 240: ...the catalytic converter a Torque tighten the catalytic converter upstream strut bolt on the catalytic converter 11 Nm the catalytic converter bracket bolt on the cata lytic converter 11 Nm a Refit the...

Page 241: ...ttery the battery see Battery Removal Refitting MR 415 80A Battery the engine undertray the engine undertray bolts a Tighten the engine undertray bolts a Perform the following operations fill the cool...

Page 242: ...ting 80B Headlights the front end panel see Front end panel Remov al Refitting 42A Upper front structure a Drain the cooling system see 19A Cooling Cooling system Draining Refilling page 19A 16 the au...

Page 243: ...al mating face a Always replace the crankshaft seal cover assem bly II REFITTING OPERATION FOR PART CONCERNED a a Fit the seal protector seal new cover assembly on the crankshaft the bolts 1 M6 90 mm...

Page 244: ...hand suspended engine mounting Removal Refitting page 19D 51 the rear suspended engine mounting see 19D Engine mounting Lower engine tie bar Re moval Refitting page 19D 85 the radiator mounting cross...

Page 245: ...e battery see Battery Removal Refitting 80A Battery a Refill and bleed the cooling system see 19A Cool ing Cooling system Draining Refilling page 19A 16 a Refill the refrigerant circuit see Refrigeran...

Page 246: ...ee Front left hand driveshaft Removal Refitting 29A Driveshafts the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the differential output seals se...

Page 247: ...oss member Removal Refitting 41A Front lower structure the differential output seals see Differential out put seal Removal Refitting 21A Manual gear box the front right hand wheel driveshaft see Front...

Page 248: ...ee Refrigerant circuit Draining Fill ing 62A Air conditioning the cooling system see 19A Cooling Cooling system Draining Refilling page 19A 16 a Remove the cooling radiator condenser fan assembly see...

Page 249: ...ove the central nut 1 from the rubber pad on the left hand suspended engine mounting a Use a copper hammer to strike the threaded rod of the left hand suspended engine mounting to sepa rate the engine...

Page 250: ...PREPARATION OPERATION a Always replace the crankshaft seal support on the gearbox side crankshaft seal on the gearbox side assembly a Use SUPER CLEANING AGENT FOR JOINT FA CES see Vehicle Parts and c...

Page 251: ...y Lower cover Removal Refitting page 10A 180 the accessories belt of the air conditioning com pressor see 11A Top and front of engine Ac cessories belt Removal Refitting page 11A 13 a Remove the engin...

Page 252: ...fill the engine oil see 10A Engine and cylinder block assembly Engine oil Draining Refilling page 10A 100 the cooling circuit see 19A Cooling Cooling system Draining Refilling page 19A 16 the refriger...

Page 253: ...iator Removal Refitting page 19A 28 assembly the electric coolant pump of the exhaust cooler see 19A Cooling Electric coolant pump Re moval Refitting page 19A 159 the additional radiator see Additiona...

Page 254: ...e gearbox from the engine see Auto matic gearbox Removal Refitting 23A Auto matic transmission a Position the engine on the component support see Engine support equipment Use a Remove the drive plate...

Page 255: ...assembly a Move the seal cover assembly evenly 4 by hand until it makes contact with the cylinder block a Remove the seal protector 5 the guide bolts a Pretighten to torque and in order the crankshaf...

Page 256: ...ssisted steering pipes Removal Refitting 36B Power assisted steering the radiator mounting cross member see Radiator mounting cross member Removal Refitting 41A Front lower structure the additional ra...

Page 257: ...sing SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consumables Products a Following the drawing apply a bead 2 of SILI CONE ADHESIVE SEALANT see Vehicle Parts and consumables fo...

Page 258: ...10A II REFITTING OPERATION FOR PART CONCERNED a Refit the sump a Torque tighten in order the sump bolts 9 N m III FINAL OPERATION a Fill up the engine oil see 10A Engine and cylinder block assembly E...

Page 259: ...TING PREPARATION OPERATION a Apply SUPER CLEANER FOR JOINT FACES see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products to the parts to be cleaned a Leave for approximately t...

Page 260: ...diameter of approximately 5 mm at a distance of ap proximately 8 mm from the inner edge of the sump to ensure correct sealing II REFITTING OPERATION FOR PART CONCERNED a Fit the lower cover a Manuall...

Page 261: ...lts 1 on the gearbox the sump bolts from the cylinder block the lower cover the sump seal REFITTING I REFITTING PREPARATIONS OPERATION a Use SURFACE CLEANER see Vehicle Parts and consumables for the r...

Page 262: ...lts 8 15 4 19 11 and 12 18 Nm sump bolts 10 13 9 14 8 15 7 16 6 17 5 18 3 20 2 21 1 and 22 15 Nm the sump bolts on the gearbox 44 Nm III FINAL OPERATION a Fill up the engine oil observing the quantity...

Page 263: ...gine see 10A Engine and cylinder block assembly Engine oil Draining Refilling page 10A 100 II REMOVAL OPERATION FOR PART CONCERNED a Remove the sump bolts 1 a Cut the silicone seal on the sump using t...

Page 264: ...L see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products with a di ameter of 5 mm 2 mm to the sump in order to pro vide a good seal 114264 Note Gradually detach the sump with...

Page 265: ...the lower cover a Pre tighten in order and to torque the sump bolts initial torque 5 Nm a Torque tighten in order the sump bolts 16 Nm III FINAL OPERATION a Refit the engine undertray the engine unde...

Page 266: ...rain the engine oil see 10A Engine and cylinder block assembly Engine oil Draining Refilling page 10A 100 a Remove the bolts 1 from the front right hand wheel drive shaft relay bearing the front right...

Page 267: ...ump is to be reused a Disconnect the connector 4 from the oil level sen sor a Remove the bolts 5 from the lower engine tie bar the lower engine tie bar 2 If replacing the sump a Remove the oil level s...

Page 268: ...IVE PADS 109153 20171 Note If the sump cannot be extracted because it is in contact with the oil pump strainer do not force the removal of the sump as this may damage the oil splash plate Loosen the o...

Page 269: ...it a new sump seal to the sump the sump fitted with its new seal a Fit without tightening the bolts from the sump on the gearbox the sump bolts on the cylinder block a Tighten to torque the sump bolts...

Page 270: ...If the sump is to be reused a Refit the lower engine tie bar a Torque tighten the lower engine tie bar bolts 180 N m a Connect the connector to the oil level sensor III FINAL OPERATION a Clip the rail...

Page 271: ...block assembly Oil level sensor Removal Re fitting page 10A 237 the rear suspended engine mounting see 19D Engine mounting Lower engine tie bar Re moval Refitting page 19D 85 a Remove the right hand d...

Page 272: ...FACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products to clean and degrease the sump joint face if it is to be re used the cylinder block gasket face a Alwyas replace...

Page 273: ...on the sump the sump a Tighten to torque and in order the sump bolts 14 N m the sump bolts on the gearbox 44 N m the sump bolt on the multifunction support 21 N m III FINAL OPERATION a Refit the relay...

Page 274: ...e 19D Engine mounting Lower engine tie bar Re moval Refitting page 19D 85 the oil level sensor see 10A Engine and cylinder block assembly Oil level sensor Removal Re fitting page 10A 237 a Fill up the...

Page 275: ...unit Removal Refitting page 12A 13 the engine cooling fan assembly see 19A Cool ing Engine cooling fan assembly Removal Refitting page 19A 121 the cooling radiator condenser intercooler see 19A Coolin...

Page 276: ...c gearbox Removal Refitting 23A Auto matic transmission a Position the engine on the component support see Engine support equipment Use a Remove the accessories belt see 11A Top and front of engine Ac...

Page 277: ...tting page 10A 153 a Remove the bolts 2 of the coolant oil heat exchanger sup port the coolant oil heat exchanger support the seal of the coolant oil heat exchanger support II OPERATION FOR REMOVAL OF...

Page 278: ...bles for the repair 04B Consuma bles Products to clean the joint face of the sump on the cylinder block the joint faces of the lower timing cover on the cyl inder block the sump the lower timing cover...

Page 279: ...sump bolts 32 N m a Refit the oil pump pinion on the oil pump chain the pinion chain assembly on the oil pump shaft a Torque tighten the oil pump pinion bolts 10 N m a Refit a new lower timing cover s...

Page 280: ...e crankshaft seal on the gearbox side see 10A Engine and cylinder block assembly Crank shaft seal gearbox end Removal Refitting page 10A 153 the drive plate see 10A Engine and cylinder block assembly...

Page 281: ...es onator Removal Refitting page 12A 28 the protection and switching unit see Protection and Switching Unit Removal Refitting 87G Engine compartment connection unit the battery disconnection unit see...

Page 282: ...mper Removal Refitting 55A Exterior protection the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels...

Page 283: ...tie bar see 19D Engine mounting Lower engine tie bar Removal Refit ting page 19D 85 a Remove the relay bearing of the front right hand wheel driveshaft Special tooling required Mot 1914 Tool for fitti...

Page 284: ...the catalytic converter upstream stay 3 a Undo the bolts of the engine oil sump a Fit a component jack to support the engine oil sump a Remove the bolts from the engine oil sump a Detach the engine o...

Page 285: ...position in order to re move the engine oil sump a Remove the engine oil sump the engine oil sump seal the oil pump II REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO 2 a Use SURFACE CLEANER see V...

Page 286: ...mables for the repair 04B Consum ables products to clean the bearing mating face on the con rod cap a Fit the tie rod of the tool Mot 1914 on the con rod body a Push the con rod upwards to release the...

Page 287: ...always to be replaced con rod cap bolts 10 03 02 10 a Fit the head of the tool Mot 1920 with the marking K9K INF on the threaded sleeve of the tool Mot 1914 a Position the lower con rod bearing shell...

Page 288: ...ition the upper con rod bearing shell so that the ends do not protrude beyond the con rod body a Lubricate the surface of the con rod bearing shell crankshaft end using new engine oil a Push the con r...

Page 289: ...engine oil sump seal a Apply SILICONE ADHESIVE SEALANT see Vehi cle Parts and consumables for the repair four beads with a diameter of 5 mm at A two drops with a diameter of 5 mm at B a Fit the engine...

Page 290: ...relay bearing of the front right hand wheel driveshaft see Front right hand driveshaft Re moval Refitting a Refit the lower engine tie bar see 19D Engine mounting Lower engine tie bar Removal Refit ti...

Page 291: ...efitting M9R 10A a The oil water heat exchanger is not sold separately in the Parts Department to replace it it is necessary to replace the oil filter unit see 10A Engine and cylinder block assembly O...

Page 292: ...a Remove the oil filter see 10A Engine and cylinder block assembly Oil filter Removal Refitting page 10A 117 II OPERATION FOR REMOVAL OF PART CONCERNED a Fit the Ms 583 on the oil water heat exchange...

Page 293: ...ip ple 49 Nm a Connect the cooling hoses to the coolant oil heat ex changer a Fit the cooling hose clips on the oil water heat ex changer using the Mot 1448 a Remove the Ms 583 from the oil water heat...

Page 294: ...Remove the oil filter 1 see 10A Engine and cyl inder block assembly Oil filter Removal Refit ting page 10A 117 a Fit the Ms 583 on the oil water heat exchanger cooling hoses 2 a Remove the clip from e...

Page 295: ...fit the new oil water heat exchanger seal the oil cooler the oil coolant heat exchanger fitting a Torque tighten the oil cooler nipple 60 Nm III FINAL OPERATION a Connect the cooling hoses to the cool...

Page 296: ...he intercooler air inlet pipe Tightening torquesm oil wa t e r h e a t exchanger bolt 39 N m oil filter holder bolt 28 N m IMPORTANT Wear latex gloves during the operation IMPORTANT Wear heat protecti...

Page 297: ...r air inlet pipe the clip 6 from the intercooler air inlet pipe a Disconnect the intercooler air inlet pipe from the tur bocharger a Move aside the intercooler air inlet pipe II OPERATION FOR REMOVAL...

Page 298: ...t new seals 10 and 11 on the oil water heat exchanger a Apply soapy water to the two seals 10 in contact with the coolant pump inlet pipe II REFITTING OPERATION FOR PART CONCERNED a Apply two drops of...

Page 299: ...AND CYLINDER BLOCK ASSEMBLY Oil coolant heat exchanger Removal Refitting K9K 10A a Fill the cooling system see 19A Cooling Cooling system Draining Refilling page 19A 16 a Refit the engine undertray th...

Page 300: ...cylinder block assembly Oil filter Removal Refitting page 10A 117 a Fit hose clamps Ms 583 1 on the cooling hoses a Separate the clips 2 on the cooling hoses using the tool Mot 1448 a Disconnect the...

Page 301: ...cooling hose clips onto the oil water heat ex changer using the tool Mot 1448 a Remove the hose clamps Ms 583 from the cooling hoses of the oil water heat exchanger a Refit the oil filter see 10A Engi...

Page 302: ...y bolts the engine undertray a Fit the tool Ms 583 onto the oil water heat ex changer cooling hoses a Remove the clips 1 from the oil water heat ex changer cooling hoses using the tool Mot 1448 a Disc...

Page 303: ...at exchanger a Torque tighten the oil water heat exchanger bolts 32 N m III FINAL OPERATION a Connect the oil water heat exchanger cooling hos es a Fit the cooling hose clips on the oil water heat ex...

Page 304: ...REFITTING I REFITTING PREPARATIONS OPERATION a Coat the threading of the oil pressure sensor with SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the repair MR 415 04B Consumables Prod...

Page 305: ...a Remove the engine undertray bolts the engine undertray Equipment required refrigerant charging station Tightening torquesm oil pressure sensor 40 Nm bracket bolt for the intermediate pipe com presso...

Page 306: ...NAL OPERATION a a Remove the blanking plugs a Lubricate the seals using air conditioning oil to make fitting easier a Connect the intermediate pipe compressor con necting pipe to the compressor a Refi...

Page 307: ...1 a Remove the intercooler air inlet pipe bolt 2 a Move the intercooler inlet air pipe to one side II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the oil pressure sensor connector 3 a Remove...

Page 308: ...s for the repair MR 415 04B Consumables Products II REFITTING OPERATION FOR PART CONCERNED a Refit the oil pressure sensor using the Mot 1495 01 a Torque tighten the oil pressure sensor 35 Nm a Connec...

Page 309: ...ctor 1 a Remove the oil pressure sensor using the Mot 1495 REFITTING I REFITTING PREPARATIONS OPERATION a Wipe any oil run off with a cloth a Always replace the oil pressure sensor II REFITTING OPERAT...

Page 310: ...sure sensor 2 REFITTING I REFITTING PREPARATION OPERATION a Coat the threading of the oil pressure sensor with SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the repair 04B Con sumabl...

Page 311: ...ie bar Removal Refitting page 19D 85 a Drain the engine see 10A Engine and cylinder block assembly Engine oil Draining Refilling page 10A 100 II OPERATION FOR REMOVAL OF PART CONCERNED a Cut the oil p...

Page 312: ...right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the engine undertray a Top up the en...

Page 313: ...lean and degrease the joint face of the engine oil pressure sensor II REFITTING OPERATION FOR PART CONCERNED a Refit the engine oil pressure sensor a Torque tighten the engine oil pressure sensor 40 N...

Page 314: ...N FOR PART CONCERNED a Disconnect the connector 1 from the oil level sen sor a Remove the oil level sensor 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the oil level sensor a Tighten t...

Page 315: ...MOVAL OPERATION FOR PART CONCERNED a Move the heat insulating material 1 away from the oil level sensor a Disconnect the connector from the oil level sensor a Remove the oil level sensor REFITTING I R...

Page 316: ...lts the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 1 for the oil level sensor from below a Remove the oil level sensor 2 from below REFITTING I REFITTING OP...

Page 317: ...s the engine undertray II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the connector 1 from the oil level sen sor a Remove the oil level sensor REFITTING I REFITTING PREPARATIONS OPERATION a Wipe...

Page 318: ...the connector 1 from the oil level sen sor a Remove the oil level sensor using a Crowfoot type end piece 2 REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit the oil level sensor a Tighten to t...

Page 319: ...L OF PART CONCERNED a Disconnect the connector 1 from the oil level sen sor a Remove the bolts 2 from the oil level sensor a Remove the oil level sensor REFITTING I REFITTING OPERATION FOR PART CONCER...

Page 320: ...10A 243 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor Removal Refitting V4Y 10A a Check the engine oil level a Adjust the engine oil level if necessary...

Page 321: ...pressure sensor Re moval Refitting page 10A 227 II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector from the oil level sensor a Remove the oil level sensor 1 REFITTING I REFITTING OP...

Page 322: ...sembly must be re moved to remove refit the oil pump see 10A En gine and cylinder block assembly Engine gearbox assembly Removal Refitting page 10A 1 a For the oil removal and refitting method see Cyl...

Page 323: ...L OF PART CONCERNED a Remove the oil splash plate bolt 1 the anti emulsion plate a Remove the oil pump bolts 2 the oil pump REFITTING I REFITTING OPERATION FOR PART CONCERNED a Position the oil pump p...

Page 324: ...pump Removal Refitting F4R 10A II FINAL OPERATION a Refit the lower cover see 10A Engine and cylinder block assembly Lower cover Removal Refit ting page 10A 180 the engine undertray the engine undert...

Page 325: ...ne undertray a Drain the engine see 10A Engine and cylinder block assembly Engine oil Draining Refilling page 10A 100 a Remove the lower cover see 10A Engine and cyl inder block assembly Lower cover R...

Page 326: ...the cylinder block 25 N m the bolt for the oil splash plate on the oil pump a Refit the oil pump strainer fitted with its new seal the oil pump strainer bolts a Tighten the oil pump strainer bolts III...

Page 327: ...Lower cover Removal Refitting page 10A 180 II REMOVAL OPERATION FOR PART CONCERNED a Remove the oil pump bolts 1 the oil pump REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the right h...

Page 328: ...bly Lower cover Removal Refitting page 10A 180 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the oil pump bolts 1 the oil pump REFITTING I REFITTING OPERATION FOR PART CONCERNED a Position the o...

Page 329: ...10A 252 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump Removal Refitting K4M 10A a Refit the engine undertray...

Page 330: ...tem see 19A Cooling Cooling system Draining Refilling page 19A 16 a Remove the cooling radiator condenser fan assembly see 19A Cooling Cooling radiator Removal Refitting page 19A 28 the front right ha...

Page 331: ...om the body a Remove the engine gearbox assembly see 10A Engine and cylinder block assembly Engine gearbox assembly Removal Refitting page 10A 1 a Fit the lifting eye on the timing end see 11A Top and...

Page 332: ...side see 10A Engine and cylinder block assembly Crank shaft seal on timing end Removal Refitting page 10A 134 the timing chain see 11A Top and front of en gine Timing chain Removal Refitting page 11A...

Page 333: ...ng eyes Removal Refitting page 11A 318 a Refit the engine and gearbox assembly see 10A En gine and cylinder block assembly Engine gearbox assembly Removal Refitting page 10A 1 the central nut of the l...

Page 334: ...on computer see 17B Petrol in jection Petrol injection computer Removal Refitting page 17B 30 the front end panel see Front end panel Remov al Refitting 42A Upper front structure the audible warning s...

Page 335: ...Refitting page 19D 51 the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft...

Page 336: ...ve the oil pump pinion bolts 2 the oil pump pinion a Move aside the oil pump chain a Remove the oil pump bolts 3 the oil pump a Remove the oil pump cover bolts 4 the oil pump cover a Remove the driven...

Page 337: ...oil pump a Torque tighten the oil pump bolts 25 N m a Fit the pinion on the oil pump chain the pinion chain assembly on the oil pump shaft a Torque tighten the oil pump pinion bolts 10 N m IV FINAL O...

Page 338: ...see Radiator mounting cross member Removal Refitting 41A Front lower structure the front bumper see Front bumper Removal Refitting 55A Exterior protection the front wheel arch liners see Front wheel...

Page 339: ...efitting page 10A 227 a In place of the oil pressure sensor fit the Mot 836 05 with suitable adapters using the Mot 1495 01 or a 22 mm long socket a Engine End pieces M4R Mot 1658 F F4R B F K9K E C F...

Page 340: ...t the vehicle a Monitor the engine oil pressure as the oil tempera ture rises approximately 80 C or the first time the engine cooling fan is activated it should not be less than the pressure at idle s...

Page 341: ...m 2 5 bar 6000 rpm 5 65 bar a Switch off the engine a Connect the air conditioning compressor connec tors a Remove the Mot 836 05 with the end pieces a Refit the oil pressure sensor see 10A Engine and...

Page 342: ...e Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the alternator see 16A Sta...

Page 343: ...olt on the air conditioning compressor connector support a Tighten the bolt on the air conditioning compressor connector support a Connect the air conditioning compressor connec tors a Refit the coola...

Page 344: ...ghts see Headlight Removal Refit ting 80B Headlights the front end panel see Front end panel Remov al Refitting 42A Upper front structure a Remove the power assisted steering pump see Power assisted s...

Page 345: ...end panel see Front end panel Remov al Refitting 42A Upper front structure the headlights see Headlight Removal Refit ting 80B Headlights the front bumper see Front bumper Removal Refitting 55A Exteri...

Page 346: ...ories belt Removal Refitting page 11A 13 the air conditioning compressor see Compressor Removal Refitting MR 415 62A Air condition ing the alternator see 16A Starting Charging Al ternator Removal Refi...

Page 347: ...right hand wheel see Wheel Removal Refitting MR 415 35A Wheels and tyres a Connect the battery see Battery Removal Refit ting MR 415 80A Battery a Perform the following operations fill the cooling sys...

Page 348: ...5A Exterior protection the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the engine undertray bolts the engine undertray the front bumper see Front bu...

Page 349: ...ont bumper see Front bumper Removal Refitting MR 416 55A Exterior protection the engine undertray the engine undertray bolts the accessories belt see 11A Top and front of engine Accessories belt Remov...

Page 350: ...Wheels and tyres the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the accessories belt see 11A Top and front of engine Accessories belt Remo...

Page 351: ...ed steering pump Removal Refitting 36B Power assisted steering the compressor see Compressor Removal Re fitting 62A Air conditioning the accessories belt see 11A Top and front of engine Accessories be...

Page 352: ...ng page 19D 51 the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1 II...

Page 353: ...ng V9X 10A the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the e...

Page 354: ...and driveshaft Removal Refitting 29A Driveshafts the radiator mounting cross member see Radiator mounting cross member Removal Refitting 41A Front lower structure the front axle subframe see Front axl...

Page 355: ...adiator mounting cross member see Radiator mounting cross member Removal Refitting 41A Front lower structure the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 29A...

Page 356: ...shafts the radiator mounting cross member see Radiator mounting cross member Removal Refitting 41A Front lower structure the front axle subframe see Front axle subframe Removal Refitting 31A Front axl...

Page 357: ...e see Front axle subframe Removal Refitting 31A Front axle compo nents the radiator mounting cross member see Radiator mounting cross member Removal Refitting 41A Front lower structure the front right...

Page 358: ...fitting 29A Driveshafts the front left hand wheel driveshaft see Front left hand driveshaft Removal Refitting 29A Driveshafts the radiator mounting cross member see Radiator mounting cross member Remo...

Page 359: ...moval Refitting 41A Front lower structure the front left hand wheel driveshaft see Front left hand driveshaft Removal Refitting 29A Driveshafts the front right hand wheel driveshaft see Front right ha...

Page 360: ...shaft Removal Refitting 29A Driveshafts the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the differential output seals see Differential out put s...

Page 361: ...ferential output seals see Differential out put seal Removal Refitting 21A Manual gear box the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the f...

Page 362: ...ont right hand driveshaft Removal Refitting 29A Driveshafts the differential output seals see Differential out put seal Removal Refitting the radiator mounting cross member see Radiator mounting cross...

Page 363: ...itting 41A Front lower structure the differential output seals see Differential out put seal Removal Refitting the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 2...

Page 364: ...al Refit ting 80B Headlights the front end panel see Front end panel Remov al Refitting 42A Upper front structure the particle filter see 19B Exhaust Particle fil ter Removal Refitting page 19B 71 a D...

Page 365: ...arts and consumables for the repair 04B Consuma bles Products to clean and degrease the drive plate the drive plate bearing face on the crankshaft the drive plate thread holes on the crankshaft a Syst...

Page 366: ...driveshaft see Front left hand driveshaft Removal Refitting 29A Drive shafts the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the front wheel arch lin...

Page 367: ...Re moval Refitting page 19D 85 the front wheels see Wheel Removal Refitting 35A Wheels and tyres the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the f...

Page 368: ...RNED a Fit the Mot 582 01 1 on the starter upper bolt a Remove the drive plate bolts the Mot 582 01 1 the drive plate REFITTING I REFITTING PREPARATION OPERATION a Visually inspect the condition of th...

Page 369: ...driveshaft Removal Refitting 29A Driveshafts the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels a...

Page 370: ...Cooling Cooling radiator Removal Refitting page 19A 28 the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the front left hand driveshaft see Front left h...

Page 371: ...e mounting to sepa rate the engine from the body a Remove the engine gearbox assembly see 10A Engine and cylinder block assembly Engine gearbox assembly Removal Refitting page 10A 1 a Fit the lifting...

Page 372: ...s to be replaced Drive plate bolt 12 07 02 24 a Visually inspect the condition of the crown wheel and the drive plate a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma...

Page 373: ...sensors Removal Refitting page 17B 17 the inlet manifold see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 the radiator cross member mounting see Radiator cross member mounting Rem...

Page 374: ...ting 80B Headlights the front bumper see Front bumper Removal Refitting 55A Exterior protection the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the fr...

Page 375: ...19A 28 assembly the electric coolant pump of the exhaust cooler see 19A Cooling Electric coolant pump Re moval Refitting page 19A 159 the additional radiator see Additional radiator Removal Refitting...

Page 376: ...mbly Removal Refitting page 10A 1 a Separate the gearbox from the engine see Auto matic gearbox Removal Refitting 23A Auto matic transmission a Position the engine on the component support see Engine...

Page 377: ...ting page 19D 1 the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the intermediate pipe compressor connecting pipe see Compressor intermediate pip...

Page 378: ...he battery see Battery Removal Refit ting 80A Battery a Refill and bleed the cooling system see 19A Cooling Cooling system Draining Refilling page 19A 16 the air conditioning circuit using a refrigera...

Page 379: ...ressions cylinder by cyl inder III FINAL OPERATION a Disconnect the petrol compression gauge a Refit the spark plugs see 17A Ignition Plugs Re moval Refitting page 17A 10 the ignition coils see 17A Ig...

Page 380: ...2 1 in place of one of the removed plugs a Moderately tighten the hose end piece Mot 1772 1 using an open jawed spanner a Screw the diesel compression gauge hose end piece adapter Mot 1772 2 onto the...

Page 381: ...ve to release all of the pres sure in the diesel compression gauge a Make progress with the diagram sheet a Take the same measurement for the other cylinders a Compare the results obtained III FINAL O...

Page 382: ...he cylinder compressions cylinder by cyl inder III FINAL OPERATION a Disconnect the petrol compression gauge a Refit the spark plugs see 17A Ignition Plugs Re moval Refitting page 17A 10 the ignition...

Page 383: ...open jawed spanner to moderately tighten the hose end piece Mot 1592 the adapter of the diesel compression gauge on the Mot 1592 a Moderately tighten the unions of the diesel com pression gauge using...

Page 384: ...cylin ders a Check that the cylinder compression values are all approximately equal a Run command VP037 Stop inhibit fuel supply a Disconnect the self contained starter a Undo the diesel compression...

Page 385: ...lly in order to open the throttle valve during the compression measure ments III FINAL OPERATION a Disconnect the petrol compression gauge a Refit the spark plugs see 17A Ignition Plugs Re moval Refit...

Page 386: ...elease the pressure a Close the discharge valve 2 of the petrol compres sion gauge a Connect a self contained starter available from the Garage equipment catalogue a Switch on the forced after ignitio...

Page 387: ...ve Check and replace the defective parts see Valve Removal Refit ting 3 if the pressure at compression end remains low on two or more cylinders that are next to one anoth er then the cylinder head gas...

Page 388: ...318 the heater plugs see 13C Preheating Heater plugs Removal Refitting page 13C 3 a Fit the hose end piece 1 in place of one of the re moved plugs a Moderately tighten the hose end piece 1 using an op...

Page 389: ...de a Connect the Diagnostic tool a In the Diagnostic tool select the repair mode select the programming mode Run command SC031 OPERATIONAL FAULT FINDING OF THE CYLINDERS 2 Manual mode a Press the vehi...

Page 390: ...r a In the Diagnostic tool select the repair mode select other configurations mode Run command VP037 STOP FUEL SUPPLY IN HIBITION a Press the vehicle start button to start the engine a Remove the self...

Page 391: ...front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection a Remove the right hand side member tie rod bolts 1 a Move aside the right hand side member tie...

Page 392: ...and push on the key at the same time until the tensioning roller locks a Remove the accessories belt a Turn the tensioning roller slightly in a clockwise di rection a Remove the 3 mm Allen key a Turn...

Page 393: ...er bolt 44 N m a Refit the fixed roller protector the new tensioning roller the tensioning roller bolts a Torque tighten the tensioning roller bolt 25 N m a Refit the new accessories belt a Remove the...

Page 394: ...hand side member tie rod bolts 44 N m a Refit the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the front right hand wheel see Wheel Removal R...

Page 395: ...h liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection II REMOVAL OPERATION FOR PART CONCERNED a Turn the tensioning roller 1 clockwise using a 16 mm spanner a Remove the...

Page 396: ...FOR PART CONCERNED a Refit the new fixed roller the new fixed roller bolt the new tensioning roller the new tensioning roller bolt a Torque tighten the fixed roller bolt 25 Nm the tensioning roller bo...

Page 397: ...ng MR 416 55A Exterior protection II REMOVAL OPERATION FOR PART CONCERNED a Turn the accessories belt tensioning roller clockwise using a 14 mm spanner a Lock the tensioning roller using a 6 mm Allen...

Page 398: ...essories belt tensioning roller 10 10 01 04 parts always to be replaced Accessories ten sioning roller bolt 10 10 01 09 Replacing the auto tensioner a a Loosen the tensioning roller bolt using the Mot...

Page 399: ...t a Retrieve the 6 mm Allen key and gradually release the tensioning roller using a 14 mm spanner a Rotate the crankshaft clockwise twice to balance the accessories belt tension on every pulley III FI...

Page 400: ...sories belt tensioning roller bolt 2 the accessories belt tensioning roller REFITTING I REFITTING PREPARATIONS OPERATION a a Clean the accessories pulley V grooves a parts always to be replaced Access...

Page 401: ...ng K9K 11A a Turn the crankshaft twice III FINAL OPERATION a Refit the front right hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front right han...

Page 402: ...liner Removal Refitting 55A Ex terior protection the engine undertray bolts the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED a Turn the accessories belt tensioning roller clockwise usin...

Page 403: ...fixed roller a Tighten to torque the tensioning roller bolts 25 N m the fixed roller bolt 25 N m a Turn the accessories belt tensioning roller clockwise using a 13 mm spanner a Lock the tensioning ro...

Page 404: ...post lift see Vehicle Towing and lifting 02A Lifting equipment a Remove the engine undertray bolts the engine undertray the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the...

Page 405: ...lacken the tensioning roller bolt 3 a Tighten the bolt 4 on the power assisted steering belt tensioning system to loosen the accessories belt 2 Alternator and air conditioning compressor accessories b...

Page 406: ...ft accessories V pulley using a brush to get rid of any deposit a parts always to be replaced Accessories belt 10 10 01 03 a parts always to be replaced Accessories belt tensioning roller 10 10 01 04...

Page 407: ...tensioner using a 6 mm Allen key a Refit a new accessories belt a Gradually release the tensioning roller using a 14 mm offset wrench and remove the 6 mm Allen key III FINAL OPERATION a Turn the crank...

Page 408: ...bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitt...

Page 409: ...Remove the tensioning roller bolt 5 the tensioning roller a Remove the guards 6 from the fixed rollers the fixed roller bolts the fixed rollers REFITTING I REFITTING PREPARATION OPERATION a parts alwa...

Page 410: ...tly fitted in the accessories pulley V grooves III FINAL OPERATION a Fit the power assisted steering pipe a Refit the power assisted steering pipe nut the power assisted steering pipe bolt a Refit the...

Page 411: ...efitting MR 416 55 Exterior protection the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the engine undertray bolts the engine undertray II OPERATION...

Page 412: ...y bolt locking the engine flywheel using a screwdriver a Torque tighten the crankshaft accessories pulley bolt 40 Nm 110 10 III FINAL OPERATION a Refit the engine undertray the engine undertray bolts...

Page 413: ...of the Mot 1789 on the cylinder block a Undo the crankshaft accessories pulley bolt 3 the bolt of the Mot 1789 on the cylinder block a Remove the Mot 1789 the crankshaft accessories pulley bolt the cr...

Page 414: ...ley bolts a Torque and angle tighten the crankshaft accesso ries pulley bolt 30 Nm 60 a Loosen the bolt of the Mot 1789 on the cylinder block a Remove the Mot 1789 III FINAL OPERATION a Refit the acce...

Page 415: ...nd wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 II O...

Page 416: ...haft accessories pulley bolt a Position the Mot 1770 a Torque tighten the crankshaft accessories pulley bolt 50 Nm 85 6 III FINAL OPERATION a Refit the accessories belt see 11A Top and front of engine...

Page 417: ...ay the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 a Unclip the heater matrix hose from the lifting eye a Unclip the gearbox breather pipe from the...

Page 418: ...move the plugs from the camshaft ends with a screwdriv er the TDC setting pin plug 5 a Position the camshaft grooves 6 almost horizontal ly and offset towards the bottom turning the crank shaft in the...

Page 419: ...PART CONCERNED a Remove the crankshaft accessories pulley bolt 9 the crankshaft accessories pulley REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Crankshaft acces sories pu...

Page 420: ...engine wiring connector the breather pipe on the gearbox a Clip the heater matrix hose onto the lifting eye a Place a drop of SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the re pai...

Page 421: ...TION FOR REMOVAL OF PART CONCERNED a Remove the crankshaft accessories pulley bolt the crankshaft accessories pulley 1 REFITTING I REFITTING PREPARATION OPERATION a In case of reuse clean the cranksha...

Page 422: ...ewdriver from the starter hole a Refit the accessories belts see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the front right hand wheel arch liner see Front wheel arch l...

Page 423: ...tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Ref...

Page 424: ...ue the crankshaft accessories pul ley bolt 50 Nm 85 6 III FINAL OPERATION a Refit the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the right hand sus...

Page 425: ...the engine undertray bolts the engine undertray the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 II OPERATION FOR REMOVAL OF PART CONCERNED a Lock t...

Page 426: ...t 4 with a spacer 5 a Turn the crankshaft clockwise timing end using the old bolt of the crankshaft accessories pulley until the collet of the crankshaft timing pinion 6 is almost vertical and facing...

Page 427: ...er block a Apply a drop of SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the re pair 04B Consumables Products to the thread of the TDC setting pin plug a Torque tighten the TDC setti...

Page 428: ...ve the engine tie bar bolt 1 on the engine tie bar mounting the engine tie bar bolt 2 on the subframe the lower linkage Special tooling required Mot 1054 TDC setting pin Mot 1496 Camshaft timing tool...

Page 429: ...shaft accessories pulley Remov al Refitting page 11A 33 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the breather...

Page 430: ...timing cover the lower timing cover bolts 8 the lower timing cover II OPERATION FOR REMOVAL OF PART CONCERNED 1 SETTING THE TIMING a Refit the crankshaft accessories pulley the crankshaft accessories...

Page 431: ...4 and rotate the engine slightly clockwise timing end until the set ting point is reached a At the setting point the camshaft grooves must be horizontal and offset below the centre line a Position the...

Page 432: ...h the camshaft pulleys a Torque tighten the toothed sprocket nuts 80 Nm a Undo the old inlet camshaft pulley nut 14 by one turn the old exhaust camshaft pulley nut 15 by one turn a Remove the tool Mot...

Page 433: ...ller 10 02 04 05 the exhaust harness seal II REFITTING OPERATION FOR PART CONCERNED 1 Adjusting the timing a Check that camshaft setting tool Mot 1496 is still in place Position of the TDC pin at the...

Page 434: ...ler fitted with its spacer the fixed roller bolt a Torque tighten the fixed roller bolt 50 Nm 104703 WARNING Always degrease the end of the crankshaft timing end the timing sprocket bore and contact s...

Page 435: ...e camshaft pulleys a Tighten to torque the toothed sprocket nuts 80 Nm the old inlet camshaft pulley nut 30 Nm the old exhaust camshaft pulley nut 30 Nm a Remove the tool Mot 1801 fitted with Mot 1509...

Page 436: ...re the end of the two turns insert the TDC pin Mot 1054 then move the crankshaft to its setting point a Fit the camshaft setting tool Mot 1496 without forcing it b Checking the tension a After the eng...

Page 437: ...pulley nut 30 Nm a Remove the bolt 20 on the tool Mot 1496 the camshaft setting tool Mot 1496 a Angle tighten the inlet camshaft pulley nut 86 6 the exhaust camshaft pulley nut 86 6 a Remove the Mot...

Page 438: ...st bracket nuts a Refit the lower linkage the engine tie bar bolt on the subframe the engine tie bar bolt on the engine tie bar mount ing a Tighten to torque the engine tie bar bolt on the subframe 11...

Page 439: ...A 13 the engine undertray bolts the engine undertray the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the air filter...

Page 440: ...11A 62 TOP AND FRONT OF ENGINE Timing belt Removal Refitting K9K 11A 2 Second timing cover assembly type 135495 135494 135493 135492...

Page 441: ...pressing on the clips 8 the lower timing cover 9 by pressing on the clips 10 3 Both continued in the same way for removal a Remove the bolts 11 from the right hand suspend ed engine mounting support a...

Page 442: ...he cam shaft pulley hub almost opposite the hole in the cyl inder head a Screw tool Mot 1489 15 into the cylinder block a Turn the crankshaft clockwise timing end smoothly until the crankshaft comes i...

Page 443: ...ler bolt the timing belt tensioning roller REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Timing belt 10 02 04 02 a parts always to be replaced Timing belt tension ing rolle...

Page 444: ...ool Mot 1430 20 in the holes of the camshaft pulley hub and of the cylinder head using an 18 mm offset wrench if necessary a Check that the mark 21 on the high pressure pump is offset by one tooth to...

Page 445: ...pressure pump pulley a Bring the timing belt tensioning roller adjustable in dex 25 opposite the lug 26 using a 6 mm Allen key turning it anti clockwise a Tighten the timing belt tensioning roller bol...

Page 446: ...OF ENGINE Timing belt Removal Refitting K9K 11A a Check that the camshaft pulley hub bolts are not ful ly up against the camshaft pulley wheel a Tighten the camshaft pulley hub bolts a Remove the Mot...

Page 447: ...pulley hub hole is opposite the cylinder head hole a Screw tool Mot 1489 into the cylinder block a Turn the crankshaft clockwise timing end smoothly until the crankshaft comes in to contact with the t...

Page 448: ...a Check that the crankshaft timing sprocket collet 29 is positioned vertically at the top 109045 Note After the two turns the adjustable index of the tensioning roller may be in two different position...

Page 449: ...index turning the key anti clockwise to the mid dle of the timing window Second position of the timing tensioning roller adjustable index a Undo the timing tension wheel bolt by up to one turn holding...

Page 450: ...iming belt refitting operation a Check that the timing tension wheel adjustable index is correctly positioned in the middle of the timing win dow otherwise repeat the timing belt tension opera tion a...

Page 451: ...ed engine mounting support bolts a Tighten the right hand suspended engine mounting support bolts a Refit the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the rig...

Page 452: ...engine mounting bolt 1 from the subframe the rear suspended engine mounting bolt 2 from the rear suspended engine mounting support Special tooling required Mot 799 01 Timing gear wheel immobil iser Mo...

Page 453: ...mounting Removal Refitting page 19D 51 the upper timing cover bolts the upper timing cover nuts the upper timing cover 3 the lower timing cover bolts 4 the lower timing cover II OPERATION FOR REMOVAL...

Page 454: ...ch has a crankshaft timing sprocket without a collet and which does not require the exhaust camshaft sprocket or camshaft dephaser to be loosened 1 Adjusting the timing a a Set the camshaft grooves ho...

Page 455: ...aft dephaser gear and the rocker cover 2 Refitting a Refit a new timing tensioning roller by positioning the lug of the timing tensioning roller in the groove 11 a Screw on the timing tensioning rolle...

Page 456: ...ock the lower timing cover a Tighten to torque the lower timing cover bolts 12 N m a Refit a new crankshaft accessories pulley a Use a screwdriver 18 to check that the flywheel does not turn clockwise...

Page 457: ...ser screw the tool Mot 1489 into the cylinder block a Move the crankshaft slowly and smoothly until it comes into contact with the tool Mot 1489 a Remove the tool Mot 1489 from the cylinder block a Ch...

Page 458: ...notch 24 REFITTING PROCEDURE 2 I REFITTING PREPARATION OPERATION a parts always to be replaced Timing belt 10 02 04 02 parts always to be replaced Timing belt tension ing roller 10 02 04 04 parts alwa...

Page 459: ...Mot 1496 if necessary Note If the stud loosens with the nut see 11A Top and front of engine Camshaft Removal Refitting page 11A 245 Technical Note 3887A 11A Top and front of engine WARNING Always deg...

Page 460: ...t 1750 a Refit the camshaft dephaser see 11A Top and front of engine Camshaft dephaser Removal Refit ting page 11A 275 the crankshaft timing sprocket a Refit the tool Mot 1489 on the cylinder block a...

Page 461: ...oint ing upwards the camshaft dephaser mark 31 vertically and pointing upwards a Make a mark 32 with a pencil between the cam shaft dephaser gear and the rocker cover 2 Refitting a Refit a new timing...

Page 462: ...a Torque tighten the timing fixed roller bolt 50 N m 3 Timing belt tension a Position the adjustable index 36 opposite the mark 37 by turning the eccentric 38 clockwise using an Allen key a Torque ti...

Page 463: ...t 100 N m a Refit the camshaft dephaser plug a Remove the timing flap from the lower timing cover the lifting eye bolt from the Mot 1496 the Mot 1496 fitted with the Mot 1750 the tool Mot 1489 from th...

Page 464: ...5 Checking the timing a Ensure that the index and the notch on the timing tensioning roller are in the correct position before checking the timing a Screw tool Mot 1489 into the cylinder block a Move...

Page 465: ...the upper timing cover bolts 46 N m the upper timing cover nuts 46 N m a Refit the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting p...

Page 466: ...Mot 1766 Top dead centre locating pin Mot 1769 Camshaft adjusting tool Tightening torquesm timing chain guide bolts initial torque 5 N m timing chain guide bolts 25 N m bolt of the timing chain tensio...

Page 467: ...pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the crankshaft seal on the timing side see 10A Engine and cylinder block assembly Crank shaft seal on...

Page 468: ...emove the timing cover a Remove the tool Mot 1431 a Align the groove 5 on the crankshaft with the hole 6 on the cylinder block pistons at mid stroke a Remove the top dead centre setting plug a In plac...

Page 469: ...er piston 9 in the com pressed position using a 3 mm Allen key 11 a Remove the hydraulic tensioner bolts 12 the timing hydraulic tensioner 9 the chain tensioner guide bolt 13 the timing chain tensione...

Page 470: ...asher on the camshaft exhaust side Timing sprocket bolt on the camshaft exhaust side Timing chain guide Timing chain guide bolt Timing chain tensioner guide Timing chain tensioner guide bolt II REFITT...

Page 471: ...timing chain on the sprocket 23 align the mark on the sprocket with the copper chain links the new timing sprocket 24 on the chain align the mark on the sprocket with the copper chain links a Refit t...

Page 472: ...the bolt of the timing chain ten sioner guide 25 N m 29 a Fit the new timing hydraulic tensioner 30 with its locking pin 32 a Torque tighten the timing hydraulic tensioner bolts 10 N m 31 a Remove the...

Page 473: ...amshaft without forcing it if necessary start the previous operations again a Fit the bolt 38 M6 50 mm long onto the tool a Torque tighten the timing sprocket bolts on the exhaust side of the camshaft...

Page 474: ...ad of 11 2 mm for a length of 10 to 15 mm on the points 1 2 3 4 5 6 1 bead of 3 5 1 mm on the outline of the cylinder head and of the cyl inder block from 6 to 1 on the edge 7 a Refit the timing cover...

Page 475: ...ting reinforcement 39 a Finger tighten the reinforcement bolts in order 1 to 4 until they make contact a Torque tighten the engine mounting reinforce ment bolts 25 N m from 1 to 4 III FINAL OPERATION...

Page 476: ...nd front of engine Accessories belt Removal Refit ting page 11A 13 a Remove the engine from the component support see Engine support equipment Use a Refit the engine gearbox assembly see 10A En gine a...

Page 477: ...ain tension ers 9 N m bolts of the inlet cam shaft dephasers 103 N m exhaust camshaft sprocket bolts 123 N m bolts of the primary chain shoe 21 N m bolt of the new primary timing chain tensioner guide...

Page 478: ...emoval Refitting page 11A 139 the camshaft position sensors see Camshaft po sition sensor Removal Refitting the alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1 a Fit the...

Page 479: ...V4Y and 713 11A II REMOVING THE TIMING CHAIN a Remove the camshaft dephaser cover bolts 2 the camshaft dephaser covers a Remove the timing cover bolts 3 the timing cover a Remove the timing cover usi...

Page 480: ...a 4 mm Allen key or an iron wire in the housing a Push on the chain guide until the piston is complete ly depressed a Keep pressing on the chain guide a Lock the tensioner by locking the lever using...

Page 481: ...ary chain shoe the primary chain the crankshaft sprocket a Compress the hydraulic tensioners of the secondary chains by pressing at 8 a Fit a spatula 9 between the hydraulic tensioner of the secondary...

Page 482: ...ring no 1 the bolts of the dephasers of the inlet camshafts the bolts of the exhaust pulleys a Remove the camshaft sprocket secondary chain assem blies taking care not to remove the iron wires of the...

Page 483: ...ephaser covers a Parts always to be replaced primary timing chain secondary timing chains primary chain hydraulic tensioner bolts of the primary chain hydraulic tensioner secondary chain hydraulic ten...

Page 484: ...Refitting V4Y and 713 11A a Check that the spigots of the inlet camshaft 14 and exhaust camshaft 15 are facing upwards and di rectly in line with the cylinders 16 a Refit the new hydraulic tensioners...

Page 485: ...fitting V4Y and 713 11A Fitting the secondary chain for the front row a Fit the line 17 of the inlet dephaser sprocket opposite the painted link 18 of the chain the two lines 19 of the exhaust sprocke...

Page 486: ...chain a Refit the camshaft sprockets secondary chain as semblies taking care not to unlock the secondary timing chain tensioners and using a spatula a Torque tighten the bolts of the new secondary ti...

Page 487: ...ioner guide 16 N m the new primary chain upper guide bolts 8 N m the new primary chain hydraulic tensioner bolts 9 N m a Unlock the tensioner of the primary timing chain a Perform two crankshaft turns...

Page 488: ...f 2 to 3 mm to camshaft bearing no 1 a Refit the no 1 camshaft bearings a Tighten to torque the upper bolts of the camshaft bearing no 1 initial torque 2 N m 26 the upper bolts of camshaft bearing no...

Page 489: ...3 6 mm to the timing cover a Refit the timing cover a Tighten to torque and in order the M6 bolts on the timing cover 13 Nm the M8 bolts on the timing cover 29 N m a Refit the new dephaser cover seals...

Page 490: ...ignition coils see 17A Ignition Coils Re moval Refitting page 17A 1 the intake distributor see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 a Refit the right hand suspended mounti...

Page 491: ...nkshaft seal on the timing side see 10A Engine and cylinder block assembly Crank shaft seal on timing end Removal Refitting page 10A 134 the alternator see 16A Starting Charging Al ternator Removal Re...

Page 492: ...pport from the back row upper timing cover a Loosen the air inlet pipe clips 5 of the damper valve a Remove the air inlet pipe of the damper valve a Remove the bolts 6 from the coolant pipe at the out...

Page 493: ...ect the turbocharger pressure sensor con nector 9 a Loosen the clip 10 for the intercooler air outlet pipe on the front row upper timing cover a Disconnect the intercooler air outlet pipe from the fro...

Page 494: ...using a indelible pencil a Align the previously made line with the bolt 15 of the oil pump chain tensioner a Remove the Top Dead Centre TDC pin plug 16 a Screw the Top Dead Centre TDC timing pin Mot 1...

Page 495: ...ulic tensioner piston a Maintain pressure on the back row tensioner guide a Lock the back row timing chain hydraulic tensioner using a 3 mm Allen key 20 a Remove the bolts 21 from the back row timing...

Page 496: ...ocket the washer 25 from the back row timing chain sprocket the timing chain sprocket timing chain assembly for the back row 26 2 Removal of the oil pump chain a Turn the oil pump chain tensioner in t...

Page 497: ...in order to compress the hydraulic tensioner piston a Maintain the pressure on the front row timing chain tensioner guide a Lock the front row timing chain hydraulic tensioner using a 3 mm Allen key...

Page 498: ...ANING AGENT FOR JOINT FACES see Vehicle Parts and consumables for the repair 04B Consumables Products clean the joint faces of the timing covers and the cylinder block a Remove the residue using a pla...

Page 499: ...on for the front row is aligned with the core plug 42 on the front row cylinder head the groove 43 fitted horizontally big offset 44 upwards a Fit a new front row timing sprocket timing chain as sembl...

Page 500: ...f the tool Mot 1880 into the groove on the camshaft without forcing it if neces sary start the previous operations again a Refit a bolt to the upper timing cover of the front row in order to secure th...

Page 501: ...sioner bolt a Remove the locking pin from the new oil pump chain tensioner 3 Refitting the back row timing chain a Check that the mark 55 on the free play take up pinion is aligned with the centring p...

Page 502: ...a Remove the locking pin from the new hydraulic ten sioner a Position the Mot 1880 a Fit the tool Mot 1880 using a bolt 63 M8x125 ap proximately 82 mm in length a Torque and angle tighten the bolts f...

Page 503: ...lower timing cover seal a Apply drops of SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the re pair 04B Consumables Products at 64 on the new the lower timing cover seal a Fit the lo...

Page 504: ...move the engine from the component support see Engine support equipment Use a Refit the engine gearbox assembly see 10A En gine and cylinder block assembly Engine gear box assembly Removal Refitting p...

Page 505: ...fitting page 11A 13 a Disconnect the wiring 1 from the camshaft dephaser solenoid valve Special tooling required Mot 919 02 Flywheel locking tool Mot 1716 Removes housing with sili cone seals Tighteni...

Page 506: ...der block a Remove the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the crankshaft seal on the timing side see 10A Engine a...

Page 507: ...does not cover the timing sprocket mark onto the crankshaft a Remove the tool Mot 919 02 a With a smooth action turn the crankshaft clockwise timing end so that marks 7 of the camshaft sprockets are...

Page 508: ...e the timing chain tensioner a Put a metal rod 10 into the tensioner to keep the chain loose a Remove the timing chain tensioner bolts 11 the timing chain tensioner 12 a Remove the bolt 13 of the timi...

Page 509: ...REFITTING PREPARATION OPERATION a a Clean the joint faces of the timing cover using SU PER CLEANING AGENT FOR JOINT FACES see Vehicle Parts and consumables for the repair 04B Consumables Products a R...

Page 510: ...always to be replaced the crankshaft accessories pulley bolt the timing chain tensioner pad the timing chain tensioner the timing chain the crankshaft seal on the timing side the timing chain guide II...

Page 511: ...133 TOP AND FRONT OF ENGINE Timing chain Removal Refitting M4R 11A a Fit the new timing chain 20 so that the marks on the timing chain 21 are aligned with the marks on each of the sprockets 115875 116...

Page 512: ...ew timing chain guide 22 the timing chain guide bolts 23 a Torque tighten the timing chain guide bolts 25 N m a Refit the new timing chain tensioner pad 24 the bolts 25 of the timing chain tensioner p...

Page 513: ...the timing chain tensioner bolts 10 N m a Remove the metal rod 28 in order to release the timing chain tensioner a Tighten the old crankshaft accessories pulley bolt fit ted with a spacer which does n...

Page 514: ...plate using the tool Mot 919 02 a Remove the old crankshaft pulley bolt and spacer a Remove the tool Mot 919 02 a a Apply a bead of SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the...

Page 515: ...oval Refitting page 10A 134 a Immobilise the flywheel or the drive plate using the tool Mot 919 02 a Refit the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pull...

Page 516: ...nect the manual gearbox to the engine see Manual gearbox Removal Refitting 21A Man ual gearbox a Refit the engine and gearbox assembly see 10A Engine and cylinder block assembly En gine gearbox assemb...

Page 517: ...the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the right hand suspended engine mounting see 19D Engine mounting Right han...

Page 518: ...n the gearbox side the gearbox side lifting eye II REMOVAL OPERATION FOR PART CONCERNED a Remove the rocker cover bolts a Remove the rocker cover centring devices using a roll pin punch and a hammer t...

Page 519: ...REFITTING I REFITTING PREPARATIONS OPERATION a Use SUPER CLEANING AGENT FOR JOINT FAC ES see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products to clean and degrease the join...

Page 520: ...ifting eye bolts a Tighten the gearbox side lifting eye bolts a Clip the injector wiring on the gearbox side lifting eye the throttle valve wiring on the gearbox side lifting eye a Remove the blanking...

Page 521: ...sories belt Removal Refitting page 11A 13 the front right hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front right hand wheel see Wheel Removal...

Page 522: ...s Re moval Refitting page 17A 10 a Remove the bolt 1 from the retaining bracket on the injec tion ignition wiring connectors the retaining bracket 2 from the injection ignition wiring connectors a Rem...

Page 523: ...ION a Refit the oil vapour rebreathing valve with a new seal a Torque tighten the oil vapour rebreathing valve 2 5 Nm a Refit the retaining bracket on the injection ignition wiring connectors the reta...

Page 524: ...oler outlet air pipe from the damper valve a Move the intercooler outlet air pipe away from the damper valve a Disconnect the damper valve connector 2 the connector 3 from the camshaft position sen so...

Page 525: ...intercooler air inlet pipe clip 7 a Disconnect the intercooler air inlet pipe from the in tercooler a Remove the intercooler air inlet pipe a Unclip 8 the cover from the injector rail protector a Remo...

Page 526: ...t bolts 13 the rail protector cover bracket the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 the right hand suspended engine mounting see 19D Engine mounting Right han...

Page 527: ...0 mm long a Always replace the rocker cover seal If replacing the rocker cover a Remove the camshaft position sensor see 13B Diesel injection Camshaft position sensor Re moval Refitting page 13B 42 a...

Page 528: ...nect the oil vapour recirculation pipe onto the rocker cover a Refit the injector rail protector cover the injector rail protector cover nut the injector rail protector cover bolt a Tighten the inject...

Page 529: ...ts the engine undertray the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft...

Page 530: ...e the rocker cover bolts a Detach the rocker cover using a screwdriver a Remove the rocker cover REFITTING I REFITTING PREPARATION OPERATION a Always replace the camshaft sensor seal the camshaft deph...

Page 531: ...a stipple roller on the joint face of the rocker cover until the joint face is completely coated a Use a cloth to remove any RESIN ADHESIVE in the rocker cover bearings 5 WARNING Do not scrape the joi...

Page 532: ...nsor bolt 10 N m a Connect the camshaft dephaser solenoid valve con nector a Refit every camshaft seal see 11A Top and front of engine Camshaft seal timing end Removal Refitting page 11A 287 the camsh...

Page 533: ...d front of en gine Oil decanter Removal Refitting page 11A 307 the coils see 17A Ignition Coils Removal Re fitting page 17A 1 the throttle valve see 12A Fuel mixture Throttle valve Removal Refitting p...

Page 534: ...10A Engine and cylinder block assembly Crank shaft seal on timing end Removal Refitting page 10A 134 the timing chain see 11A Top and front of en gine Timing chain Removal Refitting page 11A 88 a Remo...

Page 535: ...oval Refit ting page 13B 161 the diesel injectors see 13B Diesel injection Diesel injector Removal Refitting page 13B 229 a Remove the bolts 1 and 2 of the fuel collector out let pipe of the cylinder...

Page 536: ...o guide the rocker cov er a Position the groove on the exhaust side of the camshaft 9 horizontally large clearance 10 facing upwards the groove on the inlet side of the camshaft 11 facing towards the...

Page 537: ...pipe of the cylinder head a Tighten the bolts of the fuel collector outlet pipe of the cylinder head a Refit the diesel injectors see 13B Diesel injection Diesel injector Removal Refitting page 13B 2...

Page 538: ...pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 a Remove the flywheel locking tool Mot 1431 a Refit the coolant pump see 19A Cooling Coolant pump Re...

Page 539: ...1 of the rocker cover the fuel pipes 2 a Disconnect the oil vapour rebreathing pipe 3 from the rocker covers the fuel supply union 4 the camshaft position sensor connector a Remove the fuel pipe suppo...

Page 540: ...union the oil vapour rebreathing pipe on the rocker cov ers a Clip the fuel pipes the electrical wiring on the rocker cover a Refit the ignition coils see 17A Ignition Coils Re moval Refitting page 17...

Page 541: ...11A 163 TOP AND FRONT OF ENGINE Rocker cover Removal Refitting V4Y 11A the inlet manifold see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 the engine cover...

Page 542: ...ge 16A 31 the timing chain see 11A Top and front of en gine Timing chain Removal Refitting page 11A 88 the timing sprockets see Timing sprocket Re moval Refitting the exhaust gas recirculation rigid p...

Page 543: ...ixture Damp er valve Removal Refitting page 12A 39 the injector rails see 13B Diesel injection Injec tor rail Removal Refitting page 13B 189 II REMOVAL OF THE ROCKER COVER 1 Front row a Remove the bol...

Page 544: ...e wiring support at the flywheel end a Separate the engine wiring from the front row rocker cover a Unclip 6 the wiring for the gas recirculation thermal regulation solenoid valve on the rocker cover...

Page 545: ...mediate coolant duct using the tool Mot 1448 a Disconnect the hose at the inlet of the exhaust fuel injector cooler to the cylinder head outlet intermedi ate duct a Remove the bolt 10 for the intermed...

Page 546: ...D FRONT OF ENGINE Rocker cover Removal Refitting V9X 11A Back row Front row a Very carefully detach the rocker cover concerned using a screwdriver in the notches using the tool Mot 1716 136285 136286...

Page 547: ...on the cylinder head a Always replace the O ring for the cylinder head out let intermediate coolant duct a Check that the rocker cover centring dowels are fit ted to the cylinder heads a Fit the notc...

Page 548: ...Front row a Disconnect the fuel discharge hose a Refit the lifting eye on the flywheel end see 11A Top and front of engine Lifting eyes Removal Re fitting page 11A 318 the upper bolt for the high pres...

Page 549: ...ge 13B 161 the high pressure pipe between the pump and the rail see 13B Diesel injection High pressure pipe between pump and rail Removal Refit ting page 13B 140 the camshaft position sensor see 13B D...

Page 550: ...move the engine from the component support see Engine support equipment Use a Refit the engine gearbox assembly see 10A En gine and cylinder block assembly Engine gear box assembly Removal Refitting p...

Page 551: ...l Refitting the rigid exhaust gas recirculation pipe see 14A Antipollution Exhaust gas recirculation rigid pipe Removal Refitting page 14A 62 a Remove the nut 1 on the intercooler air inlet pipe the b...

Page 552: ...e sensor a Pull the clip 6 of the intercooler air outlet pipe a Move the intercooler air outlet pipe to one side a Unclip the wiring 7 of the damper valve a Unclip the injector rail protector cover at...

Page 553: ...nnectors 24 a Move aside the diesel injector wiring a Remove the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 the right hand suspended engine mounting see 19D Engine m...

Page 554: ...a Remove the tie rod rear bolts 12 a Remove the radiator mounting cross member bolts 13 a Fit the Mot 1720 14 fitted with the Mot 1672 15 a Remove the Mot 1453 fitted with the Mot 1453 01 a Disconnec...

Page 555: ...aust gas temperature sensor wiring 18 from the lifting eye on the timing end a Remove the bolts 19 from the lifting eye at the timing end the lifting eye on the timing end the air inlet metal tube the...

Page 556: ...arts and con sumables for the repair 04B Consumables Products a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products and CLEAN CLOTHS to degrease the cylinder...

Page 557: ...rocker cover a Remove the bolt from the camshaft position sensor the camshaft position sensor a Refit the camshaft position sensor onto the new rocker cover II REFITTING OPERATION FOR PART CONCERNED a...

Page 558: ...9D 51 the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 a Connect the diesel injector connectors a Clip on the diesel injector wiring a Connect the camshaft position se...

Page 559: ...Removal Refitting page 11A 33 the rear suspended engine mounting see 19D Engine mounting Lower engine tie bar Re moval Refitting page 19D 85 the front right hand driveshaft see Front right hand drive...

Page 560: ...Removal Refitting F4R 11A a Remove the valve rockers 1 the hydraulic tappets 2 a Undo the air filter unit air outlet pipe clips 3 14499 Note T o prevent any risk of unpriming the hydraulic tappets ma...

Page 561: ...o double non return valve connector 7 a Unclip the hoses on the air filter unit air outlet pipe a Remove the air filter box air outlet pipe a Disconnect the coolant temperature sensor connec tor 8 a M...

Page 562: ...rottle valve connector 13 the brake servo vacuum pipe union 14 on the in take distributor the petrol vapour rebreather pipe union 15 on the intake distributor a Move the injector wiring to one side a...

Page 563: ...s and consumables for the repair MR 415 04B 123153 123152 IMPORTANT Wear goggles with side protectors for this opera tion IMPORTANT Wear latex gloves during the operation WARNING Do not scrape the joi...

Page 564: ...d for any cracks with the cylin der head testing kit see Garage Equipment cata logue a Rebuild the cylinder head see Reassembling the cylinder head Technical Note 6027A 10A Engine and peripherals 2 PR...

Page 565: ...s the oil vapour rebreather solenoid valve connector a Clip the wiring of the air inlet pressure sensor a Connect the air inlet pressure sensor connector a Refit the engine wiring bolt on the cylinder...

Page 566: ...ter Removal Refitting page 19B 32 the front right hand driveshaft see Front right hand driveshaft Removal Refitting MR 415 29A Driveshafts the suspended engine mounting see 19D Engine mounting Lower e...

Page 567: ...ded engine mounting Removal Refitting page 19D 51 the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the starter see 16A Starting Charging Starter Removal Refitting...

Page 568: ...oler air outlet pipe from the damper valve a Pull the intercooler air outlet pipe clip 2 a Disconnect the intercooler air outlet pipe from the in tercooler a Remove the intercooler outlet air pipe a R...

Page 569: ...l ing system Draining Refilling page 19A 16 a Unclip the water chamber hose 6 a Remove the clips 7 from the water chamber hoses using the Mot 1448 a Disconnect the hoses 8 from the water chamber a Rem...

Page 570: ...opera tion IMPORTANT Wear latex gloves during the operation WARNING Do not scrape the joint faces of the aluminium any damage caused to the joint face will result in a risk of leaks WARNING Do not al...

Page 571: ...N m a Check that all of the new cylinder head mounting bolts are tightened to the correct torque 25 N m a Angle tighten in order the new cylinder head bolts 270 10 III FINAL OPERATION a Remove the bla...

Page 572: ...intercooler a Connect the intercooler air outlet pipe to the damper valve a Tighten the intercooler air outlet pipe clip a Refit the intercooler air inlet pipe bolt the intercooler air inlet pipe nut...

Page 573: ...ndertray the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pu...

Page 574: ...ube the dipstick guide a Remove the bolts 3 from the exhaust bracket the ring between the exhaust manifold and the cat alytic converter a Remove the nut 4 from the exhaust manifold stay the bolt 5 fro...

Page 575: ...mber the heater matrix inlet hose clip 8 on the water chamber a Disconnect the cooling radiator top hose from the water cham ber the heater matrix inlet hose from the water cham ber the connector 9 fr...

Page 576: ...ENGINE Cylinder head Removal Refitting K4M 11A REFITTING I REFITTING PREPARATION OPERATION a Always replace the cylinder head bolts the ring between the exhaust manifold and the cat alytic converter...

Page 577: ...Garage Equipment cata logue a Rebuild the cylinder head see Reassembling the cylinder head Technical Note 6023A 10A Engine and peripherals a Place the pistons at half stroke a Check that the centring...

Page 578: ...between the exhaust manifold and the catalytic converter a Torque tighten the exhaust bracket bolts 22 N m a Refit the dipstick guide the dipstick the camshafts see 11A Top and front of engine Camshaf...

Page 579: ...el mixture Inlet distributor Removal Refitting page 12A 75 the coils see 17A Ignition Coils Removal Re fitting page 17A 1 the throttle valve see 12A Fuel mixture Throttle valve Removal Refitting page...

Page 580: ...aft accessories pulley Removal Refitting page 11A 33 the flywheel locking tool Mot 1431 the crankshaft seal on the timing side see 10A Engine and cylinder block assembly Crank shaft seal on timing end...

Page 581: ...al Refit ting page 13B 140 the oil decanter see 11A Top and front of en gine Oil decanter Removal Refitting page 11A 307 the diesel return rail see 13B Diesel injection Diesel injector fuel return rai...

Page 582: ...mum loosening torque of 40 N m to avoid the breaking the bolts the EGR pipe at the EGR cooler outlet the seals of the EGR pipe at the EGR cooler outlet M9R and 754 or 800 or 802 or 803 or 805 or 806 o...

Page 583: ...etween the EGR cooler control solenoid valve and the EGR cooler II REMOVAL OF CYLINDER HEAD a Remove the cylinder head bolts the cylinder head the cylinder head gasket M9R and 754 or 800 or 802 or 803...

Page 584: ...val Refitting M9R 11A a Remove the hydraulic tappet valve rocker assem blies 114253 Note Mark each hydraulic tappet valve rocker assem bly in relation to the cylinder head Immerse the hydraulic tappet...

Page 585: ...s to be replaced Exhaust gas recir culation rigid pipe 11 07 01 08 II OPERATION FOR REFITTING THE CYLINDER HEAD a Check that the cylinder head seal matches the cylin der head see Cylinder head Check a...

Page 586: ...mm on the cylinder head gasket at 14 timing end a Position the pistons at mid stroke by turning the crankshaft in a clockwise direction a Refit the cylinder head a Tighten to torque and in order the c...

Page 587: ...ts of the EGR pipe at the EGR cooler outlet a In order fit without tightening the bolts of the EGR pipe on the EGR solenoid valve end the bolts of the EGR pipe on the EGR cooler end a Refit the new EG...

Page 588: ...um pump Removal Refitting the turbocharger oil pipes see 12B Turbocharg ing Turbocharger oil pipe Removal Refitting page 12B 35 Depending on the version the catalytic pre con verter or the catalytic c...

Page 589: ...14A An tipollution Exhaust gas recirculation rigid pipe Removal Refitting page 14A 62 the engine gearbox assembly see 10A Engine and cylinder block assembly Engine gearbox assembly Removal Refitting p...

Page 590: ...f the water oil exchanger pipe using the tool Mot 1448 a Remove the oil water exchanger pipe the inlet manifold see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 the ignition coils...

Page 591: ...y Removal Refitting page 11A 33 the sump see 10A Engine and cylinder block assembly Lower cover Removal Refitting page 10A 180 the oil level sensor see 10A Engine and cylinder block assembly Oil level...

Page 592: ...ing a magnet the dipstick 6 a Remove the bolts 7 of the rigid cooling pipes the rigid cooling pipes the coolant outlet unit see 19A Cooling Water chamber Removal Refitting page 19A 100 II OPERATION FO...

Page 593: ...Finish cleaning the gasket faces using a GREY ABRASIVE PAD part number 77 01 405 943 a parts always to be replaced cylinder head bolts 10 02 01 14 parts always to be replaced Cylinder head gas ket 10...

Page 594: ...g SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consumables Products and clean cloths a Apply beads of SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the re pai...

Page 595: ...e a first tightening of the cylinder head bolts 93 3 a second tightening of the cylinder head bolts 93 3 a Refit the thermostat see 19A Cooling Thermostat Removal Refitting page 19A 89 the cylinder he...

Page 596: ...page 17B 39 the timing chain see 11A Top and front of en gine Timing chain Removal Refitting page 11A 88 the crankshaft seal on the timing side see 10A Engine and cylinder block assembly Crank shaft...

Page 597: ...ge 17A 1 the intake distributor see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 a Refit the oil water exchanger pipe the clips 19 of the oil water exchanger pipe using the tool Mo...

Page 598: ...d 713 11A a Remove the engine lifting eye at the timing end see 11A Top and front of engine Lifting eyes Re moval Refitting page 11A 318 a Refit the engine gearbox assembly see 10A En gine and cylinde...

Page 599: ...Starter Removal Refitting page 16A 31 the timing chain see 11A Top and front of en gine Timing chain Removal Refitting page 11A 88 the timing sprockets see Timing sprocket Re moval Refitting the exha...

Page 600: ...ting eyes Removal Re fitting page 11A 318 the rocker covers see 11A Top and front of en gine Rocker cover Removal Refitting page 11A 139 a Remove the hydraulic tappet valve rocker assem blies a Remove...

Page 601: ...he gearbox side the seal from the inter intake distributors pipe on the gearbox side the O ring from the inter intake distributors pipe on the gearbox side a Remove the bolts 4 from the inter intake d...

Page 602: ...se support a Remove the dipstick 6 the bolts 7 from the dipstick well a Remove the nuts 8 from the front row exhaust manifold heat shield a Disconnect the diesel fuel discharge hose from the front row...

Page 603: ...e exhaust manifold heat shield on the back row the exhaust manifold heat shield on the back row II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the front row cylinder head bolts 11 on the timing e...

Page 604: ...ll the seals for the inter intake distributor pipes the O rings for the inter intake distributor pipes the seals from the cylinder head outlet intermediate coolant duct the O ring for the coolant pump...

Page 605: ...9X 11A Front row Back row a At 14 apply beads of SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the repair 04B Consumables Products with a width of 5 mm to the joint faces of the cyli...

Page 606: ...icle Parts and consumables for the repair 04B Consumables Products with a width of 5 mm to the joint faces of the cylinder heads II REFITTING OPERATION FOR PART CONCERNED a 138140 138138 135578 135577...

Page 607: ...ide a new O ring to the inter intake distributors pipe on the timing side the inter intake distributors pipe on the timing side a new seal to the inter intake distributors pipe on the gearbox side a n...

Page 608: ...d rail Removal Refit ting page 13B 140 the camshaft position sensor see 13B Diesel in jection Camshaft position sensor Removal Refitting page 13B 42 the diesel injector fuel return rails see 13B Diese...

Page 609: ...ccessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 a Remove the engine from the component support see Engine support equipment Use a Refit the engine gearbo...

Page 610: ...e timing side see 10A Engine and cylinder block assembly Crank shaft seal on timing end Removal Refitting page 10A 134 the timing chain see 11A Top and front of en gine Timing chain Removal Refitting...

Page 611: ...s see Timing sprocket Re moval Refitting the injector rail see 13B Diesel injection Injec tor rail Removal Refitting page 13B 189 the camshafts see 11A Top and front of engine Camshaft Removal Refitti...

Page 612: ...the cylinder head bolts 40 N m a Tighten to angle and in order the cylinder head bolts 100 a Loosen all the cylinder head bolts a Tighten in order and to torque the cylinder head bolts 1st tightening...

Page 613: ...nd Removal Refitting page 10A 134 a Immobilise the flywheel or the drive plate using the tool Mot 919 02 a Refit the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessorie...

Page 614: ...s duct at the turbocharger outlet see Turbocharger outlet exhaust gas duct Re moval Refitting the exhaust gas recirculation rigid pipe see 14A Antipollution Exhaust gas recirculation rigid pipe Remova...

Page 615: ...rging pressure regulation pipe 2 on the turbocharger a Disconnect the exhaust gas recirculation solenoid valve con nector 3 the vacuum pipe 4 of the exhaust gas recircula tion valve solenoid valve the...

Page 616: ...ng pipe at 7 a Use the tool Mot 1448 to separate the clip 8 on the cooling pipe of the exhaust gas cooler a Disconnect the cooling pipe from the exhaust gas cooler a Use the tool Mot 1448 to separate...

Page 617: ...r 12 for the fuel pressure regulation solenoid valve the connector 13 from the fuel flow regulating so lenoid valve a Unclip the injection wiring at 14 a Move aside the injection wiring a Remove the a...

Page 618: ...f the exhaust fuel injector solenoid valve the fuel supply pipe opening of the exhaust fuel in jector solenoid valve the fuel supply pipe opening of the exhaust fuel in jector a Disconnect the fuel dr...

Page 619: ...d requires two people Note T urn the camshaft slightly to facilitate the removal of the cylinder head bolt on the camshaft position sensor target 19712 IMPORTANT Wear goggles with side protectors for...

Page 620: ...m a Angle tighten in order the cylinder head bolts 270 10 III FINAL OPERATION a Refit the inner timing cover a Fit the alternator in place a Refit the alternator upper bolt a Torque tighten the altern...

Page 621: ...ging pressure regulation pipe on the turbocharger a Refit the dipstick guide the dipstick the turbocharger oil return pipe see 12B Turbo charging Turbocharger oil pipe Removal Re fitting page 12B 35 t...

Page 622: ...11A 244 TOP AND FRONT OF ENGINE Cylinder head Removal Refitting K9K and 782 11A...

Page 623: ...es pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 a Remove the engine tie bar bolt 1 on the subframe the bolt 2 from the engine tie bar on the engin...

Page 624: ...al Refitting F4R 11A II REMOVAL OPERATION FOR PART CONCERNED a Remove the camshafts 3 a Remove the valve rockers 4 the hydraulic tappets 5 123155 14499 Note T o prevent any risk of unpriming the hydra...

Page 625: ...ON a Refit the rocker cover see 11A Top and front of en gine Rocker cover Removal Refitting page 11A 139 the camshaft seals on the timing end see 11A Top and front of engine Camshaft seal timing end R...

Page 626: ...ndertray bolts a Refit the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the front right hand wheel arch liner see Front wheel arch liner Removal Refi...

Page 627: ...ng page 19D 51 the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Re...

Page 628: ...cylinder head to lock the camshaft pulley wheel a Tighten the camshaft pulley hub bolts 3 a Remove the nut 4 from the camshaft pulley the Mot 1606 the camshaft pulley a Mark the position of the camsha...

Page 629: ...al Refitting page 11A 287 a Fit the camshaft pulley a Refit a new camshaft pulley nut a Undo the camshaft pulley hub bolts a Fit the Mot 1606 on the cylinder head to lock the camshaft pulley wheel a T...

Page 630: ...ounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 t...

Page 631: ...ssories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the right hand suspended engine...

Page 632: ...d front of engine Camshaft seal timing end Removal Refitting page 11A 287 the camshaft dephaser see 11A Top and front of engine Camshaft dephaser Removal Refit ting page 11A 275 the timing belt see 11...

Page 633: ...11A 255 TOP AND FRONT OF ENGINE Camshaft Removal Refitting K4M 11A the engine cover...

Page 634: ...the timing side see 10A Engine and cylinder block assembly Crank shaft seal on timing end Removal Refitting page 10A 134 the timing chain see 11A Top and front of en gine Timing chain Removal Refitti...

Page 635: ...and the in jectors see 13B Diesel injection High pressure pipe between rail and injector Removal Refit ting page 13B 161 the diesel injectors see 13B Diesel injection Diesel injector Removal Refitting...

Page 636: ...the bearings on the rocker cover a Check that the teeth of the high pressure pump drive pinion are not chipped flaked or scratched a parts always to be replaced camshaft timing sprocket bolt 10 02 02...

Page 637: ...groove on the inlet side of the camshaft 14 facing towards the rocker cover boss 15 III FINAL OPERATION a Refit the rocker cover see 11A Top and front of en gine Rocker cover Removal Refitting page 1...

Page 638: ...t the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 a Remove the flywheel locking tool Mot 1431 a Refit the coolant pump see...

Page 639: ...mp Removal Refitting 36B Power assisted steering the inlet manifold see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 the ignition coils see 17A Ignition Coils Re moval Refitting pa...

Page 640: ...e the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the sump see 10A Engine and cylinder block assembly Lower cover Removal...

Page 641: ...the camshaft bearing cap bolts 6 the camshaft bearing caps 6 a Remove the camshafts REFITTING I REFITTING PREPARATION OPERATION a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair...

Page 642: ...tioning them correctly see Camshaft Check by positioning the camshaft lugs 7 in the cylinder shafts 8 a Refit the camshaft bearing caps 9 a Tighten to torque and in order the bolts of the camshaft bea...

Page 643: ...assembly Oil level sensor Removal Re fitting page 10A 237 the sump see 10A Engine and cylinder block assembly Lower cover Removal Refitting page 10A 180 the crankshaft accessories pulley see 11A Top a...

Page 644: ...Refitting 36B Power assisted steering the accessories belts see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 a Top up the engine oil see 10A Engine and cylin der block a...

Page 645: ...11A Top and front of en gine Timing chain Removal Refitting page 11A 88 the timing sprockets see Timing sprocket Re moval Refitting the exhaust gas recirculation rigid pipe see 14A Antipollution Exhau...

Page 646: ...Removal Refitting page 13B 189 the rocker covers see 11A Top and front of en gine Rocker cover Removal Refitting page 11A 139 II CAMSHAFT REMOVAL OPERATION a Fit the rocker cover on the tool Mot 1573...

Page 647: ...supporting the camshaft exhaust side a Torque and angle tighten the high pressure pump drive pinion bolt 40 N m 34 6 II CAMSHAFT REFITTING OPERATION a Fit the rocker cover on the Mot 1573 a Using eng...

Page 648: ...r see 10A Engine and cyl inder block assembly Oil pressure sensor Re moval Refitting page 10A 227 the oil filter see 10A Engine and cylinder block assembly Oil filter Removal Refitting page 10A 117 th...

Page 649: ...ming side see 10A Engine and cylinder block assembly Crank shaft seal on timing end Removal Refitting page 10A 134 the timing chain see 11A Top and front of en gine Timing chain Removal Refitting page...

Page 650: ...e camshafts 5 REFITTING I REFITTING PREPARATION OPERATION a a Clean the joint faces of the cylinder head cover with SUPER CLEANING AGENT FOR JOINT FACES see Vehicle Parts and consumables for the re pa...

Page 651: ...r and the plug wells a Refit the cylinder head cover the cylinder head cover bolts a Pretighten to torque and in order the cylinder head cover bolts first initial torque 2 N m the cylinder head cover...

Page 652: ...he timing side see 10A Engine and cylinder block assembly Crank shaft seal on timing end Removal Refitting page 10A 134 a Immobilise the flywheel or the drive plate using the tool Mot 919 02 a Refit t...

Page 653: ...he camshaft dephaser see 10A Engine and cylinder block assembly En gine gearbox assembly Removal Refitting page 10A 1 a For the camshaft dephaser removal refitting proce dure see Timing cylinder head...

Page 654: ...n the engine undertray bolts the engine undertray the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and...

Page 655: ...n relation to the wheel to the left or right a If there is a rotation of the hub in relation to the wheel the camshaft dephaser is faulty and must be replaced a Grease the end of the inlet camshaft ti...

Page 656: ...ng 55A Ex terior protection the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the throttle valve see 12A Fuel mixture Throttle valve Removal Refitting page 12A 49 the air fil...

Page 657: ...GINE Camshaft dephaser Removal Refitting V4Y 11A a Removal refitting of the camshaft dephaser is in cluded in the removal refitting of the timing chain see 11A Top and front of engine Timing chain Rem...

Page 658: ...re preferable to close the inlet valves earlier to avoid incorrect filling and a loss of torque due to the reflux of fresh gases The higher the engine speed the later the inlet valves must be closed I...

Page 659: ...mshaft dephaser Function M4R 11A after the engine has started outside idling speed and no load threshold of mapping reached according to load and engine speed reached threshold of mapping reached acco...

Page 660: ...RATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 3 of the camshaft dephaser solenoid valve equipped with a new seal a Remove the bolt 4 from the camshaft dephaser solenoid valve the cam...

Page 661: ...t hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the engine cover the engine tie bar the engine tie bar bolts a Torque tighte...

Page 662: ...er solenoid valve a Remove the bolt 2 from the camshaft dephaser solenoid valve the camshaft dephaser solenoid valve REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the camshaft dephaser so...

Page 663: ...from the alternator and from the air conditioning compressor see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the thermostat see 19A Cooling Thermostat Removal Refitting...

Page 664: ...haser solenoid valve a Refit a new camshaft dephaser solenoid valve seal the camshaft dephaser solenoid valve a Torque tighten the camshaft dephaser solenoid valve bolt 9 N m a Connect the camshaft de...

Page 665: ...see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Remov...

Page 666: ...pulley nuts without tightening them a Fit the tool Mot 1801 fitted with Mot 1509 01 a Tighten to torque the toothed sprocket nuts 80 Nm the camshaft pulley nuts 30 Nm 86 6 a Remove the tool Mot 1801 f...

Page 667: ...3 the front right hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front right hand wheel see Wheel Removal Refitting MR 415 35A Wheels and tyres t...

Page 668: ...uspended engine mounting Removal Refitting page 19D 51 the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the crankshaft accessories pulley see 11A Top and front of...

Page 669: ...re that the end piece 6 of the tool Mot 1577 is always removed a Loosen bolts 7 and 8 fully from the Mot 1577 a Position the claws of the Mot 1577 on the cam shaft a Push the tool Mot 1577 until conta...

Page 670: ...the tim ing end using SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Con sumables Products and a CLEAN CLOTH a parts always to be replaced Camshaft seal on timing end 10 02 02 0...

Page 671: ...camshaft seal a Fit the cover 13 and the collar nut 14 of the Mot 1632 105531 21687 Note For camshaft seals delivered fitted to a protective sleeve do not remove the camshaft seal from its pro tectiv...

Page 672: ...lar nut from the Mot 1632 the cover from the Mot 1632 the stud of the Mot 1632 the protective sleeve 2 Second fitting of the camshaft seal a Depending on the case the Parts Department deliv ers seals...

Page 673: ...fitting page 11A 50 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the air filter unit see 12A Fuel mixture Air filter un...

Page 674: ...gine undertray bolts the engine undertray the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of...

Page 675: ...on the claws of the Mot 1577 on the cam shaft a Push the Mot 1577 until contact is made between the ends of the claws and the camshaft seal a Separate the claws by turning the nut 3 clockwise using an...

Page 676: ...a Position the claws of the Mot 1577 on the cam shaft a Push the Mot 1577 until contact is made between the ends of the claws and the camshaft seal a Separate the claws by turning the nut 5 clockwise...

Page 677: ...1 Refitting the exhaust side seal a Position the protector fitted with a new seal 9 on the camshaft taking care not to touch the seal WARNING Do not scrape the joint faces of the aluminium any damage...

Page 678: ...crew the stud 10 of theonto the camshaft a Fit the cover 11 and the collar nut 12 of the a Screw on the collar nut until the cover touches the cylinder head a Remove the collar nut from the tool the c...

Page 679: ...moval Refitting K4M 11A 2 Refitting the inlet side seal a Position the protector fitted with a new seal 13 on the camshaft taking care not to touch the seal a Remove the camshaft seal protector a Scre...

Page 680: ...page 11A 50 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the accessories belt see 11A Top and front of engine Ac...

Page 681: ...11A 303 TOP AND FRONT OF ENGINE Camshaft seal timing end Removal Refitting K4M 11A...

Page 682: ...aust be ginning of inlet position a Check the valve clearance X of the cylinder 4 using a set of feeler gauges inlet valve clearance of 0 20 mm exhaust valve clearance of 0 40 mm a Note the clearance...

Page 683: ...Calibrate the Dial gauge a Lift the rod 7 of the Dial gauge without changing the position of the dial gauge holder assembly a Mount the valve tappet 8 to be measured on the plate of the Mot 252 01 a T...

Page 684: ...return rail see 13B Diesel injection Diesel injector fuel return rail Re moval Refitting page 13B 108 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mount...

Page 685: ...air inlet pipe a Move the intercooler inlet air pipe to one side a Remove the coils see 17A Ignition Coils Re moval Refitting page 17A 1 a Unclip the coil wiring the upstream oxygen sensor wiring a Di...

Page 686: ...er cover a Apply RESIN ADHESIVE see Vehicle Parts and consumables for the repair MR 415 04B Con sumables Products to the oil decanter joint face using a stipple roller 123170 123167 WARNING When clean...

Page 687: ...heat shield bolts a Fit the intercooler air inlet pipe a Connect the intercooler air inlet pipe a Refit the intercooler air inlet pipe bolt a Tighten the intercooler air inlet pipe bolt a Tighten the...

Page 688: ...D FRONT OF ENGINE Oil decanter Removal Refitting M4R 11A a The oil decanter is integrated into the rocker cover To remove the oil decanter see 11A Top and front of engine Rocker cover Removal Refittin...

Page 689: ...pipe bolts 2 at the intercooler inlet a Rotate the clip 3 on the intercooler air inlet pipe a Disconnect the intercooler air inlet pipe a Move aside the intercooler air inlet pipe a Remove the injecto...

Page 690: ...replaced Oil decanter seal 11 04 06 24 a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consum ables Products to clean and degrease the joint faces of the cylinder head cove...

Page 691: ...esel in jection Injector rail protector Removal Refit ting page 13B 126 a Connect the intercooler air inlet pipe on the turbo charger a Refit the bolts of the intercooler air inlet pipe on the air inl...

Page 692: ...s the oil separator joint face if it is to be re used the rocker cover joint face a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consum ables Products to degrease the oil s...

Page 693: ...y coated II REFITTING OPERATION FOR PART CONCERNED a Refit the oil separator a Torque tighten in order the new oil separator bolts 15 N m III FINAL OPERATION a Refit the intake distributor see 12A Fue...

Page 694: ...Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the turbocharger see 12B Turbocharging Tur bocharger Removal Refitting page 12B 4 the coolant outlet u...

Page 695: ...00 the turbocharger see 12B Turbocharging Tur bocharger Removal Refitting page 12B 4 the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the exhaust gas recirculatio...

Page 696: ...ner see Front wheel arch liner Removal Refitting 55A Ex terior protection the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 1...

Page 697: ...mounting see 19D Engine mounting Right hand sus pended engine mounting Removal Refitting page 19D 51 REFITTING THE LIFTING EYE INSIDE THE FRONT RIGHT HAND WHEEL ARCH I REFITTING OPERATION FOR THE LIFT...

Page 698: ...Refitting page 19A 100 the engine wiring support nuts a Unclip the engine wiring a Remove the engine wiring supports a Move aside the engine wiring II OPERATION FOR REMOVAL OF PART CONCERNED a Remove...

Page 699: ...V4Y 11A the vacuum pipe from the brake servo a Fit the clip onto the oil vapour rebreathing pipe using the Mot 1448 a Fill and bleed the cooling system see 19A Cool ing Cooling system Draining Refill...

Page 700: ...LIFTING EYE a Remove the bolts 2 from the lifting eye at the timing end the lifting eye on the timing end REFITTING THE TIMING END LIFTING EYE I REFITTING OPERATION FOR THE LIFTING EYE a Refit the en...

Page 701: ...II REMOVAL OPERATION FOR THE LIFTING EYE a Remove the gearbox side lifting eye bolts 6 the gearbox side lifting eye REFITTING THE LIFTING EYE ON THE GEARBOX END I REFITTING OPERATION FOR PART CONCERNE...

Page 702: ...inlet circuit 123973 1 Air resonator air inlet pipe 2 Air resonator 3 Air filter box air inlet pipe 4 Air filter unit 5 Air flowmeter 6 Air filter box outlet air pipe 7 Air resonator 8 Throttle valve...

Page 703: ...gram of the air inlet circuit 123800 1 Air resonator 2 Air filter unit 3 Air flowmeter 4 Air filter box outlet air pipe 5 Turbocharger 6 Intercooler air inlet pipe 7 Air to air intercooler 8 Intercool...

Page 704: ...UIT DIAGRAM 125427 1 Air inlet 2 Air resonator 3 Air filter box air inlet pipe 4 Air filter box 5 Air filter box air outlet pipe 6 Turbocharger 7 Intercooler air inlet pipe 8 Air to air intercooler 9...

Page 705: ...scription K4M 12A Air inlet circuit 128001 1 Air resonator air inlet pipe 2 Air resonator 3 Air inlet pipe of the air filter box 4 Air filter unit 5 Air filter unit air outlet pipe 6 Air resonator 7 T...

Page 706: ...Air flowmeter 4 Air filter unit air outlet pipe 5 Turbocharger 6 Turbocharger air outlet pipe 7 Intercooler 8 Intercooler air outlet pipe 9 Damper valve air inlet pipe 10 Damper valve 11 Inter cylind...

Page 707: ...the air inlet circuit 144358 1 Air resonator 2 Air filter unit 3 Air flowmeter 4 Air filter outlet air pipe 5 Turbocharger air inlet pipe 6 Turbocharger 7 Intercooler air inlet pipe 8 Intercooler 9 I...

Page 708: ...A 7 FUEL MIXTURE Air filter Removal Refitting K4M or M4R 12A REMOVAL I REMOVAL PREPARATION OPERATION a Unclip the air filter unit cover at 1 a Unclip the air filter unit cover at 1 M4R 123390 K4M 1282...

Page 709: ...r unit cover a Remove the air filter from the air filter unit REFITTING I REFITTING PREPARATION OPERATION a Clean the air filter housing II REFITTING OPERATION FOR PART CONCERNED a Refit the air filte...

Page 710: ...r filter cover a Remove the filter element REFITTING I REFITTING PREPARATION OPERATION a Clean the air filter box II REFITTING OPERATION FOR PART CONCERNED a a Refit the filter element correctly in th...

Page 711: ...REMOVAL OF PART CONCERNED a Remove the air filter 2 REFITTING I REFITTING PREPARATION OPERATION a Clean the air filter housing II REFITTING OPERATION FOR PART CONCERNED a Refit the air filter III FINA...

Page 712: ...ter cover a Remove the air filter REFITTING I REFITTING PREPARATION OPERATION a Clean the air filter housing II REFITTING OPERATION FOR PART CONCERNED a Refit the air filter in the air filter unit a F...

Page 713: ...CERNED a Loosen the air filter unit cover bolts 3 a Move aside the air filter cover a Remove the air filter REFITTING I REFITTING PREPARATION OPERATION a Clean the air filter housing II REFITTING OPER...

Page 714: ...he air flow sensor connector 1 the air filter box outlet air pipe a Unpick the air flowmeter electrical wiring on the air filter air outlet pipe a Remove the turbocharger control solenoid valve 2 from...

Page 715: ...Protection and Switching Unit a Unclip the protection and switching unit 4 from its mounting a Disconnect the connectors 5 from the Protection and Switching Unit a Move aside the Protection and Switch...

Page 716: ...ilter box air outlet pipe clip on the air flowmeter side 5 5 Nm a Connect the air flowmeter connector a Position the Protection and Switching Unit mounting a Connect the Protection and Switching Unit...

Page 717: ...a Loosen the air filter box air outlet pipe clip 1 on the air flowmeter a Disconnect the air flowmeter connector 2 a Disconnect the air filter box air outlet pipe 3 from the air flowmeter Tightening t...

Page 718: ...al Refitting M4R 12A a Remove the battery tray upper cover 4 the battery tray right hand side section 5 a Remove the Protection and Switching Unit housing bolt 6 a Remove the Protection and Switching...

Page 719: ...flowmeter bolts on the air filter box a Torque tighten the air flowmeter bolts on the air filter box 4 Nm II REFITTING OPERATION FOR PART CONCERNED a Refit the air filter box a Connect the air filter...

Page 720: ...Remove the battery tray side cover a Disconnect the air filter box inlet air pipe 3 a Remove the air filter unit REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the air filter box a Connect...

Page 721: ...om the throttle valve a Move the air filter unit air outlet pipe 3 to one side a Remove the battery cover a Unclip the wiring 4 of the Protection and Switching Unit box from the right hand side sectio...

Page 722: ...NG I REFITTING OPERATION FOR PART CONCERNED a Refit the air filter unit a Connect the air filter unit air inlet pipe on the air filter unit a Clip on the air filter unit II FINAL OPERATION a Refit the...

Page 723: ...re that the battery cover is properly fitted into the battery tray at 9 a Clip on the back of the battery cover a Lock the battery cover clips by a quarter of a turn a Fit the air filter unit air outl...

Page 724: ...a Move aside the Protection and Switching Unit a Remove the Protection and Switching Unit mounting unit the battery disconnection unit upper mounting nut 5 the upper mounting the injection computer pr...

Page 725: ...rk with that of the air pipe see 12A Fuel mixture Air flowmeter Removal Refitting page 12A 33 a Torque tighten the clip of the air filter unit air out let pipe 5 5 N m a Position the injection compute...

Page 726: ...Turn the clip 1 of the battery disconnection unit cover a quarter of a turn a Remove the battery disconnection unit cover by pressing on the clip a Unlock the push button 2 by pulling it upwards a Un...

Page 727: ...ection unit upper mounting nut 5 the battery disconnection unit upper mounting the injection computer protector the injection computer bolts a Move the injection computer aside a Loosen the clip of th...

Page 728: ...ol valve on the turbocharger vacuum control valve wiring a Fit the air filter unit air outlet pipe a Torque tighten the clip of the air filter unit air out let pipe 6 N m a Position the injection comp...

Page 729: ...al Refitting 35A Wheels and tyres the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front bumper see Front bumper Removal Refitting 55A Exterior pro...

Page 730: ...PERATION FOR PART CONCERNED a Refit the air resonator a Clip the air resonator air inlet pipe on the body II FINAL OPERATION a Refit the air pipe at the air filter unit inlet the right hand side secti...

Page 731: ...ray at 7 a Clip on the back of the battery cover a Lock the battery cover clips by a quarter of a turn a Refit the front bumper see Front bumper Removal Refitting 55A Exterior protection the front whe...

Page 732: ...er Removal Refitting 55A Exterior protection II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the air resonator air inlet pipe 1 from the body a Remove the air resonator nut 2 the air resonator REF...

Page 733: ...isconnection unit bolts 1 a Move aside the support battery disconnection unit assembly II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the air resonator 2 a Remove the air resonator REFITTING I RE...

Page 734: ...t pipe to the air flowmeter a Remove the air pipe a Disconnect the air flowmeter connector 2 a Unclip the air filter box cover at 3 a Remove the air filter cover with the air flowmeter II REMOVAL OPER...

Page 735: ...lowmeter on the air filter box cover the air flowmeter bolts a Torque tighten the air flowmeter bolts 4 Nm III FINAL OPERATION a Refit the air filter box cover with the air flowmeter a Clip on the air...

Page 736: ...R PART CONCERNED a Remove the bolts 3 from the air flowmeter the air flowmeter REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the air flowmeter seal II REFITTING OPERATION FOR PART CONC...

Page 737: ...a Move the injection computer aside a Loosen the clip of the air filter unit air outlet pipe a Move the air outlet pipe of the air filter unit to one side II OPERATION FOR REMOVAL OF PART CONCERNED a...

Page 738: ...unit air outlet pipe with that of the air flowmeter a Torque tighten the clip of the air filter unit air out let pipe 6 N m a Position the injection computer on the air filter unit a Refit the inject...

Page 739: ...air flowmeter the air flowmeter seal REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Air flowmeter seal 11 04 06 26 II REFITTING OPERATION FOR PART CONCERNED a Refit a new ai...

Page 740: ...rcooler air outlet pipe to one side a Disconnect the intercooler air outlet pipe on the in tercooler a Remove the front engine cover a Undo the clip 2 from the intercooler outlet pipe a Disconnect the...

Page 741: ...cer 7 the air inlet spacer seal REFITTING I REFITTING PREPARATION OPERATION a Using SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products clean and degrease the be...

Page 742: ...ntercooler outlet air pipe clip 5 5 N m a Clip the intercooler air outlet pipe onto the intercool er a Refit the engine undertray the engine cover a Apply the after repair procedure using the Diagnos...

Page 743: ...1 a Remove the turbocharger pressure sensor nut 2 the turbocharging pressure sensor the engine undertray bolts the engine undertray a Pull the intercooler air outlet pipe clip 3 using a flat blade scr...

Page 744: ...the damper valve strut bolts 7 on the damper valve the damper valve strut the damper valve the damper valve seal REMOVAL I REMOVAL PREPARATION OPERATION a Parts always to be replaced the intercooler...

Page 745: ...ler air outlet pipe clip on the damper valve side 5 5 N m a Fit the turbocharging pressure sensor a Refit the turbocharging pressure sensor nut a Tighten the turbocharger pressure sensor nut a Connect...

Page 746: ...Disconnect the intercooler outlet air pipe on the damper valve II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 2 from the damper valve strut the damper valve stay a Disconnect the conne...

Page 747: ...air inlet valve II REFITTING OPERATION FOR PART CONCERNED a Refit the new damper valve seal the damper flap with a new seal the damper valve nuts a Tighten the damper valve nuts a Connect the damper...

Page 748: ...move the damper valve bolts 3 the damper valve the damper valve seal REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Damper valve seal 11 01 10 04 II REFITTING OPERATION FOR...

Page 749: ...to repair mode display the before after repair procedure for the computer selected select Damper valve in the List of compo nents stored by the computer section carry out the operations described in...

Page 750: ...er box air outlet pipe on the throttle valve the oil vapour rebreathing hose 2 on the rocker cover a Move the air filter box air outlet pipe 3 away from the throttle valve Special tooling required Ms...

Page 751: ...the throttle valve a Fit the 5 Ms 583 to the throttle valve coolant hoses a Remove the clip 6 from the throttle valve coolant hoses using the Mot 1448 on the throttle valve a Disconnect the throttle...

Page 752: ...ttle valve coolant hose clips using the Mot 1448 to the throttle valve a Remove the Ms 583 from the throttle valve coolant hoses a Connect the throttle valve connector III FINAL OPERATION a Fit the ai...

Page 753: ...t the connector 2 from the throttle valve a Remove the throttle valve bolts 3 the throttle valve the throttle valve seal REFITTING I REMOVAL PREPARATION OPERATION a Always replace the throttle valve s...

Page 754: ...Fit the intercooler outlet air pipe a Refit the intercooler air outlet pipe bolts a Tighten the intercooler outlet air pipe bolts a Refit the bolt of the air pipe retaining bracket on the inlet distri...

Page 755: ...pipe from the air filter unit from the throttle valve a Move the air filter unit air outlet pipe 3 to one side II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the union 4 of the fuel vapour r...

Page 756: ...it is to be re used the inlet manifold seal housing II REFITTING OPERATION FOR PART CONCERNED a Refit a new seal on the intake distributor the throttle valve a In order torque tighten the throttle va...

Page 757: ...nit air outlet pipe a Connect the air filter unit air outlet pipe onto the air filter unit the throttle valve a Torque tighten the clip of the air filter unit air outlet pipe on the throttle valve 5 5...

Page 758: ...e aside the air filter unit air outlet pipe on the throttle valve II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 3 from the throttle valve a Remove the throttle valve bolts 4 th...

Page 759: ...non return valve pipe on the air filter unit air outlet pipe a Connect the brake servo non return valve to the in take distributor a Refit the engine cover a Apply the after repair procedure using the...

Page 760: ...nsumables for the repair 04B Con sumables Products into the air vent until all traces of clogging have disappeared Equipment required compressed air nozzle IMPORTANT Wear leaktight gloves Nitrile type...

Page 761: ...r the re pair 04B Consumables Products a Use a compressed air nozzle to blast the throttle valve edges and the air vent parts always to be replaced Throttle valve seal 11 04 06 25 III FINAL OPERATION...

Page 762: ...efilling page 19A 16 a Remove the coolant outlet unit see 19A Cooling Water chamber Removal Refitting page 19A 100 the thermostat see 19A Cooling Thermostat Removal Refitting page 19A 89 the lower eng...

Page 763: ...ing hose clip 4 between the ex pansion bottle and the inter cylinder head pipe using the Mot 1448 a Disconnect the cooling hose clip between the ex pansion bottle and the inter cylinder head pipe a Re...

Page 764: ...pe the inter cylinder head cooling pipe seals a Remove the support bolts 9 from the cooling pipe at the expansion bottle outlet a Move aside the cooling pipe support at the expan sion bottle outlet a...

Page 765: ...e heater plugs on the back row a Remove the support bolts 13 from the exhaust gas intercooler control solenoid valve a Move aside the support from the exhaust gas inter cooler control solenoid valve a...

Page 766: ...intake distributor seal on the front row REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced inlet distributor seal 10 07 01 07 a Always replace the inter cylinder head intake d...

Page 767: ...ew inter cylinder head cooling pipe seals the inter cylinder head cooling pipe a Torque tighten the inter cylinder head cooling pipe bolts 12 N m a Connect the coolant temperature sensor connector a R...

Page 768: ...haust gas recirculation rigid pipe Removal Refitting page 14A 62 the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 a Fill and bleed the cooling system see 19A Cool ing...

Page 769: ...efilling page 19A 16 a Remove the coolant outlet unit see 19A Cooling Water chamber Removal Refitting page 19A 100 the thermostat see 19A Cooling Thermostat Removal Refitting page 19A 89 the lower eng...

Page 770: ...oling hose clip 4 between the ex pansion bottle and the inter cylinder head pipe using the Mot 1448 a Disconnect the cooling hose between the expansion bottle and the inter cylinder head pipe a Remove...

Page 771: ...he inter cylinder head cooling pipe seals a Remove the support bolts 9 from the cooling pipe at the expansion bottle outlet a Move aside the cooling pipe support at the expan sion bottle outlet a Remo...

Page 772: ...e heater plugs on the back row a Remove the support bolts 14 from the exhaust gas intercooler control solenoid valve a Move aside the support from the exhaust gas inter cooler control solenoid valve a...

Page 773: ...rt bolt 17 a Move aside the fuel pipe support a Remove the bolts 18 from the oil vapour rebreath ing diaphragm a Separate the oil vapour rebreathing hose clip from the oil vapour rebreathing diaphragm...

Page 774: ...4B Consumables Products the joint face between the intake distributor and the cylinder head II REFITTING OPERATION FOR PART CONCERNED a Refit a new intake distributor seal on the back row the intake d...

Page 775: ...Mot 1448 a Connect the cooling hose to the exhaust fuel injector cooler a Fit the clip onto the cooling hose at the exhaust fuel injector cooler using the Mot 1448 a Connect the heater matrix outlet...

Page 776: ...stributor lower bolts 27 Nm intake distributor upper bolts 20 Nm throttle valve bolts 10 Nm air filter box air outlet pipe clip on the throttle valve 5 5 Nm IMPORTANT During this operation be sure to...

Page 777: ...r a Disconnect the oil vapour rebreathing hose on the intake dis tributor the brake servo pipe union from the inlet manifold the fuel return pipe union on the intake distributor a Fit blanking plugs o...

Page 778: ...intake distributor upper bolts 20 Nm III FINAL OPERATION a Refit the dipstick a Remove the blanking plugs a Connect the fuel return pipe union on the intake distributor the brake servo pipe union on...

Page 779: ...12A 78 FUEL MIXTURE Inlet distributor Removal Refitting M4R 12A a Refit the engine cover...

Page 780: ...pressure sensor a Disconnect the fuel supply pipe union from the injec tor rail at 5 a Fit anti contamination caps Tightening torquesm injector rail bolts 10 Nm intake distributor bolts 25 Nm right h...

Page 781: ...lts 9 the right hand suspended engine mounting bolt 10 on the intake distributor the intake distributor the intake distributor seal REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the in...

Page 782: ...ort bolt on the intake distrib utor the right hand suspended engine mounting bolt on the intake distributor a Tighten to torque and in order the intake distributor bolts 25 Nm a Tighten the cylinder h...

Page 783: ...12A 82 FUEL MIXTURE Inlet distributor Removal Refitting F4R 12A the oil vapour rebreathing pipe union on the oil va pour heater a Refit the engine cover...

Page 784: ...EGR solenoid valve see 14A Antipollution Exhaust gas recirculation solenoid valve Re moval Refitting page 14A 11 the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the front r...

Page 785: ...istributor seal REFITTING I REFITTING PREPARATION OPERATION a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products to clean and degrease the bearing face betw...

Page 786: ...lights the front bumper see Front bumper Removal Refitting 55A Exterior protection the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the front right h...

Page 787: ...s 1 to 5 of the inlet manifold 9 N m bolts 6 to 8 of the inlet manifold 12 N m IMPORTANT During this operation be sure to refrain from smoking or bringing red hot objects close to the working area be...

Page 788: ...r bolts 8 the intake distributor the inlet manifold seals REFITTING I REFITTING PREPARATION OPERATION a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products t...

Page 789: ...ing to the inlet manifold the brake servo pipe union the oil vapour rebreathing hose the inlet manifold pressure sensor a Clip the following onto the inlet manifold the engine wiring the petrol vapour...

Page 790: ...canister the damper valve control solenoid valve Special tooling required Mot 1448 Remote operation pliers for hose clips Ms 583 Pipe clamps Tightening torquesm inlet manifold mount ings initial torq...

Page 791: ...a Disconnect the hose from the fuel vapour recircula tion solenoid valve a Remove the fuel vapour recirculation solenoid valve the engine cover mounting bolt 9 a Remove the engine cover mounting a Fi...

Page 792: ...III FINAL OPERATION a Fit the support of the ignition coil connector on the inlet manifold a Torque tighten the support bolt of the ignition coil connector on the inlet manifold 25 N m a Connect the...

Page 793: ...e air pipe to the control diaphragm the air pipe to the inlet manifold the damper valve control solenoid valve connector a Refit the throttle valve see 12A Fuel mixture Throttle valve Removal Refittin...

Page 794: ...1A 13 the power assisted steering pump see Power as sisted steering pump Removal Refitting 36B Power assisted steering the alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1...

Page 795: ...onsuma bles Products to clean and degrease the cylinder head gasket face the gasket face of the injector holder shim in case of reuse II REFITTING OPERATION FOR PART CONCERNED a Refit a new seal on th...

Page 796: ...emoval Refitting 62A Air conditioning the alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1 the power assisted steering pump see Power as sisted steering pump Removal Refit...

Page 797: ...jector holder shim seals REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Inlet shim seal 11 04 04 09 II REFITTING OPERATION FOR PART CONCERNED a Refit new seals on the inject...

Page 798: ...order and to torque the nuts and bolts of the injector holder shim torque 25 N m III FINAL OPERATION a Refit the injector rail see 17B Petrol injection Injec tor rail Injectors Removal Refitting page...

Page 799: ...stributor Removal Refitting page 12A 75 a Remove the exhaust manifold stay bolts 1 the exhaust manifold stay a Remove the bolts 2 from the exhaust clamp a Remove the bolts 3 from the exhaust manifold...

Page 800: ...g SUR FACE CLEANER see Vehicle Parts and con sumables for the repair MR 415 04B Vehicle Parts and consumables for repair a Always replace the ring 4 between the exhaust manifold and the catalytic conv...

Page 801: ...at shield the exhaust manifold heat shield bolts a Tighten the exhaust manifold heat shield bolts a Refit the exhaust manifold stay the exhaust manifold stay bolts the exhaust bracket bolts a Torque t...

Page 802: ...talytic converter see 19B Exhaust Cata lytic converter Removal Refitting page 19B 32 the turbocharger see 12B Turbocharging Tur bocharger Removal Refitting page 12B 4 II REMOVAL OPERATION FOR PART CON...

Page 803: ...tic converter Removal Refitting page 19B 32 the relay bearing the relay bearing bolts a Tighten the relay bearing bolts a Refit the front right hand driveshaft see Front right hand driveshaft Removal...

Page 804: ...ing Filling 21A Manual gearbox a Remove the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the right hand differential output seal see Differ entia...

Page 805: ...rigid pipe seals II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the exhaust manifold nuts the exhaust manifold the exhaust manifold gasket REFITTING I REFITTING PREPARATION OPERATION a Using SUR...

Page 806: ...w exhaust manifold nuts a Pretighten to torque and in order the exhaust mani fold nuts initial torque 18 N m a Torque tighten in order the exhaust manifold nuts 30 N m III FINAL OPERATION a Refit new...

Page 807: ...al output seal see Differ ential output seal Removal Refitting 21A Manual gearbox the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts a Fill and top...

Page 808: ...ling 21A Manual gearbox a Remove the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the right hand differential output seal see Differ ential output seal...

Page 809: ...ERATION FOR REMOVAL OF PART CONCERNED a a Remove the bolts 2 from the EGR rigid pipe on the exhaust manifold by applying a maximum loosening torque of 40 N m 123929 123928 123889 Note If the bolts do...

Page 810: ...ulation pipe bolt 11 07 01 18 parts always to be replaced exhaust manifold seal 10 07 02 07 parts always to be replaced Exhaust gas recir culation pipe seal 11 07 01 15 II REFITTING OPERATION FOR PART...

Page 811: ...oils Draining Filling 21A Manual gearbox a Refit the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Drive shafts a Refit the front right hand wheel arch liner see Fr...

Page 812: ...Disconnect the intercooler outlet air pipe on the damper valve a Remove the bolts 2 from the damper valve strut the damper valve strut a Disconnect the connector 3 from the damper valve a Remove the...

Page 813: ...bocharger Removal Refitting page 12B 4 a Remove the bolts 4 of the timing end lifting eye air inlet metal tube assembly the lifting eye on the timing end 5 air inlet metal tube 6 a Remove the rail pr...

Page 814: ...w exhaust manifold gasket in the position marked during removal the exhaust manifold a Torque tighten in order the exhaust manifold nuts 26 N m III FINAL OPERATION a Fit the exhaust gas recirculation...

Page 815: ...xhaust gas recirculation solenoid valve Removal Refitting page 14A 11 a Connect the damper valve connector a Refit the damper valve strut a Connect the intercooler air outlet pipe on the damper valve...

Page 816: ...m the exhaust bracket the ring between the exhaust manifold and the cat alytic converter a Remove the nut 2 from the exhaust manifold stay the bolt 3 from the exhaust manifold stay the exhaust manifol...

Page 817: ...from the heater ma trix hose bracket a Remove the bolt 5 from the heater matrix hose bracket the heater matrix hose bracket a Remove the bolts 6 from the upper heat shield the upper heat shield II OPE...

Page 818: ...nd consumables for the repair 04B Consuma bles Products to clean and degrease the exhaust manifold joint face if it is to be re used the cylinder head joint face a Always replace the ring 8 between th...

Page 819: ...xhaust manifold a Torque tighten in order the exhaust manifold nuts 26 Nm III FINAL OPERATION a Refit the upper heat shield the exhaust manifold stay a Tighten to torque the exhaust manifold stay bolt...

Page 820: ...ust manifold Removal Refitting K4M 12A a Refit the intake distributor see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 the engine undertray a Connect the battery see Battery Remova...

Page 821: ...A 52 the exhaust gas temperature sensor see 19B Ex haust Exhaust gas temperature sensor Re moval Refitting page 19B 85 the turbocharger oil pipes see 12B Turbocharg ing Turbocharger oil pipe Removal R...

Page 822: ...pollution Exhaust gas recirculation as sembly Removal Refitting page 14A 52 the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 the exhaust gas pressure sensor see 19B Ex...

Page 823: ...gine cover the engine undertray bolts the engine undertray the front catalytic pre converter see Front catalyt ic pre converter Removal Refitting a Disconnect the front row upstream oxygen sensor conn...

Page 824: ...ts a Torque tighten the exhaust manifold studs 15 Nm II REFITTING OPERATION FOR PART CONCERNED a Refit a new front exhaust manifold seal the front exhaust manifold a Torque tighten in order the exhaus...

Page 825: ...ee Front end panel Remov al Refitting 42A Upper front structure the engine undertray bolts the engine undertray the oil filter see 10A Engine and cylinder block assembly Oil filter Removal Refitting p...

Page 826: ...he multifunction support a Unclip the fuel drain hose from the front row multi function support a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the c...

Page 827: ...ger REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced exhaust manifold seal 10 07 02 07 a parts always to be replaced exhaust manifold stud on cylinder head if loosened 10 07 0...

Page 828: ...Without tightening fit the rear exhaust manifold onto the turbocharger a Refit the front exhaust manifold spacers a Fit without tightening the new front exhaust manifold nuts a Torque tighten in order...

Page 829: ...ront end panel see Front end panel Remov al Refitting 42A Upper front structure the audible warning see Audible warning Re moval Refitting 82B Horn the bonnet catch see Bonnet lock Removal Refitting 5...

Page 830: ...ee Wheel Removal Refitting 35A Wheels and tyres the front right hand driveshaft see Front right hand driveshaft Removal Refitting 29A Driveshafts the inlet manifold see 12A Fuel mixture Inlet distribu...

Page 831: ...ighten in order the rear exhaust manifold bolts 31 N m III FINAL OPERATION a Clip the back row upstream oxygen sensor onto its support a Connect the back row upstream oxygen sensor con nector a Refit...

Page 832: ...m see 19A Cooling Cool ing system Draining Refilling page 19A 16 Special tooling required Mot 1448 Remote operation pliers for hose clips Tightening torquesm rear exhaust manifold nuts initial torque...

Page 833: ...the turbocharger rigid cooling pipe the turbocharger heat shield nuts 3 a Loosen the nut 4 on the turbocharger heat shield a Remove the lower engine tie bars see 19D Engine mounting Lower engine tie...

Page 834: ...ter lower stay nuts 8 the catalytic pre converter strut a Loosen the nut 9 on the catalytic pre converter up per stay a Remove the catalytic pre converter upper stay a Remove the nut 10 on the rigid c...

Page 835: ...uspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 a Unclip the cooling hose at the inlet of the exhaust gas cooler from the back row r...

Page 836: ...alve a Remove the bolts 17 from the exhaust gas cooler the nuts 18 from the turbocharger exhaust gas cooler a Move aside the exhaust gas cooler exhaust gas recirculation solenoid valve assembly a Remo...

Page 837: ...d exhaust manifold seal 10 07 02 07 a parts always to be replaced exhaust manifold stud on cylinder head if loosened 10 07 02 10 a parts always to be replaced exhaust manifold nut 10 07 02 08 a parts...

Page 838: ...rear exhaust manifold and the turbocharger the rear exhaust manifold starting with the turbo charger then the cylinder head a Without tightening fit the rear exhaust manifold onto the turbocharger a R...

Page 839: ...tor cooler on the catalytic pre converter and the turbo charger a Refit the nut of the rigid cooling pipes of the exhaust fuel injector cooler on the catalytic pre converter the catalytic pre converte...

Page 840: ...12A 139 FUEL MIXTURE Rear exhaust manifold Removal Refitting V9X 12A a Fill and bleed the cooling system see 19A Cool ing Cooling system Draining Refilling page 19A 16 a Refit the engine cover...

Page 841: ...sequences swarf found in the engine oil circuit circulation of swarf within the circuit Risks after replacing the turbocharger premature wear on the bearing system destruction of turbocharger INSTRUCT...

Page 842: ...the air filter unit and the turbo charger A the air pipe B between the turbocharger and the in tercooler For air pipes comprising several components mark 10 the fitting position of each component sep...

Page 843: ...block assembly Engine oil Draining Refilling page 10A 100 Replace the oil filter see 10A Engine and cylinder block assembly Oil filter Removal Refitting page 10A 117 Only fill the engine with a suitab...

Page 844: ...and the flowmeter wiring from the air filter unit air outlet pipe a Undo the clips on the air filter box outlet air pipe a Remove the air filter box air outlet pipe Equipment required roller type stu...

Page 845: ...raining Filling 21A Manual gearbox a Remove the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the front right hand driveshaft see Front right hand driveshaft Removal Refittin...

Page 846: ...l tool if the turbocharger is being reused REFITTING I REFITTING PREPARATION OPERATION a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products to clean and deg...

Page 847: ...a roller type stud removal tool or using the stud recesses a Refit the new stud on the exhaust manifold a Torque tighten the exhaust manifold stud 9 N m a Remove the intercooler air inlet pipe seal on...

Page 848: ...new turbocharger seal the turbocharger onto the exhaust manifold a In order fit without tightening the transversal bolt 14 the nuts 15 the nut 16 a Pretighten to torque the turbocharger lower nuts in...

Page 849: ...inlet pipe to the turbocharger a Refit the intercooler air inlet pipe bolts on the inlet distributor a Tighten the intercooler air inlet pipe bolts on the inlet distributor a Fit the cooling radiator...

Page 850: ...m turbocharger oil return pipe bolts 12 Nm oil return pipe retaining bolt on the turbocharger 12 Nm turbocharger upper nut 15 Nm 75 6 turbocharger lower nuts 15 Nm 75 6 turbocharger bracket bolt 11 Nm...

Page 851: ...e solenoid valve the connector 7 on the braking assistance double non return valve a Unclip the anti surge valve hose clip 8 the turbocharging pressure regulation valve hose clip 9 the turbocharging p...

Page 852: ...r engine tie bar Re moval Refitting page 19D 85 the front right hand driveshaft see Front right hand driveshaft Removal Refitting MR 415 29A Driveshafts the catalytic converter see 19B Exhaust Cata ly...

Page 853: ...CE CLEANER see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products clean and degrease the turbocharger oil return pipe joint face Note If a stud comes loose during removal sme...

Page 854: ...eel Removal Refitting MR 415 35A Wheels and tyres the engine undertray the engine undertray bolts a Tighten the engine undertray bolts a Refit the air filter box air outlet pipe a Clip the turbocharge...

Page 855: ...ndo the clips on the air outlet pipe of the air filter unit a Remove the air outlet pipe from the air filter box Special tooling required Ms 583 Pipe clamps Mot 1448 Remote operation pliers for hose c...

Page 856: ...fitting 35A Wheels and tyres a Drain the gearbox see Manual gearbox oils Draining Filling 21A Manual gearbox a Remove the front right hand driveshaft see Front right hand driveshaft Removal Refitting...

Page 857: ...talytic pre converter Removal Refitting page 19B 22 the turbocharger oil pipes see 12B Turbocharg ing Turbocharger oil pipe Removal Refitting page 12B 35 II OPERATION FOR REMOVAL OF PART CONCERNED a a...

Page 858: ...arger rigid cooling pipe seal REFITTING I REFITTING PREPARATION OPERATION a Using SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products clean and degrease the bear...

Page 859: ...s to be replaced the catalytic pre converter seal the exhaust manifold stud the turbocharger studs if the turbocharger is being reused 1 Refitting preparation operation if the turbocharger is to be re...

Page 860: ...er onto the exhaust manifold a Fit without tightening and in order the transversal bolt 17 nuts 18 and 19 on the turbocharger a Pre tighten to torque the turbocharger lower nuts initial torque 12 N m...

Page 861: ...nual gearbox oils Drain ing Filling a Refit the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the engine undertray a Fit the intercooler air inlet pipe a Clip the intercooler...

Page 862: ...ip 3 from the intercooler inlet air pipe a Disconnect the intercooler air inlet pipe from the tur bocharger a Move aside the intercooler air inlet pipe a Remove the turbocharger oil supply pipe see 12...

Page 863: ...bocharger seal on the exhaust manifold REFITTING I REFITTING PREPARATION OPERATION a a parts always to be replaced seal between ex haust manifold and turbocharger 10 09 01 07 a Clean the bearing faces...

Page 864: ...charger 28 N m a Connect the pressure regulator valve hose on the pressure regulator valve side III FINAL OPERATION a Refit the turbocharger oil return pipe see 12B Turbo charging Turbocharger oil pi...

Page 865: ...le noid valve at 1 the oil vapour rebreathing pipe 2 a Loosen the turbocharger air inlet pipe clip 3 a Remove the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fittin...

Page 866: ...move the nut 5 of the intercooler air inlet pipe support a Remove the intercooler inlet air pipe a Remove the exhaust gas recirculation rigid pipe see 14A Antipollution Exhaust gas recirculation rigid...

Page 867: ...emove the exhaust gas cooler nuts 8 on the turbocharg er the bolts 9 from the intercooler a Move aside the exhaust gas recirculation solenoid valve exhaust gas cooler assembly a Remove the exhaust gas...

Page 868: ...arger cooling hose using the Mot 1448 a Disconnect the turbocharger cooling hose a Remove the clip 14 between the turbocharger and the back row exhaust manifold the clip 15 between the turbocharger an...

Page 869: ...19B 85 the exhaust gas pressure sensor 21 see 19B Exhaust Exhaust gas pressure sensor Re moval Refitting page 19B 93 the turbocharger upper oil pipe see 12B Turbo charging Turbocharger oil pipe Remov...

Page 870: ...ocharger air outlet pipe If replacing the turbocharger a Refit the turbocharger upper oil pipe see 12B Turbo charging Turbocharger oil pipe Removal Re fitting page 12B 35 the exhaust gas pressure sens...

Page 871: ...gas recirculation solenoid valve exhaust gas cooler assembly a Fit without tightening new exhaust gas cooler nuts on the turbocharger the exhaust gas cooler bolts on the back row rocker cover the bol...

Page 872: ...rger oil pipe Removal Refitting page 12B 35 the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the engine undertray a Connect the vacuum pipes of t...

Page 873: ...ation rigid pipe Removal Refitting page 14A 62 the exhaust gas pressure sensor see 19B Ex haust Exhaust gas pressure sensor Removal Refitting page 19B 93 the damper valve see 12A Fuel mixture Damp er...

Page 874: ...irculation assembly see 14A Antipollution Exhaust gas recirculation as sembly Removal Refitting page 14A 52 the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 the exhaus...

Page 875: ...erter Removal Refitting page 19B 32 a Disconnect the cooling hoses from the heater ma trix Special tooling required Ms 583 Pipe clamps Mot 1448 Remote operation pliers for hose clips Mot 1202 01 Clip...

Page 876: ...er cooling hoses a Move the clip away from the turbocharger cooling hose using the Mot 1448 or Mot 1202 01 or Mot 1202 02 a Disconnect the turbocharger cooling hoses a Remove the hollow bolts 2 on the...

Page 877: ...turbocharger oil supply pipe hollow bolt onto the cylinder block the turbocharger oil supply pipe bolt on the cylinder block a Torque tighten the turbocharger oil supply pipe hollow bolt on the cylin...

Page 878: ...otection the front right hand driveshaft see Front right hand driveshaft Removal Refitting MR 415 29A Driveshafts the rear suspended engine mounting see 19D Engine mounting Lower engine tie bar Re mov...

Page 879: ...N m III FINAL OPERATION a Refit the catalytic converter see 19B Exhaust Cata lytic converter Removal Refitting page 19B 32 the rear suspended engine mounting see 19D Engine mounting Lower engine tie...

Page 880: ...c converter see 19B Exhaust Catalytic converter Removal Refitting page 19B 32 a Remove the catalytic pre converter see 19B Ex haust Catalytic pre converter Removal Refit ting page 19B 22 II OPERATION...

Page 881: ...see 19B Exhaust Catalytic pre converter Removal Refitting page 19B 22 a Refit the engine tie bar see 19D Engine mounting Lower engine tie bar Removal Refitting page 19D 85 the differential output seal...

Page 882: ...y pipe nut on the cylinder head 35 N m turbocharger oil supply pipe hollow bolt 14 N m turbocharger oil return pipe bolts 12 N m IMPORTANT Wear leaktight gloves Nitrile type for this opera tion IMPORT...

Page 883: ...e air flow sensor connector 1 the turbocharging regulation solenoid valve con nector 2 a Unclip the electric wiring 3 from the air filter unit air outlet pipe a Undo the clips 4 for the air filter uni...

Page 884: ...l Mot 1746 the turbocharger oil supply pipe hollow bolt 14 N m III FINAL OPERATION a Fit the air filter unit air outlet pipe a Tighten the clips on the air outlet pipe of the air filter unit a Clip th...

Page 885: ...onnect the battery see Battery Removal Re fitting 80A Battery a Remove the engine undertray bolts the engine undertray the catalytic converter see 19B Exhaust Cata lytic converter Removal Refitting pa...

Page 886: ...oil return pipe O ring with engine oil II REFITTING OPERATION FOR PART CONCERNED a Fit the turbocharger oil return pipe on the cylinder block a Refit the turbocharger oil return pipe bolts a Torque ti...

Page 887: ...re converter stay studs on the cylin der block and on the gearbox 8 N m catalytic pre converter upper stay nut 21 N m lower stay nuts on the upper stay 21 N m lower stay nuts on the cylinder block and...

Page 888: ...charger cooling hose using the Mot 1448 a Disconnect the turbocharger cooling hose a Remove the nut 2 of the turbocharger cooling hose on the catalytic pre converter the turbocharger heat shield nuts...

Page 889: ...lower stay nuts 8 the catalytic pre converter lower stay a Loosen the nut 9 of the catalytic pre converter up per stay a Remove the catalytic pre converter upper stay a Remove the nut 10 of the rigid...

Page 890: ...tic pre convert er and the turbocharger a Rotate the clip 13 on the intercooler air inlet pipe a Disconnect the intercooler air inlet pipe a Remove the intercooler inlet air pipe a Unclip the turbocha...

Page 891: ...ve the lower oil return pipe bolts 17 the lower oil return pipe the lower oil pipe seals REFITTING THE OIL SUPPLY PIPE AND THE LOWER OIL RETURN PIPE OF THE TURBOCHARGER I REFITTING PREPARATION OPERATI...

Page 892: ...e intercooler air inlet pipe on the turbocharger side II REFITTING OPERATION FOR PART CONCERNED 1 Refitting the oil supply pipe a Refit new seals on the turbocharger oil supply pipe a new turbocharger...

Page 893: ...per stay a Torque tighten the catalytic pre converter stay studs on the cylinder block and on the gearbox 8 N m a Fit without tightening the lower stay nuts on the cylinder block and on the gearbox t...

Page 894: ...Tur bocharger oil pipe Removal Refitting page 12B 35 the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the exhaust gas recirculation rigid pipe see 14A Antipollut...

Page 895: ...oil pipe Removal Refitting page 12B 35 the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 a Fill and bleed the cooling system see 19A Cool ing Cool...

Page 896: ...age 14A 52 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the turbocharger oil supply pipe hollow bolt 1 a Loosen the nut 2 of the turbocharger oil supply pipe using the tool Mot 1566 or the tool...

Page 897: ...oval Refitting page 14A 62 the exhaust gases duct at the turbocharger outlet see Turbocharger outlet exhaust gas duct Re moval Refitting the engine undertray the exhaust fuel injector cooler see 19B E...

Page 898: ...T CONCERNED a Refit the new seals onto the turbocharger oil return pipe a Lubricate the turbocharger oil return pipe O ring with clean engine oil a Refit the turbocharger oil return pipe a Torque tigh...

Page 899: ...protection the front bumper see Front bumper Removal Refitting MR 416 55A Exterior protection a Fit a safety strap s to the engine cooling fan condenser cooling radiator assembly a Remove the power as...

Page 900: ...new seal on the intercooler air inlet pipe a Connect the intercooler air inlet pipe a Push the intercooler air inlet pipe clip III FINAL OPERATION a Refit the radiator mounting cross member see Radia...

Page 901: ...e front wheels see Wheel Removal Refitting MR 415 35A Wheels and tyres the front wheel arch liners see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the radiator mounting cro...

Page 902: ...radia tor deflectors on the intercooler a Press on the intercooler pads 3 a Rotate the intercooler 4 a Separate the intercooler from the cooling radiator REFITTING I REFITTING PREPARATION OPERATION a...

Page 903: ...l the intercooler air outlet pipe seal a a Fit the new seal taking care to observe the fitting di rection II REFITTING OPERATION FOR PART CONCERNED a Clip the intercooler at 5 the intercooler at 6 the...

Page 904: ...utlet pipe a Refit the radiator mounting cross member see Radiator mounting cross member Removal Refitting MR 415 41A Front lower structure the front wheel arch liners see Front wheel arch liner Remov...

Page 905: ...g cross member see Radiator mounting cross member Removal Refitting MR 416 41A Front lower structure II OPERATION FOR REMOVAL OF PART CONCERNED a Pivot the turbocharger air outlet pipe clip 1 a Discon...

Page 906: ...p the turbocharger air outlet pipe to the intercool er III FINAL OPERATION a Remove the radiator mounting cross member see Radiator mounting cross member Removal Refitting MR 416 41A Front lower struc...

Page 907: ...g 55A Exterior protec tion the front bumper see Front bumper Removal Refitting 55A Exterior protection the radiator mounting cross member see Radiator mounting cross member Removal Refitting 41A Front...

Page 908: ...osen the clip 4 on the intercooler outlet air pipe a Disconnect the intercooler air outlet pipe a Move the intercooler outlet air pipe to one side a Rotate the clip 5 on the intercooler air inlet pipe...

Page 909: ...cooling hose support from the intercooler a Refit on the new intercooler the cooling hose support on the intercooler the air conditioning pipe support the bolts of the air conditioning pipe support RE...

Page 910: ...ercooler air outlet pipe on the intercooler a Connect the intercooler air outlet pipe on the inter cooler a Tighten the clip on the intercooler outlet pipe III FINAL OPERATION a Fit the air conditioni...

Page 911: ...ntercooler Removal Refitting V9X 12B the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels and tyres...

Page 912: ...2 for the intermediate pipe on the si lencer a Disconnect the intermediate pipe and the silencer IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and...

Page 913: ...the connector pipe seal a Lower the intermediate pipe and place it on the front and rear axles a Remove the particle filter see 19B Exhaust Parti cle filter Removal Refitting page 19B 71 a Remove the...

Page 914: ...thout damaging it II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the fuel pipe filler neck 8 from the body a Disconnect the priming pump union 9 from the fuel supply pipe a Insert the blanking pl...

Page 915: ...anual priming pump union to the fuel heater the manual priming pump union to the fuel supply pipe a Clip on the fuel pipe filler neck III FINAL OPERATION a Fit the bulkhead heat shield a Refit the bul...

Page 916: ...itting 55A Ex terior protection a Remove the right and left hand subframe protector bolts 1 the right and left hand subframe protectors IMPORTANT To avoid all risk of damage to the systems apply the s...

Page 917: ...silencer a Remove the intermediate pipe bolts 3 on the cata lytic converter a Lower the intermediate pipe and place it on the front and rear axles a Remove the particle filter see 19B Exhaust Parti c...

Page 918: ...thout damaging it II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the fuel pipe filler neck 6 from the body a Disconnect the priming pump union 7 from the fuel supply pipe a Insert the blanking pl...

Page 919: ...pump union 10 from the fuel filter a Insert the blanking plugs a Unclip the manual priming pump from the body a Remove the manual priming pump REFITTING I REFITTING PREPARATION OPERATION a Always rep...

Page 920: ...onverter the intermediate pipe bolts on the catalytic convert er a Fit the intermediate pipe bolts on the catalytic con verter without tightening them a Refit the intermediate pipe clip onto the silen...

Page 921: ...MPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and opera tion recommendations before carrying out any repair see 13B Diesel injection Diesel injec ti...

Page 922: ...pipes a Refit a new manual priming pump a Fit a union to the new manual priming pump pipe a Remove the blanking plugs from the fuel unions a Connect the fuel inlet union to the electric diesel fuel he...

Page 923: ...e 13B Diesel injection Diesel injection Precautions for the repair page 13B 1 a Remove the fuel filter clip nut 1 a Move aside the fuel filter taking care not to pull on the fuel pipes a a Disconnect...

Page 924: ...ection Diesel injection Precautions for the repair page 13B 1 a Disconnect the connector 3 from the electric diesel heater a Remove the fuel filter clip nut 4 a Move aside the fuel filter taking care...

Page 925: ...ect the fuel supply pipes a Refit the fuel filter clip nut a Connect the electric diesel fuel heater connector a Open the air bleed screw on the fuel filter a Position a hose on the air bleed screw an...

Page 926: ...efitting F4R or K4M or M4R 13A a The fuel filter is located in the tank and built into the pump sender filter assembly To remove the fil ter remove the pump sender filter assembly see 19C Tank Pump se...

Page 927: ...al Refitting V4Y 13A a The fuel filter is located in the tank and integrated into the pump sender filter assembly To re move the filter remove the pump sender filter assembly see 19C Tank Pump sender...

Page 928: ...el see Wheel Removal Refitting 35A Wheels and tyres the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the fuel filter see 13A Fuel supply Fuel...

Page 929: ...the engine then let it run for a few minutes to check that it starts properly and to check that there are no leaks REFITTING 2ND FITTING I REFITTING PREPARATION OPERATION a II REFITTING OPERATION FOR...

Page 930: ...e measuring unions Mot 1311 08 Union for taking fuel pres sure measurements IMPORTANT During this operation be sure to refrain from smoking or bringing red hot objects close to the working area be car...

Page 931: ...on Mot 1311 08 2 the T union Mot 1311 08 2 on the injector rail the injector rail fuel supply union 3 on the T union Mot 1311 08 a Disconnect fuel supply pipe union on the injector rail a Connect the...

Page 932: ...n the injector rail the injector rail fuel supply union 3 on the T union Mot 1311 08 a Start the engine a Record the pressure this should be constant at 3 5 bar a Switch off the engine III FINAL OPERA...

Page 933: ...1 08 Union for taking fuel pres sure measurements IMPORTANT During this operation be sure to refrain from smoking or bringing red hot objects close to the working area beware of fuel splashes when dis...

Page 934: ...he T union Mot 1311 08 a Start the vehicle to run the fuel pump a Read the pressure which should be constant a Switch off the engine III FINAL OPERATION a Disconnect the fuel pipe quick release union...

Page 935: ...he T union Mot 1311 08 Special tooling required Mot 1311 01 Pressure gauges and petrol pressure measuring unions Mot 1311 08 Union for taking fuel pres sure measurements Equipment required graduated m...

Page 936: ...union Mot 1311 08 a Unclip the fuel pipe from the right hand suspended engine mounting a Connect the T union Mot 1311 08 1 to the injector rail the fuel supply union to the T union Mot 1311 08 II FUEL...

Page 937: ...t the brown 12 track connector a Clip the Protection and Switching Unit cover back on a Disconnect the fuel supply union on the T union Mot 1311 08 the T union Mot 1311 08 on the injector rail a Conne...

Page 938: ...cylinder a Unclip the Protection and Switching Unit cover the Protection and Switching Unit Special tooling required Mot 1311 01 Pressure gauges and petrol pressure measuring unions Mot 1311 08 Union...

Page 939: ...d Switching Unit a Clip the Protection and Switching Unit the Protection and Switching Unit cover a Disconnect the fuel supply pipe quick release union from the T union Mot 1311 08 the quick release T...

Page 940: ...once only and used plugs must be discarded after use once used the plugs are soiled and cleaning them is not sufficient to make them reusable Unused plugs must also be discarded and must not be used w...

Page 941: ...nt air can be a source of impurities After opening the fuel circuit the use of brushes clean ing agents air blow guns rifle type brushes or stan dard cloths is strictly prohibited these items are like...

Page 942: ...air tools workbench and also parts unions and around the injection system Check that no bristles from the brush have come away and that the area is clean Open the circuit at the unions and immediately...

Page 943: ...13B 4 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B K9K...

Page 944: ...13B 5 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B Set of plugs for DELPHI injection...

Page 945: ...13B 6 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B 20977...

Page 946: ...13B 7 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B Set of plugs for SIEMENS injection...

Page 947: ...13B 8 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B 113430...

Page 948: ...13B 9 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B M9R...

Page 949: ...13B 10 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B Set of plugs...

Page 950: ...13B 11 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B 113737...

Page 951: ...13B 12 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B V9X...

Page 952: ...13B 13 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B Set of plugs...

Page 953: ...13B 14 DIESEL INJECTION Diesel injection Precautions for the repair K9K or M9R or V9X 13B 138585...

Page 954: ...iesel injectors 4 Rail pressure sensor 5 Fuel temperature sensor 6 High pressure pump 7 Air flowmeter 8 Diesel injection computer 9 Turbocharger control solenoid valve 10 EGR cooling control solenoid...

Page 955: ...ion List and location of components M9R and 742 or 744 or 746 or 748 or 754 13B 122432 5 Fuel temperature sensor M9R and 742 or 746 113291 6 High pressure pump M9R and 744 or 748 or 754 124534 6 High...

Page 956: ...injection List and location of components M9R and 742 or 744 or 746 or 748 or 754 13B 122399 8 Diesel injection computer 122424 9 Turbocharger control solenoid valve 122431 10 Camshaft position senso...

Page 957: ...13B 18 DIESEL INJECTION Diesel injection List and location of components M9R and 742 or 744 or 746 or 748 or 754 13B 122426 12 Damper valve 13 Turbocharger pressure sensor 122429 16 Preheating unit...

Page 958: ...ure pump 3 Exhaust gas recirculation sole noid valve 4 Diesel injectors 5 Camshaft position sensor 6 Turbocharging air pressure sen sor 7 Air flowmeter 8 Protection and Switching Unit 9 Diesel injecti...

Page 959: ...B 20 DIESEL INJECTION Diesel injection List and location of components K9K 13B 111748 2 High pressure pump 111746 4 Diesel injectors 121888 5 Camshaft position sensor 122399 9 Diesel injection compute...

Page 960: ...injection List and location of components K9K 13B 123827 10 Coolant temperature sensor 114076 11 Rail pressure sensor 111747 12 Fuel temperature sensor 123846 13 Flow regulation solenoid valve 14 Pres...

Page 961: ...13B 22 DIESEL INJECTION Diesel injection List and location of components K9K 13B 123824 15 Crankshaft position sensor 122429 16 Pre postheating unit...

Page 962: ...ressure regulator 3 Injectors 4 Rail pressure sensor 5 Diesel temperature sensor 6 High pressure pump 7 Air flowmeter 8 Injection computer 9 Turbocharger control solenoid valve 10 EGR cooler control s...

Page 963: ...jection List and location of components M9R and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 13B 122432 5 Diesel temperature sensor 124534 6 High pressure pump 122425 7 Air flowmeter 12...

Page 964: ...mponents M9R and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 13B 122424 9 Turbocharger control solenoid valve 122431 11 Camshaft position sensor 123692 12 EGR solenoid valve 13 Turboch...

Page 965: ...perature sensor 4 High pressure pump 5 Air flowmeter 6 Injection computer 7 Turbocharger control solenoid valve 8 Exhaust gas cooler control sole noid valve 9 Camshaft position sensor 10 Exhaust gas r...

Page 966: ...JECTION Diesel injection List and location of components V9X 13B 137913 15 Exhaust gas temperature sensor 137863 16 Rail pressure sensor 137873 17 Electrical diesel fuel reheater 137954 18 Crankshaft...

Page 967: ...ECTION Diesel injection List and location of components V9X 13B 137917 19 Exhaust fuel injector 133892 20 Fuel pressure regulator 133903 21 Particle filter pressure sensor 133905 22 Particle filter te...

Page 968: ...13B 29 DIESEL INJECTION Diesel injection List and location of components V9X 13B 136260 23 Coolant temperature sensor 137878 24 Pre postheating unit...

Page 969: ...EL INJECTION Diesel injection List and location of components K9K and 782 13B 123520 1 Manual priming pump 138816 2 High pressure pump 138817 3 Exhaust gas recirculation sole noid valve 138545 4 Diese...

Page 970: ...SEL INJECTION Diesel injection List and location of components K9K and 782 13B 138549 5 Camshaft position sensor 138399 6 Turbocharging pressure sensor 143758 7 Air flowmeter 122399 8 Diesel injection...

Page 971: ...DIESEL INJECTION Diesel injection List and location of components K9K and 782 13B 114213 9 Coolant temperature sensor 138544 10 Rail pressure sensor 138897 11 Fuel temperature sensor 138394 12 Damper...

Page 972: ...List and location of components K9K and 782 13B 139195 13 Exhaust fuel injector solenoid valve 144222 14 Thermoplunger unit 144362 15 Electric diesel fuel heater 138541 16 Flow regulation solenoid val...

Page 973: ...CTION Diesel injection List and location of components K9K and 782 13B 123824 18 Crankshaft position sensor 122429 19 Pre postheating unit 139171 20 Exhaust gas temperature sensor 139201 21 Exhaust ga...

Page 974: ...13B 35 DIESEL INJECTION Diesel injection List and location of components K9K and 782 13B 139172 22 Exhaust fuel injector...

Page 975: ...ed in the procedure before repair section a Remove the battery see Battery Removal Refitting MR 415 80A Battery the battery tray see Battery tray Removal Re fitting MR 415 80A Battery II OPERATION FOR...

Page 976: ...the injection computer mounting nut a Connect the diesel injection computer connectors II FINAL OPERATION a Refit the battery tray see Battery tray Removal Re fitting MR 415 80A Battery the battery se...

Page 977: ...the procedure before repair section a Remove the battery see Battery Removal Refitting MR 415 80A Battery the battery tray see Battery tray Removal Re fitting MR 415 80A Battery II REMOVAL OPERATION...

Page 978: ...the injection computer mounting nut a Connect the diesel injection computer connectors II FINAL OPERATION a Refit the battery tray see Battery tray Removal Re fitting MR 415 80A Battery the battery se...

Page 979: ...m the diesel injec tion computer a Remove the protector cover 2 of the diesel injec tion computer II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the diesel injection computer bolts 3 the diesel i...

Page 980: ...sel injection com puter a Connect the diesel injection computer connectors a Connect the battery see Battery Removal Refit ting 80A Battery a Apply the after repair procedure using the Diagnos tic too...

Page 981: ...ler air inlet pipe on the intake distributor a Rotate the intercooler air inlet pipe clip 3 on the tur bocharger side a Remove the cooling radiator top hose the intercooler inlet air pipe II REMOVAL O...

Page 982: ...tion sensor seal a Lubricate the camshaft position sensor seal with en gine oil a Refit the camshaft position sensor the camshaft position sensor bolt a Tighten the camshaft position sensor bolt III F...

Page 983: ...rcooler air inlet pipe bolts on the intake dis tributor the cooling radiator top hose nut on the intercooler air inlet pipe a Tighten the intercooler air inlet pipe bolts on the intake dis tributor th...

Page 984: ...et pipe on the damper valve a Disconnect the intercooler air outlet pipe on the damper valve a Move aside the intercooler air outlet pipe from the damper valve II REMOVAL OPERATION FOR PART CONCERNED...

Page 985: ...eal II REFITTING OPERATION FOR PART CONCERNED a Refit the new camshaft position sensor seal the camshaft position sensor the camshaft position sensor bolt a Tighten the camshaft position sensor bolt a...

Page 986: ...the camshaft position sensor seal REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced camshaft sensor seal 11 11 04 02 a Lubricate the camshaft position sensor seal with en gine...

Page 987: ...intercooler air inlet pipe a Disconnect the intercooler air inlet pipe a Move aside the intercooler air inlet pipe a Disconnect the turbocharger pressure sensor con nector 4 a Unclip the wiring 5 fro...

Page 988: ...the camshaft position sensor seal REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced camshaft sensor seal 11 11 04 02 a parts always to be replaced turbocharger air cooler air o...

Page 989: ...nect the camshaft position sensor connector III FINAL OPERATION a Refit the injector rail protector cover a Clip on the damper valve wiring a Fit the clip for the intercooler air outlet pipe a Clip th...

Page 990: ...ft position sensor bolt 2 the crankshaft position sensor the crankshaft position sensor O ring REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the crankshaft position sensor O ring II RE...

Page 991: ...13B 52 DIESEL INJECTION Crankshaft position sensor Removal Refitting M9R 13B III FINAL OPERATION a Refit the engine undertray the engine undertray bolts...

Page 992: ...I REMOVAL OPERATION FOR PART CONCERNED a Disconnect the crankshaft position sensor connector 1 a Remove the crankshaft position sensor bolt 2 the crankshaft position sensor REFITTING I REFITTING OPERA...

Page 993: ...FOR REMOVAL OF PART CONCERNED a Disconnect the crankshaft position sensor connector 1 a Remove the crankshaft position sensor bolt 2 the crankshaft position sensor REFITTING I REFITTING OPERATION FOR...

Page 994: ...outlet air pipe away from the damper valve a Disconnect the damper valve connector 2 the connector 3 from the camshaft position sen sor a Detach 4 the electrical wiring from the injector rail protecto...

Page 995: ...pipe 11 a Disconnect the diesel injector fuel return rail from the high pressure pump a Fit a blanking plug on the diesel injector fuel return rail opening a Connect the 8 mm diameter angled union fi...

Page 996: ...a Move the intercooler inlet air pipe to one side a Remove the dipstick the dipstick well bolts a Move the dipstick well to one side a Disconnect the 8 mm diameter angled union fitted with its hose c...

Page 997: ...ling required Mot 1771 Kit for measuring SIEMENS injector leakage flow rate Equipment required graduated measuring cylinder self contained starter Diagnostic tool tweezers IMPORTANT To avoid all risk...

Page 998: ...a Unclip the wiring 7 of the damper valve a Unclip the injector rail protector cover at 8 a Remove the bolts 9 from the injector rail protector cover the cover of the injector rail protector a Discon...

Page 999: ...ctions VP036 Inhibit fuel supply a Run the starter for 15 seconds a Check that the minimum flow is 25 ml for 15 sec onds a Run command VP037 Stop fuel supply inhibition a Disconnect the Diagnostic too...

Page 1000: ...rail to the high pressure pump a Refit the injector rail protector cover a Clip on the damper valve wiring a Fit the clip for the intercooler air outlet pipe a Clip the intercooler air outlet pipe on...

Page 1001: ...ler inlet air pipe to one side a Remove the injector rail protector see 13B Diesel injec tion Injector rail protector Removal Refitting page 13B 126 the high pressure pipe between the pump and the rai...

Page 1002: ...h pressure pump O ring REFITTING I REFITTING PREPARATION OPERATION a Always replace the high pressure pump O ring the high pressure pump bolts the intercooler air inlet pipe seal If replacing the high...

Page 1003: ...arm 8 on the separator a Remove the high pressure pump pinion the separator and the arm a Refit the pinion to the new high pressure pump a Secure the high pressure pump pinion in a vice s protective j...

Page 1004: ...e pump the high pressure pump bolts 115069 Note Check that the intercooler air inlet pipe seal is fit ted in the right direction on the turbocharger side WARNING Do not remove the blanking plugs from...

Page 1005: ...k that there are no leaks a Disconnect the intercooler air inlet pipe from the tur bocharger a Move the intercooler inlet air pipe to one side a Refit the injector rail protector see 13B Diesel in jec...

Page 1006: ...onnect the intercooler air inlet pipe on the turbo charger side a Move the intercooler inlet air pipe to one side a Remove the injector rail protector see 13B Diesel injec tion Injector rail protector...

Page 1007: ...r connector 5 on the high pressure pump the fuel pipes 6 on the high pressure pump a Remove the high pressure pump bolts 7 the high pressure pump the high pressure pump O ring REFITTING I REFITTING PR...

Page 1008: ...l at the tur bocharger end using a tweezers a a Refit a new seal to the intercooler air inlet pipe at the turbocharger end a Rotate the intercooler air inlet pipe clip in order to re fit it in its gro...

Page 1009: ...ive jaws a Torque tighten the high pressure pump pinion nut 90 N m II REFITTING OPERATION FOR PART CONCERNED a a Lubricate the new high pressure pump seal with en gine oil a Refit the new high pressur...

Page 1010: ...njector rail protector see 13B Diesel injec tion Injector rail protector Removal Refitting page 13B 126 a Fit the intercooler air inlet pipe a Clip the intercooler air inlet pipe on the turbocharger s...

Page 1011: ...ont of engine Crankshaft accessories pulley Removal Refitting page 11A 33 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 1...

Page 1012: ...alve connector 3 the connector 4 from the camshaft position sen sor a Unpick the electrical wiring from the injector rail pro tector cover a Move the electrical wiringto one side a Remove the bolt 5 o...

Page 1013: ...ector rail protector cover the dipstick the dipstick well bolts 11 the dipstick well a Clean the high pressure pump supply 12 and 13 fuel return rail unions see 13B Diesel injection Diesel injection P...

Page 1014: ...the fuel temperature sensor connector 18 a Unclip the injection wiring clip 19 a Remove the nut 20 from the injection wiring brack et a Move aside the rail protector injection wiring a Remove the rail...

Page 1015: ...for the repair page 13B 1 a Disconnect the diesel return union 23 from the high pressure pump a Fit suitable blanking plugs on the diesel return pipe and on the high pressure pump II OPERATION FOR RE...

Page 1016: ...ing it by the lower mounting on the pulley side a Refit the high pressure pump pulley the high pressure pump pulley nut a Immobilise the high pressure pulley using a offset spanner or with the Mot 799...

Page 1017: ...turbocharger a Refit the nut on the intercooler air inlet pipe the bolt on the intercooler air inlet pipe a Tighten the nut on the intercooler air inlet pipe the bolt on the intercooler air inlet pipe...

Page 1018: ...computer a Check that there are no diesel leaks check the sealing after repair see 13B Diesel in jection High pressure pipe Check page 13B 134 run the engine at idling speed until the engine cool ing...

Page 1019: ...13B Diesel injection Injector rail protector Removal Re fitting page 13B 126 the high pressure pipe between the pump and the rail see 13B Diesel injection High pressure pipe between pump and rail Rem...

Page 1020: ...ect the fuel return union 2 on the high pressure pump the fuel supply union 3 on the high pressure pump a Fit blanking plugs on the fuel supply and return unions a Remove the high pressure pump bolts...

Page 1021: ...h jaws a Fit the Mot 1906 5 on the high pressure pump pinion a Fit the washers of the Mot 1906 on the high pres sure pump the nuts 6 of the Mot 1906 on the high pressure pump a Tighten the nuts 6 on t...

Page 1022: ...pinion the separator and the arm a Refit the pinion to the new high pressure pump the high pressure pump nut a Put the high pressure pump in a vice with jaws a Fit the Mot 1906 the washers of the Mot...

Page 1023: ...unit Removal Refitting page 12A 13 a Connect the battery see Battery Removal Refit ting 80A Battery a Fill and bleed the cooling system see 19A Cool ing Cooling system Draining Refilling page 19A 16 a...

Page 1024: ...ne Crankshaft accessories pulley Removal Refitting page 11A 33 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the t...

Page 1025: ...ming cover bolts 4 the inner timing cover a Disconnect the fuel supply pipe union 5 from the high pressure pump a Fit a suitable blanking plug on the opening of the fuel supply pipe union the high pre...

Page 1026: ...13B II FINAL OPERATION a Remove the high pressure pump bolts 7 the high pressure pump REFITTING I REFITTING PREPARATION OPERATION If replacing the high pressure pump a Remove the bolt 8 from the high...

Page 1027: ...lenoid valve supply pipe the high pressure pump a Remove the high pressure pump pulley a a Place the high pressure pump in a vice with jaws securing it at the lower mounting on the high pres sure pump...

Page 1028: ...I REFITTING OPERATION FOR PART CONCERNED a Refit the high pressure pump a Torque tighten the high pressure pump bolts 23 N m III FINAL OPERATION a Remove the blanking plugs from the opening of the hig...

Page 1029: ...tting 55A Ex terior protection the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the high pressure pipe between the pump and the rail see 13B Diesel injection High pressure p...

Page 1030: ...lter box air outlet pipe the turbocharging pressure regulator control pipe of the turbocharger on the air filter unit air outlet pipe a Remove the air filter box air outlet pipe II OPERATION FOR REMOV...

Page 1031: ...to clean the fuel pressure regulator bearing faces a Wipe the bearing face of the fuel pressure regulator on the high pressure pump using a compressed air nozzle see 13B Diesel injection Diesel injec...

Page 1032: ...el pressure regulator bolts 6 Nm a Connect the fuel pressure regulator connector III FINAL OPERATION a Fit the engine wiring a Remove the blanking plug a Connect the fuel return pipe quick release uni...

Page 1033: ...lter box air outlet pipe the turbocharging pressure regulator control pipe on the air filter box air outlet pipe a Loosen the air filter box air outlet pipe clip on the tur bocharger side a Remove the...

Page 1034: ...high pressure pump a Flush the fuel pressure regulator housing by activat ing the manual priming pump II REFITTING OPERATION FOR PART CONCERNED a Refit the fuel pressure regulator rotating it slightly...

Page 1035: ...bles Products to clean the bearing faces of the fuel pressure regulator a Wipe the bearing face of the fuel pressure regulator on the high pressure pump using a compressed air nozzle see 13B Diesel in...

Page 1036: ...fuel pressure regulator by gently rotating it clockwise and gently pushing it until it is complete ly in a Torque tighten the fuel pressure regulator bolts 6 N m a Connect the fuel pressure regulator...

Page 1037: ...er air inlet pipe bolts 2 a Rotate the intercooler air inlet pipe clip 3 a Remove the injector rail protector see 13B Diesel injection Injector rail protector Removal Refit ting page 13B 126 II OPERAT...

Page 1038: ...the injector rail a Fit a blanking plug on the injector rail a Disconnect the fuel return pipe 6 from the injector return rail a Fit a blanking plug on the injector return rail a Disconnect the diese...

Page 1039: ...RT CONCERNED a a Fit the fuel return pipe a Remove the blanking plugs 115068 115069 Note Check that the intercooler air inlet pipe seal is fit ted in the right direction on the turbocharger side WARNI...

Page 1040: ...e 13B 126 a Connect the intercooler air inlet pipe to the turbo charger a Refit the bolts for the intercooler inlet air pipe on the intake distributor a Tighten the intercooler air inlet pipe bolts on...

Page 1041: ...inlet pipe on the inlet distributor a Rotate the intercooler air inlet pipe clip 3 at the tur bocharger end a Disconnect the intercooler air inlet pipe on the turbo charger side a Move the intercoole...

Page 1042: ...fuel return pipe 4 a Fit blanking plugs a Disconnect the fuel return pipe 5 on the high pres sure pump a Fit a blanking plug a Remove the fuel return pipe REFITTING I REFITTING PREPARATION OPERATION...

Page 1043: ...t pipe on the turbocharger side a Refit the intercooler air inlet pipe bolts on the inlet distributor a Tighten the intercooler air inlet pipe bolts on the inlet distributor a Fit the radiator top hos...

Page 1044: ...ve the cover of the front row injector rail pro tector Equipment required Diagnostic tool IMPORTANT Consult the safety and cleanliness advice and oper ation recommendations before carrying out any rep...

Page 1045: ...ON FOR PART CONCERNED a Refit the fuel return pipe a Clip the fuel return pipe on the fuel supply pipe the fuel return pipe on its support a Remove the blanking plug from the fuel return pipe union a...

Page 1046: ...Refitting V9X 13B a Check the correct operation of the high pressure fuel cir cuit that there are no leaks a Refit the cover of the front row injector rail protector a Clip on the cover of the front r...

Page 1047: ...a Move aside the cooling radiator top hose a Remove the intercooler air inlet pipe bolts 2 a Rotate the intercooler air inlet pipe clip 3 a Remove the injector rail protector see 13B Diesel injec tio...

Page 1048: ...on the injector fuel return rail a Remove the bolt 2 from the injector fuel return rail union a Lift up the clips 3 between the fuel return rail and the injectors using a flat blade screwdriver a Disc...

Page 1049: ...the injector fuel return rail a Clip on the injector fuel return rail unions a Connect the injector fuel return rail quick release union a Refit the injector fuel return rail bolt on the rocker cover...

Page 1050: ...cooler inlet air pipe to one side a Refit the injector rail protector see 13B Diesel in jection Injector rail protector Removal Refit ting page 13B 126 a Connect the intercooler air inlet pipe to the...

Page 1051: ...d injector Removal Refitting page 13B 161 Special tooling required Mot 1448 Remote operation pliers for hose clips Equipment required Diagnostic tool IMPORTANT Consult the safety and cleanliness advic...

Page 1052: ...he back row injector rail protector a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Separate the clip 5 of the exhaust gas recirculation solenoid valve cool...

Page 1053: ...row injector rail protector a Undo the clamp 8 on the intercooler air outlet pipe the clip 9 of the intercooler air outlet pipe on the damper valve a Remove the intercooler air outlet pipe II OPERATI...

Page 1054: ...he exhaust gas recirculation solenoid valve the cooling hose a Refit the high pressure pipe between injector 1 and the injector rail see 13B Diesel injection High pres sure pipe between rail and injec...

Page 1055: ...13B 116 DIESEL INJECTION Diesel injector fuel return rail Removal Refitting V9X 13B a Check the correct operation of the high pressure fuel cir cuit that there are no leaks a Refit the engine cover...

Page 1056: ...ft position sen sor a Unpick the electrical wiring from the injector rail pro tector cover a Move the electrical wiring to one side a Remove the bolt 4 on the intercooler air inlet pipe the nut 5 on t...

Page 1057: ...OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the fuel temperature sensor connector 11 a Clean the diesel injector fuel return rail unions 12 on the high pressure pump see 13B Diesel injec tion...

Page 1058: ...move the diesel injector fuel return rail unions 16 while pressing 15 on the lower tabs of the clips using a thin flat blade screwdriver a Fit suitable blanking plugs on the diesel injector fuel retur...

Page 1059: ...rail using SILICONE FREE LUBRICANT see Ve hicle Parts and consumables for the repair 04B Consumables Products so that the seals are completely covered with product a Position the unions of the diesel...

Page 1060: ...tector cover a Fit the intercooler air inlet pipe the clip on the intercooler inlet air pipe in its original position a Clip the intercooler air inlet pipe on the turbocharger a Refit the nut on the i...

Page 1061: ...side the intercooler air inlet pipe Equipment required tweezers IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and opera tion recommendations before...

Page 1062: ...pressure sensor a Pull the clip 6 of the intercooler air outlet pipe a Move the intercooler air outlet pipe to one side a Unclip the wiring 7 of the damper valve a Unclip the injector rail protector c...

Page 1063: ...he blanking plugs a Disconnect the union 14 of the diesel injector fuel return rail a Insert the blanking plugs a Unclip the diesel injector fuel return rail 15 a Remove the diesel injector fuel retur...

Page 1064: ...king plugs from the opening of the diesel fuel return pipe union the opening of the diesel injector fuel return rail a Connect the diesel return pipe the fuel temperature sensor connector III FINAL OP...

Page 1065: ...ove the nut 1 from the cooling radiator top hose on the intercooler air inlet pipe the bolts 2 from the intercooler air inlet pipe on the intake distributor a Move aside the cooling radiator top hose...

Page 1066: ...ITTING OPERATION FOR PART CONCERNED a Refit the injection rail protector the injector rail protector bolts a Tighten the injector rail protector bolts a Refit the injector rail protector panel III FIN...

Page 1067: ...28 DIESEL INJECTION Injector rail protector Removal Refitting M9R 13B a Tighten the intercooler air inlet pipe bolts on the air intake distributor the cooling radiator top hose nut a Refit the engine...

Page 1068: ...jec tion Precautions for the repair page 13B 1 IMPORTANT Use the diagnostic tool before any operation is car ried out on the injection circuit to check that the rail is not under pressure that the fue...

Page 1069: ...he vacuum pipe from the rail protector at 5 a Remove the bolts 6 of the front row injector rail protector the front row injector rail protector the seal of the front row injector rail protector REFITT...

Page 1070: ...oval Re fitting 80A Battery a Remove the engine cover the engine undertray bolts the engine undertray a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove...

Page 1071: ...of the back row injector rail protector the back row injector rail protector the seal of the back row injector rail protector REFITTING THE BACK ROW INJECTOR RAIL PROTECTOR I REFITTING PREPARATION OP...

Page 1072: ...2 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the lower engine tie bars see 1 9 D Engine mounting Lower engine t...

Page 1073: ...amper valve connector 2 the connector 3 from the camshaft position sen sor a Detach the electrical wiring from the injector rail pro tector cover a Move aside the electrical wiring a Remove the interc...

Page 1074: ...NED a Apply the checking procedure using the Diagnostic tool connect the Diagnostic tool select the diesel injection computer go to repair mode display the before after repair procedure for the comput...

Page 1075: ...Clip the intercooler air inlet pipe to the turbocharger a Refit the nut to the intercooler air inlet pipe the intercooler air inlet hose bolt a Tighten the nut to the intercooler air inlet pipe the i...

Page 1076: ...nlet pipe a Move aside the intercooler air inlet pipe Equipment required Diagnostic tool tweezers IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and...

Page 1077: ...intercooler air outlet pipe a Clip the intercooler air outlet pipe on the damper valve a Connect the turbocharger pressure sensor connec tor a Refit the clip of the intercooler air inlet pipe a Clip t...

Page 1078: ...tercooler air outlet pipe seal a new intercooler air inlet pipe seal a Refit the injector rail protector cover a Clip on the damper valve wiring a Fit the clip for the intercooler air outlet pipe a Cl...

Page 1079: ...13B 126 Tightening torquesm nut of the high pressure pipe between the pump and the rail on the high pressure pump side 32 N m nut of the high pressure pipe between the pump and the rail on the injec t...

Page 1080: ...high pressure pipe mounting between the pump and the rail the nut 7 of the high pressure pipe between the pump and the rail on the high pressure pump using the tool part number 77 11 223 720 the nut...

Page 1081: ...h pres sure pipe and the rocker cover a Fit without tightening the nuts on the high pressure pipe between the pump and the rail starting with the nut on the injector rail side a Tighten to torque the...

Page 1082: ...over III FINAL OPERATION a Temporarily refit the intercooler air inlet pipe a Connect the battery see Battery Removal Refit ting 80A Battery a Start the engine a Accelerate several times under no load...

Page 1083: ...emove the injector rail protector see 13B Diesel injec tion Injector rail protector Removal Refitting page 13B 126 Equipment required tweezers Tightening torquesm nut of the high pressure pipe between...

Page 1084: ...een the pump and the rail on the injector rail using the tool part number 77 11 223 721 the nut 8 of the high pressure pipe between the pump and the rail on the high pressure pump using the tool part...

Page 1085: ...et pipe in order to refit it in its groove 115068 115069 Note Check that the intercooler air inlet pipe seal is fit ted in its groove the right way round WARNING Before fitting a new high pressure pip...

Page 1086: ...the nut on the high pressure pipe between the pump and the rail on the high pressure pump side the bolts for the high pressure pipe between the pump and the rail on the rocker cover a Tighten the bolt...

Page 1087: ...injector rail pro tector cover Special tooling required Mot 1566 Tool for removing high pres sure pipes Mot 1746 Offset wrench for tightening High Pressure pump pipes Tightening torquesm yellow high p...

Page 1088: ...er air inlet pipe clip 6 a Disconnect the intercooler air inlet pipe from the tur bocharger a Move the intercooler air inlet pipe to one side a Detach the injector rail protector cover 7 a Remove the...

Page 1089: ...opening the injector rail opening REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the high pressure pipe between the pump and the rail II REFITTING OPERATION FOR PART CONCERNED a Take th...

Page 1090: ...rail protector cover the injector rail protector cover nut the injector rail protector cover bolt a Tighten the injector rail protector cover nut the injector rail protector cover bolt a Clip on the...

Page 1091: ...ssure pump side 30 N m nut of the high pressure pipe between the high pressure pump and the injector rail on the injec tor rail end 30 N m camshaft position sen sor bolt 10 N m IMPORTANT Consult the s...

Page 1092: ...high pressure union using a spanner the nut 4 of the high pressure pipe between the high pressure pump and the injector rail on the in jector rail using the tool Mot 1566 while holding the high press...

Page 1093: ...e injector rail on the rocker cover the protector for the nut of the high pressure pipe between the high pressure pump and the injector rail on the high pressure pump side III FINAL OPERATION a Refit...

Page 1094: ...ng high pres sure pipes Equipment required tweezers Tightening torquesm high pressure pipe nut between the pump and the rail on the high pres sure pump 28 N m high pressure pipe nut between the pump a...

Page 1095: ...sensor a Pull the clip 6 of the intercooler air outlet pipe a Move the intercooler air outlet pipe to one side a Unclip the wiring 7 of the damper valve a Unclip the injector rail protector cover at 8...

Page 1096: ...on the opening of the exhaust fuel injector solenoid valve on the opening of the union of the exhaust fuel in jector solenoid valve supply pipe a Unclip the diesel injector wiring 15 a Disconnect the...

Page 1097: ...the high pressure pipe between the pump and the rail on the high pressure pump the nut 24 of the high pressure pipe between the pump and the rail on the injector rail the high pressure pipe between t...

Page 1098: ...9 04 04 a Use a tweezers to remove the intercooler air outlet pipe seal the intercooler air inlet pipe seal a a Refit a new intercooler air outlet pipe seal 20960 WARNING Before fitting a new high pre...

Page 1099: ...ter plug connectors the connectors of the diesel injectors a Clip on the diesel injector wiring a Remove the blanking plugs from the opening of the union of the exhaust fuel injector solenoid valve su...

Page 1100: ...il see 13B Diesel injection Diesel injector fuel return rail Re moval Refitting page 13B 108 Equipment required tweezers Tightening torquesm nuts on the high pres sure pipes between the rail and the i...

Page 1101: ...r air inlet pipe seal a a Remove the intercooler air inlet pipe seal on the tur bocharger side using a tweezers 123589 Note Loosen the nuts pipe by pipe WARNING T o prevent impurities from entering th...

Page 1102: ...or fuel return rail Re moval Refitting page 13B 108 the oil separator see 11A Top and front of en gine Oil decanter Removal Refitting page 11A 307 a Temporarily refit the intercooler air inlet pipe a...

Page 1103: ...ector rail pro tector cover Special tooling required Mot 1566 Tool for removing high pres sure pipes Mot 1746 Offset wrench for tightening High Pressure pump pipes Tightening torquesm yellow high pres...

Page 1104: ...intercooler air inlet pipe from the tur bocharger a Move the intercooler inlet air pipe to one side a Unclip 7 the cover from the injector rail protector a Remove the injector rail protector cover bol...

Page 1105: ...on the rail side the nut for the high pressure pipe between the rail and the injector at the injector end the high pressure pipe between the rail and the in jector concerned a Insert the correct blank...

Page 1106: ...6 flow regulation solenoid valve connector the fuel temperature sensor connector 17 a Unclip the injection wiring clip 18 a Remove the nut 19 from the injection wiring brack et a Move aside the rail p...

Page 1107: ...the yellow high pressure pipe unions between the rail and the injector 24 N m the silver high pressure pipe unions between the rail and the injector 28 N m 2 Refitting the four high pressure pipes a R...

Page 1108: ...ail protector cover nut the injector rail protector cover bolt a Tighten the injector rail protector cover nut the injector rail protector cover bolt a Clip on the injector rail protector cover a Fit...

Page 1109: ...on the high pres sure pipes between the injector rail and the injectors on the injector rail side 30 N m nuts on the high pres sure pipes between the injector rail and the injectors on the injector si...

Page 1110: ...between the injector rail and the injectors in the injector rail tapers the high pressure pipe olives between the injector rail and the injectors in the injector tapers a Fit the nuts of the high pre...

Page 1111: ...epair mode select the programming mode select command SC 035 HIGH PRESSURE FUEL CIRCUIT FAULT FINDING a Check the correct operation of the high pressure fuel cir cuit that there are no leaks a Refit t...

Page 1112: ...the injector rail and the injectors in the injector rail tapers the high pressure pipe olives between the injector rail and the injectors in the injector tapers a Fit the nuts of the high pressure pi...

Page 1113: ...circulation solenoid valve a Connect the battery see Battery Removal Refit ting 80A Battery a Prime the diesel circuit using the manual priming pump a Switch on forced after ignition a Connect the Dia...

Page 1114: ...moving high pres sure pipes Equipment required tweezers Tightening torquesm nuts on the high pres sure pipes between the rail and the injector on the injector rail side 28 N m nuts on the high pres su...

Page 1115: ...ip the wiring 5 of the turbocharging pressure sensor a Pull the clip 6 of the intercooler air outlet pipe a Move the intercooler air outlet pipe to one side a Unclip the wiring 7 of the damper valve a...

Page 1116: ...the high pressure pipe s between the in jector rail and the injectors a Fit blanking plugs on the opening s of the injector rail on the opening s of the injector s 2 Removing four high pressure pipes...

Page 1117: ...ensor connec tor 13 a Unclip the diesel drain pipe 14 from the injector rail protector a Unclip the alternator wiring 15 from the injector rail protector a Disconnect the union 16 of the exhaust fuel...

Page 1118: ...isconnect the diesel temperature sensor connector 19 the connector 20 for the fuel pressure regulation solenoid valve the connector 21 from the fuel flow regulating so lenoid valve a Unclip the diesel...

Page 1119: ...emove the high pressure pipes between the rail and the injectors a Fit blanking plugs on the injector rail openings on the injector openings 1327 WARNING The injector intermediate union 25 must be hel...

Page 1120: ...10 09 04 04 a Use a tweezers to remove the intercooler air outlet pipe seal the intercooler air inlet pipe seal a a Refit a new intercooler air outlet pipe seal 20960 WARNING Before fitting a new high...

Page 1121: ...connector the heater plug connectors the connectors of the diesel injectors a Clip on the diesel injector wiring a Remove the blanking plugs from the opening of the union of the exhaust fuel injector...

Page 1122: ...sen sor a Connect the turbocharger pressure sensor connec tor a Refit the clip of the intercooler air inlet pipe a Clip on the intercooler air inlet pipe a Refit the bolt on the intercooler air inlet...

Page 1123: ...of the high pressure pipe between the rails on the front row rail 30 N m nut of the high pressure pipe between the rails on the back row rail 30 N m IMPORTANT Consult the safety and cleanliness advic...

Page 1124: ...l protector from the front row see 13B Diesel injection Injector rail protector Re moval Refitting page 13B 126 a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 1...

Page 1125: ...p 7 of the intercooler air outlet pipe on the damper valve a Remove the intercooler air outlet pipe a Disconnect the heater plug connectors 8 a Move aside the heater plug wiring a Remove the bolts 9 f...

Page 1126: ...he high pressure pipe between the rails on the front row rail the olive of the high pressure pipe between the rails on the back row rail the rubber pads correctly between the high pres sure pipe and t...

Page 1127: ...er on the back row a Clip the injector rail protector cover on the back row a Clip the cooling hose the wiring of the exhaust gas recirculation solenoid valve a Connect the battery see Battery Removal...

Page 1128: ...njec tion Injector rail protector Removal Refitting page 13B 126 the oil decanter see 11A Top and front of en gine Oil decanter Removal Refitting page 11A 307 the high pressure pipes between the rail...

Page 1129: ...g bolts on the cylinder head a Move aside the engine harness mounting and the engine harness a Remove the injector rail bolts 7 the injector rail the injector rail seal REFITTING I REFITTING PREPARATI...

Page 1130: ...Fuel mixture Damp er valve Removal Refitting page 12A 39 the fuel return pipe see 13B Diesel injection Diesel return pipe Removal Refitting page 13B 98 the high pressure pipe between the pump and the...

Page 1131: ...distributor a Tighten the intercooler air inlet pipe bolts on the in take distributor a Fit the cooling radiator top hose on the intercooler air inlet pipe a Tighten the cooling radiator top hose nut...

Page 1132: ...the injector rail the injector rail REFITTING I REFITTING PREPARATION OPERATION a Always replace the high pressure pipe between the pump and the rail the high pressure pipes between the rail and the i...

Page 1133: ...onnect the battery see Battery Removal Refit ting 80A Battery a Refit the engine cover a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool select injection comput...

Page 1134: ...er stay 21 N m lower stay nuts on the cylinder block and on the gearbox 21 N m nuts of the lower stay on the catalytic pre con verter 21 N m turbocharger heat shield nuts 8 N m IMPORTANT To avoid all...

Page 1135: ...High pressure pipe between pump and rail Removal Refit ting page 13B 140 a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the high pressure pipe betw...

Page 1136: ...e front row 25 N m a Refit the injector rail protector on the front row see 13B Diesel injection Injector rail protector Remov al Refitting page 13B 126 a Fill and bleed the cooling system see 19A Coo...

Page 1137: ...esel injection High pressure pipe between rail and injector Removal Refitting page 13B 161 a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the high p...

Page 1138: ...5 from the catalytic pre converter lower stay a Remove the nuts 6 from the lower stay of the cata lytic pre converter a Remove the studs 7 from the lower stay of the catalytic pre converter the nuts 8...

Page 1139: ...e the rigid cooling pipes from the exhaust fuel injector cooler a Remove the turbocharger heat shield a Remove the nuts 11 from the turbocharger strut the bolts 12 from the turbocharger strut the turb...

Page 1140: ...pply and return pipes from the damper valve strut a Remove the damper valve strut II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the injector rail pressure sensor connec tor 16 from the back...

Page 1141: ...a Refit the damper valve see 12A Fuel mixture Damper valve Removal Refitting page 12A 39 a Torque tighten the new turbocharger studs 13 N m if they were loosened during removal a Refit the turbocharg...

Page 1142: ...efilling page 19A 16 a Refit the front bumper see Front bumper Removal Refitting 55A Exterior protection the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec ti...

Page 1143: ...see 13B Diesel injection High pressure pipe between rail and injector Removal Refit ting page 13B 161 the high pressure pipe between the pump and the rail see 13B Diesel injection High pressure pipe...

Page 1144: ...N Injector rail Removal Refitting K9K and 782 13B select Injector rail pressure sensor in the List of components controlled by this computer sec tion carry out the operations described in the After re...

Page 1145: ...njector rail pressure sensor 1 cannot be separat ed from the injector rail In the event of a fault on the rail pressure sensor re place the rail pressure sensor injector rail and high pressure pipes a...

Page 1146: ...MPORTANT Consult the safety and cleanliness advice and oper ation recommendations before carrying out any repair see 13B Diesel injection Diesel injec tion Precautions for the repair page 13B 1 WARNIN...

Page 1147: ...e sensor 5 a Fit a blanking plug REFITTING I REFITTING OPERATION FOR PART CONCERNED a a Remove the blanking plug 118569 118571 WARNING To prevent impurities from entering the circuit place protective...

Page 1148: ...ler air inlet pipe to the turbocharger a Fit the cooling radiator top hose a Refit the intercooler air inlet pipe bolts on the intake dis tributor the cooling radiator top hose nut on the intercooler...

Page 1149: ...n Exhaust gas recirculation rigid pipe Removal Refitting page 14A 62 the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 Equipment required Diagnostic tool Tightening tor...

Page 1150: ...r of the back row see 13B Diesel injection High pressure pipe between rail and injector Removal Refitting page 13B 161 the injector rail protector on the back row see 13B Diesel injection Injector rai...

Page 1151: ...13B 212 DIESEL INJECTION Rail pressure sensor Removal Refitting V9X 13B that there are no leaks a Refit the engine cover...

Page 1152: ...13B The injector rail pressure sensor cannot be separated from the injector rail In the event of a fault on the rail pressure sensor re place the rail pressure sensor injector rail assembly see 13B D...

Page 1153: ...the intercooler air inlet pipe on the intake distributor a Rotate the intercooler air inlet pipe clip 3 on the tur bocharger side a Move the intercooler inlet air pipe to one side a Remove the front r...

Page 1154: ...ure pump REFITTING I REFITTING OPERATION FOR PART CONCERNED a a Fit the pipe between the fuel filter and the high pres sure pump a Clip on the pipe between the fuel filter and the high pressure pump 1...

Page 1155: ...ion the front right hand wheel see Wheel Removal Refitting MR 415 35A Wheels and tyres a Clip the intercooler air inlet pipe to the turbocharger a Fit the cooling radiator top hose a Refit the interco...

Page 1156: ...mperature sensor onto the fuel return pipe a Connect the fuel temperature sensor connector II FINAL OPERATION a Connect the battery see Battery Removal Refit ting 80A Battery a Refit the engine cover...

Page 1157: ...re sensor cannot be separated from the diesel injector fuel return rail In the event of a fault on the fuel temperature sensor replace the diesel injector fuel return rail fuel temperature sensor asse...

Page 1158: ...sen sor a Unpick the electrical wiring from the injector rail pro tector cover a Move the electrical wiringto one side Special tooling required Mot 1771 Kit for measuring SIEMENS injector leakage flo...

Page 1159: ...r pipe a Disconnect the intercooler air inlet pipe from the tur bocharger a Move the intercooler inlet air pipe to one side a Unclip 7 the cover from the injector rail protector a Remove the injector...

Page 1160: ...brackets 12 on the injector fuel return union clips towards the rocker cover to unlock them and posi tion them fully up against the rocker cover 111747 111749 WARNING Ensure that the clip is not comp...

Page 1161: ...er 15 of the tool Mot 1711 a Refit the dipstick well the dipstick well bolts a Tighten the dipstick well bolts a Refit the dipstick a Fit the intercooler air inlet pipe the intercooler inlet air pipe...

Page 1162: ...the dipstick well bolts a Move the dipstick well to one side a Disconnect the four transparent pipes from the Mot 1771 a Push the injector diesel return union clips towards the front of the vehicle to...

Page 1163: ...Clip the intercooler air inlet pipe to the turbocharger a Refit the nut to the intercooler inlet air pipe the intercooler air inlet hose bolt a Tighten the nut to the intercooler inlet air pipe the i...

Page 1164: ...pe Special tooling required Mot 1711 Kit for measuring the injector fuel flow rate Equipment required self contained starter Diagnostic tool tweezers IMPORTANT To avoid all risk of damage to the syste...

Page 1165: ...r a Pull the clip 6 of the intercooler air outlet pipe a Move the intercooler air outlet pipe to one side a Unclip the wiring 7 of the damper valve a Unclip the injector rail protector cover at 8 a Re...

Page 1166: ...iesel injector return volume is great er than or equal to 20 ml a Repeat the starting phase twice allowing an interval of 30 seconds between each starting phase a Run command VP037 Stop fuel supply in...

Page 1167: ...n the damper valve a Clip on the wiring of the turbocharging pressure sen sor a Connect the turbocharger pressure sensor connec tor a Refit the clip of the intercooler air inlet pipe a Clip the interc...

Page 1168: ...il see 13B Diesel injection Diesel injector fuel return rail Re moval Refitting page 13B 108 Special tooling required Mot 1817 Injector well cleaning kit Equipment required indelible pencil tweezers D...

Page 1169: ...on to the cylinders using a indelible pencil a Remove the injector clamp bolts 4 the injector clamps the injectors one by one a Remove the heat protection washer 123590 WARNING T o prevent impurities...

Page 1170: ...wipe the injector with a new wipe see Vehicle Parts and consumables for the re pair 04B Consumables Products and see 13B Diesel injection Diesel injection Precau tions for the repair page 13B 1 a Alwa...

Page 1171: ...y the after repair procedure using the Diagnos tic tool connect the Diagnostic tool select the injection computer go to repair mode display the Before After repair procedure for the computer selected...

Page 1172: ...13B 233 DIESEL INJECTION Diesel injector Removal Refitting M9R 13B a Refit the nut of the cooling radiator top hose on the intercooler air inlet pipe a Refit the engine cover...

Page 1173: ...sel return pipe Removal Refitting page 13B 98 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolt 1 from the diesel injector clamp con cerned the diesel injector clamp concerned the spacer fr...

Page 1174: ...iesel injection Diesel injection Precau tions for the repair page 13B 1 II REFITTING OPERATION FOR PART CONCERNED a Remove the new diesel injector from its packaging a Remove the blanking plug from th...

Page 1175: ...B the high pressure pipe between the rail and injector on the injector concerned see 13B Diesel injec tion High pressure pipe between rail and injec tor Removal Refitting page 13B 161 a Connect the ba...

Page 1176: ...g out any repair see 13B Diesel injection Diesel injec tion Precautions for the repair page 13B 1 IMPORTANT Use the diagnostic tool before any operation is car ried out on the injection circuit to che...

Page 1177: ...njector fuel return rail a Move aside the fuel return rail a Insert the blanking plugs a Disconnect the injector connectors 2 a Mark the injectors in relation to the cylinders using a indelible pencil...

Page 1178: ...they were removed the injector clamps a Torque tighten the injector clamp bolts 35 N m a Connect the injector connectors a Remove the blanking plugs from the injectors a Position the fuel return rail...

Page 1179: ...IRCUIT FAULT FINDING a Check the correct operation of the high pressure fuel cir cuit that there are no leaks a Refit the engine cover REMOVING INJECTORS 3 AND 5 ON THE BACK ROW I REMOVAL PREPARATION...

Page 1180: ...the injector clamps the injectors a Remove the heat protection washers 134100 Note If the injectors are seized remove the bonnet see Bonnet Removal Refitting 48A Non side opening elements the injector...

Page 1181: ...e removed the injector clamps a Torque tighten the injector clamp bolts 35 N m a Connect the injector connectors a Remove the blanking plugs a Position the fuel return rail on the injectors a Connect...

Page 1182: ...rtray a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting pag...

Page 1183: ...move the heat protection washer 134100 Note If the injector is seized remove the bonnet see Bonnet Removal Refitting 48A Non side opening elements the injector using the tool Mot 921 01 and the tool E...

Page 1184: ...nect the injector connector a Remove the blanking plug a Position the fuel return rail on the injector a Connect the fuel return rail to the injector a Clip the fuel return rail unions onto the inject...

Page 1185: ...he manual priming pump a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool select the injection computer go to repair mode display the before after repair procedu...

Page 1186: ...diesel injec tor s concerned the bracket of the diesel injector s concerned Equipment required compressed air nozzle Diagnostic tool Tightening torquesm diesel injector bracket bolt 27 N m IMPORTANT...

Page 1187: ...on an extension piece 4 a Wrap a CLEANING CLOTH see Vehicle Parts and consumables for the repair 04B Consum ables Products around the socket extension piece assembly a Soak a CLEANING CLOTH in INJECTO...

Page 1188: ...ion High pressure pipe between rail and injec tor Removal Refitting page 13B 161 a Connect the battery see Battery Removal Refit ting 80A Battery a Check that there are no diesel leaks a Apply the aft...

Page 1189: ...the engine undertray II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the pre postheating unit connector a Remove the pre postheating unit nut the pre postheating unit REFITTING I REFITTING OPERA...

Page 1190: ...r Removal Refitting 55A Ex terior protection II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the pre postheating unit connector 1 a Remove the pre postheating unit nut 2 the pre postheating un...

Page 1191: ...lve a Disconnect the damper valve connector 2 the connector 3 from the camshaft position sen sor a Unpick the electrical wiring from the injector rail pro tector cover a Move aside the electrical wiri...

Page 1192: ...injector rail protector a Remove the injector rail protector cover bolt 8 the injector rail protector cover nut 9 the injector rail protector cover II REMOVAL OPERATION FOR PART CONCERNED a Disconnect...

Page 1193: ...protector cover nut the injector rail protector cover bolt a Clip on the injector rail protector cover a Fit the intercooler air inlet pipe the intercooler inlet air pipe clip in its original posi tio...

Page 1194: ...move the front engine cover a Unclip and move aside the fuel pipe at 1 II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the heater plug connectors 2 a Clean and blast around the heater plugs to pr...

Page 1195: ...gs a Torque tighten the heater plugs 18 Nm a Connect the heater plug connectors II FINAL OPERATION a Clip on the fuel pipe a Refit the engine cover 123618 Note If the heater plugs are seized see Heate...

Page 1196: ...front engine cover 2 Cylinder 3 heater plug a Remove the front engine cover a Unclip the fuel pipes from the support at 1 a Move the fuel pipesto one side 3 Cylinder 1 heater plug a Remove the engine...

Page 1197: ...ater plug connectors II FINAL OPERATION 1 Heater plug for cylinders 2 4 6 5 a Refit the engine cover 2 Cylinder 3 heater plug a Position the fuel pipes a Clip the fuel pipes onto the support a Refit t...

Page 1198: ...nlet pipe the bolt 2 on the intercooler air inlet pipe the clip 3 from the intercooler air inlet pipe a Disconnect the intercooler air inlet pipe a Move aside the intercooler air inlet pipe Equipment...

Page 1199: ...ipe a Move the intercooler air outlet pipe to one side a Unclip the wiring 7 of the damper valve a Unclip the injector rail protector cover at 8 a Remove the bolts 9 from the injector rail protector c...

Page 1200: ...it a new intercooler air outlet pipe seal a new intercooler air inlet pipe seal II REFITTING OPERATION FOR PART CONCERNED a Refit the heater plugs using a hose a Torque tighten the heater plugs 15 N m...

Page 1201: ...13C 13 PREHEATING Heater plugs Removal Refitting K9K and 782 13C a Refit the bolt on the intercooler air inlet pipe the nut on the intercooler air inlet pipe...

Page 1202: ...ing for medium and high loads Oil vapour rebreathing circuit for low loads Oil vapour rebreathing opening for low loads 21915 1 Oil vapour rebreathing circuit for medium and high loads 21884 2 Oil vap...

Page 1203: ...14A 2 ANTIPOLLUTION Oil vapour rebreathing circuit Description F4R 14A Oil decanter 21883 5 Oil decanter...

Page 1204: ...14A 3 ANTIPOLLUTION Oil vapour rebreathing circuit Operating diagram M9R 14A 124686 1 Engine 2 Oil decanter 3 Air filter box 4 Air filter box air outlet pipe 5 Turbocharger...

Page 1205: ...tities of oil vapour are sucked back in by the vacu um prevailing in the air inlet duct B At medium or high load the vacuum pressure pre vailing in the air inlet duct pulls the valve diaphragm and sma...

Page 1206: ...ram F4R 14A Operating diagram of the oil vapour rebreathing circuit for medium and high loads Operating diagram of the oil vapour rebreathing circuit for low loads 101956 101957 1 Engine 2 Oil decante...

Page 1207: ...on Operating diagram M9R 14A 113323 1 Engine 2 Air filter box 3 Turbocharger 4 Air to air intercooler 5 Air inlet valve 6 Exhaust gas recirculation sole noid valve 7 Inlet manifold 8 Exhaust manifold...

Page 1208: ...NTIPOLLUTION Fuel vapour recirculation circuit Operating diagram F4R or K4M or M4R 14A 97393 1 1 Inlet manifold 2 Fuel vapour absorber bleed solenoid valve 3 Fuel vapour absorber 4 Fuel tank 5 Fresh a...

Page 1209: ...diagnostic fault finding fuel va pour absorber bleeding is not authorised The opening cyclic ratio of the fuel vapour absorber bleed solenoid valve can be viewed on the Diagnos tic tool by reading pa...

Page 1210: ...RATION FOR PART CONCERNED a Refit the fuel vapour absorber on the fuel tank a Clip the fuel vapour absorber on the fuel tank II FINAL OPERATION a Refit the fuel tank see 19C Tank Fuel tank Removal Ref...

Page 1211: ...rcuit NO under bleed conditions see 14A Antipollu tion Fuel vapour recirculation circuit Check page 14A 8 the vacuum must be increased In the same time the value of the parameter on the Diag nostic to...

Page 1212: ...ooling hose a Remove the bolts 2 from the intercooler air inlet pipe on the intake distributor a Rotate the intercooler air inlet pipe clip 3 at the tur bocharger end a Disconnect the intercooler air...

Page 1213: ...EGR solenoid valve strut 6 the EGR solenoid valve the EGR solenoid valve seal REFITTING I REFITTING PREPARATION OPERATION a Clean the EGR solenoid valve only the mechanical part using a parts washer...

Page 1214: ...re Damp er valve Removal Refitting page 12A 39 the intercooler inlet air pipe a Clip the intercooler air inlet pipe on the turbocharger the intercooler air inlet pipe on the intercooler a Refit the in...

Page 1215: ...Refitting M9R and 742 or 744 or 746 or 748 14A display the before after repair procedure for the computer selected select the EGR valve in the List of compo nents stored by the computer section carry...

Page 1216: ...e engine cover the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 a Remove the nut 1 from the cooling radiator top hose a Move aside the cooling radiator top hose a Remo...

Page 1217: ...clip 4 on the in tercooler side a Disconnect the intercooler air inlet pipe on the inter cooler side a Remove the intercooler air inlet pipe a Remove the bolts 5 from the exhaust gas recirculation ri...

Page 1218: ...culation solenoid valve only the mechanical part using a parts washer see Exhaust gas recirculation solenoid valve Cleaning a Clean and degrease the bearing faces of the ex haust gas recirculation sol...

Page 1219: ...cooler air inlet pipe to the turbo charger and the intercooler a Refit the engine undertray the engine undertray bolts the bolts on the intercooler air inlet pipe a Tighten the intercooler air inlet p...

Page 1220: ...oid valve the exhaust gas recirculation solenoid valve using the Mot 1729 if necessary in case it is jammed the exhaust gas recirculation solenoid valve seal REFITTING I REFITTING PREPARATIONS OPERATI...

Page 1221: ...ON a Refit the oil vapour rebreathing pipe a Connect the oil vapour rebreathing pipe to the oil vapour rebreathing valve on the air filter box outlet air pipe a Refit the engine cover a Apply the afte...

Page 1222: ...oling required Mot 1448 Remote operation pliers for hose clips Equipment required parts washer Diagnostic tool Tightening torquesm exhaust gas recircula tion solenoid valve bolts on the exhaust gas co...

Page 1223: ...ng see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the rigid exhaust gas recirculation pipe see 14A Antipollution Exhaust gas recirculation rigid pipe Remova...

Page 1224: ...nkshaft position sensor wiring 7 from the catalytic pre converter lower stay a Remove the nuts 8 from the catalytic pre converter lower stay a Remove the catalytic pre converter lower stay studs 9 the...

Page 1225: ...from the exhaust fuel injector cooler rigid cooling pipes a Move aside the exhaust fuel injector cooler rigid cooling pipes a Remove the turbocharger heat shield a Disconnect the exhaust gas cooler ho...

Page 1226: ...1448 a Disconnect the hose from the exhaust gas cooler a Move aside the exhaust gas cooler hose II OPERATION FOR REMOVAL OF PART CONCERNED a Separate the clip 18 from the exhaust gas recircu lation s...

Page 1227: ...using ABRASIVE PADS on the exhaust gas recirculation solenoid valve the exhaust gas recirculation cooler a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Produc...

Page 1228: ...ic pre converter the catalytic pre converter upper stay a Fit the nut of the catalytic pre converter upper stay without tightening it a Refit the catalytic pre converter lower stay a Fit the lower sta...

Page 1229: ...bolt on the subframe a Fill and bleed the cooling system see 19A Cool ing Cooling system Draining Refilling page 19A 16 a Refit the engine undertray the engine cover a Connect the battery see Battery...

Page 1230: ...ove the air filter unit air outlet pipe a Unclip the control pipe 3 of the turbocharging pres sure regulation valve from the turbocharger air inlet pipe Special tooling required Ms 583 Pipe clamps Mot...

Page 1231: ...f the turbocharger air inlet pipe on the exhaust gas recirculation assembly the engine undertray a Remove the turbocharger air inlet pipe bolts 6 on the turbo charger the turbocharger air inlet pipe t...

Page 1232: ...ve the bolts 12 from the exhaust gas recirculation so lenoid valve the exhaust gas recirculation solenoid valve the exhaust gas recirculation solenoid valve seal REFITTING I REFITTING PREPARATION OPER...

Page 1233: ...en the turbocharger air inlet pipe bolts on the tur bocharger 8 N m the nut of the turbocharger air inlet pipe on the exhaust gas recirculation assembly 8 N m a Refit the engine undertray a Connect th...

Page 1234: ...age 12A 39 the EGR solenoid valve see 14A Antipollution Exhaust gas recirculation solenoid valve Re moval Refitting page 14A 11 II REMOVAL OPERATION FOR PART CONCERNED a Remove the bolts 1 from the ex...

Page 1235: ...1448 a Disconnect the coolant inlet hose a Disconnect the vacuum pipe 3 from the intercooler a Separate the clips 4 from the coolant outlet hose using the Mot 1448 a Remove the bolts 5 from the inter...

Page 1236: ...the intercooler bolts in order a Position the clips on the coolant outlet hose using the Mot 1448 a Connect the intercooler vacuum pipe the coolant inlet hose a Position the clip on the coolant inlet...

Page 1237: ...11 the engine undertray bolts the engine undertray a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the water chamber see 19A Cooling Water chamber R...

Page 1238: ...t gas cooler hoses using the tool Mot 1448 III FINAL OPERATION a Refit the starter see 16A Starting Charging Starter Removal Refitting page 16A 31 the new exhaust gas recirculation rigid pipe see 14A...

Page 1239: ...the bearing faces using ABRASIVE PADS on the exhaust gas recirculation solenoid valve the exhaust gas recirculation cooler a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B C...

Page 1240: ...14A 39 ANTIPOLLUTION Exhaust gas cooler Removal Refitting V9X 14A a Connect the battery see Battery Removal Refit ting 80A Battery...

Page 1241: ...14A Antipollution Exhaust gas recirculation as sembly Removal Refitting page 14A 52 Special tooling required Mot 1448 Remote operation pliers for hose clips Ms 583 Pipe clamps Equipment required twee...

Page 1242: ...eal the bolts 2 from the exhaust gas cooler mounting the exhaust gas cooler the exhaust gas cooler mounting seal on the fly wheel end 2 Second fitting a Remove the following on the workbench the bolts...

Page 1243: ...DS see Vehicle Parts and consumables for the repair 04B Consuma bles Products to clean the exhaust gas intercooler joint faces if they are being reused the exhaust gas cooler mounting joint face on th...

Page 1244: ...seal on the exhaust gas cooler mounting on the flywheel end a Fit without tightening the exhaust gas cooler bolts on the exhaust gas cooler mounting on the flywheel end a Refit the exhaust gas cooler...

Page 1245: ...im ing end a Tighten to torque the exhaust gas cooler mounting bolts on the cylinder head on the flywheel end 25 N m the exhaust gas cooler mounting bolts on the cylinder head on the timing end 25 N m...

Page 1246: ...tercooler air inlet pipe the clip on the intercooler inlet air pipe in its original position a Refit the nut on the intercooler air inlet pipe the bolt on the intercooler air inlet pipe the oil vapour...

Page 1247: ...ee 19B Ex haust Exhaust gas pressure sensor Removal Refitting page 19B 93 the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 the exhaust gas recirculation assembly see 1...

Page 1248: ...nd CLEAN CLOTHS to degrease the joint faces of the exhaust gas cooler if it is to be reused the joint face of the exhaust gas cooler support on the gearbox side the joint face of the exhaust gas coole...

Page 1249: ...r mounting bolts at the gearbox end on the exhaust gas cooler 12 N m the exhaust gas cooler mounting bolts at the timing end on the exhaust gas cooler 12 N m III FINAL OPERATION a Refit the exhaust ga...

Page 1250: ...Refitting page 14A 52 II REMOVAL OPERATION FOR PART CONCERNED 1 Step for removing the exhaust gas recirculation mounting on the gearbox side a Remove the following on the workbench the bolts 1 from t...

Page 1251: ...culation mount ing seal on the gearbox side If replacing the exhaust gas recirculation mounting on the gearbox side a Use ABRASIVE PADS to clean the pressure faces between the exhaust gas intercooler...

Page 1252: ...but do not tighten them a Fit the exhaust gas recirculation assembly a Refit the exhaust gas recirculation assembly bolts a Tighten the exhaust gas recirculation assembly bolts a Adjust the exhaust ga...

Page 1253: ...ebreathing pipe 1 from the air filter box outlet air pipe from the oil vapour rebreathing valve a Remove the oil vapour rebreathing pipe a Remove the intercooler air inlet pipe bolt 2 the nut 3 from t...

Page 1254: ...a Remove the bolts 6 from the rail protector bracket a Remove the bolts 7 from the timing end lifting eye air in let metal tube assembly the timing end lifting eye the air inlet metal tube the engine...

Page 1255: ...ation as sembly the exhaust gas recirculation assembly REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the rigid exhaust gas recirculation pipe the rigid exhaust gas recirculation pipe s...

Page 1256: ...lts a Tighten the rail protector bracket bolts a Refit the damper valve see 12A Fuel mixture Damper valve Removal Refitting page 12A 39 a Connect the exhaust gas recirculation solenoid valve connector...

Page 1257: ...ust gas recirculation rigid pipe Removal Refitting page 14A 62 the exhaust gas pressure sensor see 19B Ex haust Exhaust gas pressure sensor Removal Refitting page 19B 93 a Remove the nut 1 for the int...

Page 1258: ...pipe the turbocharger air outlet pipe the seals from the turbocharger air outlet pipe a Disconnect the connector 5 from the exhaust gas recirculation solenoid valve a Disconnect the pipes 6 from the e...

Page 1259: ...he exhaust gas recirculation valve solenoid valve a Disconnect the exhaust gas temperature sensor connector 9 a Unclip the connector 10 from the exhaust gas tem perature sensor on the air inlet metal...

Page 1260: ...nd the air inlet metal tube the air inlet metal tube seals the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 a Fit the tools Ms 583 13 on each cooling pipe of the exhau...

Page 1261: ...48 a Remove the tools Ms 583 a Refit the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 new seals on the air inlet metal tube the air inlet metal tube the lifting eye on...

Page 1262: ...exhaust gas pressure sensor see 19B Ex haust Exhaust gas pressure sensor Removal Refitting page 19B 93 the exhaust gas recirculation rigid pipe see 14A Antipollution Exhaust gas recirculation rigid p...

Page 1263: ...r flowmeter wiring on the air filter box air outlet pipe a Disconnect the oil vapour rebreathing pipe to the oil decanter the vacuum pipe to the vacuum pump a Loosen the air filter box air outlet pipe...

Page 1264: ...04B Consumables Products to clean and degrease the exhaust gas recirculation rigid pipe joint faces the exhaust manifold joint face the intercooler joint face a Parts always to be replaced the exhaus...

Page 1265: ...ip the oil vapour rebreathing pipe the air flowmeter wiring on the air filter box air outlet pipe the turbocharger control solenoid valve pipe the vacuum pipe to the vacuum pump a Refit the air filter...

Page 1266: ...id valve pipe on the air filter unit air outlet pipe the air flowmeter wiring on the air filter unit air outlet pipe a Disconnect the oil vapour rebreathing pipe on the oil decanter the vacuum pipe to...

Page 1267: ...shield of the rigid exhaust gas recirculation pipe on the exhaust side the heat shield on the rigid exhaust gas recircula tion pipe on the exhaust side II OPERATION FOR REMOVAL OF PART CONCERNED a Und...

Page 1268: ...ew rigid exhaust gas recirculation pipe a Fit without tightening the new bolts to the exhaust gas recirculation rigid pipe on the exhaust manifold the bolt securing the exhaust gas recirculation rigid...

Page 1269: ...e vacuum pump the oil vapour rebreathing pipe on the oil separator a Clip the air flowmeter wiring on the air filter unit air outlet pipe the turbocharger control solenoid valve pipe on the air filter...

Page 1270: ...aust gas recirculation assembly a Remove the clip 1 of the exhaust gas recirculation rigid pipe the bolts 2 from the EGR rigid pipe the exhaust gas recirculation rigid pipe the seal between the exhaus...

Page 1271: ...S see Vehicle Parts and consumables for the repair 04B Consum ables Products to clean the exhaust manifold joint face a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consum...

Page 1272: ...id pipe on the exhaust gas manifold a Tighten to torque the bolts of the exhaust gas recirculation rigid pipe on the exhaust manifold 36 N m the new clip of the exhaust gas recirculation rigid pipe 5...

Page 1273: ...valve con nector 1 the fuel temperature sensor connector 2 a Unclip the fuel return pipes 3 from their supports the wiring 4 from its support a Remove the fuel pipes support bolt 5 the fuel pipe supp...

Page 1274: ...ributor the exhaust gas recirculation solenoid valve II REFITTING OPERATION FOR PART CONCERNED a Refit new exhaust gas recirculation rigid pipe seals a new exhaust gas recirculation rigid pipe a Fit w...

Page 1275: ...ulation rigid pipe Removal Refitting V9X 14A a Connect the fuel temperature sensor connector the exhaust gas recirculation solenoid valve con nector a Refit the engine cover a Connect the battery see...

Page 1276: ...pipe using the tool Mot 1567 the EGR rigid pipe REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Exhaust gas recir culation rigid pipe 11 07 01 08 parts always to be replaced...

Page 1277: ...lation rigid pipe a Torque tighten the clips of the rigid exhaust gas recirculation pipe 5 N m III FINAL OPERATION a Refit the exhaust gases duct at the turbocharger outlet see Turbocharger outlet exh...

Page 1278: ...Front wheel arch liner Removal Refitting MR 415 55A Exterior protection the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 a Unclip the fuel supply pip...

Page 1279: ...Remove the expansion bottle II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the alternator connector 4 a Remove the alternator 5 nut a Move aside the alternator wiring a Remove the alternator...

Page 1280: ...rds the engine a Refit the expansion bottle bolt a Tighten the expansion bottle bolt a Remove the blanking plugs from the fuel supply pipe a Connect the fuel supply pipe to the injector rail a Clip th...

Page 1281: ...11A 13 a Drain the refrigerant circuit using a refrigerant charging station see Refrigerant circuit Drain ing Filling MR 415 62A Air conditioning a Remove the air conditioning compressor see Com press...

Page 1282: ...the new accessories belt see 11A Top and front of engine Accessories belt Removal Refit ting page 11A 13 the front right hand wheel arch liner see Front wheel arch liner Removal Refitting MR 415 55A E...

Page 1283: ...g 55A Exterior protection the headlights see Headlight Removal Refit ting 80B Headlights the front end panel see Front end panel Remov al Refitting 42A Upper front structure the accessories belt see 1...

Page 1284: ...r inlet pipe a Disconnect the intercooler air inlet pipe a Remove the engine undertray bolts the engine undertray a Turn the clip 7 of the intercooler air inlet pipe on the intercooler a Disconnect th...

Page 1285: ...protector bolt 8 the alternator protector II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the nut 9 on the alternator positive termi nal a Disconnect the alternator positive terminal the alternato...

Page 1286: ...ing to the rail protector a Fit the clips of the intercooler air inlet pipe in their orig inal positions the intercooler air inlet pipe a Clip the intercooler air inlet pipe onto the intercooler a Ref...

Page 1287: ...sure sensor 3 a Loosen the clip 4 for the intercooler air outlet pipe at the damper valve end a Disconnect the intercooler air outlet pipe at the damper valve end a Remove the engine undertray bolts t...

Page 1288: ...l Refit ting 36B Power assisted steering a Remove the front bumper see Front bumper Removal Refitting 55A Exterior protection the headlights see Headlight Removal Refit ting 80B Headlights the front e...

Page 1289: ...ternator a Torque tighten the alternator bolts 25 N m a Connect the alternator regulator connector a Refit the alternator positive terminal wiring the alternator positive terminal nut a Torque tighten...

Page 1290: ...intercooler end a Refit the intercooler air outlet pipe a Connect the intercooler air outlet pipe to the inter cooler until it clicks into place a Gently pull the pipe to check that the union is locke...

Page 1291: ...el arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the engine undertray bolts the engine undertray the accessories belt see 11A Top and front of engine Accessories bel...

Page 1292: ...ioning connecting pipes II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the nut 3 on the alternator positive termi nal a Disconnect the alternator connector 4 a Move aside the alternator wiring a...

Page 1293: ...t the screen washer bottle filler neck the fan assembly see 19A Cooling Engine cool ing fan assembly Removal Refitting page 19A 121 the power assisted steering pump see Power as sisted steering pump R...

Page 1294: ...ies belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 a Remove the bolts 1 from the air conditioning com pressor a Move aside the air conditioning compressor a Attach...

Page 1295: ...the tool Mot 1448 the oil water heat exchanger rigid inlet pipe II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the alternator connector 2 a Remove the nut 3 from the alternator positive ter...

Page 1296: ...RATION a Refit the oil water heat exchanger rigid inlet pipe a Fit the clip for the oil water heat exchanger rigid inlet pipe on the oil water heat exchanger using the tool Mot 1448 a Remove the tool...

Page 1297: ...g 55A Ex terior protection the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the engine undertray the engine cover a Connect the battery see Battery Removal Refit ting 80A Ba...

Page 1298: ...ing page 19D 85 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the accessories belt see 11A Top and front of engine...

Page 1299: ...REFITTING OPERATION FOR PART CONCERNED a Refit the alternator a Torque tighten the alternator bolts 25 N m a Position the alternator wiring a Torque tighten the nut for the positive terminal of the a...

Page 1300: ...Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the front ri...

Page 1301: ...front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the accessories belt...

Page 1302: ...ED a Screw the new alternator pulley onto the alternator rotor a Set up the tools from the kit Mot 1732 the torx 50 bit 3 in the alternator rotor the splined socket 4 in the alternator pulley a Immobi...

Page 1303: ...see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the front ri...

Page 1304: ...ng page 19D 85 the right hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the accessories belt see 11A Top and front of engine...

Page 1305: ...or electric wrench a Remove the alternator pulley 2 Removing the alternator pulley using a hand wrench a Place the alternator in a vice fitted with jaws a Remove the alternator pulley cover 3 a Fit th...

Page 1306: ...he end piece holder 6 of the Mot 1732 on the end piece 5 a Hold the alternator pulley in position using a 15 mm wrench 7 a Pivot the ratchet 8 clockwise a Remove the alternator pulley REFITTING I REFI...

Page 1307: ...he alternator pulley cover II FINAL OPERATION a Refit the alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1 the accessories belt see 11A Top and front of engine Accessories...

Page 1308: ...ntercooler air inlet pipe a Move aside the coolant pipe 2 a Remove the intercooler air inlet pipe bolts 3 from the intake distributor a Rotate the intercooler air inlet pipe clip 4 on the tur bocharge...

Page 1309: ...e the earth strap bolt 6 a Move the earth strap to one side II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 7 from the starter a Unpick the wiring harness a Remove the starter by passing...

Page 1310: ...trap bolt 21 Nm a Refit the starter connections a Torque tighten the nut on the positive terminal of the starter 8 Nm 10 the nut on the excitation terminal of the starter 5 Nm 11 a Fit the intercooler...

Page 1311: ...istributor 8 Nm a Fit the coolant pipe clip on the intercooler air inlet pipe a Refit the coolant pipe nut on the air pipe a Tighten the coolant pipe nut on the air pipe a Refit the battery tray see B...

Page 1312: ...sensor connector 1 the oil pressure sensor 2 a Remove the bolt 3 from the wiring bracket on the gearbox a Move aside the wiring bracket on the gearbox a Remove the nut 4 on the starter excitation conn...

Page 1313: ...AL OPERATION a Fit the starter wiring harness a Tighten to torque the nut on the starter excitation connector 5 Nm the nut on the starter power supply connector 9 Nm a Fit the wiring bracket to the ge...

Page 1314: ...and tyres the engine undertray bolts the engine undertray the rear suspended engine mounting see 19D Engine mounting Lower engine tie bar Re moval Refitting page 19D 85 the front right hand driveshaf...

Page 1315: ...eld the starter heat shield II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the earth cable nut from the starter the nut on the excitation terminal of the starter 4 the nut on the positive termina...

Page 1316: ...9B 64 the catalytic converter rear strut a Tighten to torque the catalytic converter rear strut nut 44 N m the catalytic converter rear strut bolt 8 Nm a Refit the front right hand driveshaft see Fron...

Page 1317: ...80A Battery a Remove the air filter box see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the engine undertray bolts the engine undertray a Remove the wiring duct nut 1 a Unclip the w...

Page 1318: ...ing K9K 16A a Disconnect the rail pressure sensor connector 3 a Disconnect the connector 4 from the oil pressure sensor the connector 5 from the oil level sensor a Move the oil pressure sensor and oil...

Page 1319: ...a Tighten the starter bolts a Reconnect the starter supply terminal a Refit the nut on the starter solenoid the starter supply nut a Tighten the nut on the starter solenoid a Torque tighten the start...

Page 1320: ...isconnect the connector 1 from the oil level sen sor II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the starter supply cable nut 2 the starter excitation cable nut 3 a Move aside the starter wiri...

Page 1321: ...II REFITTING OPERATION FOR PART CONCERNED a Refit the starter a Torque tighten the starter bolts 44 Nm a Fit the starter wiring harness a Tighten to torque the starter supply cable nut 8 N m the star...

Page 1322: ...rth strap bolt 3 a Move the starter wiring aside a Remove the starter bolts 4 the starter REFITTING I REFITTING PREPARATION OPERATION a Check that the centring dowel is in place II REFITTING OPERATION...

Page 1323: ...efitting V4Y 16A a Refit the nut for the starter excitation terminal a Torque tighten the starter excitation terminal nut 5 N m III FINAL OPERATION a Refit the engine undertray a Connect the battery s...

Page 1324: ...Refitting page 10A 117 the oil pressure sensor see 10A Engine and cyl inder block assembly Oil pressure sensor Re moval Refitting page 10A 227 a Remove the bolts 1 from the oil water heat exchanger th...

Page 1325: ...sealing panel the starter a Position the starter excitation cable a Torque tighten the starter excitation nut 5 N m a Position the starter supply cable a Torque tighten the starter supply nut 8 N m a...

Page 1326: ...emoval Refitting F4R 17A REMOVAL I REMOVAL PREPARATION OPERATION a Remove the front engine cover II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the coil connectors 1 a Remove the coil bolts 2 th...

Page 1327: ...and consumables for the repair MR 415 04B Consumables Products with a diameter of 2 mm to the four ignition coils on the inner edge of the high tension caps II REFITTING OPERATION FOR PART CONCERNED...

Page 1328: ...cover the intake distributor see 12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connectors 1 from the ignition coils a Rem...

Page 1329: ...diameter of 2 mm to the four ignition coils on the inner edge of the high tension caps II REFITTING OPERATION FOR PART CONCERNED a Refit the ignition coils the ignition coil bolts a Torque tighten th...

Page 1330: ...REMOVAL I REMOVAL PREPARATION OPERATION a Remove the engine cover II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connectors 1 from the coils a Remove the coil bolts 2 the coils Tightenin...

Page 1331: ...les for the repair 04B Consum ables Products 2 mm in diameter on the internal perimeter of the high tension caps on the four coils a Always replace the coil bolts II REFITTING OPERATION FOR PART CONCE...

Page 1332: ...t bolts 1 a Move aside the engine cover support a Disconnect the connectors 2 from the ignition coils 2 Coils located on the back row a Remove the intake distributor see 12A Fuel mix ture Inlet distri...

Page 1333: ...17A 8 IGNITION Coils Removal Refitting V4Y 17A II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the rear and front row ignition coil bolts 4 the ignition coils 133477 133476...

Page 1334: ...h tension cap II REFITTING OPERATION FOR PART CONCERNED a Refit the ignition coils a Torque tighten the ignition coil bolts on the front and back rows 7 N m III FINAL OPERATION 1 Coils located on the...

Page 1335: ...ct the spark plug elec trode gaps using a set of feeler gauges II REFITTING OPERATION FOR PART CONCERNED a Refit the spark plugs a Torque tighten the spark plugs 28 N m using Ele 1382 fitted with the...

Page 1336: ...1382 01 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the spark plugs a Torque tighten the spark plugs 17 5 N m using the tool Ele 1382 with the red sleeve equipped with the tool Ele 138...

Page 1337: ...ry correct the electrode gap for each spark plug II REFITTING OPERATION FOR PART CONCERNED a Refit the spark plugs a Torque tighten the spark plugs 28 N m using Ele 1382 fitted with the grey sleeve II...

Page 1338: ...spark plugs using Ele 1382 1 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the spark plugs a Torque tighten the spark plugs 17 5 N m using the tool Ele 1382 with the red sleeve II FINAL O...

Page 1339: ...17B 1 PETROL INJECTION Petrol injection List and location of components M4R 17B 124349 123390 1 Air flowmeter 2 Throttle valve 123388 3 Camshaft position sensor...

Page 1340: ...injection List and location of components M4R 17B 115156 4 Crankshaft position sensor 115097 5 Pinking sensor 6 Oil pressure sensor 7 Oil level sensor 115153 8 Coolant temperature sensor 115496 9 Cam...

Page 1341: ...ECTION Petrol injection List and location of components M4R 17B 123376 10 Fuel vapour rebreathing sole noid valve 123459 11 Petrol injection computer 123364 12 Injector rail Injectors 123358 13 Upstre...

Page 1342: ...17B 4 PETROL INJECTION Petrol injection List and location of components M4R 17B 123356 14 Downstream oxygen sensor 122742 15 Accelerator pedal potentiometer...

Page 1343: ...ol injection List and location of components F4R 17B 124124 1 Turbocharger 2 Upstream oxygen sensor 3 Petrol injection computer 4 Throttle valve 5 Protection and switching unit 123144 6 Fuel vapour re...

Page 1344: ...nstream oxygen sensor 21922 9 Ignition coils 10 Inlet pressure sensor 11 Petrol injectors 12 Injector rail 21927 13 Turbocharging pressure regula tion solenoid valve 14 Anti surge valve 15 Turbochargi...

Page 1345: ...TION Petrol injection List and location of components F4R 17B 22804 19 Crankshaft position sensor 21918 20 Pinking sensor 21 Oil pressure sensor 124357 22 Fuel vapour absorber 122742 23 Accelerator pe...

Page 1346: ...haft dephaser solenoid valve 3 Air inlet pressure sensor 4 Coil 5 Throttle valve 6 Protection and Switching Unit 7 Petrol injection computer 8 Coolant temperature sensor 9 Camshaft position sensor 10...

Page 1347: ...l injection List and location of components K4M 17B 4 Ignition coil 11 Air temperature sensor 128263 5 Throttle valve 128274 8 Coolant temperature sensor 128620 6 Protection and Switching Unit 123459...

Page 1348: ...10 PETROL INJECTION Petrol injection List and location of components K4M 17B 128446 2 Camshaft dephaser solenoid valve 128633 9 Camshaft position sensor 128400 12 Injector rail 128282 10 Pinking sens...

Page 1349: ...ETROL INJECTION Petrol injection List and location of components K4M 17B 128369 13 Upstream oxygen sensor 123356 14 Downstream oxygen sensor 124801 15 Fuel vapour absorber 128373 16 Crankshaft positio...

Page 1350: ...17B 12 PETROL INJECTION Petrol injection List and location of components K4M 17B 122742 17 accelerator pedal...

Page 1351: ...and location of components V4Y 17B 134511 1 Petrol injection computer 2 Max fuse box 3 Protection and switching unit 4 Battery disconnection unit 5 Airflow meter 6 Motorised throttle valve 134517 7 Da...

Page 1352: ...B 9 Damper valve control solenoid valve 10 Fuel vapour recirculation sole noid valve 134522 11 Ignition coils 12 Camshaft position sensor 133840 133841 13 Front row camshaft dephaser solenoid valve 14...

Page 1353: ...onents V4Y 17B 116541 17 Upstream oxygen sensor front row 16 Downstream oxygen sensor front row 116545 18 Upstream oxygen sensor back row 19 Downstream oxygen sensor back row 134520 20 Pinking sensor...

Page 1354: ...17B 16 PETROL INJECTION Petrol injection List and location of components V4Y 17B 134510 24 Crankshaft position sensor 122742 25 Accelerator pedal potentiometer...

Page 1355: ...d Mot 1495 01 22 mm socket for removal refitting of oxygen sensors Tightening torquesm upstream oxygen sen sor 44 Nm downstream oxygen sensor 44 Nm WARNING Do not use any product designed to improve t...

Page 1356: ...nnector II FINAL OPERATION a Refit the engine undertray the engine undertray bolts a Tighten the engine undertray bolts REMOVAL OF THE DOWNSTREAM OXYGEN SENSOR I REMOVAL PREPARATION OPERATION a Positi...

Page 1357: ...ED a Refit the downstream oxygen sensor using the Mot 1495 01 a Torque tighten the downstream oxygen sensor 44 Nm a Connect the downstream oxygen sensor connector a Clip the downstream oxygen sensor c...

Page 1358: ...protective gloves during the operation IMPORTANT Wear protective gloves during the operation WARNING Do not use any product designed to improve the electrical contact in the injection computer and oxy...

Page 1359: ...d the turbocharger heat shield bolts a Tighten the heat shield bolts a Refit the engine cover REMOVING THE DOWNSTREAM OXYGEN SENSOR I REMOVAL PREPARATION OPERATION a Remove the engine cover the air fi...

Page 1360: ...a Tighten the downstream oxygen sensor using the tool Mot 1495 01 a Connect the downstream oxygen sensor connector to the gearbox a Clip the downstream oxygen sensor connector to the gearbox II FINAL...

Page 1361: ...g the Mot 1495 01 Special tooling required Mot 1495 01 22 mm socket for removal refitting of oxygen sensors WARNING Do not use any product designed to improve the electrical contact in the injection c...

Page 1362: ...ble II FINAL OPERATION a Connect the brake servo vacuum pipe union to the intake manifold a Refit the engine cover REMOVAL OF THE DOWNSTREAM OXYGEN SENSOR I REMOVAL PREPARATION OPERATION a Position th...

Page 1363: ...oxygen sensor 4 using the Mot 1495 01 REFITTING THE DOWNSTREAM OXYGEN SENSOR I REFITTING OPERATION FOR PART CONCERNED a Refit the downstream oxygen sensor using the Mot 1495 01 a Connect the downstrea...

Page 1364: ...uare drive and 24 mm hexagonal ext Tightening torquesm front row downstream oxygen sensor 50 N m front row upstream oxy gen sensor 50 N m back row downstream oxygen sensor on the catalytic pre convert...

Page 1365: ...connec tor from its mounting a Cut the oxygen sensor wiring clip 2 Back row downstream oxygen sensors a Remove the intake distributor see 12A Fuel mix ture Inlet distributor Removal Refitting page 12A...

Page 1366: ...FITTING I REFITTING OPERATION FOR PART CONCERNED 1 Front row downstream oxygen sensors a Refit the front row downstream oxygen sensor using the Mot 1495 a Torque tighten the front row downstream oxyge...

Page 1367: ...or a Fit a new clip on the oxygen sensor wiring the alternator wiring a Torque tighten the alternator positive terminal nut 15 N m 2 Back row oxygen sensors a Clip the back row upstream oxygen sensor...

Page 1368: ...mounting with the petrol injection computer a Disconnect the connector 2 from the petrol injec tion computer Equipment required Diagnostic tool WARNING Do not use any product designed to improve the...

Page 1369: ...ol in jection computer mounting a Connect the petrol injection computer connectors a Fit the petrol injection computer mounting with the petrol injection computer II FINAL OPERATION a Refit the batter...

Page 1370: ...efit the protective cover on the petrol injection com puter a Connect the battery see Battery Removal Refit ting 80A Battery a Apply the after repair procedure using the Diagnos tic tool connect the D...

Page 1371: ...17B 33 PETROL INJECTION Petrol injection computer Removal Refitting V4Y 17B carry out the operations described in the After re pair procedure section...

Page 1372: ...r 3 a Remove the crankshaft position sensor bolt 4 the crankshaft position sensor REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the crankshaft position sensor the crankshaft position sens...

Page 1373: ...17B 35 PETROL INJECTION Crankshaft position sensor Removal Refitting M4R 17B a Refit the engine undertray the engine undertray bolts a Tighten the engine undertray bolts...

Page 1374: ...ect the crankshaft position sensor connector 1 a Remove the crankshaft position sensor bolt 2 the crankshaft position sensor REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the crankshaft p...

Page 1375: ...sor connector 1 a Remove the crankshaft position sensor bolt 2 the crankshaft position sensor REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit the crankshaft position sensor a Torque tighten t...

Page 1376: ...ON FOR REMOVAL OF PART CONCERNED a Disconnect the crankshaft position sensor connector 2 a Remove the crankshaft position sensor bolt 3 the crankshaft position sensor REFITTING I REFITTING OPERATION F...

Page 1377: ...t pipe a Disconnect the intercooler air inlet pipe on the turbo charger side a Remove the intercooler inlet air pipe Tightening torquesm injector rail bolts 10 Nm clamp of the intercooler air inlet pi...

Page 1378: ...port and on the fuel supply pipe union a Disconnect the oil vapour rebreathing pipe union 4 the petrol vapour rebreather pipe union 5 the inlet air pressure sensor connector 6 the oil vapour heater co...

Page 1379: ...NED a a Remove the injector rail bolts 9 the injector rail pulling it carefully On the workbench a Remove the clip 10 from each injector the injectors 11 123735 IMPORTANT Be careful when removing the...

Page 1380: ...nector on each injector a Fit the petrol vapour rebreather pipe the oil vapour rebreathing pipe a Connect the oil vapour heater connector the air inlet pressure sensor connector the petrol vapour rebr...

Page 1381: ...a Disconnect the connector 2 from each injector II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the injector rail bolts 3 the injector rail injector assembly 4 Equipment required Diagnostic tool...

Page 1382: ...injector rail REFITTING I REFITTING PREPARATION OPERATION a Always replace the injector seals the injector retaining clips II REFITTING OPERATION FOR PART CONCERNED a Refit the injector rail injector...

Page 1383: ...12A Fuel mixture Inlet distributor Removal Refitting page 12A 75 the engine cover a Connect the battery see Battery Removal Refit ting 80A Battery a Apply the after repair procedure using the Diagnos...

Page 1384: ...l supply pipe union 1 from the in jector rail a Insert the blanking plugs Tightening torquesm injector rail bolts 10 N m IMPORTANT Wear leaktight gloves nitrile type for this opera tion IMPORTANT Duri...

Page 1385: ...rail injector assembly a Disconnect the connector 3 from each injector a Unclip the wiring on the injector rail a Remove the injector rail injector assembly a Remove the clip 4 from each injector the...

Page 1386: ...ION FOR PART CONCERNED a Fit the injector rail injector assembly a Connect the connector on each injector a Clip the wiring on the injector rail a Torque tighten in order the injector rail bolts 10 N...

Page 1387: ...OF PART CONCERNED a Remove the injector rail bolts 3 Tightening torquesm injector rail bolts initial torque 10 N m injector rail bolts torque 22 N m IMPORTANT During this operation be sure to refrain...

Page 1388: ...new seals on the injectors the injectors new injector clips on the injector rail the injector rail a Pre tighten to torque and in order the injector rail bolts initial torque 10 N m a Tighten to torq...

Page 1389: ...A 124800 1 Engine 2 Cooling radiator 3 Water oil heat exchanger 4 Heater matrix 5 Cylinder head thermostat 6 Throttle body heater 7 Cylinder block thermostat 8 Expansion bottle 9 Heater matrix output...

Page 1390: ...ing diagram M9R 19A M9R and 742 or 744 or 746 or 748 or 754 and PK4 123063 1 Engine 2 Exhaust gas cooler 3 Water pump 4 Expansion bottle 5 Cooling radiator 6 Coolant oil heat exchanger 7 Thermostat 8...

Page 1391: ...d 800 or 802 or 806 or 816 and PK4 123062 1 Engine 2 Exhaust gas cooler 3 Water pump 4 Expansion bottle 5 Cooling radiator 6 Coolant oil heat exchanger 7 Thermoplungers 8 Electric coolant pump 9 Bleed...

Page 1392: ...or 849 and AJ0 123061 1 Engine 2 Exhaust gas cooler 3 Water pump 4 Expansion bottle 5 Cooling radiator 6 Coolant oil heat exchanger 7 Thermoplungers 8 Automatic transmission oil cooler 9 Electric coo...

Page 1393: ...A 125000 1 Radiator 2 Expansion bottle 3 Heater matrix 4 Electric coolant pump 5 Thermostat 6 Engine oil coolant heat exchanger 7 Turbocharger 8 Automatic transmission oil cool ant heat exchanger 9 3...

Page 1394: ...ngine cooling system Operating diagram K9K and 780 19A 124157 1 Cooling radiator 2 Expansion bottle 3 Water oil heat exchanger 4 Water pump 5 Engine 6 Thermostat 7 Coolant outlet unit 8 Heater matrix...

Page 1395: ...19A 7 COOLING Engine cooling system Operating diagram K4M 19A 128623 1 Engine 2 Cooling radiator 3 Heater matrix 4 Expansion bottle 5 Water pump 6 Thermostat 7 Bleed screws 8 Choke...

Page 1396: ...tor 3 Expansion bottle 4 Heater matrix 5 Automatic gearbox oil tempera ture heat exchanger 6 Coolant outlet unit 7 Choke 8 Thermostat 9 Engine oil coolant heat exchanger 10 The hose at the engine oil...

Page 1397: ...ional radiator 4 Exhaust gas cooler electric cool ant pump 5 Gearbox oil coolant heat exchanger 6 Turbocharger electric coolant pump 7 Heater matrix 8 Turbocharger 9 Exhaust fuel injector 10 Thermosta...

Page 1398: ...tem Operating diagram K9K and 782 19A 144357 1 Cooling radiator 2 Expansion bottle 3 Coolant oil heat exchanger 4 Water pump 5 Engine 6 Thermostat 7 Water chamber 8 Heater matrix 9 Thermoplungers 10 E...

Page 1399: ...consumables for the repair F4R or K9K or M4R or M9R or V9X 19A CONSUMABLES Use GLACEOL RX TYPE D coolant Note Ready to use coolant or antifreeze must be diluted with distilled water in accordance with...

Page 1400: ...eat exchange The system must not operate using pure water WARNING Drain with the engine warm Flush and refill with the engine cold or warm Never flush a warm engine risk of major thermal shock WARNING...

Page 1401: ...x type radiator located under the dashboard which helps to cool the engine Volume of coolant Special notes protection down to 25 C 2 for cold and temperate countries protection down to 40 C 2 extreme...

Page 1402: ...ault finding and filling bleeding the cooling circuit Ms 554 07 Instrument for testing the cooling circuit and the expan sion bottle valve Contains caps 554 01 554 04 554 06 IMPORTANT When working in...

Page 1403: ...ng circuit a Replace the expansion bottle cap with the adapter Ms 554 01 a Connect on the adapter Ms 554 01 the tool Ms 554 07 a Pump with the Ms 554 07 to put the cooling circuit under pressure a Sto...

Page 1404: ...et of trim removal levers Mot 1700 Fault finding and filling bleeding the cooling circuit Ms 554 07 Instrument for testing the cooling circuit and the expan sion bottle valve Contains caps 554 01 554...

Page 1405: ...hose clip Mot 1448 using the tool a Fit the coolant pump inlet pipe hose the coolant pump inlet pipe hose clip using the tool Mot 1448 a Fit the coolant outlet hose on the oil filter unit using the t...

Page 1406: ...oil vapour rebreathing hose the oil vapour rebreathing hose from the oil separa tor a Unclip the brake servo vacuum pipe from the air filter box air outlet pipe a Unclip the oil vapour rebreathing hos...

Page 1407: ...COOLING Cooling system Draining Refilling F4R or K4M or K9K or M4R or M9R or V4Y 19A a Remove the bleed screw 2 from the water cham ber a Remove the bleed screw 3 from the water cham ber F4R 15155 K9K...

Page 1408: ...ng 4 a Move aside the engine wiring 4 a Remove the bleed screw 5 from the water cham ber a Unclip the heater matrix outlet cooling hose at 6 a Move aside the heater matrix outlet cooling hose a Remove...

Page 1409: ...oil vapour rebreathing hose union onto the air filter unit air outlet pipe a Clip the brake servo vacuum pipe onto the air filter unit air outlet pipe a Clip the oil vapour rebreathing hose onto the...

Page 1410: ...speed at 3000 rpm using a pedal press until the fan assembly has been acti vated for a third time a Check that the heating is operating correctly a Allow the engine to cool until the coolant tempera t...

Page 1411: ...cial tooling required Mot 1448 Remote operation pliers for hose clips Mot 1700 Fault finding and filling bleeding the cooling circuit Ms 554 07 Instrument for testing the cooling circuit and the expan...

Page 1412: ...cooling hose from the addi tional cooling radiator a Remove the drain screw 4 from the cylinder block a Use a compressed air nozzle to blow air into the cooling system through the expansion bottle ope...

Page 1413: ...lant recom mended by the manufacturer see Vehicle Parts and consumables for the repair 04B Consum ables Products using the tool Mot 1700 Consult the user s manual for this tool see Cooling system fill...

Page 1414: ...aces soiled by the coolant IV BLEEDING a Deactivate the air conditioning system so that the fan assembly is not operating from the start of the operation a Start the engine a Refit the bleed screw 8 a...

Page 1415: ...Draining Refilling V9X 19A the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels and tyres the engi...

Page 1416: ...nt charging station see Refrigerant circuit Draining Fill ing 62A Air conditioning a Move aside the degassing hose clip 1 from the ex pansion bottle on the cooling radiator side using the tool Mot 144...

Page 1417: ...engine cooling fan assembly wiring the engine cooling fan assembly resistor wiring a Disconnect the air pressure sensor 5 the air temperature sensor 6 a Move aside the following from the engine coolin...

Page 1418: ...te pipe connecting pipe a Remove the expansion valve condenser connecting pipe the compressor intermediate pipe connecting pipe a Move aside the top cooling hose clip 9 from the cooling radiator using...

Page 1419: ...condenser cooling radiator engine cooling fan assembly intercooler assembly On the workbench a Pull the air pipes clip at the intercooler inlet and out let 11 a Disconnect the intercooler air inlet a...

Page 1420: ...R 19A a Unclip the intercooler at 15 and 13 a Rotate the intercooler at 14 and 16 a Remove the intercooler a Unclip the engine cooling fan assembly at 17 a Remove the engine cooling fan assembly follo...

Page 1421: ...T CONCERNED a Refit the condenser cooling radiator engine cooling fan assembly intercooler assembly III FINAL OPERATION a Refit the cooling radiator air scoops a Connect the top cooling hose to the co...

Page 1422: ...nel Remov al Refitting 42A Upper front structure the headlights see Headlight Removal Refit ting 80B Headlights the cooling radiator upper cover the front bumper see Front bumper Removal Refitting 55A...

Page 1423: ...page 19A 16 the refrigerant circuit see Refrigerant circuit Draining Filling 62A Air conditioning Special tooling required Mot 1448 Remote operation pliers for hose clips Equipment required refrigera...

Page 1424: ...p the fan assembly wiring 3 the fan assembly resistor wiring a Remove the expansion bottle cooling hose clip 4 from the radiator using the tool Mot 1448 the upper cooling hose clip 5 on the radiator u...

Page 1425: ...ing the tool Mot 1448 the upper cooling hose clip 5 on the cooling radi ator using the tool Mot 1448 a Disconnect the expansion bottle cooling hose on the cooling radiator the upper cooling hose from...

Page 1426: ...ndenser the compressor condenser connecting pipe the expansion valve condenser connecting pipe a Fit protective plugs on the air conditioning pipe unions II OPERATION FOR REMOVAL OF PART CONCERNED a R...

Page 1427: ...or the upper cooling hose from the cooling radiator a Fit the expansion bottle cooling hose clip on the cool ing radiator using the tool Mot 1448 the upper cooling hose clip on the cooling radiator us...

Page 1428: ...19A 40 COOLING Cooling radiator Removal Refitting K4M or M4R 19A fill the refrigerant circuit see Refrigerant circuit Draining Filling 62A Air conditioning a Refit the engine cover M4R...

Page 1429: ...see 19A Cooling Cooling system Draining Refilling page 19A 16 a Remove the front bumper see Front bumper Removal Refitting 55A Exterior protection the headlights see Headlight Removal Refit ting 80B...

Page 1430: ...Disconnect the fan assembly connector a Unclip the blower unit wiring a Move aside the fan assembly wiring a Disconnect the engine cooling fan assembly con nectors a Unclip the blower unit wiring a Mo...

Page 1431: ...a Disconnect the hose between the cooling radiator and the expansion bottle on the cooling radiator side a Remove the clip 5 from the cooling radiator top hose using the tool Mot 1448 a Disconnect the...

Page 1432: ...ly 122867 122869 Note Use blanking plugs for the fuel circuits with part numbers 77 01 208 209 or 77 01 476 857 to plug any openings exposed to the open air The y must be clean Do not use any which ha...

Page 1433: ...assembly in the direction of the ar row by pressing on the retaining brackets 9 a Unclip the condenser by pulling it at a right angle in relation to the cooling radiator 1 a Pull the condenser horizon...

Page 1434: ...the cooling radiator the condenser the intercooler a parts always to be replaced turbocharger air cooler air inlet pipe seal 10 09 04 04 parts always to be replaced turbocharger air cooler air outlet...

Page 1435: ...of the fan assembly resistors the connector of the air conditioning pressure sen sor a Rotate the intercooler air inlet pipe clip in order to fit the clip into the neck of the intercooler air inlet pi...

Page 1436: ...19A 48 COOLING Cooling radiator Removal Refitting M9R 19A a Refit the engine undertray...

Page 1437: ...ts the front end panel see Front end panel Remov al Refitting MR 416 42A Upper front struc ture a Drain the cooling system see 19A Cooling Cooling system Draining Refilling page 19A 16 the refrigerant...

Page 1438: ...efitting K9K 19A a Unclip the fan assembly wiring the fan assembly resistor wiring a Disconnect the connector 3 from the air condition ing pressostat a Unclip the air conditioning pressostat wiring a...

Page 1439: ...or using the Mot 1448 the clip 8 for the bottom cooling hose on the cool ing radiator using the Mot 1448 a Disconnect the expansion bottle degassing hose 5 from the cooling radiator the top cooling ho...

Page 1440: ...on the cooling radiator a Clip the fan unit onto the cooling radiator II REFITTING OPERATION FOR PART CONCERNED a Refit the cooling radiator engine cooling fan as sembly intercooler assembly III FINAL...

Page 1441: ...p the intercooler air outlet pipe onto the intercool er a Refit the condenser see Condenser Removal Refitting MR 415 62A Air conditioning a Fill the refrigerant circuit see Refrigerant circuit Drainin...

Page 1442: ...48 Remote operation pliers for hose clips Equipment required refrigerant charging station Tightening torquesm connecting pipe bracket nut for the compressor condenser 8 N m connecting pipe bracket nut...

Page 1443: ...nectors 1 from the fan assem bly a Unclip the fan assembly wiring a Remove the expansion bottle cooling hose clip 2 from the radiator using the tool Mot 1448 the clip of the top cooling hose 3 on the...

Page 1444: ...rom the compressor condenser connecting pipe bracket on the condenser the nut 8 from the expansion valve condenser connecting pipe bracket a Disconnect the following from the condenser the compressor...

Page 1445: ...recommended to lubricate the new seals with air conditioning oil to make fitting easier see Air condi tioning Parts and consumables for the repair 62A Air conditioning a Fit new seals to the refriger...

Page 1446: ...hose on the cooling radi ator using the tool Mot 1448 a Clip the fan assembly wiring a Connect the fan assembly connectors a Refit the front end panel see Front end panel Remov al Refitting 42A Upper...

Page 1447: ...mote operation pliers for hose clips Equipment required refrigerant charging station tweezers Tightening torquesm connecting pipe bracket nut for the compressor condenser 8 N m connecting pipe bracket...

Page 1448: ...frigerant circuit Drain ing Filling 62A Air conditioning a Remove the engine cooling fan assembly see 19A Cooling Engine cooling fan assembly Removal Refitting page 19A 121 a Remove the right hand air...

Page 1449: ...ndenser connecting pipe a Remove the condenser air conditioning pipe seals a Insert the blanking plugs a Separate the clip of the top cooling hose 5 on the cooling radiator using the tool Mot 1448 a D...

Page 1450: ...e a Loosen the clip 8 on the intercooler air outlet pipe a Disconnect the intercooler air outlet pipe a Move the intercooler outlet air pipe to one side a Unclip the air conditioning pipe 9 from the i...

Page 1451: ...h a Unclip the condenser at 10 a Lift the condenser a Remove the condenser a Press on the intercooler tabs 11 a Rotate the intercooler a Disconnect the intercooler from the cooling radiator a Remove t...

Page 1452: ...PERATION FOR PART CONCERNED a Refit the cooling radiator condenser intercooler assembly III FINAL OPERATION a Fit the cooling hose on the intercooler a Clip the cooling hose onto the intercooler a Fit...

Page 1453: ...ing Engine cooling fan assembly Removal Refitting page 19A 121 the front end panel see Front end panel Remov al Refitting 42A Upper front structure the audible warning see Audible warning Re moval Re...

Page 1454: ...age 19D 51 the timing belt see 11A Top and front of engine Timing belt Removal Refitting page 11A 50 a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Clean t...

Page 1455: ...the water pump the coolant pump bolts a Tighten to torque and in order the coolant pump bolts 10 Nm III FINAL OPERATION a Refit the timing belt see 11A Top and front of engine Timing belt Removal Refi...

Page 1456: ...terior protection the front right hand wheel see Wheel Removal Refitting MR 415 35A Wheels and tyres a Fill the cooling system see 19A Cooling Cooling system Draining Refilling page 19A 16 a Connect t...

Page 1457: ...Refitting page 11A 13 the alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1 Tightening torquesm coolant pump bolts 25 Nm WARNING Prepare for the flow of fluid and protect t...

Page 1458: ...e alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1 the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the front right hand...

Page 1459: ...19A 16 a Remove the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection...

Page 1460: ...lant pump seal 10 06 01 21 a Clean the joint faces using SURFACE CLEANER see Vehicle Parts and consumables for the re pair 04B Consumables Products 123622 123623 WARNING Do not scrape the joint faces...

Page 1461: ...ump pulley bolts 10 N m a Refit the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the front right hand wheel arch liner see Front wheel arch liner Rem...

Page 1462: ...engine Accessories belt Removal Refitting page 11A 13 the crankshaft accessories pulley see 11A Top and front of engine Crankshaft accessories pulley Removal Refitting page 11A 33 a Drain the cooling...

Page 1463: ...or a Remove the alternator upper bolt 5 a Tilt the alternator slightly towards the front of the ve hicle a Remove the inner timing cover bolts 7 the inner timing cover II OPERATION FOR REMOVAL OF PART...

Page 1464: ...a parts always to be replaced coolant pump seal 10 06 01 21 a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products to clean and degrease the cylinder block ga...

Page 1465: ...new coolant pump seal the coolant pump the bolts 2 and 5 of the coolant pump a Coat the coolant pump bolt 1 with one or two drops of FRENETANCHE see Vehicle Parts and con sumables for the repair 04B C...

Page 1466: ...the accessories belt see 11A Top and front of engine Accessories belt Removal Refitting page 11A 13 the engine undertray the engine undertray bolts the front right hand wheel arch liner see Front whee...

Page 1467: ...ght hand suspended engine mounting see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the timing belt see 11A Top and front of engine Timing belt Removal Refitt...

Page 1468: ...lock gasket face a a Apply a bead 2 of RESIN ADHESIVE see Vehi cle Parts and consumables for the repair 04B Consumables Products with a width of 0 6 to 1 mm IMPORTANT Wear goggles with side protectors...

Page 1469: ...e Accessories belt Removal Refitting page 11A 13 the front section of the front right hand wheel arch liner see Front wheel arch liner Removal Re fitting 55A Exterior protection the front right hand w...

Page 1470: ...ling system Draining Refilling page 19A 16 a Remove the cooling radiator condenser motor driven fan assembly see 19A Cooling Cooling radia tor Removal Refitting page 19A 28 the front right hand drives...

Page 1471: ...and gearbox assembly see 10A Engine and cylinder block assembly En gine gearbox assembly Removal Refitting page 10A 1 a Fit the lifting eye on the timing end see 11A Top and front of engine Lifting ey...

Page 1472: ...ings 5 REFITTING I REFITTING PREPARATION OPERATION a Always replace the coolant pump O rings the back row camshaft dephaser cover seal a Use SUPER CLEANING AGENT FOR JOINT FA CES see Vehicle Parts and...

Page 1473: ...11A Top and front of engine Timing chain Removal Refitting page 11A 88 III FINAL OPERATION a Apply a bead of SILICONE ADHESIVE SEALANT see Vehicle Parts and consumables for the re pair 04B Consumable...

Page 1474: ...sconnection unit see Battery dis connection unit Removal Refitting 80A Bat tery the front left hand driveshaft see Front left hand driveshaft Removal Refitting 29A Drive shafts the front right hand dr...

Page 1475: ...system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the right hand su...

Page 1476: ...g see 19D Engine mounting Right hand suspended engine mounting Removal Refitting page 19D 51 the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the...

Page 1477: ...inlet union Special tooling required Mot 1448 Remote operation pliers for hose clips Tightening torquesm coolant inlet union bolts 17 Nm IMPORTANT When working in the engine compartment take care as t...

Page 1478: ...ostat at the coolant pump following the di rection indicated in the diagram the coolant inlet union the coolant inlet union bolts a Torque tighten the coolant inlet union bolts 17 Nm a Connect the hos...

Page 1479: ...see 19A Cooling Wa ter chamber Removal Refitting page 19A 100 a Remove the thermostat 5 REFITTING THE WATER CHAMBER THERMOSTAT I REFITTING PREPARATION OPERATION a Always replace the thermostat seal at...

Page 1480: ...ATION FOR REMOVAL OF PART CONCERNED a Remove the clip 1 from the thermostat cover hose using the tool Mot 1448 a Disconnect the hose from the thermostat cover a Remove the thermostat cover bolts 2 Spe...

Page 1481: ...PART CONCERNED a Refit the new seal on the thermostat the thermostat the thermostat cover bolts a Connect the hose to the thermostat cover a Fit the clip to the thermostat cover using the tool Mot 144...

Page 1482: ...t Removal Refitting K4M 19A a The thermostat cannot be separated from the water chamber Replace the water chamber thermostat assem bly if the thermostat is faulty see 19A Cooling Wa ter chamber Remova...

Page 1483: ...camshaft dephaser solenoid valve Special tooling required Mot 1448 Remote operation pliers for hose clips Tightening torquesm thermostat bolts 10 N m IMPORTANT When working in the engine compartment...

Page 1484: ...hten the thermostat bolts 10 N m a Connect the cooling hose a Fit the cooling hose clip using the tool Mot 1448 III FINAL OPERATION a Connect the connector of the front row camshaft dephaser solenoid...

Page 1485: ...parts always to be replaced thermostat seal 10 06 03 03 II REFITTING OPERATION FOR PART CONCERNED a Refit a new thermostat seal the thermostat III FINAL OPERATION a Refit the coolant outlet unit see...

Page 1486: ...rotection the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels and tyres a Fill and bleed the cooli...

Page 1487: ...itting K9K 19A a The thermostat cannot be separated from the water chamber It is necessary to replace the water chamber thermostat assembly in the event of a thermostat fault see 19A Cooling Water cha...

Page 1488: ...rs for hose clips Tightening torquesm water chamber bolts 25 N m IMPORTANT When working in the engine compartment take care as the radiator fan s may start up unexpect edly risk of being cut To avoid...

Page 1489: ...he water chamber bolts 25 N m III FINAL OPERATION a Connect the coolant hoses to the water chamber a Position the coolant hose clips on the water cham ber using the Mot 1448 a Refit the gearbox breath...

Page 1490: ...emoval Refitting page 19A 167 a Remove the clips 1 from the water chamber inlet and outlet hoses using the tool Mot 1448 a Disconnect the water chamber inlet and outlet hos es Special tooling required...

Page 1491: ...tube 4 the thermostat unit bolts 5 the thermostat unit the thermostat the thermostat seal a Using SURFACE CLEANER see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products clean...

Page 1492: ...et hose clips us ing the tool Mot 1448 a Refit the coolant temperature sensor see 19A Cooling Coolant temperature sensor Removal Refitting page 19A 167 III FINAL OPERATION a Perform the following oper...

Page 1493: ...moval Refitting page 12A 13 a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 II REMOVAL OPERATION FOR PART CONCERNED a Remove the clip 1 from the heater matrix...

Page 1494: ...ber the water chamber bolts a Tighten the water chamber bolts a Connect the cooling radiator top hose a Fit the cooling radiator top hose clip using the Mot 1448 a Connect the heater matrix outlet hos...

Page 1495: ...19A 107 COOLING Water chamber Removal Refitting M9R 19A a Fill and bleed the cooling system see 19A Cool ing Cooling system Draining Refilling page 19A 16...

Page 1496: ...48 a Disconnect the hoses 3 from the water chamber a Disconnect the coolant temperature sensor connec tor 4 a Remove the water chamber bolts 5 the water chamber the water chamber seal REFITTING I REFI...

Page 1497: ...Mot 1448 a Clip the hose onto the water chamber III FINAL OPERATION a Refit the engine undertray the engine undertray bolts the air filter box see 12A Fuel mixture Air filter unit Removal Refitting p...

Page 1498: ...chamber bolts 12 N m heater matrix hose bracket bolt 10 N m IMPORTANT When working in the engine compartment take care as the radiator fan s may start up unexpect edly risk of being cut To avoid any...

Page 1499: ...er the heater matrix hose clip 4 on the water cham ber a Disconnect from the water chamber the cooling radiator top hose the heater matrix hose II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the...

Page 1500: ...he heater matrix hose bracket a Torque tighten the heater matrix hose bracket bolt 10 N m III FINAL OPERATION a Refit the coolant temperature sensor see 19A Cooling Coolant temperature sensor Removal...

Page 1501: ...oolant temperature sensor Removal Refitting page 19A 167 Special tooling required Mot 1448 Remote operation pliers for hose clips Tightening torquesm water chamber nuts 25 N m rigid cooling pipe bolt...

Page 1502: ...om the electrical wiring mounting the electrical wiring mounting a Remove the bolts 5 from the rigid cooling pipe a Move aside the rigid cooling pipe a Separate the clips 6 on the cooling hoses using...

Page 1503: ...III FINAL OPERATION a Fit the rigid cooling pipe a Refit the rigid cooling pipe bolt a Torque tighten the rigid cooling pipe bolt 10 N m a Connect the cooling hose at the rear of the water chamber a...

Page 1504: ...e air filter unit a Tighten to torque Torque tighten the clip on the throttle valve air inlet pipe 6 N m the air filter unit air outlet pipe clip 6 N m a Connect the brake servo vacuum pipe a Refit th...

Page 1505: ...r pipe a Remove the air outlet pipe from the air filter box Special tooling required Mot 1448 Remote operation pliers for hose clips Tightening torquesm water chamber bolts 10 N m air filter box air o...

Page 1506: ...t 5 from the turbocharger oil pipe a Move aside the turbocharger oil pipe a Disconnect the coolant hose 6 from the water chamber inlet a Separate the clip 7 of the coolant hose at the water chamber ou...

Page 1507: ...RFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consuma bles Products to clean and degrease the water chamber joint face the cylinder head joint face a Remove the intercooler air in...

Page 1508: ...inlet pipe a Refit the nut for the turbocharger air outlet pipe a Clip the intercooler air inlet pipe on the turbocharger a Refit the air outlet pipe onto the air filter unit a Connect the oil vapour...

Page 1509: ...Removal Refitting MR 415 35A Wheels and tyres the front wheel arch liners see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the lower cross member see Radiator mounting cros...

Page 1510: ...rd protector II FINAL OPERATION a Refit the intercooler see 12B Turbocharging In tercooler Removal Refitting page 12B 59 MR 415 12B Turbocharging a Refit the lower cross member see Radiator mounting c...

Page 1511: ...Cooling radiator Removal Refitting page 19A 28 II REMOVAL OPERATION FOR PART CONCERNED a Unclip the engine cooling fan assembly at 1 a Remove the engine cooling fan assembly from the cooling radiator...

Page 1512: ...R 416 55A Exterior protection the engine undertray the engine undertray bolts a Tighten the engine undertray bolts a Refit the engine cover a Connect the battery see Battery Removal Refit ting MR 415...

Page 1513: ...ery a Remove the cooling assembly protector bolts 1 a Remove the cooling assembly protector clips 2 the cooling assembly protector the engine undertray bolts the engine undertray a Disconnect the pres...

Page 1514: ...ON FOR PART CONCERNED a Fit the engine cooling fan assembly a Clip the engine cooling fan assembly to the cooling radiator a Fit the engine cooling fan assembly wiring a Clip the engine cooling fan as...

Page 1515: ...hoses a Remove the front wheels see Wheel Removal Refitting MR 415 35A Wheels and tyres the front wheel arch liners see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the engi...

Page 1516: ...oling fan as sembly fan on its shaft using indelible pencil a Remove the engine cooling fan assembly fan bolts 3 the fan assembly propellor a Remove the engine cooling fan bolts 4 the engine cooling f...

Page 1517: ...efit the intercooler see 12B Turbocharging Inter cooler Removal Refitting page 12B 59 the radiator mounting cross member see Radiator mounting cross member Removal Refitting MR 416 41A Front lower str...

Page 1518: ...ner Removal Refitting 55A Exterior protec tion the front bumper see Front bumper Removal Refitting 55A Exterior protection the headlights see Headlight Removal Refit ting 80B Headlights the audible wa...

Page 1519: ...bottom hose from the engine cooling fan assembly a Unclip the engine cooling fan assembly from the ra diator at 5 by pushing it upwards to detach the brackets holding it a Remove the engine cooling f...

Page 1520: ...ture the bonnet catch see Bonnet lock Removal Refitting 52A Non side opening element mecha nisms the audible warning see Audible warning Re moval Refitting 82B Horn the headlights see Headlight Remova...

Page 1521: ...light Removal Refit ting 80B Headlights the audible warning see Audible warning Re moval Refitting 82B Horn the bonnet catch see Bonnet lock Removal Refitting 52A Non side opening element mecha nisms...

Page 1522: ...a Refit the front end panel see Front end panel Remov al Refitting 42A Upper front structure the bonnet catch see Bonnet lock Removal Refitting 52A Non side opening element mecha nisms the audible war...

Page 1523: ...s and tyres the front left hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection II OPERATION FOR REMOVAL OF PART CONCERNED a Clamp the heating element unit hoses...

Page 1524: ...ghten the earth wire nut a Connect the thermoplunger unit hoses a Refit the clips on the heating element unit hoses us ing tool Mot 1448 a Remove the tools Ms 583 a Connect the battery see Battery Rem...

Page 1525: ...ne undertray II OPERATION FOR REMOVAL OF PART CONCERNED a Pinch the pipes of the thermoplunger unit using the tools Ms 583 1 a Separate the clips 2 on the thermoplunger unit pipes using the tool Mot 1...

Page 1526: ...unit a Connect the thermoplunger unit connector the thermoplunger unit pipes a Position the clips on the thermoplunger unit pipes using the tool Mot 1448 a Remove the tools Ms 583 from the pipes of th...

Page 1527: ...s sisted steering pump Removal Refitting MR 415 36B Power assisted steering the alternator see 16A Starting Charging Al ternator Removal Refitting page 16A 1 the air conditioning compressor see Compre...

Page 1528: ...coolant pump inlet pipe bracket bolt on the cyl inder block a Torque tighten the coolant pump inlet pipe brack et bolt on the cylinder block 38 N m a Connect the hose from the coolant pump inlet pipe...

Page 1529: ...m the following operations fill the refrigerant circuit see Refrigerant circuit Draining Filling MR 415 62A Air conditioning fill the cooling system see 19A Cooling Cooling system Draining Refilling p...

Page 1530: ...1 the engine undertray bolts the engine undertray a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the exhaust gas cooler see 14A Antipol lution Exhau...

Page 1531: ...Mot 1448 the hose clip between the coolant outlet union and the coolant pump inlet pipe using the Mot 1448 II REFITTING OPERATION FOR PART CONCERNED a Position the coolant pump inlet pipe a Refit the...

Page 1532: ...e moval Refitting page 14A 11 the engine undertray bolts the engine undertray a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 a Remove the water chamber see 1...

Page 1533: ...e seal the coolant outlet union seal the EGR rigid pipe a Refit a new coolant pump inlet pipe seal a new coolant outlet union seal the hose between the coolant outlet union and the coolant pump inlet...

Page 1534: ...olenoid valve see 14A Antipollution Exhaust gas recirculation solenoid valve Re moval Refitting page 14A 11 the damper valve see 12A Fuel mixture Damp er valve Removal Refitting page 12A 39 the air fi...

Page 1535: ...he dipstick 1 the bolts 2 from the dipstick tube the dipstick tube a Remove the clip 3 from the heater matrix cooling hose using the tool Mot 1202 01 or Mot 1202 02 or Mot 1448 a Disconnect the heater...

Page 1536: ...efit the coolant pump inlet pipe fitted with a new seal a Torque tighten in order the coolant pump inlet pipe bolts 25 N m III FINAL OPERATION a Connect the heater matrix cooling hose onto the coolant...

Page 1537: ...e 12B Turbocharging Turbocharger oil pipe Removal Refitting page 12B 35 the turbocharger see 12B Turbocharging Tur bocharger Removal Refitting page 12B 4 the coolant outlet unit see 19A Cooling Water...

Page 1538: ...he coolant pump inlet pipe a Fit the expansion bottle outlet cooling hose clip on the coolant pump inlet pipe using the tool Mot 1448 III FINAL OPERATION a Refit the rear inlet manifold see 12A Fuel m...

Page 1539: ...bumper Removal Refitting 55A Exterior protection the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Whee...

Page 1540: ...cuits are designed to be pressurised so be careful at high temperatures risk of serious burns Do not remove the cap from the expansion bottle while the engine is hot Take care when carrying out a repa...

Page 1541: ...r Mot 1202 01 or Mot 1202 02 remove the clip 4 from the expansion bottle bottom hose the clip 5 from the expansion bottle top hose a Disconnect the expansion bottle bottom hose the expansion bottle to...

Page 1542: ...02 02 fit the expansion bottle bottom hose clip the expansion bottle top hose clip II FINAL OPERATION a Remove the tool Ms 583 a Fit the manual priming pump on the expansion bot tle a Fit the power as...

Page 1543: ...ised so be careful at high temperatures risk of serious burns Do not remove the cap from the expansion bottle while the engine is hot Take care when carrying out a repair under the bon net as the radi...

Page 1544: ...unting a Unclip the fuel pipes 4 from the expansion bottle a Move the fuel pipes away from the expansion bottle a Unclip the manual priming pump from the expansion bottle at 5 a Remove the manual prim...

Page 1545: ...bottle at Y REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the expansion bottle a Connect the bottom cooling hose to the expansion bottle a Fit the bottom cooling hose clip using the tool...

Page 1546: ...emoval Refitting V9X 19A a Fit the power assisted steering reservoir a Clip in the power assisted steering reservoir a Refit the windscreen washer filler neck a Top up the coolant level in the expansi...

Page 1547: ...the clip 2 from the fuse box a Move the fuse box to one side II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 3 from the electric cool ant pump a Remove the electric coolant pump...

Page 1548: ...ERATION FOR PART CONCERNED a Connect the electric coolant pump hoses a Refit the clips on the electric coolant pump hoses us ing tool Mot 1448 a Remove tools Ms 583 from the electric coolant pump hose...

Page 1549: ...bolts the engine undertray the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 a Remove the bolt 1 from the max fuse box a Remove the clip 2 from the max fuse box a...

Page 1550: ...REMOVAL OF PART CONCERNED a Fit the tools Ms 583 on the hoses at the electric coolant pump inlet and outlet a Separate the cooling hose clip 5 at the electric coolant pump inlet using the tool Mot 144...

Page 1551: ...REFITTING THE TURBOCHARGER ELECTRIC COOLANT PUMP I REFITTING OPERATION FOR PART CONCERNED a Refit the electric coolant pump to its mounting the electric coolant pump clips the electric coolant pump el...

Page 1552: ...OVAL PREPARATION OPERATION a Position the vehicle on a two post lift see Vehicle Towing and lifting 02A Lifting equipment a Disconnect the battery see Battery Removal Re fitting 80A Battery a Remove t...

Page 1553: ...c coolant pump and of the pre postheating unit a Remove the pre postheating unit nut 14 a Remove the pre postheating unit a Remove the electric coolant pump support bolt 15 the electric coolant pump e...

Page 1554: ...pump connector the cooling hose at the electric coolant pump inlet a Fit the cooling hose clip at the electric coolant pump inlet using the tool Mot 1448 a Connect the cooling hose at the electric co...

Page 1555: ...ngine is hot Take care when carrying out a repair under the bon net as the radiator fan s may start to operate with out warning Do not open the bleed screw s with the engine run ning WARNING When carr...

Page 1556: ...ant temperature sensor seal II REFITTING OPERATION FOR PART CONCERNED a Refit the coolant temperature sensor fitted with a new seal a Torque tighten the coolant temperature sensor 25 Nm a Connect the...

Page 1557: ...oling system Draining Refilling page 19A 16 bleed the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 Tightening torquesm coolant temperature sensor 33 Nm IMPORTANT The c...

Page 1558: ...19A 170 COOLING Coolant temperature sensor Removal Refitting F4R 19A a Refit the engine undertray the engine undertray bolts a Tighten the engine undertray bolts a Refit the engine cover...

Page 1559: ...el mixture Air filter unit Removal Refitting page 12A 13 II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the coolant temperature sensor connec tor 1 a Remove the clip 2 from the coolant temperatu...

Page 1560: ...ture sensor into its hous ing a Refit the coolant temperature sensor clip a Connect the coolant temperature sensor connector III FINAL OPERATION a Refit the air filter box see 12A Fuel mixture Air fil...

Page 1561: ...temperatures risk of serious burns Do not remove the cap from the expansion bottle while the engine is hot Take care when carrying out a repair under the bon net as the radiator fan s may start to ope...

Page 1562: ...es Products to clean and degrease the seal housing in the water chamber the seal mating face of the coolant temperature sensor if reused II REFITTING OPERATION FOR PART CONCERNED a Refit the coolant t...

Page 1563: ...l tooling required Mot 1448 Remote operation pliers for hose clips Tightening torquesm coolant temperature sensor 25 N m clips for the air filter unit air outlet pipe and at the inlet of the throttle...

Page 1564: ...tighten the coolant temperature sensor 25 N m a Connect the coolant temperature sensor connector III FINAL OPERATION a Fill and bleed the cooling system see 19A Cool ing Cooling system Draining Refill...

Page 1565: ...tening torquesm air filter unit air outlet pipe clips 6 N m IMPORTANT When working in the engine compartment take care as the radiator fan s may start up unexpect edly risk of being cut To avoid any r...

Page 1566: ...ERATION FOR PART CONCERNED a Refit a new seal on the coolant temperature sensor the coolant temperature sensor the coolant temperature sensor clip a Connect the coolant temperature sensor connector II...

Page 1567: ...19B 1 EXHAUST Exhaust List and location of components 19B...

Page 1568: ...19B 2 EXHAUST Exhaust List and location of components 19B K4M or M4R 122599...

Page 1569: ...T Exhaust List and location of components 19B 1 Silencer 2 Expansion chamber 3 Catalytic converter 4 Cutting zone between the cata lytic converter and the expan sion chamber marked on the pipe by two...

Page 1570: ...19B 4 EXHAUST Exhaust List and location of components 19B F4R 122601...

Page 1571: ...unroof Note From 02 04 2008 the exhaust pipe is no longer a single unit from the connecting hose to the clamp connection with the silencer The cutting zone on the exhaust pipe between the connecting h...

Page 1572: ...19B 6 EXHAUST Exhaust List and location of components 19B V4Y 133612...

Page 1573: ...19B 7 EXHAUST Exhaust List and location of components 19B 1 Front catalytic pre converter 2 Rear catalytic pre converter 3 Catalytic converters under body 4 Expansion chamber 5 Silencer...

Page 1574: ...19B 8 EXHAUST Exhaust List and location of components 19B K9K and 780 122598...

Page 1575: ...g zone between the inter mediate pipe front section and the intermediate pipe from 02 04 2008 marked on the pipe by two punch marks 3 Intermediate pipe front section with ball joint bracket on the cat...

Page 1576: ...19B 10 EXHAUST Exhaust List and location of components 19B K9K and 782 144210...

Page 1577: ...n termediate pipe front section and an intermediate pipe assembled together to be cut in the cutting zone before refitting on the vehicle and to be assembled using an exhaust sleeve see 19B Exhaust Ex...

Page 1578: ...19B 12 EXHAUST Exhaust List and location of components 19B M9R and 742 or 744 or 746 or 748 or 754 122600...

Page 1579: ...he repair page 19B 18 1 Silencer 2 Connecting hose of the exhaust pipe 3 Cutting zone between the con necting hose and the intermedi ate pipe from 02 04 2008 marked on the pipe by two punch marks 4 In...

Page 1580: ...19B 14 EXHAUST Exhaust List and location of components 19B M9R and 802 or 805 or 806 or 809 or 816 or 845 or 849 122602...

Page 1581: ...r page 19B 18 1 Silencer 2 Particle filter 3 Connecting hose of the exhaust pipe 4 Cutting zone between the parti cle filter and the intermediate pipe from 02 04 2008 marked on the pipe by two punch m...

Page 1582: ...19B 16 EXHAUST Exhaust List and location of components 19B V9X 137052...

Page 1583: ...r page 19B 18 1 Connecting hose of the exhaust pipe 2 Particle filter 3 Silencer 4 Cutting zone between the parti cle filter and the intermediate pipe from 02 04 2008 marked on the pipe by two punch m...

Page 1584: ...rease the pressure faces of the connection using SURFACE CLEANER and clean cloths always replace the seal or sealing ring on the connec tion III SPECIAL NOTES ON THE SINGLE UNIT EXHAUST PIPE 1 Cutting...

Page 1585: ...hey touch the pipe in order to clamp the tool onto the pipe Turn the cutting tool using the handle and pressing it against the pipe as indicated in the diagram above Tighten the two bolts on the tool...

Page 1586: ...Check that the two cut marks 3 are aligned if applica ble Position the sleeve so that there is no risk of contact between its bolt or bolts and the heat shields Torque tighten the exhaust sleeve nut...

Page 1587: ...hicle Parts and consumables for the repair 04B Consumables Products If the application of exhaust mastic does not fix the leak remove and replace the used exhaust sleeve check the condition of the exh...

Page 1588: ...the turbo charger the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the engine undertray bolts the engine undertray a Drain the gearbox see Manual gearbox oils Draining Fill...

Page 1589: ...using a roller type stud removal tool the connecting hose seal the engine tie bar see 19D Engine mounting Lower engine tie bar Removal Refitting page 19D 85 II OPERATION FOR REMOVAL OF PART CONCERNED...

Page 1590: ...to be replaced catalytic converter stud on the turbocharger if loosened 10 09 01 04 parts always to be replaced Catalytic converter nut 10 08 02 16 parts always to be replaced seal between turbo char...

Page 1591: ...the flexible pipe a Refit a new seal between the connecting hose and the catalytic pre converter new catalytic pre converter studs a Tighten the catalytic pre converter studs using a roller type stud...

Page 1592: ...a Drain the cooling system see 19A Cooling Cool ing system Draining Refilling page 19A 16 Special tooling required Mot 1448 Remote operation pliers for hose clips Tightening torquesm new catalytic pr...

Page 1593: ...turbocharger heat shield a Remove the lower engine tie bars see 19D Engine mounting Lower engine tie bar Removal Refit ting page 19D 85 a Unclip the crankshaft position sensor wiring 5 from the cataly...

Page 1594: ...r lower stay nuts 8 the catalytic pre converter strut a Loosen the nut 9 on the catalytic pre converter up per stay a Remove the catalytic pre converter upper stay a Remove the nut 10 on the rigid coo...

Page 1595: ...ect the crankshaft position sensor connector 12 a Move the crankshaft position sensor wiring to one side a Remove the nuts 13 of the exhaust fuel injector cooler a Move aside the exhaust fuel injector...

Page 1596: ...bocharger heat shield nuts the studs on the heat shield of the turbocharger if they were loosened during the removal operation a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04...

Page 1597: ...torque the catalytic pre converter upper stay nut 21 N m the nuts of the lower stay on the upper bracket 21 N m the nuts of the lower stay on the cylinder block and on the gearbox 21 N m the lower sta...

Page 1598: ...Re moval Refitting page 19D 85 the front right hand driveshaft see Front right hand driveshaft Removal Refitting MR 415 29A Driveshafts the relay bearing bolts the relay bearing a Remove the bolts 1 f...

Page 1599: ...e downstream oxygen sensor connec tor a Remove the bolt 6 securing the catalytic converter bracket on the catalytic converter the bolt 7 securing the upstream strut of the cata lytic converter on the...

Page 1600: ...r 11 Nm a Connect the downstream oxygen sensor connector a Attach the downstream oxygen sensor wiring III FINAL OPERATION a Refit the new exhaust bracket seal exhaust bracket nuts a Refit the heat shi...

Page 1601: ...D a Remove the bolts 1 from the exhaust flange the catalytic converter the exhaust flange sealing ring REFITTING I REFITTING PREPARATIONS OPERATION a Use ABRASIVE PADS to clean the catalytic con verte...

Page 1602: ...haust pipe heat shields are in place and properly attached that there is no contact with the underbody that there are no leaks III FINAL OPERATION a Refit the upstream and downstream oxygen sensors se...

Page 1603: ...undertray bolts the engine undertray a Drain the gearbox see Manual gearbox oils Draining Filling MR 415 21A Manual gearbox a Remove the front right hand wheel driveshaft see Front right hand drivesh...

Page 1604: ...ine tie bar see 19D Engine mounting Lower engine tie bar Removal Refitting page 19D 85 a Move aside the connecting hose to facilitate removal of the catalytic converter II OPERATION FOR REMOVAL OF PAR...

Page 1605: ...studs15 Nm II REFITTING OPERATION FOR PART CONCERNED a a Fit the new catalytic converter seal on the turbocharg er the catalytic converter inserting the lower part first a Rotate the catalytic convert...

Page 1606: ...g MR 415 21A Manual gearbox the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting MR 415 29A Driveshafts a Fill and top up the gearbox see Manual gearbox oils Drainin...

Page 1607: ...ery a Remove the engine cover the engine undertray bolts the engine undertray a Remove the bolts 1 from the lower engine tie bar the lower engine tie bar II OPERATION FOR REMOVAL OF PART CONCERNED a R...

Page 1608: ...ter exhaust bracket sealing ring 8 the seal between the catalytic converter and the turbocharger REFITTING I REFITTING PREPARATION OPERATION a Always replace the catalytic converter exhaust bracket se...

Page 1609: ...converter upstream strut bolts on the catalytic converter the catalytic converter downstream strut bolt on the catalytic converter the catalytic converter nuts on the turbocharger a Refit the exhaust...

Page 1610: ...p between the cata lytic pre converter and the expansion chamber 21 N m IMPORTANT Catalytic converters contain ceramic fibres these are contained within a closed unit and cannot dis perse Drilling or...

Page 1611: ...he catalytic pre converter and the catalytic converter the catalytic converter a Fit the catalytic converter on the expansion cham ber a Refit new nuts between the catalytic pre converter and the cata...

Page 1612: ...2 19B a The catalytic converter 1 is integrated into the par ticle filter a Replace the particle filter catalytic converter con necting hose assembly in the event of a catalytic converter fault see 19...

Page 1613: ...FITTING OPERATION FOR PART CONCERNED a Refit the expansion chamber the clip between the expansion chamber and the silencer Equipment required component jack IMPORTANT Wear heat protective gloves durin...

Page 1614: ...ge 19B 18 a Tighten the sleeve while supporting the exhaust pipe to ensure they are aligned III FINAL OPERATION a Check that all the exhaust pipe heat shields are in place and properly attached that t...

Page 1615: ...ove the clip 2 between the expansion cham ber and the rear silencer Tightening torquesm clip between the expan sion chamber and the rear silencer 21 N m clip between the cata lytic converter and the e...

Page 1616: ...TING OPERATION FOR PART CONCERNED a Refit the expansion chamber a new clip between the expansion chamber and the rear silencer a new clip between the catalytic converter and the expansion chamber a Ti...

Page 1617: ...PARATION OPERATION a parts always to be replaced clip between expan sion chamber and silencer 10 08 02 19 II REFITTING OPERATION FOR PART CONCERNED a Refit the expansion chamber a new clip between the...

Page 1618: ...e 19B 18 a Tighten the sleeve while supporting the exhaust pipe to ensure they are aligned III FINAL OPERATION a Check that all the exhaust pipe heat shields are in place and properly attached that th...

Page 1619: ...the sound insula tion between the connecting hose and the expan sion chamber a Remove the four sound insulations a Separate the clips to facilitate access to the cutting zone between the connecting h...

Page 1620: ...amber assem bly using a component jack a Tighten the connecting hose nuts on the catalytic converter a Refit the silencer see 19B Exhaust Silencer Re moval Refitting page 19B 64 a Tighten the bolt of...

Page 1621: ...d insula tion between the connecting hose and the expan sion chamber a Check for leaks and contact with the underbody see 19B Exhaust Exhaust Precautions for the re pair page 19B 18 Lower the vehicle...

Page 1622: ...Exhaust Exhaust Precautions for the repair page 19B 18 between the intermediate pipe front section and the interme diate pipe in the designated cutting zone see 19B Exhaust Exhaust List and location...

Page 1623: ...PRODUCED FROM 02 04 2008 a Refit the intermediate pipe using a component jack a Fit a new exhaust clamp between the intermediate pipe and the silencer a Fit without tightening the exhaust clamp betwee...

Page 1624: ...between the intermediate pipe and the silencer the new intermediate pipe using a component jack a Fit without tightening the exhaust clamp between the intermediate pipe and the silencer to keep the i...

Page 1625: ...Intermediate pipe Removal Refitting K9K 19B a Refit the engine undertray a Check for leaks and contact with the underbody see 19B Exhaust Exhaust Precautions for the re pair page 19B 18 Lower the vehi...

Page 1626: ...VEHICLES PRODUCED FROM 02 04 2008 a Cut the exhaust pipe see 19B Exhaust Exhaust Precautions for the repair page 19B 18 between the connecting hose and the intermediate pipe in Equipment required com...

Page 1627: ...filter Removal Re fitting page 19B 71 a Use GREY ABRASIVE PADS see Vehicle Parts and consumables for the repair 04B Consum ables Products to clean the bearing faces of the connecting hose and the cata...

Page 1628: ...pe and the silencer to keep the inter mediate pipe on the silencer a Fit a new exhaust sleeve between the connecting hose and the intermediate pipe see 19B Exhaust Exhaust Precautions for the repair p...

Page 1629: ...e exhaust clamp between the intermediate pipe and the silencer to keep the inter mediate pipe on the silencer a Fit a new exhaust sleeve between the intermediate pipe front section and the intermediat...

Page 1630: ...e particle filter Special tooling required Mot 1857 Pliers for removing exhaust pipe rubber mounting bushes Equipment required component jack component support IMPORTANT To avoid all risk of damage to...

Page 1631: ...t 1857 on the welded thread 2 of the silencer with the pliers open with the pushing shaft A of the tool against the end of the welded thread and the fork B of the tool behind the rubber mounting bush...

Page 1632: ...3 from the silencer supports on the body 3 Silencer removal procedure a Remove the mounting bolts 4 of the silencer outlet pipes on the body the silencer 137903 137905 Note Place a component jack und...

Page 1633: ...t the silencer using the component support a Fit the welded threads of the silencer in the rubber mounting bushes until the conical end piece of the welded threads protrudes from the rubber mounting b...

Page 1634: ...ove the exhaust pipe clamp from the silencer a Position a component support under the silencer 1 Removal procedure using Mot 1857 Mot 1857 tool a Place tool Mot 1857 on the welded thread 2 of the sile...

Page 1635: ...soapy water type solution to lubricate the holes in the rubber mounting bushes for the welded threads a Fit the silencer using a component jack a Fit the welded threads of the silencer in the rubber m...

Page 1636: ...lexible pipe 2 Particle filter 3 Rubber mounting bush 4 Particle filter pressure sensor 5 Upstream pressure measure ment tapping 6 Downstream pressure measure ment tapping 7 Particle filter upstream t...

Page 1637: ...ment line 1 from its adapter union 2 the particle filter downstream temperature sensor 3 from its adapter union 4 if equipped Equipment required component jack Diagnostic tool Tightening torquesm ada...

Page 1638: ...m tempera ture sensor connector 6 a Unclip the particle filter downstream temperature sensor connector on the exhaust heat shield a Unclip the downstream pressure measurement line and the downstream e...

Page 1639: ...nstream pressure mea surement line particle filter downstream tempera ture sensor clips assembly into the engine compartment a Remove the nuts 11 from the connecting hose on the catalytic pre converte...

Page 1640: ...compartment a Fit the particle filter using a component jack a Refit a new seal between the particle filter and the con necting hose the particle filter on the connecting hose a new seal between the...

Page 1641: ...ticle filter or if the adapter union was loos ened a Torque tighten the adapter union of the particle fil ter downstream pressure measurement line 44 N m a Coat the threaded union of the particle filt...

Page 1642: ...l Re fitting page 19D 85 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the exhaust heat shield clip 1 a Move the exhaust heat shield to one side slightly Special tooling required Mot 1807 Spanne...

Page 1643: ...ensor wiring from the heat shield a Disconnect the particle filter temperature sensor connector 2 a Move aside the particle filter temperature sensor wir ing a Remove the bolt 3 from the particle filt...

Page 1644: ...arti cle filter pressure sensor from the heat shield a Separate the particle filter pressure measurement pipe particle filter pressure sensor assembly a Remove the nuts 6 from the connecting hose on t...

Page 1645: ...ticle filter the seal between the connecting hose and the cat alytic pre converter In the event of replacement a a Remove the connecting hose nuts 8 the connecting hose the seal between the flexible p...

Page 1646: ...procedure a new seal between the connecting hose and the particle filter the connecting hose REFITTING I REFITTING PREPARATION OPERATION a Always replace the seal between the catalytic pre converter a...

Page 1647: ...the particle filter temperature sensor wiring a Connect the particle filter temperature sensor con nector a Clip the particle filter temperature sensor wiring the particle filter downstream temperatur...

Page 1648: ...1 of the particle filter temperature sensor a Remove the take off pipe 2 from the particle filter temperature sensor using the tool Mot 1807 a Remove the take off pipe 3 from the particle filter pres...

Page 1649: ...lt 6 the particle filter the exhaust flange seal REFITTING I REFITTING PREPARATION OPERATION a Always replace the exhaust flange seal a Use SURFACE CLEANER see Vehicle Parts and consumables for the re...

Page 1650: ...ressure sensor pipe a Torque tighten the particle filter pressure sensor take off pipe 21 N m a Refit the take off pipe of the particle filter tempera ture sensor using the tool Mot 1807 a Torque tigh...

Page 1651: ...Remove the exhaust gas temperature sensor 3 us ing the tool Mot 1807 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the exhaust gas temperature sensor a Torque tighten the exhaust gas tem...

Page 1652: ...oling pipe the turbocharger heat shield nuts 3 a Loosen the turbocharger heat shield nut 4 a Remove the lower engine tie bars see 19D Engine mounting Lower engine tie bar Removal Refit ting page 19D 8...

Page 1653: ...position sensor wiring 5 from the catalytic pre converter lower stay a Remove the nuts 6 from the catalytic pre converter lower stay a Remove the catalytic pre converter lower stay studs 7 the cataly...

Page 1654: ...of the exhaust fuel injector cooler a Move aside the rigid cooling pipes of the exhaust fuel injector cooler a a Remove the turbocharger heat shield II OPERATION FOR REMOVAL OF PART CONCERNED a Disco...

Page 1655: ...turbo charger a Refit the nut of the rigid cooling pipes of the exhaust fuel injector cooler on the catalytic pre converter the catalytic pre converter upper stay a Fit without tightening the nut of t...

Page 1656: ...55A Exterior protection the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels and tyres the engine u...

Page 1657: ...Antipollution Exhaust gas recirculation as sembly Removal Refitting page 14A 52 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the exhaust gas temperature sensor 1 us ing the tool Mot 1807 REFIT...

Page 1658: ...19B 93 the exhaust gas recirculation rigid pipe see 14A Antipollution Exhaust gas recirculation rigid pipe Removal Refitting page 14A 62 the exhaust gases duct at the turbocharger outlet see Turbocha...

Page 1659: ...engine cover II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the exhaust gas pressure sensor con nector 1 a Remove the exhaust gas pressure sensor pipe hollow bolt 2 on the turbocharger the ex...

Page 1660: ...aust gas pressure sensor on its mount ing a Connect the exhaust gas pressure sensor pipe a Refit the exhaust gas pressure sensor clip the exhaust gas pressure sensor pipe clip using the tool Mot 1448...

Page 1661: ...nut 2 on the turbocharger rigid cooling pipe the turbocharger heat shield nuts 3 a Loosen the turbocharger heat shield nut 4 a Remove the lower engine tie bars see 19D Engine mounting Lower engine ti...

Page 1662: ...osition sensor wiring 5 from the catalytic pre converter lower stay a Remove the nuts 6 from the catalytic pre converter lower stay a Remove the catalytic pre converter lower stay studs 7 the catalyti...

Page 1663: ...of the exhaust fuel injector cooler a Move aside the rigid cooling pipes of the exhaust fuel injector cooler a a Remove the turbocharger heat shield II OPERATION FOR REMOVAL OF PART CONCERNED a Discon...

Page 1664: ...it the exhaust gas pressure sensor clip a Refit the exhaust gas pressure sensor the exhaust gas pressure sensor clip a Fit the exhaust gas pressure sensor nut without tightening it a Refit the exhaust...

Page 1665: ...Refit the lower engine tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 the rigid cooling pipe nut on the turbocharger a Torque tighten the turbocharger heat shie...

Page 1666: ...ir outlet pipe a Remove the air filter unit air outlet pipe a Unclip the control pipe 3 of the turbocharging pres sure regulation valve from the turbocharger air inlet pipe a Disconnect the oil vapour...

Page 1667: ...rculation assembly the engine undertray a Remove the turbocharger air inlet pipe bolts 6 on the turbo charger the turbocharger air inlet pipe the turbocharger air inlet pipe seal II OPERATION FOR REMO...

Page 1668: ...exhaust gas pressure sensor hollow bolt 32 N m a Connect the exhaust gas pressure sensor connec tor III FINAL OPERATION a Refit the new seal of the turbocharger air inlet pipe the turbocharger air in...

Page 1669: ...al Refitting page 19B 71 II OPERATION FOR REMOVAL OF PART CONCERNED a Detach the particle filter downstream temperature sensor 1 from the particle filter downstream pres sure measurement connection Ti...

Page 1670: ...nsumables for the repair MR 415 04B Con sumables Products 1 With adapter replacement a Refit the particle filter upstream pressure measure ment connection on its screw adapter to the exhaust pipe with...

Page 1671: ...pres sure measurement connection 21 Nm a Clip the particle filter downstream temperature sen sor onto the particle filter downstream pressure measurement connection respecting the colour coding on th...

Page 1672: ...9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolt 1 from the particle filter pressure sensor mounting a Move aside t...

Page 1673: ...04B Consumables Products a Torque tighten the particle filter pressure sensor nut 21 N m using a crow foot type wrench a Fit the particle filter pressure measurement pipe particle filter pressure sen...

Page 1674: ...19B 108 EXHAUST Particle filter pressure sensor Removal Refitting V9X 19B...

Page 1675: ...Remove the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the take off pipe 1 from the particle filter pressure sensor a Remove the bolt 2 from the particle filter pressure sens...

Page 1676: ...NT or COPPER ALUMINIUM LUBRICANT see Vehicle Parts and consumables for the re pair 04B Consumables Products II REFITTING OPERATION FOR PART CONCERNED a Refit the particle filter pressure sensor a Conn...

Page 1677: ...OPERATION a Torque tighten the particle filter upstream temper ature sensor adapter union 44 N m if it has been replaced Equipment required Diagnostic tool Tightening torquesm particle filter upstream...

Page 1678: ...re are no faults using the Diagnostic tool REMOVING THE PARTICLE FILTER DOWNSTREAM TEMPERATURE SENSOR a I REMOVAL PREPARATION OPERATION a Position the vehicle on a two post lift see Vehicle Towing and...

Page 1679: ...particle filter downstream temperature sensor adapter union if it has been loosened a Torque tighten the particle filter downstream tem perature sensor adapter union 44 N m if it has been replaced 124...

Page 1680: ...downstream tem perature sensor 30 N m a Clip the particle filter downstream temperature sen sor wiring onto the exhaust heat shield respecting the colour coding on the wiring a Connect the particle f...

Page 1681: ...Unclip the particle filter temperature sensor connector from the heat shield the particle filter temperature sensor wiring from the heat shield a Disconnect the particle filter temperature sensor conn...

Page 1682: ...ith COPPER ALUMINIUM LUBRI CANT see Vehicle Parts and consumables for the repair 04B Consumables Products a Torque tighten the particle filter temperature sen sor 30 N m using the tool Mot 1807 a Posi...

Page 1683: ...ng the particle filter temperature sensor coat the sensor threading with COPPER ANTI SEIZE AGENT or COPPER ALUMINIUM LUBRICANT see Vehicle Parts and consumables for the re pair 04B Consumables Product...

Page 1684: ...or connec tor 2 a Unclip the alternator wiring 3 IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and opera tion recommendations before carrying out a...

Page 1685: ...the exhaust fuel in jector solenoid valve the fuel supply pipe opening of the exhaust fuel in jector a Remove the bolt 8 of the exhaust fuel injector solenoid valve the exhaust fuel injector solenoid...

Page 1686: ...r so lenoid valve the fuel supply pipe of the exhaust fuel injector II FINAL OPERATION a Connect the fuel drain pipe a Clip the alternator wiring a Connect the injector rail pressure sensor connector...

Page 1687: ...RNED a Disconnect the fuel supply union 1 from the ex haust fuel injector a Insert the blanking plugs a Separate the fuel supply union from the exhaust fuel injector a Disconnect the exhaust fuel inje...

Page 1688: ...ter go to repair mode display the before after repair procedure for the computer selected select Exhaust fuel injection system in the List of components controlled by this computer section carry out t...

Page 1689: ...uel in jector a Insert the blanking plugs a Remove the bolt 5 from the exhaust fuel injector bracket using a Torx T45 socket and an extension the exhaust fuel injector bracket Tightening torquesm exha...

Page 1690: ...G OPERATION FOR PART CONCERNED a Refit the exhaust fuel injector fitted with a new seal the exhaust fuel injector bracket the exhaust fuel injector bracket bolt a Torque tighten the exhaust fuel injec...

Page 1691: ...tie bars see 1 9 D Engine mounting Lower engine tie bar Removal Re fitting page 19D 85 II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the exhaust fuel injector connector 1 the fuel supply un...

Page 1692: ...seal on the exhaust fuel injector cooler II REFITTING OPERATION FOR PART CONCERNED a Refit a new seal for the exhaust fuel injector cooler the exhaust fuel injector cooler a Torque tighten the nuts of...

Page 1693: ...uel in jector a Insert the blanking plugs II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the nuts 5 of the exhaust fuel injector cooler Tightening torquesm the nuts of the exhaust fuel injector c...

Page 1694: ...er if it is to be re used of the turbocharger outlet exhaust gas duct When replacing the exhaust fuel injector cooler a Remove the exhaust fuel injector see 19B Ex haust Exhaust fuel injector Removal...

Page 1695: ...an only be carried out after the SERVICE warning light has come on accompanied by the message REGENERATE PARTICLE FILTER or by the orange warning light CHECK EMISSIONS see the relevant Driver s Handbo...

Page 1696: ...ace the oil filter see 10A Engine and cylinder block assembly Oil filter Removal Refitting page 10A 117 see MR 415 10A Engine and pe ripherals IMPORTANT During forced regeneration of the particle filt...

Page 1697: ...carried out after the SERVICE warning light has come on accompanied by the REGENERATE PARTICLE FILTER message or the orange CHECK ANTI POLLUTION SYSTEM warning light see driver s Handbook for vehicle...

Page 1698: ...Replace the oil filter see 10A Engine and cylinder block assembly Oil filter Removal Refitting page 10A 117 IMPORTANT During forced regeneration of the particle filter the temperature of the exhaust p...

Page 1699: ...ed out after the SERVICE warning light has come on accompanied by the message REGENERATE PARTICLE FILTER or by the orange warning light CHECK EMISSIONS see the relevant Driver s Handbook IMPORTANT Dur...

Page 1700: ...ts IMPORTANT During forced regeneration of the particle filter the temperature of the exhaust pipe rises signifi cantly Always use one of the two kits approved for the high temperatures reached during...

Page 1701: ...connecting hose the seal between the flexible pipe and the particle filter REFITTING I REFITTING PREPARATION OPERATION a Always replace the seal between the connecting hose and the par ticle filter t...

Page 1702: ...REFITTING OPERATION FOR PART CONCERNED a Refit new studs on the particle filter if they were loos ened during the removal procedure a new seal between the connecting hose and the particle filter the c...

Page 1703: ...onnecting hose on the parti cle filter the connecting hose the connecting hose seal on the catalytic pre con verter then discard it the connecting hose seal on the particle filter then discard it III...

Page 1704: ...using SUR FACE CLEANER see Vehicle Parts and con sumables for the repair 04B Consumables Products and clean cloths I FOR VEHICLES PRODUCED BEFORE 02 04 2008 a Refit partially the connecting hose fitte...

Page 1705: ...catalytic converter then discard it REFITTING a Parts always to be replaced the connecting hose seal on the catalytic converter the exhaust clip a Clean the bearing faces of the connecting hose and th...

Page 1706: ...lencer a Refit the connecting hose fitted with a new seal on the catalytic converter a Tighten the connecting hose nuts on the catalytic converter a Fit a new exhaust sleeve between the connecting hos...

Page 1707: ...connecting hose suspension stud on the front axle subframe the connecting hose nuts 1 on the catalytic con verter the connecting hose the connecting hose seal on the catalytic converter then discard i...

Page 1708: ...e between the connecting hose and the intermediate pipe see 19B Exhaust Exhaust Precautions for the repair page 19B 18 a Tighten the bolt of the connecting hose suspension stud on the front axle subfr...

Page 1709: ...782 19B a The connecting hose 1 is integrated into the parti cle filter a Replace the particle filter catalytic converter con necting hose assembly in the event of a connecting hose fault see 19B Exha...

Page 1710: ...from the fuel sender module fuel pipes Special tooling required Mot 1397 Universal spanner for remov ing fuel gauge nuts IMPORTANT During this operation be sure to refrain from smoking or bringing re...

Page 1711: ...lace the fuel sender module nut the seal II REFITTING OPERATION FOR PART CONCERNED a Position the new seal 3 in the neck correctly the fuel sender module 4 on the fuel tank a lug on the fuel sender mo...

Page 1712: ...e mark 5 on the nut is aligned with the mark 6 on the fuel tank a Connect the fuel sender module fuel pipe union the fuel sender module connector III FINAL OPERATION a Close the fuel sender module acc...

Page 1713: ...ial tooling required Mot 1397 Universal spanner for remov ing fuel gauge nuts IMPORTANT During this operation be sure to refrain from smoking or bringing red hot objects close to the working area be c...

Page 1714: ...he seal II REFITTING OPERATION FOR PART CONCERNED a Position the new seal 3 in the neck correctly the fuel sender module 4 on the fuel tank a lug on the fuel sender module and a recess in the fuel tan...

Page 1715: ...til the mark 5 on the nut is aligned with the mark 6 on the fuel tank a Connect the fuel sender module fuel pipe union the fuel sender module connector III FINAL OPERATION a Close the fuel sender modu...

Page 1716: ...er a Connect the fuel supply pipe to the fuel filter a Refit the front right hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the front right hand wheel see...

Page 1717: ...19C 8 TANK Fuel tank Draining K9K or M9R or V9X 19C a Connect the battery see Battery Removal Refit ting 80A Battery...

Page 1718: ...red pneumatic transfer pump for fuels IMPORTANT During this operation be sure to refrain from smoking or bringing red hot objects close to the working area be careful of fuel splashes when disconnecti...

Page 1719: ...ansfer pump for fuels to the T union outlet a Drain the fuel tank REFITTING a Disconnect the pneumatic transfer pump for fuels from the T union outlet a Remove the T union Mot 1311 08 a Connect the fu...

Page 1720: ...Exhaust Silencer Removal Refitting page 19B 64 Equipment required component support Tightening torquesm four wheel drive actua tor s new nuts 84 N m earth strap nut 8 N m fuel tank bolts 21 N m elect...

Page 1721: ...r page 19B 18 and see Exhaust Parts and consumables for the repair a Remove the clip 5 between the connector pipe and the si lencer the connector pipe a Remove the intermediate pipe see 19B Exhaust In...

Page 1722: ...onic parking brake control unit mounting a Unpick the electronic parking brake control unit mounting wiring from the fuel tank a Remove the rear left hand underbody protector clip the underbody protec...

Page 1723: ...of the four wheel drive actuator link age on the compensator side the position head down of the four wheel drive ac tuator bolts a Remove the nut 12 from the earth strap a Disconnect the connectors 13...

Page 1724: ...of the bolts 17 on the four wheel drive actuator a Remove the bolts 18 from the four wheel drive actuator the four wheel steering actuator a Unclip the rigid brake pipes 19 from their support 128340 N...

Page 1725: ...otective sheath of the battery disconnection unit supply wiring the nut 21 from the protective sheath of the bat tery disconnection unit supply wiring a Unclip the brake pipes 23 from their support a...

Page 1726: ...TTING I REFITTING PREPARATION OPERATION a parts always to be replaced Fuel pipe clip be tween the fuel tank filler neck and the fuel tank 11 08 01 05 a Always replace the four wheel drive actuator nut...

Page 1727: ...sensor module see Fuel level sensor module Removal Refitting on a new fuel tank a Refit the fuel filter for the exhaust fuel injector II REFITTING OPERATION FOR PART CONCERNED a Fit the fuel tank in p...

Page 1728: ...or s new nuts 84 N m the earth strap nut 8 N m a Refit the ball joint protector a Torque tighten the fuel tank bolts 21 N m III FINAL OPERATION a Remove the component support a Connect the fuel tank f...

Page 1729: ...it the intermediate pipe see 19B Exhaust In termediate pipe Removal Refitting page 19B 56 a Refit the intermediate pipe a Fit a new sleeve between the particle filter and the intermediate pipe see 19B...

Page 1730: ...pipe union Equipment required component support Tightening torquesm four wheel drive actua tor s new nuts 84 N m earth strap nut 8 N m fuel tank bolts 21 N m filler neck earth bolt 21 N m electronic p...

Page 1731: ...Removal Refitting page 19B 47 a Disconnect the connector 4 from the electronic parking brake control unit a Remove the bolts 5 from the electronic parking brake control unit mounting a Move aside the...

Page 1732: ...olt 7 the heat shield the nut 8 from the brake pipe mounting a Cut the clip 9 on the filler neck fuel tank con necting hose on the fuel tank side a Remove the filler neck earth bolt a Disconnect the f...

Page 1733: ...at 11 a Mark the routing of the four wheel steering actuator wir ing the position of the four wheel steering actuator link age on the compensator side the position head down of the four wheel steerin...

Page 1734: ...emove the ball joint protector 16 a Mark the location of the bolts 17 on the four wheel steering actuator a Remove the bolts 17 of the four wheel steering actuator the four wheel steering actuator 18...

Page 1735: ...19C 26 TANK Fuel tank Removal Refitting F4R or K4M or M4R or V4Y 19C a Unclip the rigid brake pipes 19 from their support 134925...

Page 1736: ...emove the protective sheath bolt 20 from the battery dis connection unit supply wiring the protective sheath nut 21 from the battery dis connection unit supply wiring the protective sheath bolt 22 fro...

Page 1737: ...e rubber bush is damaged in the forged wrench re place the rubber bush see Rear axle rubber bush 4 wheel steering actuator Removal Refitting 33A Rear axle components If the fuel tank is being replaced...

Page 1738: ...k a Connect the connectors a Refit the earth strap a Torque tighten the four wheel drive actuator s new nuts 84 N m the earth strap nut 8 N m a Refit the ball joint protector a Torque tighten the fuel...

Page 1739: ...n chamber see 19B Exhaust Expansion chamber Removal Refitting page 19B 47 a Remove the blanking plug from the fuel pipe union a Connect the fuel vapour absorber pipe union the fuel pipe union to the f...

Page 1740: ...see Rear wheel arch liner Removal Refitting 55A Ex terior protection Tightening torquesm filler neck earth bolt 21 N m IMPORTANT During this operation be sure to refrain from smoking or bringing red...

Page 1741: ...connecting hose on the fuel tank side a Disconnect the filler neck hose from the fuel tank a Remove the filler neck REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Fuel pipe...

Page 1742: ...ht hand wheel arch liner see Rear wheel arch liner Removal Refitting 55A Ex terior protection the rear right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the filler neck bolts on the fu...

Page 1743: ...Refitting 55A Ex terior protection Tightening torquesm fuel tank bolts 21 N m electronic parking brake control unit mounting bolts 21 N m filler neck earth bolt 21 N m IMPORTANT During this operation...

Page 1744: ...9C a Remove the earth bolt 2 from the filler neck a Remove the earth bolt 3 from the filler neck a Remove the rear left hand underbody protector nuts the rear left hand underbody protector clip the re...

Page 1745: ...lectronic parking brake control unit mounting the fuel tank bolts 5 a Undo the fuel tank bolts 6 ELECTRONIC PARKING BRAKE 124244 124243 Note Do not remove the bolts from the fuel tank and the electron...

Page 1746: ...t the filler neck hose to the fuel tank the filler neck anti splashback pipe a Refit a new clip on the fuel tank end of the filler neck fuel tank connecting hose III FINAL OPERATION a Torque tighten t...

Page 1747: ...t Removal Refitting page 12A 13 the engine undertray bolts the engine undertray a Remove the rear suspended engine mounting bolts 1 the rear suspended engine mounting a Remove the tie rod rear bolts 2...

Page 1748: ...2 3 in place of the tie rod rear bolts a Position the first retaining bar of the tool Mot 1720 4 a Remove the radiator mounting cross member bolts 5 a Fit the long pins of the tool Mot 1852 6 in place...

Page 1749: ...engine mounting Removal Refitting M4R 19D a Fit the retaining bar of the tool Mot 1672 8 per pendicular to the retaining bars of the tool Mot 1720 a Lock the retaining bar of the tool Mot 1672 on bot...

Page 1750: ...ove the central nut 11 from the suspended engine mounting rubber pad shaft on the gearbox the nuts 12 from the suspended engine mounting rubber pad on the gearbox a Slightly lower the engine until the...

Page 1751: ...earbox a Remove the bolts 17 from the suspended engine mounting rubber pad shaft on the gearbox the suspended engine mounting rubber pad shaft from the gearbox 18 REFITTING I REFITTING OPERATION FOR P...

Page 1752: ...unting rubber pad on the gearbox 105 N m II FINAL OPERATION a Refit the air filter box see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the battery tray see Battery tray Removal Re f...

Page 1753: ...ttery tray see Battery tray Removal Re fitting 80A Battery the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the diesel injection computer see 13B Diesel in jectio...

Page 1754: ...moval Refitting M9R and 742 or 744 or 746 or 748 or 754 or 800 or 802 or 806 or 808 or 816 19D a Fit the Mot 1453 2 fitted with the Mot 1453 01 a Remove the lower engine tie bar see 19D Engine mountin...

Page 1755: ...816 19D II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the gearbox support nut 3 a Gently lower the gearbox to detach the gearbox sup port from the rubber pad a Remove the nuts 4 from the rubber...

Page 1756: ...the rubber pad the rubber pad bolts 9 a Tighten the rubber pad bolts 9 a Refit the rubber pad nut 10 a Tighten the rubber pad nut 10 II FINAL OPERATION a Refit the lower engine tie bar see 19D Engine...

Page 1757: ...air filter box see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the upper engine tie bar bolts 1 the upper engine tie bar Special...

Page 1758: ...using a copper hammer a Mark the position of the left hand suspended engine mounting rubber pad on the left hand suspended engine mounting support using a indelible pencil a Remove the left hand suspe...

Page 1759: ...OPERATION FOR PART CONCERNED a Refit the left hand suspended engine mounting support on the gearbox the left hand suspended engine mounting support bolts on the gearbox a Torque tighten the the left h...

Page 1760: ...ne mounting shaft of the rubber pad using the tool Mot 1453 fit ted with the tool Mot 1453 01 a Refit the left hand suspended engine mounting shaft nut a Tighten the left hand suspended engine mountin...

Page 1761: ...g page 12A 13 a Remove the bolt 1 from the max fuse box the max fuse box clip 2 a Move the max fuse box to one side Special tooling required Mot 1852 Conversion support studs for Mot 1720 tool Mot 172...

Page 1762: ...hannel a Remove the engine undertray bolts the engine undertray a Remove the lower engine tie bar bolt 4 on the lower engine tie bar support the bolt 5 from the lower engine tie bar on the sub frame t...

Page 1763: ...1852 8 in place of the tie rod rear bolts a Position the first retaining bar of the tool Mot 1720 9 a Remove the radiator mounting cross member bolts 10 a Fit the long pins of the tool Mot 1852 11 in...

Page 1764: ...ine mounting Removal Refitting F4R and PK4 19D a Fit the retaining bar of the tool Mot 1672 13 per pendicular to the retaining bars of the tool Mot 1720 a Lock the retaining bar of the tool Mot 1672 o...

Page 1765: ...ONCERNED a Remove the central nut 16 of the left hand suspended en gine mounting rubber pad the upper bolts of the left hand suspended engine mounting rubber pad 17 on the body a Loosen the lower bolt...

Page 1766: ...o contact with the suspended engine mounting rubber pad support on the gearbox a Torque tighten the left hand suspended engine mounting rubber pad central nut 62 N m III FINAL OPERATION a Remove the r...

Page 1767: ...19D 21 ENGINE MOUNTING Left hand suspended engine mounting Removal Refitting F4R and PK4 19D the battery see Battery Removal Refitting 80A Battery the engine cover...

Page 1768: ...y tray Removal Re fitting 80A Battery the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the diesel injection computer see 13B Diesel in jection Diesel injection co...

Page 1769: ...R and 805 or 809 or 845 or 849 19D a Fit the Mot 1453 fitted with the Mot 1453 01 a Remove the lower engine tie bar see 19D Engine mounting Lower engine tie bar Removal Refit ting page 19D 85 II OPERA...

Page 1770: ...bolts 9 on the side member a Torque tighten the gearbox support bolts on the side member 105 N m 9 a Refit the gearbox support 10 on the gearbox the gearbox support bolts 11 on the gearbox a Torque ti...

Page 1771: ...805 or 809 or 845 or 849 19D the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the battery tray see Battery tray Removal Re fitting 80A Battery the battery see Ba...

Page 1772: ...Remove the petrol injection computer mounting nut 1 a Move aside the wiring harness channel at 2 a Fit the Mot 1453 3 a safety strap s a Mark the position of the suspended mounting on the body Specia...

Page 1773: ...ber pad shaft on the gearbox a Slightly lower the gearbox a Remove the nuts 5 from the suspended engine mounting rubber pad on the gearbox the suspended engine mounting rubber pad from the gearbox a R...

Page 1774: ...aft on the gearbox the suspended engine mounting rubber pad shaft from the gearbox REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the suspended engine mounting rubber pad shaft on the gear...

Page 1775: ...rbox 105 Nm the nut on the suspended engine mounting rub ber pad shaft on the gearbox 62 Nm II FINAL OPERATION a Remove the safety strap s the Mot 1453 a Refit the petrol injection computer mounting b...

Page 1776: ...er unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 the battery disconnection unit see Battery dis connection unit Removal Refitting 80A Bat tery a Remove the mountings 1 of the...

Page 1777: ...rom the engine wiring guide the engine wiring guide a Remove the engine tie bar bolts 3 the engine tie bar a Remove the tie rod rear bolts 4 a Fit the short pins of the tool Mot 1852 5 in place of the...

Page 1778: ...nting Removal Refitting V4Y 19D a Remove the radiator mounting cross member bolts 7 a Fit the long pins of the tool Mot 1852 8 in place of the radiator mounting cross member bolts a Position the secon...

Page 1779: ...engine mounting Removal Refitting V4Y 19D a Fit the retaining bar of the tool Mot 1672 10 per pendicular to the retaining bars of the tool Mot 1720 a Lock the retaining bar of the tool Mot 1672 on bo...

Page 1780: ...move the central nut 13 from the suspended engine mounting support shaft on the gearbox the bolts 14 of the rubber pad of the suspended engine mounting from the gearbox a Slightly lower the engine unt...

Page 1781: ...rbox 62 N m III FINAL OPERATION a Remove the retaining shoe of the tool Mot 1672 a Unlock the retaining bar of the tool Mot 1672 a Remove the retaining bar of the tool Mot 1672 the retaining bars of t...

Page 1782: ...tery tray Removal Re fitting 80A Battery the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 a Remove the bolt 1 from the max fuse box the max fuse box clip 2 a Move...

Page 1783: ...er mounting the engine wiring channel a Remove the lower engine tie bar bolt 4 on the engine tie bar support the bolt 5 from the lower engine tie bar on the sub frame the lower engine tie bar a Remove...

Page 1784: ...1852 8 in place of the tie rod rear bolts a Position the first retaining bar of the tool Mot 1720 9 a Remove the radiator mounting cross member bolts 10 a Fit the long pins of the tool Mot 1852 11 in...

Page 1785: ...ine mounting Removal Refitting F4R and AJ0 19D a Fit the retaining bar of the tool Mot 1672 13 per pendicular to the retaining bars of the tool Mot 1720 a Lock the retaining bar of the tool Mot 1672 o...

Page 1786: ...ubber pad on the left hand suspended engine mounting a Slightly lower the engine until the shaft detaches from the suspended engine mounting on the gear box a Remove the upper bolts of the left hand s...

Page 1787: ...ended engine mounting rubber pad support on the gearbox a Torque tighten the central nut of the suspended engine mounting shaft on the gearbox 62 N m III FINAL OPERATION a Remove the retaining shoe of...

Page 1788: ...ng Removal Refitting F4R and AJ0 19D the front left hand wheel arch liner see Front wheel arch liner Removal Refitting 55A Ex terior protection the front left hand wheel see Wheel Removal Refitting 35...

Page 1789: ...adlight see Headlight Removal Refitting 80B Headlights the air filter unit see 12A Fuel mixture Air filter unit Removal Refitting page 12A 13 a Remove the bolt 1 from the max fuse box a Remove the cli...

Page 1790: ...wiring protective sheath the nut 5 of the engine wiring protective sheath a Unclip the supply wiring 6 of the battery disconnec tion unit a Remove the earth nuts 7 from the front left hand side membe...

Page 1791: ...Removal Re fitting page 19D 85 a Move aside the rigid cooling pipes a Loosen the bolt 10 of the upper engine tie bar bracket a Remove the bolts 11 of the upper engine tie bar bracket the upper engine...

Page 1792: ...ins of the tool Mot 1852 16 in place of the radiator mounting cross member bolts a Position the second retaining bar 17 of the tool Mot 1720 a Fit the retaining bar 18 of the tool Mot 1672 per pendicu...

Page 1793: ...t 1672 un der the gearbox casing II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the central nut 21 from the suspended en gine mounting support shaft on the gearbox a Slightly lower the engine unt...

Page 1794: ...ended engine mounting rubber pad on the gearbox a Remove the rubber pad of the suspended engine mounting from the gearbox a Remove the bolt 24 from the power assisted steer ing pipe support a Remove t...

Page 1795: ...r pad on the gearbox comes into contact with the suspended engine mounting rubber pad support on the gearbox a Torque tighten the central nut of the suspended engine mounting shaft on the gearbox 62 N...

Page 1796: ...t Removal Refitting page 12A 13 the left hand headlight see Headlight Removal Refitting 80B Headlights the front bumper see Front bumper Removal Refitting 55A Exterior protection the front wheel arch...

Page 1797: ...e rod rear bolts 1 a Fit the short pins of the tool Mot 1852 2 in place of the tie rod rear bolts a Position the first retaining bar of the tool Mot 1720 3 a Remove the radiator mounting cross member...

Page 1798: ...ight hand suspended engine mounting Removal Refitting F4R 19D a Fit the long pins of the tool Mot 1852 5 in place of the radiator mounting cross member bolts a Position the second retaining bar of the...

Page 1799: ...ed engine mounting Removal Refitting F4R 19D a Fit the retaining bar of the tool Mot 1672 7 per pendicular to the retaining bars of the tool Mot 1720 a Lock the retaining bar of the tool Mot 1672 on t...

Page 1800: ...e of the tool Mot 1672 un der the sump a Unclip the fuel supply pipe at 10 a Remove the bolts 11 from the expansion bottle a Move aside the expansion bottle by pushing the expansion bottle towards the...

Page 1801: ...ten the upper suspended engine mounting a Tighten to torque the bolts securing the engine rubber pad on the body 62 N m the engine cover bolts on the engine mounting 62 N m II FINAL OPERATION a Fit th...

Page 1802: ...ion support studs for Mot 1720 tool Mot 1720 Engine stand Mot 1672 Lower engine support Tightening torquesm bolts of the suspended engine mounting rubber pad 62 N m bolts of the suspended engine mount...

Page 1803: ...52 3 in place of the tie rod rear bolts a Position the first retaining bar of the tool Mot 1720 4 a Remove the radiator mounting cross member bolts 5 a Fit the long pins of the tool Mot 1852 6 in plac...

Page 1804: ...nded engine mounting Removal Refitting M4R 19D a Fit the retaining bar of the tool Mot 1672 8 per pendicular to the retaining bars of the Mot 1720 a Lock the retaining bar of the tool Mot 1672 on two...

Page 1805: ...tool Mot 1672 un der the sump a Unclip the fuel supply pipe 11 the expansion bottle from the suspended engine mounting cover a Disconnect the fuel supply pipe 12 from the injector rail a Insert the b...

Page 1806: ...suspended engine mounting a Remove the bolts 14 from the suspended engine mounting cover the right hand suspended engine mounting REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the right h...

Page 1807: ...suspended engine mounting cover a Remove the blanking plugs from the fuel supply pipe a Connect the fuel supply pipe on the injector rail a Remove the retaining shoe of the tool Mot 1672 a Unlock the...

Page 1808: ...mounting fuel pipes a Remove the bolts 1 from the expansion bottle a Pull the expansion bottle in the direction of the ar row a Move aside the expansion bottle to access the en gine mounting bolts a...

Page 1809: ...ne stand REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the engine mounting the engine mounting bolts on the engine a Torque tighten the engine mounting bolts on the engine 62 Nm a Lower t...

Page 1810: ...a Tighten the engine tie bar bolt on the engine a Tighten to torque and in order the engine tie bar bolt on the body 115 Nm the engine tie bar strut bolt on the engine 62 Nm II FINAL OPERATION a Remo...

Page 1811: ...liner Removal Refitting MR 416 55A Exterior protection a Unclip the fuel pipes at 1 a Remove the bolt 2 from the expansion bottle Special tooling required Mot 1453 Engine anchorage support with multip...

Page 1812: ...ertray the bolts 4 from the lower engine tie bar the lower engine tie bar II REMOVAL OPERATION FOR PART CONCERNED a Remove the bolt 5 from the upper engine tie bar on the cyl inder head the bolt 6 fro...

Page 1813: ...Lower the engine using the Mot 1453 equipped with the Mot 1453 01 to bring the rubber pad in contact with the body a Position the rubber pad according to the marks made during removal a Refit the rig...

Page 1814: ...nting Removal Refitting K9K 19D a Refit the front right hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front right hand wheel see Wheel Removal R...

Page 1815: ...lift see Vehicle Towing and lifting 02A Lifting equipment a Remove the engine cover the engine undertray bolts the engine undertray a Position the Mot 1720 1 Special tooling required Mot 1720 Engine s...

Page 1816: ...at 2 a Remove the bolts 3 from the expansion bottle a Unclip the expansion bottle a Unclip the expansion bottle by pushing the expansion bottle towards the wing A pulling the expansion bottle upwards...

Page 1817: ...the suspended engine mounting a Torque tighten the suspended engine mounting cover bolts 62 Nm a Lower the engine until the rubber pad touches the suspended engine mounting a Position the suspended e...

Page 1818: ...olts the engine undertray a Remove the engine tie bar bolts 1 the engine tie bar a Remove the tie rod rear bolts 4 Special tooling required Mot 1852 Conversion support studs for Mot 1720 tool Mot 1720...

Page 1819: ...52 5 in place of the tie rod rear bolts a Position the first retaining bar 6 of the tool Mot 1720 a Remove the radiator mounting cross member bolts 7 a Fit the long pins of the tool Mot 1852 8 in plac...

Page 1820: ...engine mounting Removal Refitting V4Y 19D a Fit the retaining bar of the tool Mot 1672 perpen dicular to the retaining bars of the tool Mot 1720 10 a Lock the retaining bar of the tool Mot 1672 on bo...

Page 1821: ...Always replace the radiator mounting cross member bolts the tie rod rear bolts II REFITTING OPERATION FOR PART CONCERNED a Refit the right suspended engine mounting a Torque tighten the right hand su...

Page 1822: ...retaining bars of the tool Mot 1720 a Remove the four pins of the tool Mot 1852 a Refit the lower engine tie bar a Torque tighten the lower engine tie bar bolts 180 N m a Refit new radiator mounting c...

Page 1823: ...indscreen washer filler neck the windscreen washer filler neck a Unclip the power assisted steering reservoir 2 a Move the power assisted steering reservoir to one side Special tooling required Mot 14...

Page 1824: ...ervoir mounting a Unclip the fuel pipes 4 from the expansion bottle a Move the fuel pipes away from the expansion bottle a Unclip the manual priming pump from the expansion bottle at 5 a Remove the ma...

Page 1825: ...g the expansion bottle at X by lifting the expansion bottle at Y a Unclip the fuel supply pipes 8 from the right hand suspended engine mounting a Move the fuel supply pipes away from the right hand su...

Page 1826: ...tool Mot 1852 11 in place of the tie rod rear bolts a Position the first retaining bar 12 of the tool Mot 1720 a Remove the radiator mounting cross member bolts 13 a Fit the long pins of the tool Mot...

Page 1827: ...engine mounting Removal Refitting V9X 19D a Fit the retaining bar 16 of the tool Mot 1672 per pendicular to the retaining bars of the tool Mot 1720 a Lock the retaining bar of the tool Mot 1672 on bo...

Page 1828: ...the retaining shoe of the tool Mot 1672 un der the gearbox casing II OPERATION FOR REMOVAL OF PART CONCERNED a Loosen the bolt 19 of the upper engine tie bar bracket a Remove the bolts 20 of the upper...

Page 1829: ...upper engine tie bar bracket 62 N m III FINAL OPERATION a Remove the retaining shoe of the tool Mot 1672 a Unlock the retaining bar of the tool Mot 1672 a Remove the retaining bar of the tool Mot 1672...

Page 1830: ...19D 84 ENGINE MOUNTING Right hand suspended engine mounting Removal Refitting V9X 19D the engine undertray a Top up the coolant level in the expansion bottle a Refit the engine cover...

Page 1831: ...e tie bar bolt 1 on the engine tie bar mounting on the sump the engine tie bar bolt 2 from the subframe the engine tie bar a Remove the rear suspended engine mounting rubber pad bolts 3 on the subfram...

Page 1832: ...nting rubber pad the rear suspended engine mounting rubber pad bolts on the subframe a Tighten the rear suspended engine mounting rubber pad bolts on the subframe a Refit the engine tie bar the engine...

Page 1833: ...ounting on the cylinder block the engine tie bar mounting 4 on the cylinder block REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the engine tie bar mounting on the cylinder block the engin...

Page 1834: ...ray bolts the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the engine tie bar bolts 1 the engine tie bar a Remove the rubber pad bolts 2 from the engine tie bar the rubber pad...

Page 1835: ...ine tie bar support bolts a Refit the rubber pad to the engine tie bar the engine tie bar rubber pad bolts a Tighten the engine tie bar rubber pad bolts a Refit the engine tie bar the engine tie bar b...

Page 1836: ...ferential output seal see Differ ential output seal Removal Refitting MR 415 21A Manual gearbox II REMOVAL OPERATION FOR PART CONCERNED a Remove the bolts 1 from the lower engine tie bar the lower eng...

Page 1837: ...al Refitting MR 415 21A Manual gearbox the front right hand wheel driveshaft see Front right hand driveshaft Removal Refitting MR 415 29A Driveshafts a Fill the manual gearbox see Manual gearbox oils...

Page 1838: ...ne mounting support bolts 3 the rear suspended engine mounting support REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the rear suspended engine mounting support a Torque tighten the rear s...

Page 1839: ...engine mounting bolts 2 on the subframe the rear suspended engine mounting rubber pad a Remove the bolts 3 from the driveshaft relay bearing the driveshaft relay bearing REFITTING I REFITTING OPERATIO...

Page 1840: ...ie bar on the gear box side the lower engine tie bar on the gearbox side a Remove the bolts 2 of the lower engine tie bar mounting from the cylinder block on the gearbox side the lower engine tie bar...

Page 1841: ...e gearbox side a Torque tighten the bolts of the lower engine tie bar on the gearbox side 105 N m II FINAL OPERATION a Refit the engine undertray REMOVING THE LOWER ENGINE TIE BAR ON THE TIMING END I...

Page 1842: ...ON THE TIMING END I REFITTING OPERATION FOR PART CONCERNED a Refit the engine tie bar rubber pad on the subframe at the timing end the lower engine tie bar mounting on the cylinder block at the timing...

Page 1843: ...ng 21A Manual gearbox II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 1 from the lower engine tie bar the lower engine tie bar the lower engine tie bar support bolts 2 the lower engine t...

Page 1844: ...e tie bar Removal Refitting K9K and 782 19D a Fill the manual gearbox see Manual gearbox oils Draining Filling 21A Manual gearbox a Refit the engine undertray the front right hand wheel see Wheel Remo...

Page 1845: ...acturer in the production of the various component units and accessories from which the vehicles are constructed All rights reserved by Renault Copying or translating in part or in full of this docume...

Page 1846: ...pair 23A 1 Automatic gearbox Identification 23A 2 Automatic gearbox Specifications 23A 3 Automatic gearbox Parts and consumables for the repair 23A 4 Automatic gearbox List and location of components...

Page 1847: ...A 110 29A DRIVESHAFTS Front left hand driveshaft Removal Refitting 29A 1 Front right hand driveshaft Removal Refitting 29A 7 Relay shaft bearing Removal Refitting 29A 14 Front driveshaft gaiter wheel...

Page 1848: ...shaft The thrust bearing guide and the clutch fork no wear or scratches During refitting Check the direction of the clutch plate Centre the clutch plate using the tool Emb 1780 Gradually torque tight...

Page 1849: ...20A 2 CLUTCH Clutch Specifications TL4 20A Pressure plate Drive plate Number of splines 21 Plate thickness 6 9 mm Plate outer diameter 225 mm 123819 123820...

Page 1850: ...20A Clutch pressure plate Clutch friction plate Clutch plate outer diameter 250 mm Clutch plate thickness 8 3 mm Number of splines 21 Clutch plate outer diameter 240 mm Clutch plate thickness 8 3 mm N...

Page 1851: ...1 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 differential output seals see 21A Manual gear box Differential output seal Removal Refit...

Page 1852: ...nd Mot 582 or Mot 1677 III FINAL OPERATION a Refit the gearbox see 21A Manual gearbox Manual gearbox Removal Refitting page 21A 14 the front axle subframe see Front axle subframe Removal Refitting 31A...

Page 1853: ...ontrols a Refit the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels and tyres the engine undertray...

Page 1854: ...ing page 29A 1 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the radiator mounting cross member see Radiator mounting cross member Remov...

Page 1855: ...ollowing procedure a a Place the base of tool Emb 1604 in a vice a Fit the pressure plate on the base then the thrust ball bearing or the copper ring 2 and the nut 3 Note The following operations must...

Page 1856: ...circlip pliers at 4 a Compress the spring 5 to reprime the automatic wear compensation a Slacken off the nut 3 completely springs com pressed a Release the pressure plate a Remove the pressure plate...

Page 1857: ...Radiator mounting cross member Removal Refitting MR 416 41A Front lower structure the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the fro...

Page 1858: ...t see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 differentia...

Page 1859: ...hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A...

Page 1860: ...or TRANSELF NFJ 75W80 PKX PFX VMX NEX NGX N0X UNX TRANSELF TRX 75W80 or TRANSELF NFP 75W80 ZFX T R A N S E L F L D 75W80 DESIGNATION STANDARD PART NUM BER TRANSELF TRX 75W80 or TRANSELF NFP 75W80 API...

Page 1861: ...engine undertray a Position the oil recovery tray under the gearbox a Undo the drain plug 1 using the Mot 1018 a Let the oil flow out of the gearbox in the oil recovery tray a Refit a new seal on the...

Page 1862: ...ox using a syringe containing recom mended oil see 21A Manual gearbox Manual gearbox oil Specifications page 21A 1 04A Lu bricants until the oil overflows out of the filler cap hole a Refit the filler...

Page 1863: ...e Towing and lifting MR 415 02A Lifting equip ment a Remove the engine undertray a Position the oil recovery tray under the gearbox a Unscrew the drain plug 1 using the Mot 1018 a Let the oil flow int...

Page 1864: ...the gearbox using a syringe containing recom mended oil see 21A Manual gearbox Manual gearbox oil Specifications page 21A 1 until the oil overflows from the fuel filler cap opening a Refit the filler...

Page 1865: ...ve shafts Front left hand driveshaft Removal Refitting page 29A 1 2 To replace the differential output seal on the right hand side a Remove the front right hand wheel see Wheel Removal Refitting MR 41...

Page 1866: ...OR PART CONCERNED 1 Refitting the differential output seal on the left hand side a Refit the left hand differential output seal using the Bvi 1719 1 and Bvi 1419 2 2 Refitting the differential output...

Page 1867: ...ission see 29A Driveshafts Front right hand driveshaft Removal Refitting page 29A 7 21492 21493 Note Do not lubricate the seal when fitting it With the new seal fitted leave the deflector pro tector p...

Page 1868: ...iveshaft on the left hand side a Refit the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Re fitting page 29A 1 3 Final operation a Top up the gearbox oil see 21A M...

Page 1869: ...riveshaft Removal Refitting page 29A 1 2 When replacing the differential output seal on the right hand side a Remove the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres the fro...

Page 1870: ...21A 11 MANUAL GEARBOX Differential output seal Removal Refitting TL4 21A REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Differential output seal 12 01 05 10...

Page 1871: ...tput seal a Fit the new differential output seal on the gearbox the mandrel 2 or 3 of the tool Bvi 1854 on the new differential output seal a Tap the tool 1 with a copper hammer to fit the new differe...

Page 1872: ...Refitting TL4 21A the front right hand wheel see Wheel Removal Refitting 35A Wheels and tyres 3 Final operation a Fill the gearbox and check the level see 21A Man ual gearbox Manual gearbox oils Drai...

Page 1873: ...ne undertray a Disconnect the rigid clutch pipe from the clutch thrust bearing a Fit blanking plugs onto the end of the clutch pipe and at the inlet of the clutch thrust bearing a Unclip the gear cont...

Page 1874: ...the cooling assembly to the upper cross member a Remove the starter see Starter Removal Refit ting 16A Starting Charging a Drain the gearbox see 21A Manual gearbox Manual gearbox oils Draining Filling...

Page 1875: ...29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 differential output seals see 21A Manual gear box Differential output seal Removal Refit ting page 21A 6 the radiator mounting...

Page 1876: ...the rubber pad of the left hand suspended engine mounting the left hand suspended engine mounting rubber pad a Tilt the engine using the tool Mot 1453 01 a Remove the bolt 7 from the wiring on the ge...

Page 1877: ...Refitting M9R and PK4 21A a Remove the gearbox bolts 9 while leaving two re taining bolts a Fit the tool component support equipped with the tool Bvi 1718 12 on the contact points 10 and bolt the tool...

Page 1878: ...gearbox the gearbox bolts a Remove the component support fitted with the tool Bvi 1718 a Torque tighten the gearbox bolts 44 Nm a Refit the retaining bracket for the heater matrix pipes 123408 123409...

Page 1879: ...ction differential output seals see 21A Manual gear box Differential output seal Removal Refit ting page 21A 6 the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Re...

Page 1880: ...damper valve a Move the intercooler outlet air pipe to one side a Disconnect the connector 2 from the reverse gear switch Special tooling required Mot 1453 Engine anchorage support with multiple adjus...

Page 1881: ...cable sleeve stops at 4 a Move the gearbox control cables to one side a Remove the engine undertray bolts the engine undertray a Disconnect the hydraulic clutch pipe 5 by pressing on the clip a Fit b...

Page 1882: ...differential output seals see 21A Manual gear box Differential output seal Removal Refit ting page 21A 6 the radiator mounting cross member see Radiator mounting cross member Removal Refitting 41A Fro...

Page 1883: ...ap s 10 a Remove the upper engine tie bar bolts 11 the upper engine tie bar a Remove the left hand suspended engine mounting shaft nut 12 a Detach the left hand suspended engine mounting shaft from th...

Page 1884: ...N FOR REMOVAL OF PART CONCERNED a Remove the upper bolts 14 from the manual gearbox the left hand suspended engine mounting shaft bolts 15 from the manual gearbox the left hand suspended engine mounti...

Page 1885: ...alytic converter downstream strut bolts 19 the catalytic converter downstream strut nut 20 the catalytic converter downstream strut a Remove the lower bolts 21 from the manual gear box 123524 Note Bef...

Page 1886: ...vi 1718 the studs from the manual gearbox a If replacing remove the following from the manual gearbox the reverse gear switch 29 the crankshaft position sensor see Crankshaft position sensor Removal R...

Page 1887: ...strut the catalytic converter downstream strut nut a Tighten the bolts on the catalytic converter downstream strut the catalytic converter downstream strut nut a Clip the drain pipe of the rail prote...

Page 1888: ...Tighten the nut of the power assisted steering pipe bracket a Clip the low pressure pipe on the front axle subframe the rigid brake pipe on the front left hand side member the wiring on the left tie r...

Page 1889: ...ball joints a Adjust the gearbox control cables see Gear control unit Adjustment a Connect the revers gear connector the intercooler outlet air pipe on the damper valve a Tighten the clip on the inter...

Page 1890: ...oval Refitting 55A Exterior protec tion the engine undertray bolts the engine undertray the starter see Starter Removal Refitting 16A Starting Charging a Disconnect the connector 1 from the reverse ge...

Page 1891: ...Manual gearbox oils Draining Filling page 21A 2 a Remove the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 the front right hand driveshaft se...

Page 1892: ...ing 10 from the front axle subframe left hand tie rod the rigid brake pipe from the front left hand side member the power assisted steering low pressure pipe from the front axle subframe a Remove the...

Page 1893: ...e servo pipe union 15 on the braking dis tributor the petrol vapour rebreather pipe union 16 128157 Note Before removing the earth terminal mark its position using an indelible marker by drawing a lin...

Page 1894: ...fitted with Mot 1453 01 17 and safety strap s 18 a Remove the left hand suspended engine mounting see Left hand suspended engine mounting Re moval Refitting 19D Engine mounting II OPERATION FOR REMOVA...

Page 1895: ...he bracket 25 and the bolt 26 a Tighten the rod anti clockwise in order to avoid tilting the manual gearbox a Remove the lower bolts 27 from the manual gearbox the manual gearbox using the component j...

Page 1896: ...tch 23 N m on the manual gearbox a Refit the new differential output seals see 21A Manual gearbox Differential output seal Re moval Refitting page 21A 6 a a Fit the new manual gearbox on the tool Bvi...

Page 1897: ...d driveshaft Removal Refitting page 29A 7 the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 a Fill the manual gearbox see 21A Manual gearbox M...

Page 1898: ...g from the reverse gear sensor a Fit the tool Ms 583 on the rigid clutch pipe at the outlet of the brake fluid reservoir a Unclip the rigid clutch pipe from the gearbox a Remove the engine undertray b...

Page 1899: ...ing an open jawed spanner the gear control cables from their support the oil vapour pipe from the gearbox a Remove the gear control cables the rigid clutch pipe a Remove the cooling assembly protector...

Page 1900: ...d tyres the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refit...

Page 1901: ...21A 42 MANUAL GEARBOX Manual gearbox Removal Refitting F4R and PK4 21A a Position the Mot 1453 and Mot 1453 01 123414...

Page 1902: ...d engine mounting rubber pad on the gearbox the suspended engine mounting rubber pad from the gearbox a Tilt the engine using the tool Mot 1453 01 a Remove the power assisted steering pipe bolts 8 the...

Page 1903: ...Removal Refitting F4R and PK4 21A a Remove the bolts 10 from the gearbox a Fit the tool component support equipped with the tool Bvi 1718 13 on the contact points 11 and screw the bolt Bvi 1718 of the...

Page 1904: ...box a Remove the component support fitted with the tool Bvi 1718 a Tighten to torque the gearbox bolts 44 Nm the gearbox nuts 44 Nm a Refit the retaining bracket on the heater matrix pipes 128681 1286...

Page 1905: ...Refitting page 29A 7 the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels and tyres a Connect the c...

Page 1906: ...le adjustments and retaining straps Mot 1453 01 Additional handle nut for engine lifting support tool Mot 1453 Bvi 1718 Component support plate for removal refitting of gear boxes Equipment required s...

Page 1907: ...Refitting 55A Exterior protec tion the engine undertray bolts the engine undertray a Drain the manual gearbox see 21A Manual gear box Manual gearbox oils Draining Filling page 21A 2 a Remove the front...

Page 1908: ...ve the hydraulic clutch pipe to one side a Remove the front axle subframe see Front axle subframe Removal Refitting 31A Front axle components a Fit the Mot 1453 8 fitted with Mot 1453 01 and safety st...

Page 1909: ...mounting shaft on the manual gearbox the left hand suspended engine mounting shaft from the manual gearbox 131087 131084 Note Before removing the earth terminal mark its position using an indelible m...

Page 1910: ...nting bolt 14 from the subframe the rear suspended engine mounting bolt 15 from the rear suspended engine mounting support the rear suspended engine mounting a Fit the Bvi 1718 to a component jack the...

Page 1911: ...e manual gearbox a Torque tighten the crankshaft position sensor bolt 8 N m a Refit the reverse gear switch wiring on the manual gearbox a Torque tighten the reverse gear switch 23 N m on the manual g...

Page 1912: ...rential output seals see 21A Manual gear box Differential output seal Removal Refit ting page 21A 6 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting p...

Page 1913: ...21A 54 MANUAL GEARBOX Manual gearbox Removal Refitting K4M and TL4 21A the engine cover...

Page 1914: ...he seal using a 2 5 mm drill bit a Fit a bolt in seal 1 a Extract the seal 1 using pliers REFITTING I REFITTING OPERATION FOR PART CONCERNED a Fit a new seal with its protector using the Bvi 1601 a Re...

Page 1915: ...iveshaft Removal Refitting page 29A 1 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the radiator mounting cross member see Radiator moun...

Page 1916: ...or mounting cross member Removal Refitting MR 416 41A Front lower structure the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the front left...

Page 1917: ...ifferential output seals see 21A Manual gear box Differential output seal Removal Refit ting page 21A 6 the radiator mounting cross member see Radiator mounting cross member Removal Refitting MR 416 4...

Page 1918: ...Removal Refitting MR 416 41A Front lower structure the front left hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection differential output seals see 21A M...

Page 1919: ...ication is only provided when the engine is running As a result of this fact and to avoid serious damage it is essential to comply with the following instructions never allow the vehicle to coast with...

Page 1920: ...Automatic gearbox Identification AJ0 23A The automatic gearbox is identified by an engraved marking 1 located underneath the automatic gearbox as well as by a self adhesive label 2 on the hydraulic di...

Page 1921: ...MATIC GEARBOX Automatic gearbox Specifications AJ0 23A Gearbox Suffix AJ0 004 005 006 007 018 Gear ratios epicyclic gear train output 1st 2nd 3rd 4th 5th 6th Reverse gear 4 2 2 405 1 583 1 161 0 856 0...

Page 1922: ...th new ones if removed the self locking nuts the differential output seals the converter seal O rings the four hydraulic distributor O rings the converter nuts the hydraulic distributor metal casing s...

Page 1923: ...losure panel 6 Oil cooler 7 Output speed sensor 8 Input speed sensor 9 Multifunction switch 10 Control lever 11 Electrical wiring 12 Hydraulic pressure measure ment plug 13 Hydraulic distributor O rin...

Page 1924: ...ights the front end panel see Front end panel Remov al Refitting MR 416 42A Front upper struc ture the particle filter see Particle filter Removal Refitting MR 415 19B Exhaust a Drain the cooling syst...

Page 1925: ...PERATION FOR PART CONCERNED a Remove the hoses and wiring fitted to the automatic transmission bell housing a Remove the starter wiring nuts 1 a Remove the starter wiring a Remove the bolt 2 from the...

Page 1926: ...RATIONS OPERATION a Check the distance X with a ruler The distance must be a minimum of 20 5 mm the condition of the drive plate and crown wheel vi sually II REFITTING OPERATION FOR PART CONCERNED a a...

Page 1927: ...Headlights the front bumper see Front bumper Removal Refitting MR 416 55A Exterior protection the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A...

Page 1928: ...xterior protection the headlights see Headlight Removal Refit ting MR 415 80B Headlights the front end panel see Front end panel Remov al Refitting MR 416 42A Upper front stucture the catalytic conver...

Page 1929: ...g a workshop hoist REFITTING I REFITTING PREPARATION OPERATION a Parts always to be replaced the self locking nuts the differential output seals the converter nuts the level setting plug seal a Check...

Page 1930: ...hts the front bumper see Front bumper Removal Refitting MR 416 55A Exterior protection the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 the f...

Page 1931: ...box Automatic gearbox oil Draining Filling page 23A 29 a Drain the refrigerant circuit using a refrigerant charging station see Refrigerant circuit Drain ing Filling 62A Air conditioning a Remove the...

Page 1932: ...hand suspended engine mounting Re moval Refitting 19D Engine mounting the left hand suspended engine mounting see Left hand suspended engine mounting Re moval Refitting 19D Engine mounting the engine...

Page 1933: ...ole the crankshaft position sensor see Crankshaft position sensor Removal Refitting 17B Petrol injection a Fit the lifting eye on the timing cover see Lifting eyes Removal Refitting 11A Top and front...

Page 1934: ...23A 16 AUTOMATIC GEARBOX Automatic gearbox Removal Refitting V4Y and AJ0 23A a Remove the gearbox bell housing mountings 5 the gearbox 134530 134510 134527 134528...

Page 1935: ...the distance X with a ruler This distance must be a minimum of 20 5 mm the condition of the drive plate and crown wheel vi sually II REFITTING OPERATION FOR PART CONCERNED a Refit the gearbox on the...

Page 1936: ...ngs of the gearbox bell housing 1 44 N m the mountings of the gearbox bell housing 2 62 N m the converter nuts 32 N m a Refit the engine gearbox assembly on the Mot 1390 a Remove the lifting eye from...

Page 1937: ...the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Ref...

Page 1938: ...atic gearbox Removal Refitting V4Y and AJ0 23A select Gearbox computer go to repair mode display the before after repair procedure for the computer selected carry out the operations described in the A...

Page 1939: ...haft Removal Refitting page 29A 1 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the air filter unit see Air filter unit Removal Re fitti...

Page 1940: ...battery disconnection unit see Battery dis connection unit Removal Refitting 80A Bat tery the electric coolant pump from the turbocharger see Electric coolant pump Removal Refit ting 19A Cooling the...

Page 1941: ...ve the bolt 3 from the rigid cooling pipes at the inlet and outlet of the gearbox oil coolant heat exchanger a Remove the bolt 4 from the rigid cooling pipes at the inlet and outlet of the gearbox oil...

Page 1942: ...bolt 7 from the rigid cooling pipe the rigid cooling pipe II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the nuts from the converter through the starter opening a Raise the engine gearbox assemb...

Page 1943: ...23A 25 AUTOMATIC GEARBOX Automatic gearbox Removal Refitting V9X and AJ0 23A a Remove the gearbox bell housing bolts 8 the gearbox bell housing nuts 9 the gearbox 138589 138588 138587 138586...

Page 1944: ...d outlet of the gearbox oil coolant heat exchanger us ing the tool a Refit the catalytic pre converter see Catalytic pre converter Removal Refitting 19B Exhaust a Fit the turbocharger air outlet pipe...

Page 1945: ...t left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 the headlights see Headlight Removal Refit ting 80B Headlights a Connect the battery see Battery Rem...

Page 1946: ...TMATIC D2 LM0 ESSO ATF LT 71141 SU0 SU1 SU4 CLIP oil AJX ELF MA TIC S6 FKX CKX ELF MA TIC CVT Note ELF RENAULTMATIC D3 SYN oil is not a substitute for ELF RENAUL TMATIC D2 DESIGNATION STANDARD PART NU...

Page 1947: ...recov ery tray a Refit the oil overflow pipe a Torque tighten the oil overflow pipe 8 N m a Refit the level setting plug a Torque tighten the level setting plug 8 N m Equipment required oil recovery...

Page 1948: ...g at the gearbox a a Remove the air filter unit see Air filter unit Re moval Refitting 12A Fuel mixture a Disconnect the speed sensor connector 3 a Remove the speed sensor bolt the speed sensor the sp...

Page 1949: ...hift the selector lever to the Park position a Fill the automatic gearbox with 3 2 litres of new oil see 23A Automatic gearbox Automatic gear box oil Specifications page 23A 28 Technical Note 6012A 04...

Page 1950: ...ssion cool to 30 C run the engine at idle speed wait for the automatic gearbox oil temperature to reach 40 C 2 place a container under the level setting plug remove the level plug a Repeat these opera...

Page 1951: ...ur rebreathing pipe a Run the engine at idle speed a Connect the Diagnostic tool a Monitor the automatic transmission oil temperature parameter a Wait for the temperature to reach 40 C 2 a Place a con...

Page 1952: ...g Filling AJ0 23A a Refit the level setting plug a Torque tighten the level setting plug 8 N m a Refit the filler pipe closure panel a Torque tighten the filling pipe closure panel bolt 6 N m a Refit...

Page 1953: ...bumper Removal Refitting 55A Exterior protection the headlights see Headlight Removal Refit ting 80B Headlights the front end panel see Front end panel Remov al Refitting 42A Upper front structure a D...

Page 1954: ...6 from the radiator lower hose us ing the tool Mot 1448 a Disconnect the radiator lower hose 7 a Release the clips 8 on the thermoplunger unit hos es using the tool Mot 1448 a Disconnect the hoses 9...

Page 1955: ...bolts the hydraulic distributor housing the hydraulic distributor housing seal II OPERATION FOR REMOVAL OF PART CONCERNED a Loosen the hydraulic distributor bolts A and B a Disconnect the internal wi...

Page 1956: ...ly when refitting it in order to engage it with the automatic gearbox lever 14 a Connect the internal wiring connector a Torque tighten the hydraulic distributor bolts 8 Nm III FINAL OPERATION a Refit...

Page 1957: ...tting 55A Exterior protec tion the front wheels see Wheel Removal Refitting 35A Wheels and tyres the battery tray see Battery tray Removal Re fitting 80A Battery the battery see Battery Removal Refitt...

Page 1958: ...protection the engine undertray bolts the engine undertray a Drain the automatic gearbox see 23A Automatic gear box Automatic gearbox oil Draining Filling page 23A 29 the cooling system see Cooling s...

Page 1959: ...move the hydraulic distributor housing bolts the hydraulic distributor housing the hydraulic distributor housing seal II OPERATION FOR REMOVAL OF PART CONCERNED a Loosen the hydraulic distributor bolt...

Page 1960: ...NG OPERATION FOR PART CONCERNED a Refit the new hydraulic distributor O rings a Tilt the hydraulic distributor slightly when refitting it in order to engage it with the automatic gearbox lever 6 a Con...

Page 1961: ...front left hand wheel see Wheel Removal Refitting 35A Wheels and tyres a Fill up and bleed the cooling system see Cooling system Draining Refilling 19A Cooling a Fill the automatic gearbox see 23A Aut...

Page 1962: ...ic gearbox Automatic gearbox oil Draining Filling page 23A 29 a Remove the hydraulic distributor housing bolts the hydraulic distributor housing the hydraulic distributor housing seal II OPERATION FOR...

Page 1963: ...lever 2 a Torque tighten the hydraulic distributor bolts 8 Nm a Connect the internal wiring connector III FINAL OPERATION a Refit a new hydraulic distributor housing seal the hydraulic distributor ho...

Page 1964: ...omatic gearbox oil Draining Filling page 23A 29 a Remove the nut 1 from the turbocharger air outlet pipe a Move aside the turbocharger air outlet pipe a Loosen the clip for the air pipe between the ri...

Page 1965: ...r housing bolts the hydraulic distributor housing the hydraulic distributor housing seal II OPERATION FOR REMOVAL OF PART CONCERNED a Loosen the hydraulic distributor bolts A and B a Disconnect the in...

Page 1966: ...the re pair 04B Consumables Products on the auto matic gearbox and on the hydraulic distributor housing taking care not to damage the contact sur faces a Remove the intercooler air inlet pipe seal on...

Page 1967: ...ween the rigid pipe and the hose at the turbocharger outlet a Tighten the clip for the air pipe between the rigid pipe and the hose at the turbocharger outlet a Refit the nut for the turbocharger air...

Page 1968: ...ec tion the front bumper see Front bumper Removal Refitting 55A Exterior protection the headlights see Headlight Removal Refit ting 80B Headlights the front end panel see Front end panel Remov al Refi...

Page 1969: ...from the radiator lower hose us ing the tool Mot 1448 a Disconnect the radiator lower hose 7 from the radi ator a Release the clips 8 on the thermoplunger unit hos es using the tool Mot 1448 a Disconn...

Page 1970: ...draulic distributor housing the hydraulic distributor housing seal II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the internal wiring connector 13 a Remove the wiring routing retaining bolt 1...

Page 1971: ...ting retainer bolt 7 N m III FINAL OPERATION a Refit a new hydraulic distributor housing seal the hydraulic distributor housing the hydraulic distributor casing bolts a Torque tighten the hydraulic di...

Page 1972: ...heels see Wheel Removal Refitting 35A Wheels and tyres the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture the battery tray see Battery tray Removal Re fitting 80A Battery the...

Page 1973: ...or protection the engine undertray bolts the engine undertray a Drain the automatic gearbox see 23A Automatic gear box Automatic gearbox oil Draining Filling page 23A 29 the cooling system see Cooling...

Page 1974: ...ulic distributor housing bolts the hydraulic distributor housing the hydraulic distributor housing seal II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the internal wiring connector 5 a Remove...

Page 1975: ...butor wiring a Connect the main connector a Clip the main connector onto its support a Connect the automatic gearbox connectors the internal wiring connector a Refit the wiring routing retaining bolt...

Page 1976: ...el Removal Refitting 35A Wheels and tyres a Fill up and bleed the cooling system see Cooling system Draining Refilling 19A Cooling a Top up the automatic transmission see 23A Auto matic gearbox Automa...

Page 1977: ...rebreathing pipe using the tool Mot 1448 a Disconnect the oil vapour rebreathing pipe a Remove the air outlet pipe to the air filter unit the air filter unit see Air filter unit Removal Re fitting 12A...

Page 1978: ...ox oil see 23A Automat ic gearbox Automatic gearbox oil Draining Filling page 23A 29 a Move aside the gearbox control cable 4 by pushing on the bracket a Remove the hydraulic distributor housing bolts...

Page 1979: ...re not to damage the contact sur faces a Always replace the hydraulic distributor housing seal II REFITTING OPERATION FOR PART CONCERNED a Refit the hydraulic distributor wiring a Clip the bonnet rele...

Page 1980: ...unit air outlet pipe and the clip at the inlet of the throttle valve 5 5 N m a Refit the brake servo vacuum pipe a Connect brake servo vacuum pipe the battery see Battery Removal Refitting 80A Batter...

Page 1981: ...iner Removal Refitting 55A Exterior protec tion the front bumper see Front bumper Removal Refitting 55A Exterior protection a Drain the cooling system see Cooling system Drain ing Refilling 19A Coolin...

Page 1982: ...e battery disconnection unit power supply wiring a Remove the wiring channel protective cover of the battery disconnection unit power supply wiring a Remove the bolt 4 from the power assisted steer in...

Page 1983: ...emove the hydraulic distributor wiring REFITTING I REFITTING PREPARATION OPERATION a Always replace the hydraulic distributor housing seal a Clean the joint faces using SURFACE CLEANER see Vehicle Par...

Page 1984: ...he max fuse box bolt the max fuse box cover the front bumper see Front bumper Removal Refitting 55A Exterior protection the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Ext...

Page 1985: ...Refitting 55A Exterior protection the headlights see Headlight Removal Refit ting 80B Headlights the front end panel see Front end panel Remov al Refitting 42A Upper front structure a Drain the autom...

Page 1986: ...Remove the clip 6 from the radiator lower hose us ing the tool Mot 1448 a Remove the radiator lower hose 7 a Release the clips 8 on the thermoplunger unit hos es using the Mot 1448 a Disconnect the h...

Page 1987: ...draulic distributor housing the hydraulic distributor housing seal II OPERATION FOR REMOVAL OF PART CONCERNED a Lift the internal wiring retaining clips 13 a Disconnect the connector 14 for the extern...

Page 1988: ...ternal wiring retaining clips III FINAL OPERATION a Refit a new hydraulic distributor housing seal the hydraulic distributor housing a Torque tighten the hydraulic distributor housing bolts 8 Nm a Fit...

Page 1989: ...see Battery tray Removal Re fitting 80A Battery the battery see Battery Removal Refitting 80A Battery a Fill and bleed the cooling system see Cooling sys tem Draining Refilling 19A Cooling a Fill the...

Page 1990: ...n the engine undertray bolts the engine undertray a Drain the automatic gearbox see 23A Automatic gear box Automatic gearbox oil Draining Filling page 23A 29 the cooling system see Cooling system Drai...

Page 1991: ...draulic distributor housing bolts the hydraulic distributor housing the hydraulic distributor housing seal II OPERATION FOR REMOVAL OF PART CONCERNED a Lift the internal wiring retaining clips 5 a Dis...

Page 1992: ...erature sensor retaining bolt 8 N m 9 and 10 a Connect the connectors for the solenoid valves the connector to the external wiring the pressure sensor connectors a Push back the internal wiring retain...

Page 1993: ...Wheel Removal Refitting 35A Wheels and tyres a Fill up and bleed the cooling system see Cooling system Draining Refilling 19A Cooling a Top up the automatic transmission see 23A Auto matic gearbox Au...

Page 1994: ...ic gearbox Automatic gearbox oil Draining Filling page 23A 29 a Remove the hydraulic distributor see 23A Auto matic gearbox Hydraulic distributor Removal Refitting page 23A 35 II OPERATION FOR REMOVA...

Page 1995: ...surfaces II REFITTING OPERATION FOR PART CONCERNED a Refit the wiring the earth terminal the temperature sensor retaining plate the temperature sensor bolt 7 the earth bolts 8 a Tighten to torque the...

Page 1996: ...up the automatic transmission see 23A Auto matic gearbox Automatic gearbox oil Draining Filling page 23A 29 a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool se...

Page 1997: ...c gearbox Automatic gearbox oil Draining Filling page 23A 29 a Remove the hydraulic distributor see 23A Auto matic gearbox Hydraulic distributor Removal Refitting page 23A 35 II OPERATION FOR REMOVAL...

Page 1998: ...aces II REFITTING OPERATION FOR PART CONCERNED a Refit the wiring the earth terminal the temperature sensor retaining plate the temperature sensor bolt 7 the earth bolts 8 a Tighten to torque the reta...

Page 1999: ...up the automatic transmission see 23A Auto matic gearbox Automatic gearbox oil Draining Filling page 23A 29 a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool se...

Page 2000: ...t wheel arch liner Removal Refitting MR 416 55A Exterior protection the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 a Drain the automatic tr...

Page 2001: ...ransmission oil cooler hoses a Remove the clips 5 from the automatic transmis sion oil cooler pipe hoses using the Mot 1448 a Disconnect the automatic transmission oil cooler pipe hoses II REMOVAL OPE...

Page 2002: ...a Refit the automatic transmission oil cooler cooling hose clips using the Mot 1448 the new automatic transmission oil cooler seal the oil cooler and its pipes the automatic transmission oil cooler bo...

Page 2003: ...xture the battery tray see Battery tray Removal Re fitting MR 415 80A Battery the battery see Battery Removal Refitting MR 415 80A Battery a Bleed the cooling system see Cooling system Draining Refill...

Page 2004: ...haft Removal Refitting page 29A 7 the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the ri...

Page 2005: ...afts Front left hand driveshaft Removal Refitting page 29A 1 the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the front wheels see Wheel Re...

Page 2006: ...er box see Air filter unit Removal Re fitting MR 415 12A Fuel mixture a Unclip the ball joint 1 from the cable on the multi function switch using an open jawed spanner a Unlock and detach the cable sl...

Page 2007: ...tool with the relevant hole 6 on the multifunction switch a Torque tighten the multifunction switch bolts 6 Nm a Remove the Bvi 1805 a Connect the multifunction switch connector II FINAL OPERATION a...

Page 2008: ...a With the multifunction switch loosened and in posi tion N place the tool Bvi 1805 1 on the control lever and align the shaft of the tool opposite the rel evant hole on the multifunction switch 2 a T...

Page 2009: ...put speed sensor bolt 2 the input speed sensor 2 Output speed sensor a Disconnect the output speed sensor connector 3 a Remove the output speed sensor bolt 4 the output speed sensor REFITTING I REFITT...

Page 2010: ...ng AJ0 23A II FINAL OPERATION a Refit the air filter box see Air filter unit Removal Re fitting MR 415 12A Fuel mixture the battery tray see Battery tray Removal Re fitting MR 415 80A Battery the batt...

Page 2011: ...tion the front bumper see Front bumper Removal Refitting 55A Exterior protection the headlights see Headlight Removal Refit ting 80B Headlights the front end panel see Front end panel Remov al Refitt...

Page 2012: ...rom the radiator lower hose us ing the tool Mot 1448 a Disconnect the lower hose 7 from the radiator a Release the clips 8 on the thermoplunger unit hos es using the tool Mot 1448 a Disconnect the the...

Page 2013: ...lean the joint faces using SURFACE CLEANER see Vehicle Parts and consumables for the re pair 04B Consumables Products on the auto matic gearbox and on the hydraulic distributor housing taking care not...

Page 2014: ...cool er a Rotate the clips of the intercooler air inlet pipe until they are replaced in their groove a Clip the air inlet pipe of the intercooler onto the tur bocharger and the intercooler a Refit the...

Page 2015: ...y tray Removal Re fitting 80A Battery the battery see Battery Removal Refitting 80A Battery a Fill and bleed the cooling system see Cooling sys tem Draining Refilling 19A Cooling a Fill the automatic...

Page 2016: ...wheel arch liner Removal Refitting 55A Ex terior protection a Drain the automatic gearbox see 23A Automatic gear box Automatic gearbox oil Draining Filling page 23A 29 the cooling system see Cooling...

Page 2017: ...REFITTING PREPARATION OPERATION a Clean the joint faces using SURFACE CLEANER see Vehicle Parts and consumables for the re pair 04B Consumables Products on the auto matic gearbox and on the hydraulic...

Page 2018: ...erior protection the front left hand wheel see Wheel Removal Refitting 35A Wheels and tyres a Fill up and bleed the cooling system see Cooling system Draining Refilling 19A Cooling a Top up the automa...

Page 2019: ...ED a Disconnect the oil pressure switch connector 1 a Remove the oil pressure switch concerned REFITTING I REFITTING PREPARATION OPERATION a Clean the joint faces using SURFACE CLEANER see Vehicle Par...

Page 2020: ...80A Battery a Top up the automatic transmission see 23A Auto matic gearbox Automatic gearbox oil Draining Filling page 23A 29 a Apply the after repair procedure using the Diagnos tic tool connect the...

Page 2021: ...arbox Automatic gearbox oil Draining Filling page 23A 29 a Remove the turbocharger outlet air pipe nut 1 a Move aside the turbocharger air outlet pipe a Loosen the clip of the air pipe between the rig...

Page 2022: ...RNED a Disconnect the oil pressure switch connector 4 a Remove the oil pressure switch concerned REFITTING I REFITTING PREPARATION OPERATION a Always replace the hydraulic distributor housing seal the...

Page 2023: ...the rigid pipe and the outlet hose of the turbocharger a Tighten the clip of the air pipe between the rigid pipe and the outlet hose of the turbocharger a Refit the turbocharger air outlet pipe nut a...

Page 2024: ...rbox converter Removal Refitting AJ0 23A a The removal refitting method for the automatic gear box converter is included in the method for removing the converter seal see 23A Automatic gearbox Convert...

Page 2025: ...protection the headlights see Headlight Removal Refit ting MR 415 80B Headlights the front end panel see Front end panel Remov al Refitting MR 416 42A Front upper struc ture the particle filter see Pa...

Page 2026: ...a Always replace the converter seal with a new seal a Check and clean the converter seal mating face on the gearbox II REFITTING OPERATION FOR PART CONCERNED a Refit the new converter seal using the...

Page 2027: ...hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 the front wheel arch liners see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection t...

Page 2028: ...tion II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the connector 1 from the automatic transmission computer a Remove the mountings 2 from the automatic transmission computer the automatic trans...

Page 2029: ...ly the after repair procedure using the Diagnos tic tool a Connect the Diagnostic tool Select gearbox computer Go to repair mode Display the gearbox computer Before after repair procedure Carry out th...

Page 2030: ...oval Refitting 35A Wheels and tyres II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the wheel speed sensor wiring harness the brake hose a Remove the hub nut 1 using the Rou 604 01 the track rod e...

Page 2031: ...ier a Refit the shock absorber base bolts the track rod end nut the hub nut using tool Rou 604 01 a Tighten to torque the shock absorber base bolts 180 Nm the track rod end nut 37 Nm the hub nut 105 N...

Page 2032: ...Draining Filling page 21A 2 II REMOVAL OPERATION FOR PART CONCERNED a Unclip the wheel speed sensor wiring the brake hose a Remove the nut 1 from the hub immobilising the hub using the Rou 604 01 the...

Page 2033: ...arrier a Refit the shock absorber base bolts the shock absorber base nuts a Torque tighten the shock absorber base nuts 180 Nm a Position the track rod a Torque tighten the track rod end nut 37 Nm a R...

Page 2034: ...s the engine undertray a Drain the manual gearbox see 21A Manual gear box Manual gearbox oils Draining Filling page 21A 2 II REMOVAL OPERATION FOR PART CONCERNED a Unclip from the base of the shock ab...

Page 2035: ...ERNED a Refit the new left hand differential output seal see 21A Manual gearbox Differential output seal Removal Refitting page 21A 6 a Engage the front left hand wheel driveshaft into the manual gear...

Page 2036: ...MOVAL OF PART CONCERNED a Unclip the wheel speed sensor wiring harness the brake hose a Remove the hub nut 1 using the Rou 604 01 the track rod end nut 2 a Detach the track rod end using the Tav 476 a...

Page 2037: ...eshaft into the gearbox a Refit the driveshaft into the relay bearing the relay bearing bolt a Torque tighten the relay bearing bolt 21 Nm a Insert the driveshaft into the stub axle carrier a Refit th...

Page 2038: ...al gearbox oils Draining Filling page 21A 2 II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the wheel speed sensor wiring the brake hose a Remove the hub nut 1 by immobilising the hub using the to...

Page 2039: ...arrier a Refit the shock absorber base bolts the shock absorber base nuts a Torque tighten the shock absorber base nuts 180 Nm a Position the track rod a Torque tighten the track rod end nut 37 Nm a R...

Page 2040: ...ine undertray bolts the engine undertray a Drain the manual gearbox see 21A Manual gear box Manual gearbox oils Draining Filling page 21A 2 II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip from the...

Page 2041: ...t a new right hand differential output seal see 21A Manual gearbox Differential output seal Removal Refitting page 21A 6 II REFITTING OPERATION FOR PART CONCERNED a Position and insert the driveshaft...

Page 2042: ...bilising the hub using tool Rou 604 01 a Clip the brake hose the wheel speed sensor wiring III FINAL OPERATION a Fill the manual gearbox see 21A Manual gearbox Manual gearbox oils Draining Filling pa...

Page 2043: ...aring 2 using a press and an ex tractor a Take care not to scratch the lip seal mating face on the relay shaft 3 REFITTING I REFITTING PREPARATIONS OPERATION a Lubricate the relay shaft mating face in...

Page 2044: ...g 2 using a press and an ex tractor a Take care not to scratch the lip seal mating face on the relay shaft 3 REFITTING I REFITTING PREPARATION OPERATION a Lubricate the relay shaft mating face into wh...

Page 2045: ...OPERATION a Always replace the relay shaft bearing the relay shaft bearing lock ring a Lubricate the relay shaft mating face into which the bearing is inserted II REFITTING OPERATION FOR PART CONCERN...

Page 2046: ...29A Driveshafts Front left hand driveshaft Remov al Refitting page 29A 1 or see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 Special tooling required Tav 1168 Clic type c...

Page 2047: ...ase the stub axle bowl a Cut off the driveshaft gaiter a Remove as much grease as possible a Using a steel inertia hammer and a roll pin punch hit the ball hub 3 a few times to detach the stub axle bo...

Page 2048: ...riveshaft a Refit the locking spring ring 8 a Spread the quantity of grease around the gaiter and the stub axle bowl a Refit the stub axle bowl 9 on the driveshaft by strik ing the stub axle bowl with...

Page 2049: ...clips or the tool Tav 1784 11 for profile end clips III FINAL OPERATION a Refit the removed driveshaft see 29A Driveshafts Front left hand driveshaft Removal Refitting page 29A 1 or see 29A Driveshaf...

Page 2050: ...Wheels and tyres the front right hand driveshaft see 29A Drive shafts Front right hand driveshaft Removal Refitting page 29A 7 Special tooling required Tav 1168 Clic type clip pliers for drive shafts...

Page 2051: ...t to damage the yoke sleeve and the propeller shaft a Push back the gaiter to release the driveshaft yoke sleeve a Remove the yoke sleeve 3 a Remove as much grease as possible from the yoke sleeve 128...

Page 2052: ...riveshaft gaiter the locking ring the large tightening clip the small tightening clip a Clean the propeller shaft the spider and the yoke sleeve using a parts washer II REFITTING OPERATION FOR PART CO...

Page 2053: ...spider 8 in the position marked during re moval a Refit the lock ring 9 a Divide the quantity of grease between the gaiter and the yoke sleeve a Fit the yoke sleeve 10 onto the spider 11 a Position t...

Page 2054: ...file end a Tighten the clips using the tool Tav 1168 12 for Clic clips or the tool Tav 1784 13 for clips with profile end III FINAL OPERATION a Refit the front right hand driveshaft see 29A Drive shaf...

Page 2055: ...ng 35A Wheels and tyres the front left hand driveshaft see 29A Drive shafts Front left hand driveshaft Removal Refitting page 29A 1 Special tooling required Tav 1168 Clic type clip pliers for drive sh...

Page 2056: ...to damage the yoke sleeve and the driveshaft a Push back the driveshaft gaiter to release the yoke sleeve a Remove the yoke sleeve 3 a Remove as much grease as possible from the yoke sleeve 128413 128...

Page 2057: ...e the cup the cup spring the driveshaft gaiter the locking ring the big securing clip the small securing clip a Using a parts washer clean the driveshaft the spi der and the yoke sleeve II REFITTING O...

Page 2058: ...aiter 7 onto the driveshaft a Insert the gaiter lip into the groove of the driveshaft a Refit the spider 8 in the position marked during re moval a Refit the lock ring 9 a Refit the cup 10 onto the cu...

Page 2059: ...aiter a Refit the big securing clip on the driveshaft gaiter Clic clip Clip with profile end a Tighten the clips using the Tav 1168 15 for clic clips or the Tav 1784 16 for profile end clips III FINAL...

Page 2060: ...29A 31 DRIVESHAFTS Front left hand driveshaft gaiter gearbox side Removal Refitting 29A the engine undertray...

Page 2061: ...s are constructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering system is forbidden without the prior written...

Page 2062: ...30A 29 Rear axle assembly Adjustment values 30A 31 Rear axle system Adjustment 30A 32 31A FRONT AXLE COMPONENTS Front axle components Precautions for the repair 31A 1 Front brake pads Removal Refitti...

Page 2063: ...escription 33A 17 Shock absorber Removal Refitting 33A 18 Rear suspension spring Removal Refitting 33A 21 31A FRONT AXLE COMPONENTS Rear stub axle carrier Removal Refitting 33A 24 Rear axle rubber bea...

Page 2064: ...servo Removal Refitting 37A 10 Vacuum pump Removal Refitting 37A 14 Accelerator pedal Removal Refitting 37A 19 Brake pedal Removal Refitting 37A 22 Brake pedal link rod Removal Refitting 37A 26 Brake...

Page 2065: ...37B 4 Lever Removal Refitting 37B 7 38C ANTI LOCK BRAKING SYSTEM ABS List and location of components 38C 1 ABS Precautions for the repair 38C 3 Hydraulic brake unit Removal Refitting 38C 4 Front wheel...

Page 2066: ...0A X braking system with ABS 3877 IMPORTANT This is a diagram of the general principle do not use it as a reference for take off points or circuit allocation When replacing components in a vehi cle s...

Page 2067: ...owed before any operation Protect any bodywork components that risk being dam aged by brake fluid with a cover 2 Instructions to be followed during the operation Fit blanking plugs recommended for the...

Page 2068: ...en before and during the brake circuit bleeding operation use brake fluid which conforms to the Renault stan dard see Vehicle Parts and consumables for the repair 04B Consumables Products check the br...

Page 2069: ...f damage to the systems apply the safety and cleanliness instructions and opera tion recommendations before carrying out any repair see 30A General information Brake cir cuit Precautions for the repai...

Page 2070: ...t 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 the brake circuit a Remove the brake circuit bleeding device f...

Page 2071: ...Tightening torque 30A I FRONT BRAKES 123488 No Description Tightening torque N m 1 Calliper bleed screw 10 2 Brake hose to the calliper 14 3 Brake hose on brake pipe 17 4 Guide pin bolts 28 5 Calliper...

Page 2072: ...ON Brake circuit Tightening torque 30A II REAR BRAKES III BRAKE CONTROL 123496 No Description Tightening torque N m 6 Calliper bleed screw 14 7 Brake hose to the calliper 14 8 Calliper support bolt 10...

Page 2073: ...Brake circuit Tightening torque 30A 123492 123487 123486 122698 Description Tightening torque N m 10 Brake servo bolts 24 11 Master cylinder nuts 20 12 Master cylinder outlet pipe 14 13 Reservoir bol...

Page 2074: ...unit inlet pipes 14 15 Hydraulic unit output pipes 14 16 Hydraulic unit mounting bolt on body 21 17 Hydraulic unit bolt on its mounting 8 18 Assisted parking brake control unit bolt 21 19 Assisted par...

Page 2075: ...n the pipe before forming the rivets II MAKING THE RIVETS a Equipment required compressed air nozzle Tightening torquesm brake pipe bolts 8 N m underbody unions female male 6 N m Note This procedure d...

Page 2076: ...a Visually check that the internal diameter of the pipe is not oval shaped a Check that the diameter of the end panel is not oval shaped using a sliding calliper Correct diameter if X1 X2 IV PREPARATI...

Page 2077: ...30A 12 GENERAL INFORMATION Rigid brake pipe Repair 30A a Measure the dimensions X3 in mm curve after curve between each curve radius centre 1 of the old pipe 128659...

Page 2078: ...ing the pipe either bend once or bend progressively by increasing the bend that is by continually decreasing the curve radius Do not install a rigid pipe on a vehicle that may have been bended and the...

Page 2079: ...m diameter after bending 4 30 mm VI REFITTING THE PIPE a a Torque tighten the brake pipe bolts 8 N m a Torque tighten the underbody unions female male 6 N m 128664 128670 Note When refitting the rigid...

Page 2080: ...slight humidity intake This is why it is recommended that you change the brake fluid see maintenance booklet for the vehicle 1 Topping up the level Wear of the brake pads will result in a gradual dro...

Page 2081: ...ter 280 296 320 Disc thickness 24 26 28 Minimum disc thickness 1 21 8 23 4 25 4 Maximum disc run out 0 024 0 025 0 03 Brake pad thickness including backplate 17 5 Minimum brake pad thickness including...

Page 2082: ...30A 17 GENERAL INFORMATION Steering Tightening torque 30A 123497 122722 116991...

Page 2083: ...e 30A Description Tightening torque Nm 1 Steering wheel bolt 44 2 Steering column nuts 21 3 Electric steering column lock 8 4 Universal joint bolt on the steering box 24 5 Wheel alignment lock nut 53...

Page 2084: ...and tyres Tyre pressure Identification page 35A 16 a Put the vehicle in the VODM position vehicle in run ning order see 30A General information Under body heights Adjustment value page 30A 21 tank ful...

Page 2085: ...hock absorbers tyres a Check the tyre size see 35A Wheels and tyres Tyres Identification page 35A 10 the tyre inflation pressure see 35A Wheels and tyres Tyre pressure Identification page 35A 16 a Put...

Page 2086: ...NG POINTS Radius under load R1 Distance between the ground and the front wheel axle R 2 Distance between the ground and the rear wheel axle 1 Front height W1 W1 Height between the ground and the surfa...

Page 2087: ...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 126086 Note For vehicles fit...

Page 2088: ...er position tank full vehicle empty without luggage etc W1 156 15 mm W2 208 15 mm Note The position of the vehicle varies according to the weight of the engine the springs and shock absorbers the tyre...

Page 2089: ...2 Hub nut K9K and K4M 280 2 Hub nut F4R M9R M4R V4Y andV9X 150 3 Lower ball joint nut 62 4 Anti roll bar link rod nuts 44 5 Rebound stop nut 62 6 Rear subframe bolt 180 7 Damper unit bolts on body 21...

Page 2090: ...ghtening torque 30A 13 Shock absorber base bolts 180 14 Brake disc protector or ball joint protector bolt 8 No Description Tightening torque N m F4R or M4R or M9R or V4Y or V9X 122711 No Description T...

Page 2091: ...in plus sign II WHEEL ALIGNMENT III CASTOR ANGLE Not adjustable IV CAMBER Not adjustable WARNING Symbols used by RENAULT toe out toe in 93011 93011 1 93011 Value for two wheels Position of vehicle 0 1...

Page 2092: ...y Adjustment values 30A V PIVOT Not adjustable 93013 Value Position of vehicle 0 15 30 Maximum left right differ ence 30 Vehicle in running order 93014 Value Position of vehicle 12 40 30 Maximum left...

Page 2093: ...Not adjustable 4 Pivot a Not adjustable a Carry out calibration of the steering wheel angle sensor Apply the after repair procedure connect the diagnostic tool select Braking computer go to repair mo...

Page 2094: ...99 No Description Tightening torque N m 1 Shock absorber lower bolt 115 2 Shock absorber upper bolt 110 3 Stub axle nut 280 4 Longitudinal suspension arm bearing bolts on axle 180 5 Longitudinal suspe...

Page 2095: ...4 WHEEL STEERING 30A 123498 No Description Tightening torque N m 1 Stub axle nut 280 2 Stub axle carrier nuts 190 3 Track rod nut on stub axle carrier 37 4 Actuator nuts 84 5 Compensator bolt 105 6 Tr...

Page 2096: ...BOL MEANINGS toe out minus sign toe in plus sign II WHEEL ALIGNMENT III CAMBER WARNING Symbols used by RENAULT toe out toe in 93011 93011 1 93011 1 Value for two wheels Position of vehicle 0 27 15 Veh...

Page 2097: ...the eccentric bolt 2 according to the values measured at the time of the check a Torque tighten the upper nut of the stub axle carri er while holding the eccentric 190 N m a Check the camber values Ti...

Page 2098: ...r procedure connect the diagnostic tool select Braking computer go to repair mode display the Before after repair procedure for the computer selected select Steering wheel angle sensor in the List of...

Page 2099: ...b carrier When removing a hub it is essential to replace the bearing with a new one It is essential to check the condition of the hub and bearing surface and the hub carrier bore before refit ting the...

Page 2100: ...nded to replace springs if the paint is damaged the spring has dents in it They are not usually symmetrical in shape and care should be taken to assemble them the right way round This can be done usin...

Page 2101: ...ugs at the end of the guide pins the guide pin bolts 3 a Hang the brake calliper from the suspension spring a Remove the brake pads Special tooling required Fre 1190 01 Brake calliper piston return to...

Page 2102: ...TTING OPERATION FOR PART CONCERNED a Fit the inner brake pad with the lugs 4 in the calliper piston a Refit the outer brake pad on the calliper mounting the calliper with the inner brake pad on the ca...

Page 2103: ...before unclipping the hose a Set the wheels straight ahead a Mark the position of the cap on the base of the shock absorber using a permanent marker a Unclip the brake hose cap 3 from the shock ab so...

Page 2104: ...absorber aligning the marks made using a perma nent marker a Refit the brake hose on the rigid pipe union the hose retaining fork a Torque tighten the brake hose union on the rigid pipe union see 30A...

Page 2105: ...a Remove the retaining spring 1 using a wide flat blade screwdriver a Unclip the brake hose 2 from the shock absorber Special tooling required Fre 1190 01 Brake calliper piston return tool Equipment...

Page 2106: ...ere are deep scratches or cracks a Replace any faulty parts see 31A Front axle com ponents Front brake calliper Repair page 31A 10 a Clean using a wire brush and BRAKE CLEANER see Vehicle Parts and co...

Page 2107: ...e wheels straight ahead a Secure the brake hose to the shock absorber III FINAL OPERATION a Remove the pedal press a Bleed the brake circuit see 30A General informa tion Braking circuit Bleed page 30A...

Page 2108: ...calliper and the piston to avoid damaging it Any trace of im pact on the end panel will render the piston unfit for use a Remove the dust seal a Remove the rectangular section seal from the calli per...

Page 2109: ...190 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 7 the front wheel see 35A Wheels and tyres Wheel Remov...

Page 2110: ...from the shock absorber a Remove the plugs at the end of the guide pins the guide pin bolts 3 a Attach the brake calliper to the shock absorber II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the...

Page 2111: ...r mounting bolts a Torque tighten the calliper mounting bolts 105 N m III FINAL OPERATION a Refit the brake calliper with the inner brake pad on the calliper mounting a Torque tighten the guide pin bo...

Page 2112: ...Refitting page 31A 12 a Suspend the calliper and calliper support assembly on the suspension spring a Remove the brake disc see 31A Front axle com ponents Front brake disc Removal Refitting page 31A 1...

Page 2113: ...or the disc protector bolts a Torque tighten the brake disc protector bolts 8 N m III FINAL OPERATION a Refit the brake disc see 31A Front axle components Front brake disc Removal Refitting page 31A 1...

Page 2114: ...front wheel see 35A Wheels and ty res Wheel Removal Refitting page 35A 1 a Mark the position of the cap 1 on the base of the shock absorber using a indelible pencil a Unclip the cap 1 from the base of...

Page 2115: ...VAL OF PART CONCERNED a Remove the brake disc bolt or bolts 3 the brake disc REFITTING I REFITTING PREPARATION OPERATION a Clean the brake discs using a parts washer a Dry the surface of the discs a C...

Page 2116: ...straight ahead a Clip the cap on the base of the shock absorber while aligning the marks made with a indelible pencil a Refit the front wheel see 35A Wheels and tyres Wheel Removal Refitting page 35A...

Page 2117: ...the Palmer tool 1 to measure the disc thick ness Measure the thickness of the disc at 4 points in order 90 apart Compare the values with those recommended by the manufacturer see 30A General informati...

Page 2118: ...35A 1 the front left hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 Bodywork 55A Exterior protection the engine undertray a Open a bleed screw a Fit the pedal press to the...

Page 2119: ...rch liner see Front wheel arch liner Removal Refitting MR 416 Bodywork 55A Exterior protection the engine undertray the front left hand wheel see 35A Wheels and ty res Wheel Removal Refitting page 35A...

Page 2120: ...Close the bleed screw a Disconnect the battery see Battery Removal Re fitting MR 415 80A Battery a Remove the battery see Battery Removal Refit ting MR 415 80A Battery a Remove the engine cover if fi...

Page 2121: ...pes into position a Torque tighten the brake pipe unions on the hydraulic unit 14 Nm the underbody pipe unions 14 Nm III FINAL OPERATION a Connect the heater matrix hoses a Remove the hose clamps a To...

Page 2122: ...page 35A 1 the front left hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 Bodywork 55A Exterior protection the engine undertray a Open a bleed screw a Fit the pedal press to...

Page 2123: ...Front wheel arch liner Removal Refitting MR 416 Bodywork 55A Exterior protection the engine undertray the front left hand wheel see 35A Wheels and ty res Wheel Removal Refitting page 35A 1 the air fil...

Page 2124: ...page 35A 1 the front left hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 Bodywork 55A Exterior protection the engine undertray a Open a bleed screw a Fit the pedal press to...

Page 2125: ...Refit the air resonator a Refit the front left hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 Bodywork 55A Exterior protection the engine undertray the front left hand whee...

Page 2126: ...rake disc protector bolts 8 N m lower ball joint nut 62 N m lower shock absorber bolts 180 N m track rod end nut 37 N m hub nut 150 N m brake calliper mounting bolts 105 N m IMPORTANT To avoid all ris...

Page 2127: ...nt brake calliper assembly on the suspension spring a Remove the brake disc see 31A Front axle com ponents Front brake disc Removal Refitting page 31A 16 a Unclip the headlight beam adjustment front s...

Page 2128: ...oint nut the brake disc protector bolts the brake disc protector a Remove the bolts from the shock absorber base a Push the driveshaft back from the hub carrier by piv oting the hub carrier a Attach t...

Page 2129: ...a Refit the hub nut a Torque tighten the hub nut 150 N m using a hub locking tool Rou 604 01 III FINAL OPERATION a Refit the brake disc see 31A Front axle components Front brake disc Removal Refittin...

Page 2130: ...31A 32 FRONT AXLE COMPONENTS Front driveshaft hub carrier Removal Refitting K4M or K9K 31A a Adjust the front axle if necessary see 30A General information Front axle system Adjustment page 30A 28...

Page 2131: ...olt 8 N m brake disc protector bolts 8 N m lower ball joint nut 62 N m lower shock absorber bolts 180 N m track rod end nut 37 N m hub nut 150 N m brake calliper mounting bolts 105 N m IMPORTANT To av...

Page 2132: ...ounting front brake calliper assembly on the suspension spring a Remove the brake disc see 31A Front axle com ponents Front brake disc Removal Refitting page 31A 16 a Unclip the headlight beam adjustm...

Page 2133: ...ower ball joint nut the brake disc protector bolts the brake disc protector a Remove the bolts from the shock absorber base a Push the driveshaft back from the hub carrier by piv oting the hub carrier...

Page 2134: ...hub nut a Refit the hub nut a Torque tighten the hub nut 150 N m using a hub locking tool Rou 604 01 III FINAL OPERATION a Refit the brake disc see 31A Front axle components Front brake disc Removal R...

Page 2135: ...ONT AXLE COMPONENTS Front driveshaft hub carrier Removal Refitting F4R or M4R or M9R or V4Y or V9X 31A a Adjust the front axle if necessary see 30A General information Front axle system Adjustment pag...

Page 2136: ...g bolts 105 N m IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and opera tion recommendations before carrying out any repair see 31A Front axle comp...

Page 2137: ...nting bolts 4 a Hang the front brake calliper mounting front brake calliper assembly on the suspension spring a Remove the front brake disc see 31A Front axle compo nents Front brake disc Removal Refi...

Page 2138: ...the shock absorber lower nuts a Use SURFACE CLEANER see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products to clean the internal and external surfaces of the bearing in conta...

Page 2139: ...m III FINAL OPERATION a Refit the front driveshaft hub carrier see 31A Front axle components Front driveshaft hub carrier Removal Refitting page 31A 28 the front brake disc see 31A Front axle compo ne...

Page 2140: ...pair mode apply the After repair procedure a Adjust the front axle see 30A General informa tion Front axle system Adjustment page 30A 28 a It is essential to initialise the discharge bulbs if fitted t...

Page 2141: ...d Diagnostic tool Tightening torquesm hub bearing assembly bolts 105 N m track rod end nut 37 N m shock absorber base bolts 180 N m hub nut 150 N m brake calliper mounting bolts 105 N m IMPORTANT To a...

Page 2142: ...unting bolts 4 a Hang the front brake calliper mounting front brake calliper assembly on the suspension spring a Remove the front brake disc see 31A Front axle components Front brake disc Removal Refi...

Page 2143: ...08 a parts always to be replaced Track rod end nut 13 04 02 03 a parts always to be replaced Front wheel hub nut 13 02 03 20 a parts always to be replaced front shock absorb er lower nut 13 02 04 11 a...

Page 2144: ...ake calliper mounting bolts a Torque tighten the brake calliper mounting bolts 105 N m a Set the wheels straight ahead a Refit the wheel speed sensor the wheel speed sensor bolt a Clip the brake hose...

Page 2145: ...F PART CONCERNED a Detach the wiring from the wheel speed sensor 1 a Remove the nut 2 of the anti roll bar linkage on the base of the shock absorber a Unclip the brake hose 3 from the base of the shoc...

Page 2146: ...tach the hub carrier a Position the appropriate cups on the tool spring compressor 8 a Position the spring compressor on the spring a Put the spring compressor spring assembly in a vice equipped with...

Page 2147: ...ress the spring REFITTING I REFITTING PREPARATION OPERATION a If necessary replace any faulty filter unit compo nents see 31A Front axle components Filter unit assembly Removal Refitting page 31A 53 a...

Page 2148: ...31A 50 FRONT AXLE COMPONENTS Front shock absorber and spring Removal Refitting 31A a Insert the spring in the neck of the cup 102201...

Page 2149: ...the stop 15 a Insert the end piece 16 in the filter block 17 a Perform a quarter of a turn to lock the end piece in the filter block a Refit the impact stop filter block assembly on the shock absorber...

Page 2150: ...e wheel speed sensor wiring the brake hose onto the shock absorber III FINAL OPERATION a Refit the front wheel see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 the scoop under the scuttle p...

Page 2151: ...and spring Re moval Refitting page 31A 47 II OPERATION FOR REMOVAL OF PART CONCERNED a Separate the various components of the spring shock absorber assembly a Visually check the condition of the compo...

Page 2152: ...lus tration II FINAL OPERATION a Refit the shock absorber spring see 31A Front axle components Front shock absorber and spring Removal Refitting page 31A 47 the front wheels see 35A Wheels and tyres W...

Page 2153: ...CONCERNED a Remove the bolts 1 from the lower arm the lower arm REFITTING I REFITTING PREPARATION OPERATION a Always replace the arm bolts the track rod end nut the lower ball joint nut the hub nut if...

Page 2154: ...MR 416 55A Exterior protection the engine undertray the front wheels see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 a Apply the after repair procedure using the Diagnos tic tool connect t...

Page 2155: ...eck the front driveshaft lower arm ball joint front driveshaft lower arm bolt front driveshaft hub car rier assembly is correctly positioned the tightening torque of the lower arm ball joint nut 1 for...

Page 2156: ...Refitting 19D Engine mounting a Fit a hose clamp Ms 583 on the low pressure pipe to restrict the flow of power assisted steering fluid Special tooling required Ms 583 Pipe clamps Tav 476 Ball joint e...

Page 2157: ...absorber at 2 a Unclip the headlight beam adjustment front sensor linkage at 3 a Disconnect the headlight beam adjustment front sensor connector 4 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove t...

Page 2158: ...rier to the base of the shock ab sorber a Extract the lower ball joint from the hub carrier using a ball joint extractor a Refit the driveshaft in the hub carrier the shock absorber base bolts 122652...

Page 2159: ...Refitting 31A a Remove the power assisted steering pipe bracket bolt 11 a Remove the bolts 12 from the heat shield the heat shield LEFT HAND DRIVE 116152 WARNING Prepare for the flow of fluid and pro...

Page 2160: ...stud by a few turns strike the bolt head to eject the cover a Remove the steering box universal joint bolt the steering box universal joint nut a Tilt the universal joint a Unclip the power assisted...

Page 2161: ...onnector 18 of the variable power assisted steering a Unclip the wiring of the variable power assisted steering a Disconnect the oxygen sensor connector a Remove the particle filter bolt 19 from the r...

Page 2162: ...ensor Removal Refitting 80B Headlights a Remove the anti roll bar see 31A Front axle compo nents Front anti roll bar Removal Refitting page 31A 68 the steering box see 36A Steering assembly Steering b...

Page 2163: ...be replaced Front wheel hub nut 13 02 03 20 a Refit the attachments the lower arms see 31A Front axle components Front driveshaft lower arm Removal Refitting page 31A 55 the steering box see 36A Stee...

Page 2164: ...nts in the hub carrier housing the track rod end in the hub carrier housing the anti roll bar tie rods a Torque tighten the lower ball joint nut 62 N m the anti roll bar tie rod nut 44 N m the track r...

Page 2165: ...sisted steering Power assisted steer ing circuit Bleeding page 36B 54 a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool select the Airbag computer display the b...

Page 2166: ...ONCERNED a Remove the anti roll bar bearing bolts 1 the anti roll bar REFITTING I REFITTING PREPARATION OPERATION a Clean the surfaces of the subframe resting against the anti roll bar bearings using...

Page 2167: ...Removal Refitting MR 416 55A Exterior protection the engine undertray the front wheels see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 a Apply the after repair procedure using the Diagnos...

Page 2168: ...tub axle carrier before refitting the bearing Replace any damaged hub carrier Use SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consumables Products to clean the inner and outer...

Page 2169: ...omponents Precautions for the repair 33A Check that the ball joint cover is present and in good condition No operations should be carried out on the following components the ball joint cover the ball...

Page 2170: ...TING I REFITTING PREPARATIONS OPERATION a Measure the thickness of the pads and then com pare them to the minimum values see 30A Gener al information Brake Specifications page 30A 16 a Use a wire brus...

Page 2171: ...de pin bolts 32 Nm a Fit the retaining spring into the base of the brake cal liper a Fit the retaining spring in place at the top of the brake calliper using a flat blade screwdriver a Refit the plugs...

Page 2172: ...nent controls Parking brake lever Adjustment page 37A 33 III FINAL OPERATION a Refit the rear wheels see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 a Check the brake fluid level FOOT BRAK...

Page 2173: ...PERATION FOR REMOVAL OF PART CONCERNED a Undo the brake hose at the pipe connection 1 a Remove the retaining fork 2 a Undo the brake hose at the pipe connection 3 a Remove the retaining fork 4 the bra...

Page 2174: ...ing fork 4 the retaining fork 2 a Torque tighten the brake hose unions 14 Nm III FINAL OPERATION a Remove the pedal press from the brake pedal a Bleed the brake circuit see 30A General informa tion Br...

Page 2175: ...ds REFITTING I REFITTING PREPARATIONS OPERATION a Check the condition of the calliper gaiter a Check the condition of the calliper piston if it is se verely scratched or cracked replace the calliper a...

Page 2176: ...Fit the retaining spring into the base of the brake cal liper a Fit the retaining spring in place at the top of the brake calliper using a flat blade screwdriver a Refit the plugs at the end of the gu...

Page 2177: ...e lever Adjustment page 37A 33 III FINAL OPERATION a Bleed the brake circuit see 30A General informa tion Braking circuit Bleed page 30A 4 a Refit the rear wheel see 35A Wheels and tyres Wheel Removal...

Page 2178: ...to avoid damaging it Any trace of im pact on the end panel will render the piston unfit for use a Remove the dust seal a Remove the rectangular section seal from the calli per groove with a round edge...

Page 2179: ...ove the piston after having smeared it with the grease supplied in the repair kit using tool Fre 1190 01 part no 77 11 223 715 the dust seal II FINAL OPERATION a Refit the brake calliper see 31A Front...

Page 2180: ...E CLEANER see Ve hicle Parts and consumables for the repair MR 415 04B Consumables Products to clean the calliper mounting the calliper the guide pin bolts the stub axle carrier a Always replace the c...

Page 2181: ...efit the brake pads see 33A Rear axle components Rear brake pads Removal Refitting page 33A 3 the rear wheel see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 IMPORTANT T o avoid any acciden...

Page 2182: ...axle com ponents Rear brake calliper mounting Remov al Refitting page 33A 13 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the disc covers 1 the stub axle nuts 2 using the Rou 604 01 the hub dis...

Page 2183: ...semblies the stub axle nuts a Torque tighten the stub axle nuts 280 Nm using the Rou 604 01 a Refit the disc covers III FINAL OPERATION a refit the calliper brackets see 33A Rear axle compo nents Rear...

Page 2184: ...the Palmer tool 1 to measure the disc thick ness Measure the thickness of the disc at 4 points in order 90 apart Compare the values with those recommended by the manufacturer see 30A General informati...

Page 2185: ...sorber upper bolts 110 Nm shock absorber lower bolts 115 N m rear axle guard bolts 8 N m IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and opera ti...

Page 2186: ...e headlight beam adjustment sensor link age II OPERATION FOR REMOVAL OF PART CONCERNED a Position a component jack under the lower cup of the spring a Remove the shock absorber lower bolt 3 the shock...

Page 2187: ...tion to the suspended wheel position a Tighten to torque the shock absorber upper bolts 110 Nm the shock absorber lower bolts 115 N m III FINAL OPERATION a Clip on the headlight beam adjustment sensor...

Page 2188: ...rd bolts 1 the rear axle guard clips 2 the rear axle guard a Unclip the headlight beam adjustment sensor link age Equipment required component jack Tightening torquesm rear axle guard bolts 8 N m shoc...

Page 2189: ...ure to the rubber bushes REFITTING I REFITTING PREPARATION OPERATION a Always replace the shock absorber bolts the rear axle guard clips II REFITTING OPERATION FOR PART CONCERNED a Fit the damper comp...

Page 2190: ...ring Removal Refitting 33A a Torque tighten the rear axle guard bolts 8 N m a Refit the rear wheels see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 a With the vehicle on the ground torque...

Page 2191: ...itting page 31A 12 the brake disc see 33A Rear axle components Rear brake disc Removal Refitting page 33A 15 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the stub axle carrier bolts 2 the stub...

Page 2192: ...mounting see 31A Front axle com ponents Front brake calliper mounting Re moval Refitting page 31A 12 the brake pads see 33A Rear axle components Rear brake pads Removal Refitting page 33A 3 the wheel...

Page 2193: ...Re moval Refitting page 33A 13 the rear brake disc see 33A Rear axle compo nents Rear brake disc Removal Refitting page 33A 15 the brake disc protector see Rear brake disc pro tector Removal Refittin...

Page 2194: ...lt 7 the rear stub axle carrier REFITTING I REFITTING PREPARATION OPERATION a Always replace the nuts of the stub axle carrier II REFITTING OPERATION FOR PART CONCERNED a Refit the stub axle carrier b...

Page 2195: ...Rear brake disc Removal Refitting page 33A 15 the brake calliper mounting see 33A Rear axle components Rear brake calliper mounting Re moval Refitting page 33A 13 the rear brake pads see 33A Rear axle...

Page 2196: ...bber part 1 at the edge of the metal part of the rubber bearing Special tooling required Tar 1850 RR axle bearing removal refitting tool Tav 1420 01 Screw jack for tools Tav 1420 Tav 1050 04 Tar 1454...

Page 2197: ...the cup A2 4 of the tool Tar 1850 under the rub ber bush the cup centring shaft 5 the support of the jack 2 the jack 6 of the tool Tav 1420 01 on its support 2 a Bring the jack 6 into contact with th...

Page 2198: ...Removal Refitting 33A REFITTING I REFITTING OPERATION FOR PART CONCERNED a 119640 2 Rubber bush with cylindrical hole on right side of vehicle 3 Rubber bush with oblong hole on left side of vehicle N...

Page 2199: ...tring shaft 12 the support 13 with the jack 10 a Bring the jack into contact with the cup centring shaft a Lower the jack 10 fully using the handle 14 a Raise the jack 10 fully using the handle 14 a R...

Page 2200: ...ipment required pedal press component jack safety strap s Tightening torquesm rear axle bolts 180 N m brake pipe unions on the rear axle 14 N m bolts on the stub axle carrier disc calliper assemblies...

Page 2201: ...allipers a Note the routing for refitting a Remove the parking brake cables from the stub axle carriers without damaging the cable protectors a Let the parking brake cables hang freely a a Unlock the...

Page 2202: ...of the rear axle a Place a safety strap s to attach the rear axle to the component jack a Remove the rear axle bolts 10 positioning the rear axle arms horizontally the rear axle this operation requir...

Page 2203: ...unions on the rear axle 14 N m a Refit the stub axle carrier disc calliper assemblies the bolts 8 securing the stub axle carrier disc calliper assemblies a Screw the brake pipe unions 7 on the callip...

Page 2204: ...nical component controls Parking brake lever Adjustment page 37A 33 III FINAL OPERATION a Refit the rear suspension springs see 33A Rear axle components Rear suspension spring Re moval Refitting page...

Page 2205: ...le guards the rear axle guards Special tooling required Mot 1390 Support for removal refitting of engine gearbox assembly Equipment required pedal press component jack safety strap s Tightening torque...

Page 2206: ...er cup of the left hand spring a Remove the rear suspension springs see 33A Rear axle components Rear suspension spring Removal Refitting page 33A 21 a Remove the bolts 3 from the support of the contr...

Page 2207: ...Remove the nuts 7 from the left underbody protectors the left underbody protectors a Fit a component jack under the fuel tank a Remove the bolt 8 from the fuel tank filler neck a Loosen the bolts 9 o...

Page 2208: ...rom the earth strap a Unclip the wiring strap 12 a Unclip the wiring at 13 a a Mark the tracks of the parking brake cables a Unhook the parking brake cables from the callipers at 14 128336 WARNING The...

Page 2209: ...ables hang freely a a Unlock the wheel speed sensors by pressing care fully on the tab 16 of the sensor holder using a flat blade screwdriver a Unclip the wheel speed sensor wiring at 17 128333 128648...

Page 2210: ...r axle com ponents Rear brake calliper mounting Remov al Refitting page 33A 13 the rear brake discs see 33A Rear axle compo nents Rear brake disc Removal Refitting page 33A 15 the rear stub axle carri...

Page 2211: ...d sensors onto the stub axle car riers a Refit the parking brake cables into their guide a Refit the parking brake cables on the brake callipers a Refit the wiring of the four wheel steering actuator...

Page 2212: ...15 N m a Clip on the headlight beam adjustment sensor link age a Refit the rear axle guards the exhaust silencer see Silencer Removal Re fitting 19B Exhaust the rear wheels see 35A Wheels and tyres Wh...

Page 2213: ...a Adjust the parking brake if not working properly see 37A Mechanical component controls Parking brake lever Adjustment page 37A 33 a Bleed the brake circuit see 30A General informa tion Braking circ...

Page 2214: ...e bolt 3 from the silencer heat shield the silencer heat shield 4 Equipment required component jack Tightening torquesm four wheel drive actua tor s new nuts 84 N m earth strap nut 8 N m fuel tank bol...

Page 2215: ...ller neck a Position a component jack under the tank a Undo the fuel tank bolts 7 a Lower the tank to gain access to the four wheel drive actuator wiring II OPERATION FOR REMOVAL OF PART CONCERNED a M...

Page 2216: ...ring actuator 13 REFITTING I REFITTING PREPARATION OPERATION a Always replace the four wheel drive actuator nuts a Check the condition of the rubber bush between the rear axle and the four wheel drive...

Page 2217: ...t the connectors a Refit the earth strap a Tighten to torque the four wheel drive actuator s new nuts 84 N m the earth strap nut 8 N m a Refit the ball joint protector III FINAL OPERATION a Refit the...

Page 2218: ...on the compensator a Loosen without removing the ball joint 2 nut 3 the nuts 4 and 5 of the con rods compensator side a Remove the ball joint 2 nut a Extract the ball joint 3 using the tool Tav 476 a...

Page 2219: ...OR PART CONCERNED a Refit the track rod a Align the eccentric bolt and compensator marks a Tighten to torque the eccentric bolt new nuts while aligning the marks 90 N m the track rod ball joint new nu...

Page 2220: ...the tool Tar 1850 a Fit the tool s Tar 1850 components in the following order the tool Tar 1850 cup 2 on the rubber bush marking C1 the tool Tar 1850 cup 3 under the rubber bush marking C3 the cup s...

Page 2221: ...the rubber bush marking C2 the tool Tar 1850 cup 7 under the rear axle marking C3 the cup s centring shaft 8 the support 9 with the jack a Bring the jack s rod into contact with the cups cen tring sha...

Page 2222: ...ar axle see 33A Rear axle components Complete rear axle system Removal Refitting page 33A 33 the silencer see Silencer Removal Refitting 19B Exhaust a Connect the battery see Battery Removal Refit tin...

Page 2223: ...the bolts 5 from the track rods the compensator bolts 6 the compensator 7 REFITTING I REFITTING PREPARATION OPERATION a Always replace the four wheel drive actuator nut the track rod nuts the compens...

Page 2224: ...uator 84 N m the eccentric bolt new nuts by lining up the marks 90 N m a Refit the four wheel drive actuator ball joint cover III FINAL OPERATION a Connect the battery see Battery Removal Refit ting 8...

Page 2225: ...ilencer Removal Re fitting 19B Exhaust a Remove the silencer heat shield clips 2 the bolt 3 from the silencer heat shield the silencer heat shield 4 Tightening torquesm four wheel steering computer nu...

Page 2226: ...four wheel steering computer nuts 8 N m the earth strap nut 8 N m a Check the sealing of the connectors of the four wheel steering computer see Connector Check Technical Note 6015A 88A Repairing elect...

Page 2227: ...ove 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 heads into contact with the w...

Page 2228: ...PART CONCERNED a Clean the mating surfaces between the wheel and the hub carrier using a wire brush a Coat the wheel mating face 3 with COPPER ANTI SEIZURE GREASE see Vehicle Parts and con sumables fo...

Page 2229: ...or 18 ALUMINIUMWHEELS 35A a Pretighten the wheel bolts to 30 N m with the wheel suspended starting with the bolts at the bottom a Rotate the wheel through 180 to bring the valve into the bottom positi...

Page 2230: ...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 heads into contact with...

Page 2231: ...NED a Clean the mating surfaces between the wheel and the hub carrier using a wire brush a Coat the wheel mating face 3 with COPPER ANTI SEIZURE GREASE see Vehicle Parts and con sumables for the repai...

Page 2232: ...etighten the wheel bolts to 30 N m with the wheel suspended starting with the bolts at the bottom a Rotate the wheel through 180 to bring the valve into the bottom position a Position the vehicle on i...

Page 2233: ...anced this causes the 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 pressur...

Page 2234: ...face and all the centring equipment ring thrust plate etc are kept clean a Try not to scratch the alloy wheel rim with the wheel tightening device a The wheel is fitted on the wheel balancer as follow...

Page 2235: ...plane of the wheel a If this is not the case remove the old wheel balanc ing weights and repeat the wheel balancing proce dure checking that the wheel balance equals 0 on each wheel plane IV FINAL OP...

Page 2236: ...cation mark 205 65 R 15 91 V 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 Maximum spe...

Page 2237: ...e the exterior bead from the tyre a Remove the exterior bead of the tyre finishing at the valve a Position the tyre lever approximately 15 cm from the valve on the outside of the wheel rim in order to...

Page 2238: ...inst the wheel rim III FINAL OPERATION a Refit the valve mechanism a Inflate the tyre to the recommended pressure see 35A Wheels and tyres Tyre pressure Identifica tion page 35A 16 a Balance the wheel...

Page 2239: ...he tyre shows signs of under inflation or overloading the rubber shows signs of chemical damage hydro carbons and other corrosive substances incorrect and irreversible repairs have previously been mad...

Page 2240: ...wheel see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 a Inflate the tyre a Locate the perforation on the exterior of the tyre and mark it with chalk a Remove the tyre a Locate the perfora...

Page 2241: ...gently on the base of the mushroom plug in side the tyre a Refit the tyre a Inflate the tyre see 35A Wheels and tyres Tyre pressure Identification page 35A 16 a Cut the protruding end of the stalk wi...

Page 2242: ...3 2 0 2 0 2 3 M4R 195 60 R 16 89H 2 3 2 5 2 0 2 1 2 5 205 60 R 16 92H 2 1 2 3 2 0 2 0 2 3 215 50 R 17 95W 2 1 2 3 2 0 2 0 2 3 225 45 R 18 95W 2 1 2 3 2 0 2 0 2 3 215 60 R 16 95V 2 1 2 3 2 0 2 0 2 3 2...

Page 2243: ...2 0 2 3 M9R k PK4 215 55 R 16 93 V 2 3 2 6 2 0 2 2 2 6 215 50 R 17 95 W 2 4 2 7 2 0 2 2 B91 2 3 K91 D91 2 7 225 45 R 18 95 W 2 4 2 7 2 0 2 2 B91 2 3 K91 D91 2 7 215 60 R 16 95 V 2 3 2 5 2 0 2 1 2 5 2...

Page 2244: ...ty res 42 mm emergency spare wheel 33 1 mm II SPECIAL NOTES ON VEHICLES FITTED WITH TYRE PRESSURE MONITORING SYSTEM The UCH is programmed for each set of four tyres When assembling a set of winter ty...

Page 2245: ...es 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 diam eter of 114 3 mm 5 holes...

Page 2246: ...el the sensors emit a radiofrequency signal a computer 2 which collects decodes and process es sensor signals and then determines which mes sage to display a display 3 integrated to the instrument pan...

Page 2247: ...ing faces on the tyre pressure monitor valve II GENERAL RECOMMENDATIONS Do not swap the wheels if they have been removed WARNING Hold the sensor in position on the wheel to prevent it from turning dur...

Page 2248: ...EMOVAL OF PART CONCERNED 1 TG1 B sensor a Remove the nut 1 whilst holding the pressure sensor on the wheel rim the pressure sensor 2 2 TG1 C sensor a Remove the nut 1 whilst holding the pressure senso...

Page 2249: ...05 03 05 3 b When replacing the pressure sensor a parts always to be replaced Pressure sensor 13 05 03 01 2 a parts always to be replaced tyre pressure moni tor valve seal 13 05 03 05 3 II REFITTING O...

Page 2250: ...ectly fitted a Refit the seal with the metallic ring on the pressure sensor a Position the pressure sensor in the valve opening checking that the seal is attached all around the edge of the opening a...

Page 2251: ...ostic tool select UCH go to repair mode display the before after repair procedure for the computer selected select Tyre pressure monitor valve in the List of components controlled by this computer sec...

Page 2252: ...36A 1 STEERING ASSEMBLY Steering List and location of components 36A 123497 1 Steering wheel 2 Steering column 3 Steering box...

Page 2253: ...s 36A F4R or M9R and 802 or 805 123501 4 Axial ball joint linkage 5 Track rod 6 Power assisted steering pump 7 Power assisted steering reser voir 8 Power assisted steering pump steering box supply pip...

Page 2254: ...and location of components 36A K9K or M4R or M9R and 742 123500 4 Axial ball joint linkage 5 Track rod 6 Power assisted steering pump assembly 7 Pump assembly steering box supply pipe 8 Steering box...

Page 2255: ...assisted steering circuit use blanking plugs on the various dis mantled parts 2 Seals To ensure a sound power assisted steering circuit seal replace the power assisted steering pipe seals each time a...

Page 2256: ...g or replacing the ax ial ball joint check that the limiter with the correct colour code is refitted 6 Power assisted steering pump Do not run the engine without steering fluid in the cir cuit 7 Pump...

Page 2257: ...emoval Refitting 55A Ex terior protection the front axle subframe see 31A Front axle com ponents Front axle subframe Removal Refit ting page 31A 58 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove...

Page 2258: ...e heat shield bolts III FINAL OPERATION a Refit the front axle sub frame see 31A Front axle components Front axle subframe Removal Refitting page 31A 58 the front and side wheel arch liners see Front...

Page 2259: ...stment lock nut 1 a Remove the track rod ball joint nut 2 a Extract the ball joint using 3 Tav 476 a Unscrew the track rod anti clockwise and note the number of turns for refitting a Remove the track...

Page 2260: ...track rod ball joint nut a Tighten to torque the track rod ball joint nut 37 N m the wheel alignment adjusting lock nut 53 N m II FINAL OPERATION a Refit the wheel see 35A Wheels and tyres Wheel Remo...

Page 2261: ...epair procedure section a Remove the front wheels see 35A Wheels and ty res Wheel Removal Refitting page 35A 1 Special tooling required Dir 1833 Steering rack locking tool Tav 476 Ball joint extractor...

Page 2262: ...eering as sembly Track rod Removal Refitting page 36A 8 the wheel alignment adjustment lock nut the steering box right hand gaiter see 36A Steer ing assembly Steering box gaiter Removal Refitting page...

Page 2263: ...hand axial ball joint linkage a Clean the gaiter steering box contact surfaces using SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consum ables Products a Refit the steering box...

Page 2264: ...a Remove the front wheels see 35A Wheels and ty res Wheel Removal Refitting page 35A 1 Special tooling required Dir 1833 Steering rack locking tool Tav 476 Ball joint extractor Dir 1305 01 Tool for r...

Page 2265: ...teering assem bly Track rod Removal Refitting page 36A 8 the wheel alignment adjustment lock nut the steering box left hand gaiter see 36A Steer ing assembly Steering box gaiter Removal Refitting page...

Page 2266: ...hand axial ball joint linkage a Clean the gaiter steering box contact surfaces using SURFACE CLEANER see Vehicle Parts and consumables for the repair 04B Consum ables Products a Refit the steering box...

Page 2267: ...415 84A Control Signals the dashboard lower trim see Dashboard lower trim Removal Refitting MR 416 57A Interior equipment the engine undertray bolts the engine undertray Equipment required Diagnostic...

Page 2268: ...nt stud by a few turns strike the bolt head to eject the cover a Remove the steering box universal joint stud bolt the steering box universal joint stud nut a Tilt the universal joint a Unclip the ste...

Page 2269: ...MR 415 82A Immobiliser REFITTING I REFITTING PREPARATION OPERATION a Always replace the steering box universal joint bolt and nut the steering wheel bolt a Refit the electric steering column lock see...

Page 2270: ...steering column nuts 21 Nm a Clip the steering gaiter on the front bulkhead III FINAL OPERATION a Refit the engine undertray the engine undertray bolts the dashboard lower trim see Dashboard lower tri...

Page 2271: ...415 84A Control Signals the dashboard lower trim see Dashboard lower trim Removal Refitting MR 416 57A Interior equipment the engine undertray bolts the engine undertray Equipment required Diagnostic...

Page 2272: ...nt stud by a few turns strike the bolt head to eject the cover a Remove the steering box universal joint stud bolt the steering box universal joint stud nut a Tilt the universal joint a Unclip the ste...

Page 2273: ...MR 415 82A Immobiliser REFITTING I REFITTING PREPARATION OPERATION a Always replace the steering box universal joint bolt and nut the steering wheel bolt a Refit the electric steering column lock see...

Page 2274: ...steering column nuts 21 Nm a Clip the steering gaiter on the front bulkhead III FINAL OPERATION a Refit the engine undertray the engine undertray bolts the dashboard lower trim see Dashboard lower tri...

Page 2275: ...od Removal Refitting page 36A 8 the wheel alignment adjustment lock nut a Remove the upper nuts 1 from the front anti roll bar tie rods a Pivot the anti roll bar 2 towards the rear of the ve hicle II...

Page 2276: ...wards the front of the vehicle a Refit the anti roll bar tie rod upper nuts a Torque tighten the front anti roll bar tie rod upper nuts 44 N m a Refit the wheel alignment adjustment lock nut the track...

Page 2277: ...36A 26 STEERING ASSEMBLY Steering box gaiter Removal Refitting 36A a Adjust the rear axle if necessary see 30A General information Rear axle system Adjustment page 30A 32 4 WHEEL STEERING...

Page 2278: ...the steering wheel a REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Steering wheel bolt 13 04 01 09 Tightening torquesm new steering wheel bolt 44 N m IMPORTANT Consult the...

Page 2279: ...ering wheel bolt 44 N m III FINAL OPERATION a Refit the driver s front airbag see Driver s frontal airbag Removal Refitting IV CHECKING AFTER REPAIR a Switch on the ignition a Check the operation of t...

Page 2280: ...e front right hand wheel arch liners see Front wheel arch liner Removal Refitting 55A Ex terior protection the accessories belt see Accessories belt Re moval Refitting 11A Top and front of engine Spec...

Page 2281: ...PREPARATION OPERATION a Always replace the high pressure pipe s O ring a Before refitting the belt clean the crankshaft pulley V grooves with a brush to remove any deposits II REFITTING OPERATION FOR...

Page 2282: ...e Accessories belt Re moval Refitting 11A Top and front of engine the front right hand wheel arch liners see Front wheel arch liner Removal Refitting 55A Ex terior protection the front right hand whee...

Page 2283: ...oler air outlet pipe the clip 2 on the intercooler air outlet pipe the air pipe 3 at the intercooler outlet Special tooling required Ms 583 Pipe clamps Mot 1448 Remote operation pliers for hose clips...

Page 2284: ...t hand wheel see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 the front right hand wheel arch liners see Front wheel arch liner Removal Refitting 55A Ex terior protection the accessories be...

Page 2285: ...he high pressure pipe s O ring a Before refitting the belt clean the crankshaft pulley V grooves with a brush to remove any deposits II REFITTING OPERATION FOR PART CONCERNED a a Refit the power steer...

Page 2286: ...ue tighten the power assisted steering pump pulley bolts 8 Nm a Refit the front right hand wheel arch liners see Front wheel arch liner Removal Refitting 55A Ex terior protection the front right hand...

Page 2287: ...PART CONCERNED a Fit the tool Ms 583 1 on the power assisted steering pump s supply pipe a Remove the clip 2 using the Mot 1448 the low pressure pipe 3 from the power assisted steering pump a Remove t...

Page 2288: ...mp the high pressure pipe union equipped with a new seal the high pressure pipe brackets the low pressure pipe a Remove the Ms 583 a Tighten to torque the high pressure pipe union 21 N m the high pres...

Page 2289: ...ded engine mounting Re moval Refitting 19D Engine mounting a Loosen the power assisted steering pump pulley bolts slightly 1 a Remove the accessories belt see Accessories belt Removal Refitting 11A To...

Page 2290: ...pipe union on the power as sisted steering pump 21 N m a Remove the tool Ms 583 a Refit the power assisted steering pulley III FINAL OPERATION a Refit the accessories belt see Accessories belt Removal...

Page 2291: ...36B 12 POWER ASSISTED STEERING Power assisted steering pump Removal Refitting D91 and V9X 36B a Refit the engine undertray the engine cover...

Page 2292: ...front of engine II OPERATION FOR REMOVAL OF PART CONCERNED a Fit the tool Ms 583 on the low pressure pipe be tween the reservoir and the power assisted steering pump a Remove the clip using the Mot 1...

Page 2293: ...h pressure pipe union on the power assisted steering pump 21 N m a Remove the tool Ms 583 III FINAL OPERATION a Refit the accessories belt see Accessories belt Re moval Refitting 11A Top and front of...

Page 2294: ...tting MR 416 55A Exterior protection II OPERATION FOR REMOVAL OF PART CONCERNED a Carefully disconnect the connectors 1 from the pump assembly to prevent damaging the locking systems a Position the Ms...

Page 2295: ...e pump assembly with its mounting REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the high pressure pipe O ring II REFITTING OPERATION FOR PART CONCERNED a Refit the pump assembly with i...

Page 2296: ...ering circuit lift the vehicle so that the wheels are off the ground start the engine turn the steering wheel so the wheels lock left then right repeat this operation three times a Top up the power as...

Page 2297: ...55A Exterior protection the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED 1 Low pressure pipe between the pump assembly and the steering box a Loosen the clip 1 from the low pressure pi...

Page 2298: ...e between the pump assembly and the steering box a Loosen the clip 3 from the low pressure pipe on the pump assembly reservoir using the Mot 1448 a Disconnect the low pressure pipe and drain the pump...

Page 2299: ...the bolt to the power assisted steering pipe bracket on the steering box the bolt to the high pressure pipe bracket on the pump assembly the high pressure pipe bracket nuts on the body III FINAL OPERA...

Page 2300: ...pressure pipe between the power assisted steering pump and the reservoir a Undo the clip 1 on the low pressure pipe using the Mot 1448 a Drain the power assisted steering fluid reservoir a Undo the cl...

Page 2301: ...A Wheels and tyres Wheel Removal Refitting page 35A 1 the front wheel arch liners partially see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front bumper see Front bumpe...

Page 2302: ...DRIVE 36B a Unclip the low pressure pipe at 5 a Remove the nuts 6 from the brackets securing the low pressure pipe between the power assisted steering fluid reservoir and the steering box a Remove th...

Page 2303: ...front wheels see 35A Wheels and tyres Wheel Removal Refitting page 35A 1 the front left hand wheel arch see Front wheel arch liner Removal Refitting MR 416 56A Exterior protection a Remove the tie rod...

Page 2304: ...DRIVE M9R and 802 or 805 and RIGHT HAND DRIVE 36B a Remove the pipe bolt 13 the high pressure pipe union 14 a Remove the power assisted steering box heat shield bolts 15 the power assisted steering bo...

Page 2305: ...he steering box a Always replace the power assisted steering pipe O rings the universal joint bolt and nut II REFITTING OPERATION FOR PART CONCERNED 1 Low pressure pipe between the power assisted stee...

Page 2306: ...9 the pipe bolt 13 the tie rod 9 the tie rod bolts 8 the universal joint 11 on the steering box the universal joint nut the universal joint bolt 10 the front left hand wheel arch liner see Front wheel...

Page 2307: ...PART CONCERNED 1 Low pressure pipe between the power assisted steering pump and the reservoir a Undo the clip 1 on the low pressure pipe using the Mot 1448 a Drain the power assisted steering fluid r...

Page 2308: ...t hand wheel see 35A Wheels and ty res Wheel Removal Refitting page 35A 1 the front wheel arch liners partially see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front bu...

Page 2309: ...805 and LEFT HAND DRIVE 36B a Unclip the low pressure pipe at 5 a Remove the clip 6 using the Mot 1448 the low pressure pipe 3 High pressure pipe between the power assisted steering pump and the stee...

Page 2310: ...teering pipes Removal Refitting F4R and LEFT HAND DRIVE M9R and 802 or 805 and LEFT HAND DRIVE 36B a Remove the power assisted steering pipe bracket bolt 7 a Remove the high pressure pipe union 8 a Re...

Page 2311: ...ervoir a Refit the low pressure pipe a Fit the clip 2 on the low pressure pipe using a Mot 1448 the clip 1 on the low pressure pipe using the Mot 1448 2 High pressure pipe between the power assisted s...

Page 2312: ...ty res Wheel Removal Refitting page 35A 1 III FINAL OPERATION a Fill the power assisted steering circuit reservoir see Vehicle Parts and consumables for the repair MR 415 04B Consumables Products a Bl...

Page 2313: ...ngine undertray bolts the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED 1 Low pressure pipe between the pump assembly and the steering box a Loosen the low pressure pipe clip 1 on the pu...

Page 2314: ...lt 3 do not keep the cover from the universal joint nut do not keep the universal joint nut do not keep a Tilt the universal joint 4 away from the steering box a Remove the nuts 5 from the low pressur...

Page 2315: ...ressure pipe clip 7 on the pump assembly reservoir using the tool Mot 1448 a Remove the low pressure pipe to drain the pump as sembly reservoir a Remove the power assisted steering pipe bracket bolt 8...

Page 2316: ...e bolt 15 securing the high pressure pipe brack et on the pump assembly the high pressure pipe between the pump assem bly and the steering box REFITTING I REFITTING PREPARATION OPERATION a Always repl...

Page 2317: ...joint on the steering box the universal joint nut the bolt from the universal joint a Torque tighten the universal joint bolt 24 Nm a Fill the pump assembly reservoir with power assist ed steering flu...

Page 2318: ...CONCERNED 1 Low pressure pipe between the power assisted steering pump and the reservoir a Loosen the clip 1 of the low pressure pipe on the power assisted steering fluid reservoir using the tool Mot...

Page 2319: ...ted steering fluid reservoir using the tool Mot 1448 a Drain the power assisted steering reservoir a Remove the power assisted steering pipe bracket bolt 5 on the steering box a Unclip the power assis...

Page 2320: ...8 the max fuse box a Remove the power assisted steering pipe bracket bolt 9 on the steering box a Remove the high pressure pipe union 10 on the power assisted steering pump a Fit a hose clamp Ms 583...

Page 2321: ...wer assisted steering pump using the tool Mot 1448 the clip of the low pressure pipe on the power as sisted steering fluid reservoir using the tool Mot 1448 a Clip the power assisted steering low pres...

Page 2322: ...on the steering box the low pressure pipe clip on the reservoir using the tool Mot 1448 a Clip the power assisted steering low pressure pipe onto the front end panel of the vehicle III FINAL OPERATION...

Page 2323: ...OPERATION FOR REMOVAL OF PART CONCERNED 1 Low pressure pipe between the power assisted steering pump and the reservoir a Loosen the clip 1 of the low pressure pipe on the power assisted steering flui...

Page 2324: ...ssure pipe 2 Low pressure pipe between the power assisted steering fluid reservoir and the steering box a Loosen the clip 3 of the low pressure pipe on the power assisted steering fluid reservoir usin...

Page 2325: ...the power assisted steering high pressure pipe from the cylinder head a Remove the power assisted steering pipe bracket bolt 8 on the steering box a Remove the high pressure pipe bolt from the gearbox...

Page 2326: ...pressure pipe the high pressure pipe union on the power assisted steering pump the bracket on the steering box a Tighten to torque the high pressure pipe union on the power as sisted steering pump 21...

Page 2327: ...CONCERNED 1 Low pressure pipe between the power assisted steering pump and the reservoir a Undo the clip 1 of the low pressure pipe using the tool Mot 1448 a Drain the power assisted steering reservoi...

Page 2328: ...Low pressure pipe between the power assisted steering fluid reservoir and the steering box a Loosen the clip 4 of the low pressure pipe on the power assisted steering fluid reservoir using the tool M...

Page 2329: ...end panel a Remove the power assisted steering low pressure pipe 3 High pressure pipe between the power assisted steering pump and the steering box a Remove the air filter unit see Air filter unit Re...

Page 2330: ...the heater matrix pipe a Disconnect the heater matrix pipe from the rigid pipe a Disconnect the pressostat connector 12 a Remove the nut 13 for the power assisted steering high pressure pipe on the r...

Page 2331: ...pressure pipe on the power as sisted steering fluid reservoir using the tool Mot 1448 a Clip the low pressure pipe onto the timing cover 2 High pressure pipe between the power assisted steering pump...

Page 2332: ...he reservoir using the tool Mot 1448 the heat shield for the steering box a Clip the power assisted steering low pressure pipe onto the front end panel of the vehicle III FINAL OPERATION a Refit the r...

Page 2333: ...ng 02A Lifting equipment a Raise the vehicle until the front wheels are lifted off the ground a Fill the power assisted steering fluid reservoir 1 a Fill the power assisted steering reservoir 1 a Fill...

Page 2334: ...three times turn the steering wheel to the left to lock the steer ing turn the steering wheel to the right to lock the steer ing a Top up the power assisted steering fluid WARNING T o prevent damagin...

Page 2335: ...uel mixture II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the brake fluid reservoir connector 1 a Drain the brake fluid reservoir a Disconnect the clutch master cylinder pipe on the brake fl...

Page 2336: ...that the pushrod goes into the master cylinder hous ing a Torque tighten the master cylinder nuts 20 N m on the brake servo a Refit the brake pipes a Torque tighten the brake pipes 14 Nm a Refit the...

Page 2337: ...der Removal Refitting 37A a Refit the engine cover a Bleed the brake circuit see 30A General informa tion Braking circuit Bleed page 30A 4 a Bleed the clutch circuit see 37A Mechanical com ponent cont...

Page 2338: ...L I REMOVAL PREPARATION OPERATION a Remove the front engine cover II REMOVAL OPERATION FOR PART CONCERNED a Remove the non return valve 1 from the brake ser vo turning the non return valve to extract...

Page 2339: ...EPARATIONS OPERATION a Check the condition of the sealing washer and the non return valve a Replace any faulty parts II REFITTING OPERATION FOR PART CONCERNED a Refit the non return valve a Connect th...

Page 2340: ...ge 35A 1 the front left hand wheel arch liner see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the engine cover II REMOVAL OPERATION FOR PART CONCERNED a Remove the non retu...

Page 2341: ...TTING OPERATION FOR PART CONCERNED a Refit the non return valve a Connect the non return valve on the vacuum pump the intake distributor the union 3 the pressure sensor connector the brake servo III F...

Page 2342: ...move the engine cover the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the non return valve 1 from the servo turning the...

Page 2343: ...n of the sealing washer and the non return valve a Replace any faulty parts II REFITTING OPERATION FOR PART CONCERNED a Refit the non return valve a Connect the non return valve pipe to the intake dis...

Page 2344: ...trim see Dashboard lower trim Removal Refitting 57A Interior equip ment the brake light switch see 37A Mechanical com ponent controls Brake pedal switch Removal Refitting page 37A 29 a Fit the tools...

Page 2345: ...NTROLS Brake servo Removal Refitting 37A Left hand drive Right hand drive a Remove the double safety connecting piece 2 between the brake servo pushrod and the brake pedal the brake servo nuts 3 the b...

Page 2346: ...les 118 5 mm for right hand drive vehicles If the dimension is not correct replace the brake ser vo II REFITTING OPERATION FOR PART CONCERNED a Refit the brake servo the brake servo nuts a Torque tigh...

Page 2347: ...ee 37A Mechanical com ponent controls Brake pedal switch Removal Refitting page 37A 29 a Connect the battery see Battery Removal Refit ting 80A Battery a Check that the connecting pin between the brak...

Page 2348: ...the gearbox breather pipe 4 the wiring 5 a Remove the vacuum pump bolts 6 the vacuum pump REFITTING I REFITTING PREPARATION OPERATION a Be sure to replace the vacuum pump seal II REFITTING OPERATION...

Page 2349: ...37A 15 MECHANICAL COMPONENT CONTROLS Vacuum pump Removal Refitting M9R 37A III FINAL OPERATION a Refit the air filter box see Air filter unit Removal Re fitting 12A Fuel mixture the engine cover...

Page 2350: ...ng bracket on the vacu um pump the vacuum pump bolts 5 the vacuum pump REFITTING I REFITTING PREPARATIONS OPERATION a Be sure to replace the vacuum pump seal II REFITTING OPERATION FOR PART CONCERNED...

Page 2351: ...R REMOVAL OF PART CONCERNED a Remove the non return valve pipe 1 on the vacuum pump the vacuum pump connector 2 the vacuum pump bolts 3 the vacuum pump REFITTING I REFITTING OPERATION FOR PART CONCERN...

Page 2352: ...move the vacuum pump bolts 3 the vacuum pump REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced Brake servo vacu um pump seal 13 03 07 02 II REFITTING OPERATION FOR PART CONCERN...

Page 2353: ...PART CONCERNED a Disconnect the accelerator pedal potentiometer con nector 1 a Remove the accelerator pedal bolts 2 the accelerator pedal REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit th...

Page 2354: ...Removal Re fitting 86A Radio II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the accelerator pedal connector a Remove the accelerator pedal bolt 2 the accelerator pedal REFITTING I REFITTING...

Page 2355: ...37A 21 MECHANICAL COMPONENT CONTROLS Accelerator pedal Removal Refitting RIGHT HAND DRIVE 37A a Refit the dashboard lower trim see Dashboard lower trim Removal Refitting 57A Interior equipment...

Page 2356: ...nterior equipment the steering column see 36A Steering assem bly Steering column Removal Refitting page 36A 16 a Cut the tool Fre 1752 along the dotted lines re specting the dimension X of 68 mm a Ins...

Page 2357: ...vent of a replacement operation remove the accelerator pedal see 37A Mechanical compo nent controls Accelerator pedal Removal Re fitting page 37A 19 REFITTING I REFITTING PREPARATION OPERATION a Alway...

Page 2358: ...a Refit the brake pedal impacter the brake light switch see 37A Mechanical com ponent controls Brake pedal switch Removal Refitting page 37A 29 a Connect the accelerator pedal potentiometer con necto...

Page 2359: ...the brake pedal link rod connecting shaft the link rod connecting shaft a Turn the brake pedal shaft 2 to release the lug a Remove the brake pedal shaft the brake pedal REFITTING I REFITTING OPERATION...

Page 2360: ...the dashboard cross member see Dashboard cross member Removal Refitting MR 416 42A Upper front structure the clutch pedal see 37A Mechanical compo nent controls Clutch pedal Removal Refit ting page 37...

Page 2361: ...e pedal link rod shaft the brake pedal link rod shaft the brake pedal link rod REFITTING I REFITTING PREPARATIONS OPERATION a Always replace the double safety connecting piece II REFITTING OPERATION F...

Page 2362: ...it the brake light switch see 37A Mechanical component controls Brake pedal switch Re moval Refitting page 37A 29 III FINAL OPERATION a Refit the clutch pedal see 37A Mechanical compo nent controls Cl...

Page 2363: ...ovebox see Glovebox Removal Refitting 57A Interior equipment II OPERATION FOR REMOVAL OF PART CONCERNED a a Disconnect the brake light switch connector 2 a Turn the brake light switch 3 a quarter of a...

Page 2364: ...ht switch is operating cor rectly depress the brake pedal to switch on the lights release the brake pedal to switch off the lights a Refit the absorbent material a Refit the glovebox see Glovebox Remo...

Page 2365: ...g MR 415 61A Heating system a Cut the carpet at 1 a Unclip the wiring harness on the control unit at 2 a Remove the soundproofing 3 from the control unit a Remove the airbag computer protector 4 II RE...

Page 2366: ...Nm a Connect the wire at 5 a Adjust the parking brake see 37A Mechanical component controls Parking brake lever Ad justment page 37A 33 II FINAL OPERATION a Refit the control unit soundproofing a Cli...

Page 2367: ...and if necessary re pair the parking brake cables the calliper piston the automatic compensation system calliper a Remove the rear wheels see 35A Wheels and ty res Wheel Removal Refitting page 35A 1...

Page 2368: ...nect a vacuum pump directly to the brake servo a Activate the vacuum pump a few times a Check that the vacuum does not fall by more than 33 mbar in 15 seconds If it does the leak may be lo cated on th...

Page 2369: ...37A 4 a Connect the non return valve to the intake distribu tor IV CHECKING THE VACUUM PUMP a Connect the external vacuum pump to the engine vacuum pump a Start the engine a Check the following value...

Page 2370: ...engine vacuum pump a Start the engine a Check that the vacuum value at the vacuum pump outlet is XXX mbar a Replace the vacuum pump if the values are different see 37A Mechanical component controls V...

Page 2371: ...trol List and location of components 6 SPEED MANUAL GEARBOX 37A No Description 1 Clutch slave cylinder clutch thrust bearing 2 Hydraulic clutch control pipes 3 Clutch master cylinder 4 Brake fluid sup...

Page 2372: ...37A 38 MECHANICAL COMPONENT CONTROLS Clutch control List and location of components 6 SPEED MANUAL GEARBOX 37A RIGHT HAND DRIVE 125077...

Page 2373: ...l po sition sensor Removal Refitting page 37A 45 the clutch end of travel switch 2 see 37A Me chanical component controls Clutch pedal po sition sensor Removal Refitting page 37A 45 a Disconnect the c...

Page 2374: ...n the pedal a Reconnect the clutch pedal position sensor connec tor a Refit the clutch end of travel switch see 37A Mechani cal component controls Clutch pedal position sensor Removal Refitting page 3...

Page 2375: ...dashboard cross member see Dashboard cross member Removal Refitting 42A Upper front structure II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the clutch start of travel switch 6 see 37A Me chanic...

Page 2376: ...g page 37A 45 a Refit the clutch pedal plate spacers the clutch pedal plate a Clip the wiring onto the clutch pedal plate a Refit the clutch pedal plate nuts a Torque tighten the clutch pedal plate nu...

Page 2377: ...f the di mension X is less than 12 mm carefully pull on the end of the piston to adjust the dimension X to be tween a minimum of 15 mm and a maximum of 20 mm II REFITTING OPERATION FOR PART CONCERNED...

Page 2378: ...edal a Connect the clutch pedal switch connectors III FINAL OPERATION a Refit the dashboard lower trim see Dashboard lower trim Removal Refitting 57A Interior equipment Note The clutch pedal switches...

Page 2379: ...mage the sensor lower mounting bracket 4 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the clutch pedal position sensor a Lock the sensor body by using the lock the section connected to t...

Page 2380: ...MPONENT CONTROLS Clutch pedal position sensor Removal Refitting ELECTRONIC PARKING BRAKE and 6 SPEED MANUAL GEARBOX 37A carry out the operations described in the After re pair procedure section a Swit...

Page 2381: ...to bleed the clutch circuit a ARC50 via the brake fluid reservoir a Syringe via the bleed hole located on the clutch slave cylinder There are two procedures used to bleed the clutch circuit a If no p...

Page 2382: ...plastic union 1 using a ring spanner and undo the bleed screw 2 Half turn bleed screw a To open the bleed screw fully turn the bleed screw 3 by hand Bleed screw with a clip a To open the bleed screw p...

Page 2383: ...hole running to an empty container placed under the bleed hole a Open the bleed screw a Open the circuit between the bleeding device and the brake fluid reservoir a Let the brake fluid run until all a...

Page 2384: ...he transparent pipe from the bleed hole a Refit the bleed plug a Top up the brake fluid level in the master cylinder reservoir a Disengage and engage the clutch quickly around twenty times a Check tha...

Page 2385: ...d without a filter Pipe without filter Filling position for pipe with filter Filling position for pipe with filter Filling position for pipe with filter a Prefill the clutch pipe using the syringe a P...

Page 2386: ...yringe containing 60 ml of ap proved brake fluid to the end of the transparent pipe a Slowly inject the entire contents of the syringe into the hydraulic clutch circuit without injecting any of the ai...

Page 2387: ...CHANICAL COMPONENT CONTROLS Clutch circuit Bleed PK4 or TL4 37A VI FINAL OPERATION a Refit the engine undertray a Remove the vehicle from the two post lift see Vehi cle Towing and lifting 02A Lifting...

Page 2388: ...Air filter unit Removal Re fitting MR 415 12A Fuel mixture the bolt 1 from the max fuse box a Move the max fuse box to one side a Remove the engine undertray bolts the engine undertray a Remove the b...

Page 2389: ...ol pipe by one notch to release the bleed opening a Release the metal clip a Depress the clutch pedal with your hand to drain the reservoir the master cylinder and the clutch pipe II OPERATION FOR REM...

Page 2390: ...e bayonet connection on the bulkhead must be clean free of grease and with out any burrs a The routing of the supply pipe must always ascend from the master cylinder to the reservoir as any low points...

Page 2391: ...lutch pedal a Refit the dashboard lower trim on the driver s side a Connect the supply pipe at the master cylinder III FINAL OPERATION a Bleed the hydraulic circuit see 37A Mechanical component contro...

Page 2392: ...ching unit see Protection and Switching Unit Removal Refitting 87G Engine compartment connection unit the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture the engine undertray b...

Page 2393: ...ng cable from the electric cool ant pump support the clutch circuit pipe from the electric coolant pump support a Separate the support electric coolant pump as sembly a Remove the bleed plug 4 a Conne...

Page 2394: ...onnect the clutch control pipe 7 a Fit blanking plugs into the openings a Disconnect the brake fluid reservoir supply pipe 8 a Disconnect the clutch master cylinder ball joint 9 from the clutch pedal...

Page 2395: ...l joint on the clutch pedal a Connect the brake fluid reservoir supply pipe III FINAL OPERATION a Clip the clutch circuit pipe on the electric coolant pump support the bonnet unlocking cable on the el...

Page 2396: ...Move the max fuse box a Remove the engine undertray bolts the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bleed plug 2 a Connect a transparent pipe to the bleed hole runn...

Page 2397: ...utch control pipe taking care not to damage anything a Connect the clutch control pipe on the side of the slave cylinder a Press the retaining clip of the clutch control pipe on the master cylinder a...

Page 2398: ...move the engine undertray bolts the engine undertray II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bleed plug 2 a Connect a transparent pipe to the bleed hole running to an empty container p...

Page 2399: ...pipe taking care not to damage anything a Connect the hydraulic clutch control pipe on the side of the slave cylinder a Press the retaining clip of the hydraulic clutch control pipe on the master cyli...

Page 2400: ...fitting 87G Engine compartment connection unit the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture the engine undertray bolts the engine undertray a Remove the bolt 1 from the...

Page 2401: ...Fit blanking plugs into each opening a Lift the retaining clip 7 from the clutch control pipe on the master cylinder a Disconnect the master cylinder slave cylinder con necting pipe 8 a Plug the openi...

Page 2402: ...unlocking cable on the electric coolant pump support a Connect the electric coolant pump connector a Refit the support electric coolant pump assembly the max fuse box the air filter unit see Air filt...

Page 2403: ...efitting 57A Interior equipment the middle air distribution duct see Rear air distri bution duct Removal Refitting 61A Heating system a Cut the carpet at 1 a Unclip the wiring on the control unit at 2...

Page 2404: ...OF PART CONCERNED a Unclip the control cables on the control unit at the anchoring ball joint 11 using an open jawed spanner the anchoring ball joint by pressing the button 12 the cable sleeve stops...

Page 2405: ...seal bolts a Tighten the bulkhead seal bolts a Clip the gearbox control cable sleeve stops on the gear box the anchoring ball joints of the gear control cables on the gearbox using pliers a Clip the...

Page 2406: ...reinforcement the reinforcement lower bolts the reinforcement upper nuts the driver s side dashboard lower trim a Clip the wiring on the reinforcement the left hand air duct the wiring on the airbag c...

Page 2407: ...on duct Removal Refitting 61A Heating system a Cut the carpet at 1 a Unclip the wiring on the control unit at 2 a Remove the soundproofing 3 from the control unit a Unclip the harness at 4 a Remove th...

Page 2408: ...top 12 a Lift the passenger side carpet a Remove the polystyrene under the carpet a Remove the bulkhead seal bolts 13 the control cables REFITTING I REFITTING OPERATION FOR PART CONCERNED a Fit the co...

Page 2409: ...N m a Adjust the control unit see 37A Mechanical com ponent controls Gear control unit Adjustment page 37A 109 a Check that the system and gear selection are work ing correctly II FINAL OPERATION a C...

Page 2410: ...lever knob by lifting it upwards the central console see Centre console Remov al Refitting 57A Interior equipment the middle air duct see Rear air distribution duct Removal Refitting 61A Heating syste...

Page 2411: ...airbag computer protector 6 the control unit see 37A Mechanical component controls Gear control unit Removal Refitting page 37A 95 II OPERATION FOR REMOVAL OF PART CONCERNED a Unlock the clip 8 a Unlo...

Page 2412: ...able the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage the...

Page 2413: ...the left hand air duct a Refit the airbag computer protector a Clip the wiring onto the airbag computer protector a Refit the control unit soundproofing a Clip the wiring onto the control unit a Clip...

Page 2414: ...ral console see Centre console Remov al Refitting 57A Interior equipment the middle centre air duct see Rear air distribu tion duct Removal Refitting 61A Heating system a Place the gear selector in po...

Page 2415: ...einforcement 10 the accelerator pedal see 37A Mechanical com ponent controls Accelerator pedal Removal Refitting page 37A 19 the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture...

Page 2416: ...ble the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage the c...

Page 2417: ...trim Removal Refitting 57A Interior equip ment the accelerator pedal see 37A Mechanical com ponent controls Accelerator pedal Removal Refitting page 37A 19 a Clip on the left hand air duct a Refit the...

Page 2418: ...57A Interior equipment the middle air duct see Rear air distribution duct Removal Refitting 61A Heating system a Place the gear selector in position D a Cut the carpet at 2 a Unclip the wiring on the...

Page 2419: ...see 37A Mechanical com ponent controls Accelerator pedal Removal Refitting page 37A 19 the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture the control unit see 37A Mechanical c...

Page 2420: ...air outlet pipe on the air filter unit a Remove the air outlet pipe to the air filter unit the protection and switching unit see Protection and Switching Unit Removal Refitting 87G Engine compartment...

Page 2421: ...cable the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage th...

Page 2422: ...tributor a Clip the non return valve pipe onto the air filter unit air outlet pipe a Refit the engine cover a Refit the protection and switching unit see Protection and Switching Unit Removal Refittin...

Page 2423: ...37A 89 MECHANICAL COMPONENT CONTROLS Automatic gear control cable Removal Refitting D91 and AJ0 and LEFT HAND DRIVE 37A...

Page 2424: ...ee Centre console Remov al Refitting 57A Interior equipment the middle air duct see Rear air distribution duct Removal Refitting 61A Heating system a Place the gear selector in position D a Cut the ca...

Page 2425: ...unit see 37A Mechanical component controls Gear control unit Removal Refitting page 37A 95 a Remove the front engine cover a Disconnect the non return valve pipe 8 from the in take distributor a Uncl...

Page 2426: ...air outlet pipe on the air filter unit a Remove the air outlet pipe to the air filter unit the protection and switching unit see Protection and Switching Unit Removal Refitting 87G Engine compartment...

Page 2427: ...ol cable the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage...

Page 2428: ...al Refitting 61A Heating system the central console see Centre console Remov al Refitting 57A Interior equipment the gear lever knob a Turn the ring on the gear lever knob a sixteenth of a turn a Refi...

Page 2429: ...l Refitting MR 416 57A Interior equipment the clip from the rear centre air duct above the soundproofing the rear centre air duct above the soundproofing a Place the gear selector in position D a Cut...

Page 2430: ...e carpet a Remove the bulkhead seal bolts 12 the gear control unit REFITTING I REFITTING PREPARATIONS OPERATION a The external control unit lever and the multifunction switch on the gearbox must be in...

Page 2431: ...the system and gear selection are work ing correctly III FINAL OPERATION a Clip on the left hand air duct a Refit the airbag computer protector a Clip the wiring harness on the airbag computer pro te...

Page 2432: ...ee Centre console Remov al Refitting 57A Interior equipment the clip of the rear centre air duct above the sound proofing the rear centre air duct above the soundproofing a Place the gear selector in...

Page 2433: ...Unclip the wiring on the control unit at 9 a Disconnect the connector 10 from the gear control unit a Remove the gear control unit nuts 11 the gear control unit REFITTING I REFITTING PREPARATION OPER...

Page 2434: ...Adjustment page 37A 109 a Check that the system and gear selection are work ing correctly III FINAL OPERATION a Refit the airbag computer protector a Clip the wiring onto the airbag computer protector...

Page 2435: ...R 415 61A Heating system a Cut the carpet at 1 a Unclip the wiring harness on the control unit at 2 a Remove the soundproofing 3 from the control unit a Unclip the harness at 4 a Remove the airbag com...

Page 2436: ...he gear control unit nuts 21 Nm a Adjust the control unit see 37A Mechanical com ponent controls Gear control unit Adjustment page 37A 109 a Check that the system and gear selection are work ing corre...

Page 2437: ...ole see Centre console Remov al Refitting 57A Interior equipment the clip from the rear centre air duct above the soundproofing the rear centre air duct above the soundproofing a Place the gear select...

Page 2438: ...ION FOR REMOVAL OF PART CONCERNED a Release the white clip 7 using a screwdriver a Release the white clip 8 a Disconnect the gear control unit connector 9 a Remove the gear control unit nuts 10 the ge...

Page 2439: ...ntrol unit Adjustment page 37A 109 a Check that the system and gear selection are work ing correctly II FINAL OPERATION a Refit the airbag computer protector a Clip the wiring onto the airbag computer...

Page 2440: ...le see Centre console Remov al Refitting 57A Interior equipment the clip from the rear centre air duct above the soundproofing the rear centre air duct above the soundproofing a Place the gear selecto...

Page 2441: ...FOR REMOVAL OF PART CONCERNED a Release the white clip 7 using a screwdriver a Release the white clip 8 a Disconnect the gear control unit connector 9 a Remove the gear control unit nuts 10 the gear...

Page 2442: ...ol unit Adjustment page 37A 109 a Check that the system and gear selection are work ing correctly II FINAL OPERATION a Refit the airbag computer protector a Clip the wiring onto the airbag computer pr...

Page 2443: ...console Remov al Refitting 57A Interior equipment the clip from the rear centre air duct above the soundproofing the rear centre air duct above the soundproofing a Place the gear selector in position...

Page 2444: ...12A Fuel mixture a Refit the control unit soundproofing a Clip the carpet at the cutting point a Clip the wiring onto the control unit a Place the gear selector in position R a Refit the rear centre...

Page 2445: ...at 1 a Unclip the wiring on the control unit at 2 a Remove the soundproofing 3 from the control unit a Remove the air filter housing see Air filter unit Re moval Refitting 12A Fuel mixture II ADJUSTME...

Page 2446: ...Refit the air filter housing see Air filter unit Re moval Refitting 12A Fuel mixture a Refit the control unit soundproofing a Clip the wiring onto the control unit a Clip the carpet at the cutting poi...

Page 2447: ...lever knob by lifting it upwards the central console see Centre console Remov al Refitting 57A Interior equipment the middle air duct see Rear air distribution duct Removal Refitting 61A Heating syst...

Page 2448: ...airbag computer protector 6 the control unit see 37A Mechanical component controls Gear control unit Removal Refitting page 37A 95 II OPERATION FOR REMOVAL OF PART CONCERNED a Unlock the clip 8 a Unl...

Page 2449: ...able the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage the...

Page 2450: ...the left hand air duct a Refit the airbag computer protector a Clip the wiring onto the airbag computer protector a Refit the control unit soundproofing a Clip the wiring onto the control unit a Clip...

Page 2451: ...tral console see Centre console Remov al Refitting 57A Interior equipment the middle centre air duct see Rear air distribu tion duct Removal Refitting 61A Heating system a Place the gear selector in p...

Page 2452: ...einforcement 10 the accelerator pedal see 37A Mechanical com ponent controls Accelerator pedal Removal Refitting page 37A 19 the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture...

Page 2453: ...able the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage the...

Page 2454: ...trim Removal Refitting 57A Interior equip ment the accelerator pedal see 37A Mechanical com ponent controls Accelerator pedal Removal Refitting page 37A 19 a Clip on the left hand air duct a Refit th...

Page 2455: ...57A Interior equipment the middle air duct see Rear air distribution duct Removal Refitting 61A Heating system a Place the gear selector in position D a Cut the carpet at 2 a Unclip the wiring on the...

Page 2456: ...see 37A Mechanical com ponent controls Accelerator pedal Removal Refitting page 37A 19 the air filter unit see Air filter unit Removal Re fitting 12A Fuel mixture the control unit see 37A Mechanical c...

Page 2457: ...air outlet pipe on the air filter unit a Remove the air outlet pipe to the air filter unit the protection and switching unit see Protection and Switching Unit Removal Refitting 87G Engine compartment...

Page 2458: ...l cable the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage t...

Page 2459: ...tributor a Clip the non return valve pipe onto the air filter unit air outlet pipe a Refit the engine cover a Refit the protection and switching unit see Protection and Switching Unit Removal Refittin...

Page 2460: ...37A 126 MECHANICAL COMPONENT CONTROLS Automatic gear control cable Removal Refitting D91 and AJ0 and LEFT HAND DRIVE 37A...

Page 2461: ...ee Centre console Remov al Refitting 57A Interior equipment the middle air duct see Rear air distribution duct Removal Refitting 61A Heating system a Place the gear selector in position D a Cut the ca...

Page 2462: ...l unit see 37A Mechanical component controls Gear control unit Removal Refitting page 37A 95 a Remove the front engine cover a Disconnect the non return valve pipe 8 from the in take distributor a Unc...

Page 2463: ...air outlet pipe on the air filter unit a Remove the air outlet pipe to the air filter unit the protection and switching unit see Protection and Switching Unit Removal Refitting 87G Engine compartment...

Page 2464: ...ol cable the bulkhead seal bolts a Tighten the bulkhead seal bolts a Clip the control cable sleeve stop on the gearbox the gear control cable anchoring ball joint on the gearbox using pliers a Engage...

Page 2465: ...val Refitting 61A Heating system the central console see Centre console Remov al Refitting 57A Interior equipment the gear lever knob a Turn the ring on the gear lever knob a sixteenth of a turn a Ref...

Page 2466: ...S Control unit Emergency handle The emergency handle must only be used if there is a battery fault or major assisted parking brake fault red warning light Using the emergency handle put the vehicle in...

Page 2467: ...ke List and location of components ELECTRONIC PARKING BRAKE 37B Lever Clutch pedal position sensor To remove the clutch pedal position sensor see 37A Mechanical component controls Clutch pedal po siti...

Page 2468: ...ally released Check that the brake cables are correctly fitted in their housings Do not refit a control unit which has been removed from another vehicle The components of the control unit cannot be re...

Page 2469: ...Disconnect the battery see Battery Removal Re fitting 80A Battery 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 Un...

Page 2470: ...onnect the control unit connector a Refit the two parking brake cables back in their mounting a Refit the assisted parking brake cables at the brake callipers a Check that the brake cables are correct...

Page 2471: ...37B 6 ELECTRONIC PARKING BRAKE Control unit Removal Refitting ELECTRONIC PARKING BRAKE 37B carry out the operations described in the After re pair procedure section...

Page 2472: ...lts 1 from the handle the lever REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the handle the handle bolts a Tighten the handle bolts II FINAL OPERATION a Refit the upper face of the centr...

Page 2473: ...38C 1 ANTI LOCK BRAKING SYSTEM ABS List and location of components 38C 110486...

Page 2474: ...ents 38C 123503 1 Hydraulic unit 2 Steering wheel angle sensor 3 ESP warning light on the instru ment panel 4 UCH 5 Yaw speed and lateral accelera tion sensor 6 Brake disc with instrumented bearing 7...

Page 2475: ...a check using the Diagnostic tool 1 Yaw speed and lateral acceleration sensor The sensor must be fitted facing the vehicle s direction of travel as shown by the arrow Be sure to replace any sensor wh...

Page 2476: ...emove the brake pipe unions 4 on the hydraulic unit the bolts 5 mounting the hydraulic unit on its sup port the hydraulic unit REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the hydraulic...

Page 2477: ...ing K9K 38C II FINAL OPERATION a Refit the soundproofing the soundproofing clips a Remove the pedal press a Connect the battery see Battery Removal Refit ting MR 415 80A Battery a Bleed the brake circ...

Page 2478: ...gine mounting the clips 1 from the soundproofing a Position the Mot 1390 a Remove the bolts from the right hand suspended engine mounting on the engine see Right hand suspended engine mounting Removal...

Page 2479: ...nnector at 6 a Remove the hydraulic unit bolts 7 on its support the hydraulic unit REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the hydraulic unit the brake pipe unions on the hydraulic...

Page 2480: ...a Refit the rear suspended engine mounting see Lower engine tie bar Removal Refitting 19D En gine mounting the engine undertray a Remove the pedal press a Bleed the brake circuit see 30A General info...

Page 2481: ...charger heat shield 1 the bulkhead heat shield clips the bulkhead heat shield 2 the engine undertray the rear suspended engine mounting see Lower engine tie bar Removal Refitting 19D En gine mounting...

Page 2482: ...ipe unions on the hydraulic unit a Tighten to torque the hydraulic unit bolts on the support 8 Nm the brake pipe unions on the hydraulic unit 14 Nm a Connect the computer connector on the hydraulic un...

Page 2483: ...ne undertray a Remove the bulkhead heat shield clips 1 a Move the bulkhead heat shield 2 to one side II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 3 from the hydraulic unit com...

Page 2484: ...hydraulic unit a Tighten to torque the hydraulic unit bolts on the support 8 Nm the brake pipe unions on the hydraulic unit 14 Nm a Clip on the hydraulic unit connector wiring a Connect the computer c...

Page 2485: ...ips 1 the bulkhead heat resistant soundproofing the air conditioning pipes between the expansion valve and the condenser see Condenser expan sion valve connecting pipe Removal Refit ting 62A Air condi...

Page 2486: ...on valve connecting pipe Removal Refit ting 62A Air conditioning a Tighten to torque the hydraulic brake unit bolts on the support 8 N m the brake pipe unions on the hydraulic brake unit 13 N m a Conn...

Page 2487: ...35A 1 a Remove the clip 1 from the front wheel arch II REMOVAL OPERATION FOR PART CONCERNED a IMPORTANT Consult the safety and cleanliness advice and oper ation recommendations before carrying out an...

Page 2488: ...he wheel speed sensor wiring at 4 a Remove the wheel speed sensor REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the wheel speed sensor a Connect the speed sensor connector a Clip on the w...

Page 2489: ...35A 1 a Remove the clip from the 1 rear wheel arch II REMOVAL OPERATION FOR PART CONCERNED a IMPORTANT Consult the safety and cleanliness advice and oper ation recommendations before carrying out any...

Page 2490: ...r a Unpick the wheel speed sensor wiring at 5 a Remove the wheel speed sensor REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the wheel speed sensor onto the sensor hold er a Connect the sp...

Page 2491: ...l Refitting MR 416 75A Front seat frames and runners II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the front left hand door sill lining see Front door sill lining Removal Refitting MR 416 71A Bo...

Page 2492: ...Connect the lateral acceleration and yaw sensor connector a Torque tighten the lateral acceleration and yaw sensor nuts 8 Nm a Position the floor carpet a Refit the floor carpet clip the front left h...

Page 2493: ...on the brake pedal to limit the out flow of brake fluid a Remove the hydraulic unit see 38C Anti lock braking system Hydraulic brake unit Removal Refitting page 38C 4 II REMOVAL OPERATION FOR PART CO...

Page 2494: ...e 38C Anti lock braking system Hydraulic brake unit Removal Refit ting page 38C 4 a Remove the pedal press a Connect the battery see Battery Removal Refit ting MR 415 80A Battery a Bleed the brake cir...

Page 2495: ...ced by the manufacturer in the production of the various component units and accessories from which the vehicles are constructed All rights reserved by Renault Copying or translating in part or in ful...

Page 2496: ...itting 61A 35 Front footwell air distribution duct Removal Refitting 61A 36 Recirculation motor Removal Refitting 61A 38 Demisting motor Removal Refitting 61A 40 Mixing motor Removal Refitting 61A 41...

Page 2497: ...ng 62A 47 Expansion valve intermediate pipe connecting pipe at the expansion valve outlet Removal Refitting 62A 63 Pressure sensor Removal Refitting 62A 77 Evaporator sensor Removal Refitting 62A 78 E...

Page 2498: ...L OPERATION FOR PART CONCERNED a Unclip the cabin filter access flap 1 a Remove the cabin filter access flap a Check for foreign bodies in the cabin filter housing and clean thoroughly if necessary a...

Page 2499: ...access flap a Clip the access flap onto the cabin filter III FINAL OPERATION a Refit the refrigerant pipe to the glovebox a Refit the front footwell air distribution duct see 61A Heating Front footwel...

Page 2500: ...or sill lining Removal Refitting MR 416 71A Body internal trim the carpet retaining clip a Partially fold back the carpet towards the rear of the vehicle a Remove the rear left hand air distribution d...

Page 2501: ...Re moval Refitting MR 416 75A Front seat frames and runners 2 Rear right hand air distribution duct a Refit the rear right hand air distribution duct the rear right hand air distribution duct clip the...

Page 2502: ...pment required refrigerant charging station Tightening torquesm expansion valve com pressor connecting pipe bracket bolt on the expansion valve 8 N m expansion valve con denser connecting pipe bracket...

Page 2503: ...utlet pipe a Loosen the clip 3 on the air filter unit air outlet pipe on the throttle valve a Move aside the air filter unit air outlet pipe on the throttle valve a Fit the 4 Ms 583 on the heater matr...

Page 2504: ...he expansion valve condenser connecting pipe on the expansion valve a Remove the expansion valve compressor connecting pipe on the expansion valve the expansion valve condenser connecting pipe on the...

Page 2505: ...stribution motor the toxicity sensor the evaporator sensor the climate control computer REFITTING I REFITTING PREPARATION OPERATION a Always replace the connecting pipe seals a Refit the following com...

Page 2506: ...Refit the air filter unit air outlet pipe on the throttle valve a Torque tighten the air filter unit air outlet pipe clip on the throttle valve 5 5 N m a Clip the brake servo non return valve pipe on...

Page 2507: ...scuttle panel grille Removal Refit ting 56A Exterior equipment the scuttle panel grille see Scuttle panel grille Removal Refitting 56A Exterior equipment the windscreen wiper arms see Windscreen wip...

Page 2508: ...return valve from the intake distributor a Unclip the brake servo non return valve hose on the air filter unit air outlet pipe a Loosen the clip on the air filter unit air outlet pipe on the throttle...

Page 2509: ...ter unit see Air filter unit Re moval Refitting 12A Fuel mixture a Fit the tool Ms 583 on the coolant pipes a Unclip the electrical wiring at 6 a Remove the bolt 7 from the max fuse box a Move the max...

Page 2510: ...air distribution duct Removal Refitting page 61A 36 a Remove the reinforcement plate bolts 9 the reinforcement plate a Remove the accelerator pedal see Accelerator pedal Removal Refitting 37A Mechanic...

Page 2511: ...iner to collect the coolant under the rigid pipes a Move the heater matrix rigid pipes aside a Remove the heater matrix REFITTING I REFITTING PREPARATION OPERATION a a Always replace the heater matrix...

Page 2512: ...e 61A 36 the dashboard lower trim see Dashboard lower trim Removal Refitting 57A Interior equip ment a Remove the tools Ms 583 a Fit the max fuse box a Refit the max fuse box bolt a Clip on the electr...

Page 2513: ...en fan assembly the blower unit with the refrigerant pipe REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the blower unit with the refrigerant pipe a Clip the blower unit wiring harness int...

Page 2514: ...ect the Diagnostic tool select Climate control computer go to repair mode display the Before after repair procedure for the selected computer select Passenger compartment ventilation fan as sembly in...

Page 2515: ...y a Remove the glovebox see Glovebox Removal Refitting 57A Interior equipment a Remove the nuts 1 from the glovebox mounting the bolt 2 from the glovebox mounting a Disconnect the glovebox refrigerant...

Page 2516: ...e refrigerant pipe to the distribution unit a Refit the glovebox mounting a Refit the glovebox refrigerant pipe to its mounting a Refit the glovebox see Glovebox Removal Refit ting 57A Interior equipm...

Page 2517: ...see Scoop under the scuttle panel grille Removal Refit ting MR 416 56A Exterior equipment II CLEANING a Draw any foreign bodies out of the passenger com partment blower unit III FINAL OPERATION a Refi...

Page 2518: ...see 61A Heating Front footwell air distribution duct Removal Refitting page 61A 36 the clutch pedal see Clutch pedal Removal Re fitting 37A Mechanical component controls II OPERATION FOR REMOVAL OF P...

Page 2519: ...ols the front footwell air distribution duct see 61A Heating Front footwell air distribution duct Removal Refitting page 61A 36 the dashboard lower trim see Dashboard lower trim Removal Refitting 57A...

Page 2520: ...HT HAND DRIVE 61A select Passenger compartment heater resistance relay 1 or passenger compartment heater resis tance relay 2 in the List of components controlled by this computer section carry out the...

Page 2521: ...emoval Refitting page 61A 36 the brake light switch see Brake pedal switch Removal Refitting 37A Mechanical compo nent controls the accelerator pedal see Accelerator pedal Re moval Refitting 37A Mecha...

Page 2522: ...ke light switch see Brake pedal switch Removal Refitting 37A Mechanical compo nent controls the front footwell air distribution duct see 61A Heating Front footwell air distribution duct Removal Refitt...

Page 2523: ...e after repair procedure for the selected computer select Passenger compartment heater resistance relay 1 or passenger compartment heater resis tance relay 2 in the List of components controlled by th...

Page 2524: ...I OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 2 from the heating resis tor a Remove the heating resistor bolts 3 the heating resistor REFITTING I REFITTING OPERATION FOR PART CO...

Page 2525: ...t the Diagnostic tool select Climate control computer go to repair mode display the Before after repair procedure for the selected computer select Passenger compartment heating resistor in the List of...

Page 2526: ...t plate II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 2 from the heating resis tor a Remove the heating resistor bolts 3 the heating resistor REFITTING I REFITTING OPERATION FO...

Page 2527: ...ol connect the Diagnostic tool select Climate control computer go to repair mode display the Before after repair procedure for the selected computer select Passenger compartment heating resistor in th...

Page 2528: ...ectors to the blower unit control unit II FINAL OPERATION a a Connect the refrigerant pipe to the blower unit a Refit the glovebox see Glovebox Removal Refit ting 57A Interior equipment a Connect the...

Page 2529: ...0A Battery a Remove the glovebox see Glovebox Removal Refitting 57A Interior equipment a Remove the nuts 1 from the glovebox mounting the bolt 2 from the glovebox mounting a Move the glovebox refriger...

Page 2530: ...ssembly a Refit the glovebox mounting a Refit the glovebox refrigerant pipe on its mounting a Refit the glovebox see Glovebox Removal Refit ting 57A Interior equipment a Connect the battery see Batter...

Page 2531: ...NED a Refit the control panel a Clip on the control panel II FINAL OPERATION a Refit the centre front panel see Centre front panel Re moval Refitting MR 416 57A Interior equip ment the radio see Radio...

Page 2532: ...tribution duct Removal Refitting 61A a If replacing the front side air distribution duct see Dashboard Removal Refitting MR 416 57A Interior equipment Note The front side air distribution duct cannot...

Page 2533: ...the dashboard 2 Passenger side a Remove the glovebox see Glovebox Removal Refitting MR 416 57A Interior equipment II OPERATION FOR REMOVAL OF PART CONCERNED 1 Driver s side a Remove the clip 2 from th...

Page 2534: ...pillar air distribution duct a Refit the clip for the front footwell air distribution duct II FINAL OPERATION 1 Driver s side a Refit the dashboard lower trim see Dashboard lower trim Removal Refittin...

Page 2535: ...tting 57A Interior equipment II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 1 from the recirculation motor a Move the recirculation motor aside a Disconnect the connector 2 from the rec...

Page 2536: ...attery Removal Refit ting 80A Battery a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool select Climate control computer go to repair mode display the Before aft...

Page 2537: ...OPERATION FOR PART CONCERNED a Refit the demisting motor a Connect the demisting motor connector II FINAL OPERATION a Refit the dashboard see Dashboard Removal Refitting 57A Interior equipment a Conn...

Page 2538: ...emove the glovebox see Glovebox Removal Refit ting 57A Interior equipment the front right hand A pillar air distribution duct see 61A Heating Front footwell air distribution duct Removal Refitting pag...

Page 2539: ...r the left hand mixer motor Passenger side a Disconnect the right hand mixer motor connector 4 a Remove the bolts 5 from the right hand mixer motor the right hand mixer motor REFITTING I REFITTING OPE...

Page 2540: ...ct Removal Refitting page 61A 36 the glovebox see Glovebox Removal Refit ting 57A Interior equipment a Refit the navigation computer see Navigation computer Removal Refitting 83C On board telematics s...

Page 2541: ...emove the glovebox see Glovebox Removal Refit ting 57A Interior equipment the front left hand footwell air distribution duct see 61A Heating Front footwell air distribution duct Removal Refitting page...

Page 2542: ...ixer motor the right hand mixer motor Passenger side a Disconnect the left hand mixer motor connector a Remove the left hand mixer motor bolts the left hand mixer motor REFITTING I REFITTING OPERATION...

Page 2543: ...ct Removal Refitting page 61A 36 the glovebox see Glovebox Removal Refit ting 57A Interior equipment a Refit the navigation computer see Navigation computer Removal Refitting 83C On board telematics s...

Page 2544: ...ERATION FOR PART CONCERNED a Refit the distribution motor a Connect the distribution motor connector II FINAL OPERATION a Refit the glovebox see Glovebox Removal Refit ting 57A Exterior equipment a Re...

Page 2545: ...4 A pillar duct linkage bolt 5 A pillar duct linkage 6 Distribution motor retaining plate I REMOVAL a 135275 135276 Note If the distribution motor cannot be positioned in face mode for the removal op...

Page 2546: ...NDITIONING 02 61A a Disconnect the connector 7 from the distribution motor a Remove the distribution motor bolts 8 a Remove the bolt 9 from the A pillar duct linkage a Remove the distribution motor re...

Page 2547: ...AIR CONDITIONING 02 61A a Remove the cam 11 II REFITTING a a Turn the linkage 12 clockwise fully a Move the linkage 13 completely upwards 135281 Note T o ensure that the system operates correctly the...

Page 2548: ...the guide finger 19 in its groove 16 a Check that the guide fingers are visible through the cam openings 20 and 21 a Refit the distribution motor retaining plate a Check that the rectangular housing...

Page 2549: ...61A 52 HEATING Distribution motor Removal Refitting AIR CONDITIONING 01 or AIR CONDITIONING 02 61A a Turn the A pillar air distribution flap linkage 25 fully clockwise 135288...

Page 2550: ...tion motor connector a Connect the battery see Battery Removal Refit ting 80A Battery a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool select Climate control c...

Page 2551: ...t the air flow increases as the speed of the passenger compartment fan assembly increases Note T o ensure that the system operates correctly program all of the flap stops 135290 Note If during the che...

Page 2552: ...N FOR PART CONCERNED a Refit the passenger compartment temperature sen sor a Connect the passenger compartment temperature sensor connector II FINAL OPERATION a Clip on the lower cover of the interior...

Page 2553: ...a Refit the humidity detector a Connect the humidity detector connector II FINAL OPERATION a Clip on the lower cover of the interior rear view mir ror a Apply the after repair procedure using the Dia...

Page 2554: ...TING Solar radiation sensor Removal Refitting 61A Note The solar radiation sensor is integrated into the rain and light sensor for removal see Rain and light sensor Removal Refitting MR 415 85A Wip in...

Page 2555: ...fitting 57A Interior equipment a Remove the dashboard see Dashboard Removal Refitting 57A Interior equipment II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the toxicity sensor connector 1 a R...

Page 2556: ...equipment a Refit the dashboard see Dashboard Removal Refitting 57A Interior equipment a Connect the battery see Battery Removal Refit ting 80A Battery a Apply the after repair procedure using the Di...

Page 2557: ...the event of contact with other unprotected parts of the body event though the safety advice has been observed rinse well with clean water continu ously for 15 minutes IMPORTANT Work requiring the us...

Page 2558: ...ZEXEL VALEO Operation on the air conditioning circuit Quantity of oil ml or cm3 Circuit oil change Measure the volume recovered and add the same quantity of new oil Split hose or other rapid leak 100...

Page 2559: ...gether until they touch placing the sensors in the air flow of an air vent setting the passenger compartment fan assembly to top speed waiting for the value to become stable recording the correction v...

Page 2560: ...on the vehicle to ac cess the scuttle panel grille place the sensor where air is drawn through the scuttle panel grille wait for the value to become stable record the T3 temperature value close the bo...

Page 2561: ...tures by following the instruc tions given in the paragraph MEASUREMENTS IV FAULT FINDING PROCEDURE a The following two following conditions must be met the difference between T3 and the higher of the...

Page 2562: ...x a label supplied with the dye capsule to indi cate that dye has been used as close as possible to the filler valves Equipment required Diagnostic tool IMPORTANT Consult the safety and cleanliness ad...

Page 2563: ...ir conditioning Air condition ing Precautions for the repair page 62A 1 WARNING Consult the device s operating manual to avoid incorrect use WARNING To avoid damaging the cold loop components cor rosi...

Page 2564: ...nfirmed as being correct if the volume of refrigerant fluid is the specified fill 35g or 100g Scenario C drain for the first time note down the value wait 2 hours repeat the cycles until the relative...

Page 2565: ...or the repair page 62A 2 a Check there are no leaks using the electronic de tector see 62A Air conditioning Refrigerant cir cuit Check page 62A 6 a Check that the air conditioning system is operating...

Page 2566: ...panel Remov al Refitting 42A Upper front structure II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the right hand air deflector Equipment required refrigerant charging station Tightening torquesm...

Page 2567: ...NDITIONING 01 or AIR CONDITIONING 02 62A a Remove the nuts from the condenser connecting pipes 1 and 2 a Disconnect the condenser connecting pipes 1 and 2 a Insert the blanking plugs a Unclip the air...

Page 2568: ...the condenser the left hand air deflector the air pipe onto the left hand deflector a Remove the blanking plugs a Connect the connecting pipes to the condenser a Torque tighten the connecting pipe nu...

Page 2569: ...ant circuit Draining Filling page 62A 7 a Use the electronic sensor see 62A Air condi tioning Refrigerant circuit Check page 62A 6 to check that there are no leaks a Check that the air conditioning sy...

Page 2570: ...val Refit ting 80B Headlights the bonnet catch see Bonnet lock Removal Refitting 52A Non side opening element mecha nisms the horn see Audible warning Removal Refit ting 82B Horn the front end panel s...

Page 2571: ...e expansion valve condenser connecting pipe a Disconnect the following from the condenser the compressor condenser connecting pipe the expansion valve condenser connecting pipe a Insert the blanking p...

Page 2572: ...frigerant circuit Draining Filling page 62A 7 a leakage test see 62A Air conditioning Refrig erant circuit Check page 62A 6 a Check the air conditioning system is operating cor rectly see 62A Air cond...

Page 2573: ...Re moval Refitting page 62A 18 a If removing or replacing the dehydrator reservoir see 62A Air conditioning Condenser Removal Refitting page 62A 10 IMPORTANT Consult the safety and cleanliness advice...

Page 2574: ...ection the headlights see Headlight Removal Refit ting MR 415 80B Headlights the front end panel see Front end panel Remov al Refitting MR 416 42A Upper front struc ture the condenser see 62A Air cond...

Page 2575: ...nosed pliers from underneath to re move the cap from the dehydrator reservoir a Remove the cap from the dehydrator reservoir a Remove the filter element using adjustable pliers REFITTING I REFITTING...

Page 2576: ...15 80A Battery a Refit the front end panel see Front end panel Remov al Refitting MR 416 42A Upper front struc ture the headlights see Headlight Removal Refit ting MR 415 80B Headlights a Check there...

Page 2577: ...Top and front of engine a Remove the bolts from the compressor connecting pipes 1 a Uncouple the compressor connecting pipes a Insert the blanking plugs Equipment required refrigerant charging station...

Page 2578: ...ugs a Connect the compressor connectors 122879 122878 WARNING Do not remove the blanking plugs from each component until the last moment Also do not remove the components from their packaging until th...

Page 2579: ...nimum Select the air recirculation position Start the engine Run the air conditioning in manual mode in the case of climate control do not press auto Run the engine at idle speed for 3 minutes with ai...

Page 2580: ...ipment required refrigerant charging station Tightening torquesm compressor bolts 25 N m compressor bolts 55 N m compressor bolts 61 N m compressor condenser connect ing pipe bracket bolt on the compr...

Page 2581: ...or the bolt 4 of the bracket for the intermediate pipe compressor connecting pipe on the com pressor a a Disconnect the compressor condenser connecting pipe from the compressor the intermediate pipe c...

Page 2582: ...CONDITIONING 01 or AIR CONDITIONING 02 62A a Remove the compressor bolts 6 and 7 the compressor a Unclip the electrical wiring on the compressor at 8 a Disconnect the compressor connectors 9 a Remove...

Page 2583: ...ew seals to the compressor connecting pipes II REFITTING OPERATION FOR PART CONCERNED a Refit the compressor a Torque tighten the compressor bolts 25 N m a Fit the compressor bolts without tightening...

Page 2584: ...cuit see 62A Air conditioning Air con ditioning Parts and consumables for the repair page 62A 2 a Fill up the refrigerant circuit using the refrigerant charging station see 62A Air conditioning Re fri...

Page 2585: ...e expansion valve compressor connecting pipe on the expansion valve the expansion valve condenser connecting pipe on the expansion valve a Insert the blanking plugs Special tooling required Car 1363 S...

Page 2586: ...g the front wing and under the ABS unit II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolt 1 from the expansion valve a Fit the first threaded rod 2 M5 X 80 80 mm long in place of the bolt 1...

Page 2587: ...new seals on the refrigerant fluid connecting pipes a Oil the seals using air conditioning oil to make fitting easier II REFITTING OPERATION FOR PART CONCERNED a Position the Car 1363 a Remove the se...

Page 2588: ...363 a Torque tighten the expansion valve bolts 6 Nm III FINAL OPERATION a Remove the blanking plugs a Fit the new seals on the high and low pressure re frigerant fluid connecting pipes a Oil the seals...

Page 2589: ...ttery a Fill the refrigerant circuit using the refrigerant charging station see 62A Air conditioning Re frigerant circuit Draining Filling page 62A 7 a Position the Car 1363 a Check that there are no...

Page 2590: ...pe bracket on the expansion valve Special tooling required Car 1363 Set of trim removal levers Equipment required refrigerant charging station Tightening torquesm expansion valve bolts 6 N m expansion...

Page 2591: ...expansion valve compressor connecting pipe from the expansion valve the expansion valve condenser connecting pipe from the expansion valve a Insert the blanking plugs a Unclip the refrigerant low pre...

Page 2592: ...lve the seals 8 of the refrigerant connecting pipes REFITTING I REFITTING PREPARATION OPERATION a Always replace the expansion valve each time it is removed after sales part kit the new expansion valv...

Page 2593: ...ditioning Air condition ing Parts and consumables for the repair page 62A 2 a Fit the Car 1363 a Move the foam seals to one side a Position the expansion valve on the threaded rods a Push the expansio...

Page 2594: ...the expansion valve the expansion valve compressor connecting pipe on the expansion valve a Connect the expansion valve condenser connecting pipe on the expansion valve the expansion valve compressor...

Page 2595: ...r heat shield a Clip on the lower heat shield a Refit the upper heat shield a Clip on the upper heat shield a Refit the scoop under the scuttle panel grille see Scoop under the scuttle panel grille Re...

Page 2596: ...ting pipe bracket bolt for the condenser expansion valve 8 N m IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and opera tion recommendations before...

Page 2597: ...alve intermediate pipe con necting pipe from the expansion valve a Remove the connecting pipe seals a Insert the blanking plugs a Remove the condenser expansion valve connecting pipe the expansion val...

Page 2598: ...g plugs a Oil the seals using air conditioning oil to make fitting easier see 62A Air conditioning Air condition ing Parts and consumables for the repair page 62A 2 a Fit new seals to the refrigerant...

Page 2599: ...l the threaded rods to fit the expansion valve to the evaporator connect ing pipes a Remove the first threaded rod 5 M5 X 80 length 80 mm a Refit the corresponding bolt to the expansion valve a Remove...

Page 2600: ...the condenser expansion valve connecting pipe to the expansion valve a Refit the expansion valve intermediate pipe con necting pipe bracket bolt the condenser expansion valve connecting pipe bracket...

Page 2601: ...vaporator see 61A Heating Distribution unit Removal Refitting page 61A 5 IMPORTANT Consult the safety and cleanliness advice and oper ation recommendations before carrying out any repair see 62A Air c...

Page 2602: ...d consumables for the repair 04B Consumables Products a Leave the product to work for 15 minutes a Refit the evaporator sensor see 62A Air condi tioning Evaporator sensor Removal Refitting page 62A 78...

Page 2603: ...Tightening torquesm bolt securing the bracket of the condenser expansion valve con necting pipe on the expansion valve 8 N m nut securing the bracket for the condenser expansion valve con necting pip...

Page 2604: ...t shield partially a Remove the bolt 3 from the engine tie bar on the body the bolt 4 from the engine tie bar on the cover the engine tie bar from the right hand suspended engine mounting a Remove the...

Page 2605: ...ndenser a Disconnect the condenser expansion valve con necting pipe from the intermediate pipe a Insert the blanking plugs a Remove the bolt 8 securing the bracket for the con denser expansion valve c...

Page 2606: ...8 N m III FINAL OPERATION a Refit the engine tie bar to the right hand suspended en gine mounting the engine tie bar bolt on the body the engine tie bar bolt on the cover a Tighten the engine tie bar...

Page 2607: ...e expansion bottle bolt a Clip on the fuel hoses a Clip on the front right hand air deflector a Refit the right hand headlight see Headlight Removal Refitting MR 415 80B Headlights the front bumper se...

Page 2608: ...xpansion bottle bolt a Remove the expansion bottle Equipment required refrigerant charging station Tightening torquesm bolt securing the bracket of the condenser expansion valve con necting pipe on th...

Page 2609: ...OR REMOVAL OF PART CONCERNED a Remove the nut 3 securing the bracket for the con denser expansion valve connecting pipe on the condenser a Disconnect the condenser expansion valve con necting pipe fro...

Page 2610: ...a Fit new seals onto the condenser expansion valve connecting pipes a Refit the condenser expansion valve connecting pipe a Clip on the condenser expansion valve connecting pipe a Connect the condens...

Page 2611: ...to check that there are no leaks a Refit the heat shield the heat shield clips a Position the expansion bottle a Refit the expansion bottle bolt a Clip on the fuel hoses a Check that the air condition...

Page 2612: ...ips the heat shield partially Equipment required refrigerant charging station Tightening torquesm condenser expansion valve connecting pipe bracket bolt on the expansion valve 8 Nm nut for the condens...

Page 2613: ...the body the bolt 3 from the engine tie bar on the cover the engine tie bar from the right hand suspended engine mounting II REMOVAL OPERATION FOR PART CONCERNED a Remove the nut 4 from the condenser...

Page 2614: ...ake fitting easier a Refit the condenser expansion valve connecting pipe a Clip on the condenser expansion valve connect ing pipe a Couple the condenser expansion valve connect ing pipe to the expansi...

Page 2615: ...r conditioning Air condi tioning Check page 62A 3 a Refit the engine tie bar on the right hand suspended en gine mounting the bolt mounting the engine tie bar on the body the bolt mounting the engine...

Page 2616: ...cket bolt on the expansion valve 8 N m IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness instructions and opera tion recommendations before carrying out any repair...

Page 2617: ...condenser expansion valve con necting pipe REFITTING I REFITTING PREPARATION OPERATION a parts always to be replaced refrigerant pipe seal 30 02 02 52 a Remove the blanking plugs a Oil the seals using...

Page 2618: ...nser expansion valve con necting pipe to the expansion valve a Refit the bolt for the condenser expansion valve connecting pipe bracket on the expansion valve a Torque tighten the condenser expansion...

Page 2619: ...of the expansion valve intermediate pipe con necting pipe to the expansion valve 8 N m nut securing the bracket of the intermediate pipe compressor connect ing pipe to the interme diate pipe 8 N m IMP...

Page 2620: ...ediate pipe a Disconnect the intermediate pipe compressor con necting pipe from the intermediate pipe a Insert the blanking plugs a Remove the bolt 2 securing the bracket of the ex pansion valve inter...

Page 2621: ...to the intermedi ate pipe a Tighten to torque the bolt securing the bracket of the expansion valve intermediate pipe connecting pipe to the expansion valve 8 N m the nut securing the bracket of the i...

Page 2622: ...ansion valve intermediate pipe con necting pipe on the expansion valve 8 N m nut securing the bracket of the intermediate pipe compressor connect ing pipe on the interme diate pipe 8 N m engine tie ba...

Page 2623: ...ITIONING 02 62A a Remove the bolt 2 from the engine tie bar on the body the bolt 3 from the engine tie bar on the cover the engine tie bar from the right hand suspended engine mounting a Remove the bo...

Page 2624: ...in termediate pipe a Disconnect the intermediate pipe compressor con necting pipe from the intermediate pipe a Insert the blanking plugs a Remove the bolt 7 securing the bracket for the ex pansion va...

Page 2625: ...e 8 N m III FINAL OPERATION a Refit the engine tie bar to the right hand suspended en gine mounting the engine tie bar bolt on the body the engine tie bar bolt on the cover a Tighten the engine tie ba...

Page 2626: ...the expansion valve intermediate pipe con necting pipe to the expansion valve 8 N m nut securing the bracket for the intermediate pipe compressor connect ing pipe to the interme diate pipe 8 N m IMPO...

Page 2627: ...on the body the bolt 3 from the engine tie bar on the cover the engine tie bar from the right hand suspended engine mounting II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the nut 4 securing the...

Page 2628: ...he expansion valve intermediate pipe con necting pipe a Clip on the expansion valve intermediate pipe con necting pipe a Connect the expansion valve intermediate pipe connecting pipe to the expansion...

Page 2629: ...7 a Use the electronic sensor see 62A Air condi tioning Refrigerant circuit Check page 62A 6 to check that there are no leaks a Check that the air conditioning system is operating correctly see 62A Ai...

Page 2630: ...me diate pipe 8 N m expansion valve intermediate pipe con necting pipe bracket bolt on the expansion valve 8 N m IMPORTANT To avoid all risk of damage to the systems apply the safety and cleanliness i...

Page 2631: ...Disconnect the expansion valve intermediate pipe connecting pipe from the intermediate pipe a Insert the blanking plugs a Remove the bolt 3 from the expansion valve in termediate pipe connecting pipe...

Page 2632: ...pipe to the intermediate pipe a Refit the bolt from the expansion valve intermedi ate pipe connecting pipe bracket on the intermedi ate pipe a Connect the expansion valve intermediate pipe connecting...

Page 2633: ...sure sensor III REFITTING OPERATION FOR PART CONCERNED a Refit the pressure sensor a Torque tighten the pressure sensor 9 N m a Connect the pressure sensor IV FINAL OPERATION a Refit the right hand ai...

Page 2634: ...a Remove the evaporator sensor REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the evaporator sensor in its housing 2 a Fit the evaporator sensor by rotating it a quarter of a turn a Conne...

Page 2635: ...ure using the Diagnos tic tool connect the Diagnostic tool select Climate control computer go to repair mode display the Before after repair procedure for the selected computer select Evaporator senso...

Page 2636: ...irror casing Removal Refitting MR 416 56A Exte rior equipment a Unclip the right hand door mirror trim piece by pressing on the lugs 1 a Remove the bolts 2 from the electric motor a Disconnect the ele...

Page 2637: ...ip the external air temperature sensor onto its sup port II FINAL OPERATION a Connect the electric motor connector a Refit the electric motor the electric motor bolts a Clip the right hand door mirror...

Page 2638: ...lip the front right hand air deflector Equipment required refrigerant charging station Tightening torquesm bolt securing the bracket of the compressor con denser connecting pipe to the compressor 8 N...

Page 2639: ...the bolt 2 securing the bracket for the compressor condenser connecting pipe from the compressor Disconnect the compressor condenser connecting pipe from the compressor a Insert the blanking plugs a R...

Page 2640: ...m the nut securing the bracket of the compressor condenser connecting pipe to the condenser 8 N m III FINAL OPERATION a Connect the battery see Battery Removal Refit ting MR 415 80A Battery a Fill up...

Page 2641: ...t required refrigerant charging station Tightening torquesm compressor condenser connect ing pipe bracket nut on the compressor 8 N m compressor condenser connect ing pipe bracket nut on the condenser...

Page 2642: ...ssor condenser con necting pipe from the condenser a Insert the blanking plugs a Remove the bolt 3 securing the bracket for the compressor condenser connecting pipe to the compressor a Disconnect the...

Page 2643: ...or a Disconnect the compressor condenser con necting pipe from the compressor a Remove the compressor condenser connect ing pipe a Remove the compressor condenser connect ing pipe seals a Insert the b...

Page 2644: ...a Connect the battery see Battery Removal Refit ting 80A Battery a Consult the amount of refrigerant and oil required before filling the refrigerant circuit see 62A Air conditioning Air conditioning P...

Page 2645: ...e intermediate pipe a Insert the blanking plugs Equipment required refrigerant charging station Tightening torquesm bolt securing the bracket of the intermediate pipe compressor connect ing pipe to th...

Page 2646: ...nnect the intermediate pipe compressor con necting pipe to the intermediate pipe a Refit the nut securing the bracket of the intermediate pipe compressor connecting pipe to the intermedi ate pipe a Ti...

Page 2647: ...climate control computer a Connect the climate control computer connectors IV FINAL OPERATION a Refit the glovebox see Glovebox Removal Refit ting 57A Interior equipment a Connect the battery see Bat...

Page 2648: ...ebox mounting the bolt 2 from the glovebox mounting a Move the glovebox refrigerant pipe to one side away from the mounting a Remove the glovebox support a Remove the passenger side front footwell air...

Page 2649: ...artment fuse and relay box mounting the passenger compartment fuse and relay box mounting a Unclip the passenger compartment fuse and relay box a Move aside the passenger compartment fuse and relay bo...

Page 2650: ...p the connector for the passenger compartment fan assembly control unit to the climate control com puter mounting unit a Refit the climate control computer mounting unit a Connect the climate control...

Page 2651: ...efit ting 57A Interior equipment a Connect the battery see Battery Removal Refit ting 80A Battery a Apply the after repair procedure using the Diagnos tic tool connect the Diagnostic tool select Clima...

Page 2652: ...ies from which the vehicles are constructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering system is forbidden...

Page 2653: ...constructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering system is forbidden without the prior written auth...

Page 2654: ...21 Side indicator Removal Refitting 80B 22 Remote headlight beam adjustment actuator Removal Refitting 80B 23 Headlight beam adjustment front sensor Removal Refitting 80B 26 Headlight beam adjustment...

Page 2655: ...g 82A 3 Electric steering column lock Removal Refitting 82A 4 Card reader Removal Refitting 82A 6 Starting aerial Removal Refitting 82A 8 82B HORN Audible warning Removal Refitting 82B 1 83A INSTRUMEN...

Page 2656: ...ht washer jet Removal Refitting 85A 27 Front screen washer jet Removal Refitting 85A 29 Rear screen washer jet Removal Refitting 85A 30 84A CONTROL SIGNALS Windscreen washer reservoir Removal Refittin...

Page 2657: ...87D 8 Sunroof switch Removal Refitting 87D 9 Sunroof opening motor Removal Refitting 87D 10 87F PARKING DISTANCE CONTROL Parking distance control List and location of components 87F 1 Parking distanc...

Page 2658: ...l Refitting 88C 14 Passenger s frontal airbag Removal Refitting 88C 16 Front chest level side airbag Removal Refitting 88C 19 Rear chest level side airbag Removal Refitting 88C 21 Side curtain airbag...

Page 2659: ...our clothing rinse all con taminated areas thoroughly in water If it comes into contact with the skin or eyes seek medical attention IMPORTANT To prevent damaging the battery or even causing it to exp...

Page 2660: ...s 80A I LIST OF COMPONENTS The distribution of electrical energy is provided by a battery a battery disconnection unit II LOCATION OF COMPONENTS Battery Battery disconnection unit Battery F4R or K4M o...

Page 2661: ...rotechnic de vice which switches off the supply in the event of an im pact To remove the battery terminal see 80A Battery Bat tery terminals Removal Refitting page 80A 12 To replace the fuses see 81C...

Page 2662: ...n unit 8 N m positive battery terminal 8 N m negative battery termi nal 8 N m IMPORTANT Consult the safety and cleanliness advice and oper ation recommendations before carrying out any repair see 80A...

Page 2663: ...over a Remove the detachable partition 5 from the battery tray II OPERATION FOR REMOVAL OF PART CONCERNED 1 DISCONNECTING a Undo the battery s negative terminal 6 a Remove the negative battery termina...

Page 2664: ...nnection unit the positive wiring nut onto the battery disconnec tion unit a Torque tighten the nut of the positive wiring on the battery disconnection unit 8 N m a Push the positive battery terminal...

Page 2665: ...roperly fitted into the notches 12 a Align the back of the battery cover 13 on the bat tery tray a Ensure that the battery cover is properly fitted on the battery tray at 14 a Clip on the back of the...

Page 2666: ...workshop hoist Tightening torquesm positive battery terminal 8 N m negative battery termi nal 8 N m IMPORTANT Consult the safety and cleanliness advice and oper ation recommendations before carrying...

Page 2667: ...the positive battery terminal 2 a Remove the positive battery terminal a Move aside the positive battery wiring a Remove the nuts 3 of the fuse box bracket the fuse box bracket 4 a Remove the fuse bo...

Page 2668: ...ve the protective cover of the battery REFITTING I REFITTING PREPARATION OPERATION a Check the battery see Battery Check Technical Note 6002A 80A Battery II REFITTING OPERATION FOR PART CONCERNED 1 RE...

Page 2669: ...ttery terminal 8 N m III FINAL OPERATION a Refit the luggage compartment floor soundproofing the luggage compartment carpet WARNING Incorrect tightening could cause heating of con tacts starting or ch...

Page 2670: ...ip the battery cover by pressing clips 2 and 3 a Remove the battery cover Tightening torquesm negative battery termi nal 8 Nm negative wiring nut 8 N m positive battery terminal 8 Nm wiring nut of the...

Page 2671: ...the wiring 6 a Unclip the negative wiring at 7 a Undo the battery s negative terminal a Remove the battery s negative terminal 2 Positive terminal a Remove the wiring nut 8 of the battery s positive t...

Page 2672: ...the negative wiring nut 8 N m 14 2 Positive terminal a Ensure that the battery s negative terminal is discon nected 128697 WARNING T o avoid any damage to the wiring observe the correct orientation o...

Page 2673: ...the wiring nut of the battery dis connection unit 8 N m 128700 WARNING T o avoid any damage to the wiring observe the correct orientation of the battery terminal WARNING Incorrect tightening could ca...

Page 2674: ...the clips are unlocked by a quarter of a turn a Ensure that the clips are properly fitted into the notches 17 a Align the back of the battery cover 18 on the bat tery tray a Ensure that the battery c...

Page 2675: ...e 80A 4 II OPERATION FOR REMOVAL OF PART CONCERNED a Undo the positive battery terminal 1 a Remove the positive battery terminal a Unclip the connector from the wiring channel at 2 Tightening torquesm...

Page 2676: ...connect the connector 3 using a flat blade screwdriver a Remove the nuts 4 of the fuse box bracket the fuse box bracket 5 a Remove the wiring nuts 6 the wiring a Move aside the wiring channel 7 a Remo...

Page 2677: ...ost a Ensure that the battery s positive terminal is correct ly oriented a Torque tighten the positive battery terminal 8 N m II FINAL OPERATION a Connect the battery see 80A Battery Battery Re moval...

Page 2678: ...e battery discon nection unit a Remove the positive wiring 3 a Remove the wiring nuts 4 from the battery discon nection unit a Move aside the battery disconnection unit wiring Tightening torquesm batt...

Page 2679: ...F4R or K4M or K9K or M4R or M9R 80A a Disconnect the connector 5 a Remove the bolt 6 a Unlock at 7 the connectors 8 a Remove the battery disconnection unit at 9 then at 10 a Disconnect the connectors...

Page 2680: ...Refit the battery disconnection unit a Connect the connector 12 a Refit the wiring 13 of the battery disconnection unit a Torque tighten the battery disconnection unit wir ing nuts 8 N m 124761 128705...

Page 2681: ...ery s pos itive terminal 8 N m II FINAL OPERATION a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4 128704 WARNING Incorrect tightening could cause heating of con tacts start...

Page 2682: ...ing nuts 2 from the battery discon nection unit a Move aside the battery disconnection unit wiring a Remove the bolt 3 of the battery disconnection unit the metal bracket 4 the nut 5 of the Protection...

Page 2683: ...FOR PART CONCERNED a Connect the connectors of the battery disconnection unit a Clip on the locks of the lower connectors a Fit the battery disconnection unit on its support a Tighten the bolts of the...

Page 2684: ...or V9X 80A II FINAL OPERATION a Check that the clip is unlocked a quarter of a turn a Refit the battery disconnection unit cover at 11 then 12 a Lock the clip a quarter of a turn a Connect the batter...

Page 2685: ...on unit Protection and Switching Unit Removal Refitting page 87G 2 II REMOVAL OPERATION FOR PART CONCERNED a Remove the blanking cover 1 a Unclip the battery tray earth wiring 2 a Remove the bolt 3 fr...

Page 2686: ...on and Switching Unit cover a Clip the earth wiring onto the battery tray II FINAL OPERATION a Refit the Protection and Switching Unit see 87G En gine compartment connection unit Protection and Switch...

Page 2687: ...ont bumper Re moval Refitting 55A Exterior protection II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the lower bolts 2 from the headlight a Remove the upper bolts 3 from the headlight a Remove th...

Page 2688: ...OR PART CONCERNED a Connect the headlight connectors a Refit the headlight II FINAL OPERATION a Refit the front bumper see Front bumper Remov al Refitting 55A Exterior protection a Connect the battery...

Page 2689: ...Remove the trim piece bolts 1 under the headlight the headlight side bolt 2 a Remove the bolts 3 from the headlight a Remove the headlight a Disconnect the headlight connectors a Remove the headlight...

Page 2690: ...ght the headlight bulbs see 80B Headlights Head light bulb Removal Refitting page 80B 10 II REFITTING OPERATION FOR PART CONCERNED a Connect the headlight connectors a Refit the headlight III FINAL OP...

Page 2691: ...y cover a Remove the detachable partition 1 from the battery tray a Check that the luggage compartment is empty that the headlights are clean a Position the headlight beam remote adjustment con trol o...

Page 2692: ...all joint and a 6 mm socket to access the horizon tal adjusting screw IV FINAL OPERATION a Refit the detachable battery tray partition the battery cover the windscreen washer bottle neck see 85A Wip i...

Page 2693: ...80B 7 HEADLIGHTS Headlight Adjustment B91 or K91 80B carry out the operations described in the After re pair procedure section...

Page 2694: ...a Check that the luggage compartment is empty that the headlights are clean a Switch on the dipped headlights II TEST OPERATION a Place a headlight adjustment and checking tool set to 1 in front of th...

Page 2695: ...adjusting screw IV FINAL OPERATION a Refit the battery cover the windscreen washer bottle neck see 85A Wip ing Washing Windscreen washer reservoir neck Removal Refitting page 85A 35 a Close the bonne...

Page 2696: ...Front bumper Removal Refitting 55A Exterior protection the headlight see 80B Headlights Headlight Removal Refitting page 80B 1 2 Front fog light bulb a Remove the front fog light see 80B Headlights F...

Page 2697: ...Wiping Washing Windscreen washer res ervoir neck Removal Refitting page 85A 35 a Unclip the expansion bottle top hose from the front cross member 2 a Depending on the equipment level unclip the pow er...

Page 2698: ...Removal Refitting page 85A 35 a Unclip the expansion bottle top hose from the front cross member a Depending on the equipment level unclip the pow er assisted steering fluid reservoir a Remove the bat...

Page 2699: ...a turn anti clockwise 7 a Remove the front fog light bulb 3 Side light bulbs a Remove the sealing cover 8 a Unclip the side light bulb holder 9 by pulling the wir ing gently a Remove the side light bu...

Page 2700: ...ector from the dipped beam headlight bulb a Unclip the dipped beam headlight bulb 11 5 Main beam headlight bulbs a Remove the sealing cover 12 a Disconnect the connector from the main beam head light...

Page 2701: ...of a turn anti clockwise a Remove the additional cornering light bulb holder a Remove the additional cornering light bulb from the bulb holder 7 Xenon bulb a Remove the sealing cover 16 a Turn the xe...

Page 2702: ...r 5 Main beam headlight bulbs a Refit a H7 bulb onto the headlight a Lock the clip onto the headlight a Connect the connector to the main beam headlight bulb a Refit the sealing cover 6 Additional cor...

Page 2703: ...am headlight and main beam headlight bulbs a Refit the detachable battery tray partition the battery cover the windscreen washer bottle neck see 85A Wip ing Washing Windscreen washer reservoir neck Re...

Page 2704: ...al Refitting page 80A 4 a Remove the front bumper see Front bumper Removal Refitting 55A Exterior protection the headlight see 80B Headlights Headlight Removal Refitting page 80B 1 II OPERATION FOR RE...

Page 2705: ...r 3 Xenon bulb a Remove the sealing cover 5 a Turn the xenon bulb locking ring a quarter of a turn anti clockwise a Remove the xenon bulb 6 a Disconnect the xenon bulb connector a Remove the xenon bul...

Page 2706: ...e bulb holder by turning it a quarter of turn clock wise the sealing cover III FINAL OPERATION Direction indicator bulb and xenon bulb a Refit the headlight see 80B Headlights Headlight Removal Refitt...

Page 2707: ...Move aside the front fog light a Disconnect the front fog light connector a Remove the front fog light REFITTING I REFITTING PREPARATIONS OPERATION a II REFITTING OPERATION FOR PART CONCERNED a Connec...

Page 2708: ...indicator from the bulb holder 3 the bulb from the bulb holder REFITTING I REFITTING PREPARATIONS OPERATION a II REFITTING OPERATION FOR PART CONCERNED a Refit the bulb onto the side indicator bulb h...

Page 2709: ...Removal Refitting page 80B 1 II OPERATION FOR REMOVAL OF PART CONCERNED a Tighten the beam adjustment bolt 1 by a few turns to facilitate uncoupling a Turn the beam adjustment actuator 2 an eighth of...

Page 2710: ...e headlight while pulling the bulb 5 a Fit the ball joint 6 into the reflector shell groove 7 a Refit the beam adjustment actuator by turning it an eighth of a turn towards the vehicle interior a Refi...

Page 2711: ...removal II FINAL OPERATION a Refit the headlight see 80B Headlights Headlight Removal Refitting page 80B 1 the front bumper see Front bumper Removal Refitting 55A Exterior protection a Connect the ba...

Page 2712: ...2 a Remove the bolt 3 from the headlight beam adjustment front sensor the headlight beam adjustment front sensor REFITTING I REFITTING PREPARATION OPERATION a II REFITTING OPERATION FOR PART CONCERNED...

Page 2713: ...using the Diagnostic tool connect the Diagnostic tool select Headlight adjustment computer go to repair mode display the Before after repair procedure for the computer selected select Headlight beam a...

Page 2714: ...or assembly 3 a Disconnect the headlight beam adjustment rear sen sor connector REFITTING I REFITTING PREPARATION OPERATION a II REFITTING OPERATION FOR PART CONCERNED a Connect the headlight beam adj...

Page 2715: ...using the Diagnostic tool connect the Diagnostic tool select Headlight adjustment computer go to repair mode display the Before after repair procedure for the computer selected select Headlight beam a...

Page 2716: ...unit REFITTING I REFITTING OPERATION FOR PART CONCERNED a a Refit the high voltage unit the high voltage unit bolts II FINAL OPERATION a Refit the headlight see 80B Headlights Headlight Removal Refitt...

Page 2717: ...80B 31 HEADLIGHTS Xenon headlight high voltage unit Removal Refitting DISCHARGE LAMPS 80B a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4...

Page 2718: ...g computer a Remove the front lighting computer REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the connector of the front lighting computer a Refit the front lighting computer II FINAL O...

Page 2719: ...er a Remove the front lighting computer REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the connector of the front lighting computer a Refit the front lighting computer II FINAL OPERATION...

Page 2720: ...e nut 2 from the rear light on the wing a Remove the rear wing light a Disconnect the connectors 3 on the rear wing light a Remove the rear wing light REFITTING I REFITTING OPERATION FOR PART CONCERNE...

Page 2721: ...p 1 a Remove the flap accessing the rear wing light 2 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the nuts 3 from the rear wing light a Unclip the rear wing light using the Car 1363 4 on the t...

Page 2722: ...t on the wing a Remove the rear wing light REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the connector for the rear light on the wing a Refit the rear light on the wing the rear wing li...

Page 2723: ...he nut 1 from the rear light on the wing a Unclip the rear light on the wing using the tool Car 1363 at 2 a Disconnect the connector 3 from the rear light on the wing a Remove the rear light on the wi...

Page 2724: ...ing a Refit the bulbs on the rear light on the wing see 81A Rear lighting Rear light bulb Removal Re fitting page 81A 8 a Connect the connector for the rear light on the wing a Clip the rear light on...

Page 2725: ...emove the tailgate light a Disconnect the connectors 3 from the tailgate light a Remove the tailgate light REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the tailgate light connectors a...

Page 2726: ...When replacing the rear light on the tailgate a Remove the bulbs from the rear light on the tailgate see 81A Rear lighting Rear light bulb Removal Refitting page 81A 8 REFITTING I REFITTING OPERATION...

Page 2727: ...element light Removal Refitting page 81A 6 3 Number plate light bulb a Remove the license plate light see 81A Rear light ing Number plate light Removal Refitting page 81A 25 4 High level brake light...

Page 2728: ...bulb holder 2 the reversing light bulb 3 Rear fog light bulb a Remove clip the rear fog light bulb holder 3 the rear fog light bulb 4 Number plate light bulb a Unclip the number plate light at 4 a Rem...

Page 2729: ...g Rear wing light Removal Refitting page 81A 1 2 Tailgate light bulbs a Refit the tailgate light see 81A Rear lighting Rear opening element light Removal Refitting page 81A 6 3 Rear fog light bulb a R...

Page 2730: ...plate light see 81A Rear light ing Number plate light Removal Refitting page 81A 25 3 High level brake light bulb a Remove the high level brake light see 81A Rear lighting 3rd brake light Removal Refi...

Page 2731: ...bulb a Refit the license plate light bulb W5W 3 High level brake light bulb a II FINAL OPERATION 1 Rear light bulbs on the wing a Refit the rear light on the wing see 81A Rear light ing Rear wing lig...

Page 2732: ...ator bulb a Remove the direction indicator bulb holder by turning it a quarter of a turn anti clockwise the bulb from the bulb holder b Brake light and side light bulb a 2 Rear light bulbs on the tail...

Page 2733: ...r b Fog light bulb a Refit the fog light bulb the fog light bulb holder by turning it a quarter of a turn clockwise c Side light bulbs a a Replace the rear light on the tailgate see 81A Rear lighting...

Page 2734: ...T CONCERNED a Disconnect the high level brake light connector 2 a Remove the high level brake light screws 3 the high level brake light REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the h...

Page 2735: ...81A REMOVAL I REMOVAL PREPARATION OPERATION a Open the rear screen a Remove the bolts 1 from the opening rear screen trim the opening rear screen trim 2 a Open the tailgate a Unclip the tailgate trim...

Page 2736: ...ke light connector 6 a Remove the high level brake light screws 7 a Remove the high level brake light by pressing the clips 8 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the high level...

Page 2737: ...81A 18 REAR LIGHTING 3rd brake light Removal Refitting K91 81A a Clip on the tailgate trim NON OPENING REAR SCREEN...

Page 2738: ...from the high level brake light trim at 1 using the tool Car 1363 the screws from the high level brake light trim a Unclip the trim high level brake light assembly us ing the tool Car 1363 at 2 then 3...

Page 2739: ...EPARATION OPERATION a II REFITTING OPERATION FOR PART CONCERNED a Clip the high level brake light onto the trim a Refit the high level brake light onto the trim III FINAL OPERATION a Connect the high...

Page 2740: ...e light Removal Refitting page 81A 15 II OPERATION FOR REMOVAL OF PART CONCERNED a REFITTING I REFITTING OPERATION FOR PART CONCERNED a Replace the high level brake light with a new one II FINAL OPERA...

Page 2741: ...ting MR 415 02A Lifting equip ment II OPERATION FOR REMOVAL OF PART CONCERNED a Remove clip a Disconnect the connector 1 from the rear fog light a Remove the bolt 2 from the rear fog light the rear fo...

Page 2742: ...fog lights Removal Refitting K91 81A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a The rear fog light is integrated into the rear wing light to remove it see 81A Rear lighting Rear wing light Rem...

Page 2743: ...ghts Removal Refitting D91 81A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a The rear fog light is integrated into the rear tailgate light for removal see 81A Rear lighting Rear opening element li...

Page 2744: ...D a Unclip the license plate lights at 1 with a small flat blade screwdriver a Disconnect the connector 2 from the number plate lights a Remove the number plate lights REFITTING REFITTING OPERATION FO...

Page 2745: ...ber plate light If replacing the bulb a Unclip the translucent cover at 2 from the number plate light a Remove the number plate light bulb REFITTING REFITTING OPERATION FOR PART CONCERNED If replacing...

Page 2746: ...I LIST OF COMPONENTS The interior lighting comprises headlining lights lower door lights a courtesy light a glovebox light under front seat lights dashboard base lights a luggage compartment light II...

Page 2747: ...2 INTERIOR LIGHTING Interior lighting List and location of components 81B Courtesy light Glovebox light Glovebox light Under front seat lights 125391 LEFT HAND DRIVE 125398 RIGHT HAND DRIVE 125401 125...

Page 2748: ...81B 3 INTERIOR LIGHTING Interior lighting List and location of components 81B Dashboard base lights Luggage compartment light Luggage compartment light 124300 124193 B91 125393 D91 137770...

Page 2749: ...nnect the headlining light connector a Remove the headlining light REFITTING REFITTING OPERATION FOR PART CONCERNED a Connect the headlining light connector a Clip on the headlining light the headlini...

Page 2750: ...ening elements trim II REMOVAL OPERATION FOR PART CONCERNED a Unclip the lower door light at 1 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the lower door light onto the front side door t...

Page 2751: ...NCERNED a Unclip the vanity light at 1 a Disconnect the vanity light connector a Remove the courtesy light REFITTING REFITTING OPERATION FOR PART CONCERNED a Connect the vanity light connector a Clip...

Page 2752: ...the storage compartment light at 2 a Disconnect the storage compartment light connec tor a Remove the glove compartment light REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the storage...

Page 2753: ...l Refitting 75A Front seat frames and runners II REMOVAL OPERATION FOR PART CONCERNED a Remove the under front seat light 1 by turning it a quarter of a turn REFITTING I REFITTING OPERATION FOR PART C...

Page 2754: ...dashboard light on passenger s side a Remove the dashboard wiring harness a Remove the under dashboard light 2 by turning it a quarter of a turn REFITTING I REFITTING OPERATION FOR PART CONCERNED a R...

Page 2755: ...mpartment light connec tor a Remove the luggage compartment light a Remove the bulb mounting 3 from the translucent cover at 4 a Remove the bulb REFITTING REFITTING OPERATION FOR PART CONCERNED a Refi...

Page 2756: ...ehicle has several fuse boxes passenger compartment fuse and relay box max fuse box Protection and Switching Unit fuses battery protection fuses II POSITION OF THE COMPONENTS Passenger compartment fus...

Page 2757: ...81C 2 FUSES Fuses List and location of components 81C Max fuse box Protection and Switching Unit fuses 128100 123036 123037 122988...

Page 2758: ...ents 81C Battery protection fuses To remove the fuse box see 80A Battery Battery terminals Removal Refitting page 80A 12 To remove the fuses see 81C Fuses Additional fuse and relay box Removal Refitti...

Page 2759: ...80A 4 a Remove the positive battery terminal see 80A Bat tery Battery terminals Removal Refitting page 80A 12 II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the cover of the additional fuse and r...

Page 2760: ...gine immobiliser system consists of an engine start button an electric steering column lock a remote door locking control a card reader three starter aerials II POSITION OF THE COMPONENTS Start button...

Page 2761: ...NE IMMOBILISER Immobiliser system List and location of components 82A Card reader Dashboard aerial Centre console aerial Luggage compartment floor aerial 124191 DOOR OPENING SYSTEM 433 NML 124208 1242...

Page 2762: ...CERNED a Connect the start button connector a Clip the start button onto the dashboard II FINAL OPERATION a Refit the centre front panel see Centre front panel Removal Refitting 57A Interior equipment...

Page 2763: ...mputer carry out the operations described in the Before repair procedure section a Remove the dashboard lower trim see Dashboard lower trim Removal Refitting 57A Interior equipment a Unclip the absorb...

Page 2764: ...im see Dashboard lower trim Removal Refitting 57A Interior equipment a Unlock the airbag computer by applying the after re pair procedure using the Diagnostic tool connect the Diagnostic tool select A...

Page 2765: ...VAL OF PART CONCERNED a Unclip the card reader mounting from the centre front panel at 1 a Unclip the card reader from the mounting at 2 a Remove the card reader at 3 REFITTING I REFITTING OPERATION F...

Page 2766: ...l Removal Refitting 57A Interior equipment a Refit the storage compartment a Refit the radio see 86A Radio Radio Removal Refitting page 86A 8 WITHOUT NAVIGATION AID and VEHICLEWITH OUT RADIO RADIO NO...

Page 2767: ...Remov al Refitting page 86A 8 a Remove the storage compartment 2 Centre console aerial a Unclip 1 the centre console rear panel a Disconnect the centre console rear panel connec tors 3 Luggage compart...

Page 2768: ...AL OPERATION 1 Dashboard aerial a Refit the storage compartment a Refit the radio see 86A Radio Radio Removal Refitting page 86A 8 2 Centre console aerial a Connect the centre console rear panel conne...

Page 2769: ...L I REMOVAL PREPARATION OPERATION a Remove the rivets 1 the bolts 2 the trim II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the horn connector a Remove the horn nut 3 a Remove the horn by 4 t...

Page 2770: ...2 HORN Audible warning Removal Refitting 82B a Remove the horn REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit the horn a Connect the horn connector a Refit the trim DOOR OPENING SYSTEM 433...

Page 2771: ...splay the before after repair procedure for the computer selected carry out the operations described in the Before repair procedure section a Disconnect the battery see 80A Battery Battery Removal Ref...

Page 2772: ...a Refit the instrument panel II FINAL OPERATION a Clip the instrument panel lower trim the steering column upper trim a Refit the covers under the steering wheel a Connect the battery see 80A Battery...

Page 2773: ...tion aerial see 83C On board telematics system Navigation aerial Removal Refitting page 83C 9 a radionavigation system see 86A Radio Radio Removal Refitting page 86A 8 a navigation computer see 83C On...

Page 2774: ...4 or NAVIGATION AID 6 83C The multimedia network interface unit is located on the dashboard cross member behind the glovebox Multimedia network interface unit The multimedia network interface unit is...

Page 2775: ...on List and location of components NAVIGATION AID 1 LEVEL or NAVIGATION AID 4 or NAVIGATION AID 6 83C Navigation aerial Navigation computer Central control K91 128098 NAVIGATION AID 4 124372 NAVIGATIO...

Page 2776: ...computer 1 using the two Ms 1373 2 a Disconnect the connectors a Disconnect the aerial Special tooling required Ms 1373 Tool for removing radios or chronotachographs Equipment required Diagnostic too...

Page 2777: ...navigation computer a In the event of a replacement apply the after repair procedure using the Diagnostic tool connect the Diagnostic tool select Navigation computer go to repair mode display the Befo...

Page 2778: ...NED a Unclip the multimedia network interface unit at 1 a Disconnect the multimedia network interface unit connector 2 a Remove the multimedia network interface unit REFITTING I REFITTING OPERATION FO...

Page 2779: ...trim Removal Refitting 57A Interior equipment a If replacing the unit apply the after repair procedure using the Diagnostic tool connect the Diagnostic tool select Interface computer between the vehi...

Page 2780: ...per face II FINAL OPERATION a Refit the centre console upper panel see Centre console upper front panel Removal Refitting 57A Interior equipment a In the event of a replacement apply the after repair...

Page 2781: ...eadlining see Headlining Removal Refit ting 71A Body internal trim II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the navigation aerial connectors 1 from the support plate a Disconnect the naviga...

Page 2782: ...the navigation aerial wiring a Remove the navigation aerial REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the navigation aerial a Fasten the navigation aerial wiring a Connect the navigat...

Page 2783: ...move the brake light switch see Brake pedal switch Removal Refitting MR 415 37A Mechan ical component controls A clutch pedal switch To remove the clutch pedal switch see Clutch pedal switch Removal R...

Page 2784: ...speed limiter List and location of components CRUISE CONTROL 83D Clutch pedal switch 4 To remove the clutch pedal switch see Clutch pedal switch Removal Refitting MR 415 37A Mechan ical component con...

Page 2785: ...anel see Centre console upper front panel Removal Re fitting 57A Interior equipment II REMOVAL OPERATION FOR PART CONCERNED a Unclip the switch at 1 REFITTING I REFITTING OPERATION FOR PART CONCERNED...

Page 2786: ...sys tem a lighting dimmer a door mirror control switch To remove the door mirror control switch see Front electric window switch Removal Refitting an ESP inhibitor switch a heated seat cover switch a...

Page 2787: ...witch 6 These components cannot be separated from the con trol panel To remove these switches see Control panel Re moval Refitting 61A Heating system Lighting dimmer Door mirror control switch To remo...

Page 2788: ...emote headlight beam adjustment control The remote headlight beam adjustment control and the lighting dimmer cannot be separated To remove the remote headlight beam adjustment con trol see 84A Control...

Page 2789: ...ng 36B Power assisted steering a Remove the cover bolts 1 under the steering wheel the cowlings under the steering wheel II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the steering column wiring...

Page 2790: ...e event of a replacement operation do not re move the pin 5 from the steering column switch as sembly a a Ensure that the wheels are set straight ahead II REFITTING OPERATION FOR PART CONCERNED a a Co...

Page 2791: ...see 88C Air bag and Pre tensioners Driver s frontal airbag Removal Refitting page 88C 14 a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4 a In the event of replacement check...

Page 2792: ...efitting 84A IV CHECKING AFTER REPAIR a Switch on the ignition a Check the operation of the rotary switch turn the steering wheel to the left until it stops turn the steering wheel to the right until...

Page 2793: ...a Switch off the ignition a Remove the fuse access flap 1 a Unclip the switch plate at 2 using the Car 1363 a Disconnect the switch plate connectors II OPERATION FOR REMOVAL OF PART CONCERNED a Uncli...

Page 2794: ...ting ELECTRONIC STABILITY PROGRAM 84A REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the ESP inhibitor switch onto the switch plate II FINAL OPERATION a Connect the switch plate connectors...

Page 2795: ...II REMOVAL OPERATION FOR PART CONCERNED a Unclip the lighting dimmer at 3 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the lighting dimmer onto the switch plate II FINAL OPERATION a Conn...

Page 2796: ...ners the front seat lower housing see Front seat lower casing Removal Refitting MR 416 77A Front seat trim II REMOVAL OPERATION FOR PART CONCERNED a Unclip the heated seat cover switch at 1 REFITTING...

Page 2797: ...see 85A Wiping Washing Windscreen wiper mechanism Removal Refitting page 85A 9 a rear screen wiper blade a rear screen wiper arm a rear screen wiper motor mechanism a rear screen wiper motor a rain a...

Page 2798: ...sm 3 Windscreen wiper motor 4 The windscreen wiper motor cannot be separated from the front windscreen wiper mechanism To remove it see 85A Wiping Washing Wind screen wiper mechanism Removal Refitting...

Page 2799: ...iping and washing List and location of components 85A Rear screen wiper motor mechanism 7 Rear screen wiper motor 8 Rain and light sensors 9 Windscreen washer pump 10 K91 and OPENING REAR SCREEN 12533...

Page 2800: ...G WASHING Wiping and washing List and location of components 85A Headlight washer pump 11 Headlight washer jets 12 Windscreen washer jets 13 Rear screen washer jet 14 DISCHARGE LAMPS 125348 124319 125...

Page 2801: ...85A 5 WIPING WASHING Wiping and washing List and location of components 85A Windscreen washer bottle 15 Windscreen washer bottle neck 16 125390 125389...

Page 2802: ...lip the windscreen wiper blade by squeezing each side at 1 a Remove the windscreen wiper blade at 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the windscreen wiper blade onto the wind s...

Page 2803: ...OR PART CONCERNED a Remove the nut cover 1 a Remove the nut 2 a Remove the wiper arm using the Ele 1841 3 REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit the wiper arm in the position marked...

Page 2804: ...85A 8 WIPING WASHING Windscreen wiper arm Removal Refitting 85A a Refit the wiper arm nut cover...

Page 2805: ...bolts 1 from the windscreen wiper mechanism a Remove the windscreen wiper mechanism a Disconnect the windscreen wiper mechanism con nector REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect...

Page 2806: ...ignition a Move the wiper stalk from 0 to 1 then from 1 to 0 a Switch off the ignition a Refit the front wiper arms see 85A Wiping Wash ing Windscreen wiper arm Removal Refitting page 85A 7 WARNING T...

Page 2807: ...ndscreen wiper motor Removal Refitting 85A The windscreen wiper motor cannot be separated from the front windscreen wiper mechanism To remove it see 85A Wiping Washing Wind screen wiper mechanism Remo...

Page 2808: ...ng B91 or K91 85A REMOVAL REMOVAL OPERATION FOR PART CONCERNED a Squeeze the clips 1 a Pivot the blade a Unclip the blade at 2 a Remove the blade at 3 REFITTING REFITTING OPERATION FOR PART CONCERNED...

Page 2809: ...ally mark the position of the rear screen wiper arm for the refitting operation II REMOVAL OPERATION FOR PART CONCERNED a Open the nut cover 1 a Remove the nut 2 from the wiper arm a Remove the rear s...

Page 2810: ...or K91 85A REFITTING REFITTING OPERATION FOR PART CONCERNED a Position the rear wiper arm on the first filament of the heated rear screen 4 a Refit the rear wiper arm in the position marked before re...

Page 2811: ...wiper arm see 85A Wiping Washing Rear screen wiper arm Removal Re fitting page 85A 13 the tailgate trim see Tailgate trim Removal Re fitting MR 416 73A Non side opening elements trim II OPERATION FOR...

Page 2812: ...ignition a Move the wiper stalk from 0 to 1 then from 1 to 0 a Switch off the ignition a Ensure that the indexing pin 7 is stopped against 8 II REFITTING OPERATION FOR PART CONCERNED a Refit the rear...

Page 2813: ...screen wiper mechanism shaft nut a Close the tailgate a Open the opening rear screen a Tighten the rear screen wiper mechanism nut a Refit the mechanism nut cover the mechanism shaft nut cover III FI...

Page 2814: ...r rivets 2 see MR 400 the rear screen wiper motor REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the rear screen wiper motor the rear screen wiper motor rivets see MR 400 a Connect the rea...

Page 2815: ...73A Non side opening ele ments trim a Remove the rear screen wiper arm see 85A Wip ing Washing Rear screen wiper arm Removal Refitting page 85A 13 II OPERATION FOR REMOVAL OF PART CONCERNED a Disconne...

Page 2816: ...rear screen wiper motor bolts coated with FRENETANCHE see Vehicle Parts and con sumables for the repair 04B Consumables Products a Ensure that the rear screen wiper mechanism index ing pin is correctl...

Page 2817: ...21 WIPING WASHING Rear screen wiper motor Removal Refitting K91 85A a Refit the rear screen wiper arm see 85A Wiping Washing Rear screen wiper arm Removal Re fitting page 85A 13 NON OPENING REAR SCRE...

Page 2818: ...iew mirror II OPERATION FOR REMOVAL OF PART CONCERNED 1 Replacing the rain and light sensor a Disconnect the connector at 2 a Unclip the two side clips 3 from the rain and light sensor using the Car 1...

Page 2819: ...nd light sensor s printed circuit unit REFITTING I REFITTING PREPARATION OPERATION a Replacing the rain and light sensor a On the inside of the windscreen clean the sensor mounting ring 7 using the Ca...

Page 2820: ...the top a Clip the rain and light sensor s printed circuit unit onto the new adhesive base the rain and light sensor onto the windscreen mounting ring using the side clips a Wait 5 minutes before conn...

Page 2821: ...rear jet 3 a a Remove the windscreen washer pump 4 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the windscreen washer pump to the bottle a Connect the rear jet supply pipe 3 the front je...

Page 2822: ...ight washer pump 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the headlight washer pump onto the bottle a a Connect the pipes to the headlight washer pump the headlight washer pump con...

Page 2823: ...Front bumper Re moval Refitting 55A Exterior protection II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the supply pipe 1 a Pull on the blanking cover 2 to open the headlight washer a Unclip...

Page 2824: ...FITTING OPERATION FOR PART CONCERNED a Clip the headlight washer onto the front bumper a Refit the headlight washer bolts a Clip on the headlight washer blanking cover a Connect the headlight washer p...

Page 2825: ...FOR PART CONCERNED a Unclip the windscreen washer jet at 1 a Disconnect the supply pipe 2 from the windscreen washer jet a Remove the windscreen washer jet REFITTING REFITTING OPERATION FOR PART CONCE...

Page 2826: ...FOR PART CONCERNED a Disconnect the supply pipe 1 from the rear screen washer jet a Remove the rear screen washer jet by moving the clips 2 using pliers REFITTING I REFITTING OPERATION FOR PART CONCE...

Page 2827: ...r jet using the tool Car 1363 a Disconnect the supply pipe from the rear screen washer jet a Remove the rear screen washer jet REFITTING REFITTING OPERATION FOR PART CONCERNED a Connect the rear scree...

Page 2828: ...OPERATION FOR PART CONCERNED a Remove the bolt 1 from the windscreen washer bottle the windscreen washer bottle REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the windscreen washer bottle...

Page 2829: ...A 26 II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the wiring at 1 a Remove the bolt 2 from the windscreen washer bottle the windscreen washer bottle REFITTING I REFITTING OPERATION FOR PART CON...

Page 2830: ...85A 34 WIPING WASHING Windscreen washer reservoir Removal Refitting 85A the front bumper see Front bumper Removal Refitting 55A Exterior protection a Fill up the windscreen washer bottle...

Page 2831: ...ed steering fluid reservoir II REMOVAL OPERATION FOR PART CONCERNED a Unclip the windscreen washer bottle neck at 1 then at 2 a Remove the windscreen washer bottle neck REFITTING I REFITTING OPERATION...

Page 2832: ...ter II LOCATION OF COMPONENTS Radio control satellite RADIO NO 01 or RADIO 01A or RADIO NO 06 or RADIO NO 07 or RADIO NO 08 or RADIO 08A or RADIO 09A or RADIO 15A WITHOUT NAVIGA TION AID and RADIO NO...

Page 2833: ...al is bonded to the tailgate lining Replacing the aerial will require the tailgate to be re placed Radio aerial amplifier Radio aerial amplifiers Radio aerial amplifier The radio aerial amplifier is i...

Page 2834: ...and location of components 86A Radio aerial amplifier Radio aerial amplifiers Radio RADIO NO 03 127602 D91 137753 137754 RADIO NO 01 or RADIO NO 07 or RADIO NO 08 WITHOUT NAVIGATION AID and RADIO NO 0...

Page 2835: ...Display Front speakers Tweeters and rear speakers WITHOUT NAVIGA TION AID 124190 RADIO NO 01 or RADIO 01A or RADIO NO 02 or RADIO NO 03 or RADIO NO 06 or RADIO NO 07 or RADIO NO 08 or RADIO 08A or RA...

Page 2836: ...6A 5 RADIO Radio List and location of components 86A Tweeters and rear speakers Centre speaker Tuner amplifier D91 124197 137280 RADIO NO 03 or RADIO NO 06 or RADIO NO 08 124324 LEFT HAND DRIVE 124371...

Page 2837: ...tion of components 86A Tuner amplifier Amplifier and subwoofer Offset multimedia socket RIGHT HAND DRIVE 125359 D91 and RADIO NO 06 or RADIO NO 08 134413 FOOT BRAKE MANUAL CONTROL and AUDIO CONNECTION...

Page 2838: ...86A 7 RADIO Radio List and location of components 86A Offset multimedia socket ELECTRONIC PARKING BRAKE and AUDIO CONNECTION 1 or AUDIO CONNECTION 3 134411...

Page 2839: ...CONCERNED a a Connect the aerial the radio connectors Special tooling required Ms 1820 Tool for removing Clarion and VDO radios Equipment required Diagnostic tool NAVIGATION AID 1 LEVEL or NAVIGATION...

Page 2840: ...pair procedure for the computer selected carry out the operations described in the After re pair procedure section a In the event of a replacement apply the after repair procedure using the Diagnostic...

Page 2841: ...uipment a Remove the dashboard lower trim see Dashboard lower trim Removal Refitting 57A Interior equipment a Unclip the absorbing material 1 a Unclip the wiring at 2 a Unclip the multimedia network i...

Page 2842: ...PART CONCERNED a Remove the receiver using the two Ms 1373 5 a Disconnect the connectors from the receiver a Disconnect the aerial connector 128707 WARNING T o ensure correct operation do not pinch t...

Page 2843: ...a Refit the glovebox see Glovebox Removal Refit ting 57A Interior equipment a In the event of a replacement apply the after repair procedure using the Diagnostic tool connect the Diagnostic tool selec...

Page 2844: ...the amplifier REFITTING I REFITTING PREPARATION OPERATION a a Separate the amplifier from its mounting in the event of a replacement operation II REFITTING OPERATION FOR PART CONCERNED a Refit the amp...

Page 2845: ...nut 1 the radio aerial wiring the radio aerial a Remove the tailgate see Tailgate Removal Re fitting 48A Non side opening elements REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the rear...

Page 2846: ...tailgate see Tailgate Removal Refit ting 48A Non side opening elements a Refit the radio aerial the radio aerial wiring the radio aerial nut II FINAL OPERATION a Refit the headlining see Headlining R...

Page 2847: ...ht hand rear quarter panel trim see Quarter panel trim Removal Refitting 71A Body internal trim a Remove the headlining see Headlining Removal Refitting 71A Body internal trim II OPERATION FOR REMOVAL...

Page 2848: ...Removal Refitting 86A a Refit the right hand rear quarter panel trim see Quarter panel trim Removal Refitting 71A Body internal trim a Refit the headlining see Headlining Removal Refitting 71A Body in...

Page 2849: ...he rear side door trim see Rear side door trim Removal Refitting 72A Side opening ele ment trim a Remove the rear panel trim see Rear panel lining Removal Refitting 71A Body internal trim II OPERATION...

Page 2850: ...trim a Turn the tweeter a quarter of a turn clockwise II FINAL OPERATION Rear tweeter a Refit the rear side door trim see Rear side door trim Removal Refitting 72A Side opening ele ment trim a Refit t...

Page 2851: ...efitting 72A Side opening element trim II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 1 a Remove the rivets 2 see MR 400 the front speaker REFITTING I REFITTING PREPARATION OPER...

Page 2852: ...AL OF PART CONCERNED a Unclip the central speaker grille using the Car 1363 1 a Remove the central speaker bolts 2 the central speaker a Disconnect the central speaker connector REFITTING REFITTING OP...

Page 2853: ...l trim II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the rear speaker connector 1 a Remove the rear speaker rivets 2 see MR 400 the rear speaker REFITTING I REFITTING PREPARATION OPERATION a...

Page 2854: ...a Remove the centre front panel see Centre front panel Removal Refitting 57A Interior equip ment Special tooling required Car 1363 Set of trim removal levers Equipment required Diagnostic tool WARNIN...

Page 2855: ...strip 1 using the tool Car 1363 a Unclip the upper trim 2 from the display using the tool Car 1363 WITHOUT NAVIGA TION AID 137273 NAVIGATION AID 1 LEVEL or NAVIGATION AID 4 or NAVIGATION AID 6 138089...

Page 2856: ...ay trim piece bolts 2 the display trim piece a Remove the display mounting 3 a Disconnect the display connector the connector of the seat belt reminder warning light a Remove the display bolts the dis...

Page 2857: ...e position marked during re moval a Connect the connector of the navigation screen the connector of the seat belt reminder warning light a Refit the display III FINAL OPERATION a Clip on the upper tri...

Page 2858: ...after repair procedure using the Diagnostic tool connect the Diagnostic tool select Navigation computer go to repair mode display the Before after repair procedure for the computer selected carry out...

Page 2859: ...the radio control satellite connector a Remove the radio control satellite bolt 1 a Unclip the radio control satellite at 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the radio control...

Page 2860: ...ole Removal Refitting 57A Interior equipment II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the offset multimedia socket using the tool Car 1363 by pressing on the clips 1 REFITTING I REFITTING O...

Page 2861: ...86A 30 RADIO Offset multimedia socket Removal Refitting AUDIO CONNECTION 1 86A II FINAL OPERATION a Refit the centre console see Centre console Re moval Refitting 57A Interior equipment...

Page 2862: ...OVAL OF PART CONCERNED a Switch off the ignition a Open the glovebox a Remove the offset audio unit bolts 1 the offset audio unit a Disconnect the offset audio unit connector 2 REFITTING REFITTING OPE...

Page 2863: ...itting page 86B 3 a computer see 83C On board telematics system Navigation computer Removal Refitting page 83C 4 a telephone control on the steering wheel see 86A Radio Radio control satellite Removal...

Page 2864: ...e List and location of components CAR PHONE PRE EQUIPMENT or HANDS FREE TELEPHONE KIT 86B Computer Hands free microphone Telephone control on the steering wheel NAVIGATION AID 4 124372 124296 HANDS FR...

Page 2865: ...lip the centre console trim 1 on the right hand side a Pull back the floor carpet a Remove the floor soundproofing 2 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the computer in the direction o...

Page 2866: ...FITTING OPERATION FOR PART CONCERNED a Connect the computer connectors a Refit the computer in its original position II FINAL OPERATION a Refit the floor soundproofing a Pull back the floor carpet a C...

Page 2867: ...PARATION OPERATION a Switch off the ignition a Remove the headlining 1 see Headlining Re moval Refitting 71A Body internal trim II REMOVAL OPERATION FOR PART CONCERNED a Unclip the hands free micropho...

Page 2868: ...CAR PHONE Hands free microphone Removal Refitting CAR PHONE PRE EQUIPMENT or HANDS FREE TELEPHONE KIT 86B II FINAL OPERATION a Refit the headlining see Headlining Removal Refitting 71A Body internal...

Page 2869: ...Removal Refitting 57A Inte rior equipment a Unclip the absorbing material 2 a Remove the bolt 3 from the passenger compart ment relay fuse box a Remove the passenger compartment relay fuse box at 4 a...

Page 2870: ...connectors a Remove the UCH REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the UCH connectors a Refit the UCH on its mounting II FINAL OPERATION a Refit the passenger compartment fuse a...

Page 2871: ...ee 80A Battery Battery Re moval Refitting page 80A 4 a In the event of a replacement operation apply the after repair procedure using the Diagnostic tool connect the Diagnostic tool select UCH go to r...

Page 2872: ...pening switch An opening aerial integrated into each front door han dle To remove the front door handles see Exterior door handle Removal Refitting 51A Side opening ele ment mechanisms An opening aeri...

Page 2873: ...7C Tailgate opening switch Rear screen opening switch Opening aerials integrated into the front door handles To remove the front door handles see Exterior door handle Removal Refitting 51A Side openin...

Page 2874: ...87C 3 OPENING ELEMENT MANAGEMENT Opening elements management List and location of components 87C Opening aerial in the rear absorber Opening aerial in the tailgate B91 125105 K91 125103...

Page 2875: ...ehicle Towing and lifting 02A Lifting equipment a Remove the rear bumper see Rear bumper Re moval Refitting 55A Exterior protection a Remove the tailgate trim see Tailgate trim Re moval Refitting 73A...

Page 2876: ...Clip the opening aerial on to the rear absorber a Connect the opening aerial connector a Clip the opening aerial connector on to the rear ab sorber a Refit the opening aerial onto the tailgate a Conn...

Page 2877: ...ailgate trim see Tailgate trim Re moval Refitting MR 416 73A Non side opening element trim a Unclip the badge 1 using the Car 1363 II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the connector 2...

Page 2878: ...onnector 5 from the tailgate open ing switch REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip on the tailgate opening switch a Connect the tailgate opening switch connector II FINAL OPERATION...

Page 2879: ...side opening element trim II REMOVAL OPERATION FOR PART CONCERNED a Unclip the rear screen opening switch at 1 a Disconnect the connector 2 from the rear screen opening switch REFITTING I REFITTING OP...

Page 2880: ...iner see Rear wheel arch trim Removal Refitting 71A Body internal trim a Remove the rear right hand light access flap II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the motor connector 1 a Remov...

Page 2881: ...NTS Front window winder switches on the driver s door 1 and safety switch 2 the child safety switch cannot be separated from the front window winder plate on the driver s door To remove the child safe...

Page 2882: ...electric sunroof switch An electric sunroof motor II LOCATION OF COMPONENTS Electric sunroof switch 1 Electric sunroof opening motor 2 and electric sunroof computer The sunroof opening motor and the...

Page 2883: ...plate at 1 using the Car 1363 a Unclip the plate at 2 using the Car 1363 a Unclip the plate at 3 using the Car 1363 a Disconnect the connector from the front window winder switch plate on the driver...

Page 2884: ...4 ELECTRIC WINDOWS SUNROOF Front electric window switches on driver s door Removal Refitting 87D a Clip the front window winder switch plate on the driv er s door onto the front driver s side door tr...

Page 2885: ...late at 1 using the Car 1363 a Unclip the plate at 2 using the Car 1363 a Unclip the plate at 3 using the Car 1363 a Disconnect the connector from the front window winder switch plate on the passenger...

Page 2886: ...6 ELECTRIC WINDOWS SUNROOF Front electric window switch on passenger door Removal Refitting 87D a Clip the front window winder switch plate on the pas senger door onto the front passenger side door t...

Page 2887: ...nclip the rear electric window plate using an unclip ping tool 1 a Disconnect the rear window winder switch connec tor a Unclip the rear electric window switch from its mounting at 2 REFITTING REFITTI...

Page 2888: ...t the rear side door trim see Rear side door trim Removal Refitting 72A Side opening ele ment trim a When replacing a front electric window motor apply the after repair procedure using the Diagnostic...

Page 2889: ...ION a Switch off the ignition II REMOVAL OPERATION FOR PART CONCERNED a Unclip the electric sunroof switch plate 1 a Disconnect the connectors a Unclip the electric sunroof switch from the plate at 2...

Page 2890: ...eadlining Removal Refitting 71A Body internal trim II REMOVAL OPERATION FOR PART CONCERNED a Disconnect the connector 2 a Remove the bolts 3 from the electric sunroof motor the electric sunroof motor...

Page 2891: ...tch a parking distance control computer a parking distance control rear buzzer 4 rear proximity sensors a parking distance control front buzzer 4 front proximity sensors II LOCATION OF COMPONENTS Park...

Page 2892: ...ontrol buzzer Rear parking distance control buzzer The rear parking distance control buzzer is located un der the rear parcel shelf trim Rear proximity sensors Front parking distance control buzzer th...

Page 2893: ...CE CONTROL Parking distance control List and location of components FRONT AND REAR PROXIMITY RADAR or REAR PROXIMITY RADAR 87F Front parking distance control buzzer Front proximity sensors RIGHT HAND...

Page 2894: ...ARATION OPERATION a Switch off the ignition a Remove the fuse access flap 1 a Unclip the switch plate at 2 using the Car 1363 a Disconnect the switch plate connectors II OPERATION FOR REMOVAL OF PART...

Page 2895: ...NT AND REAR PROXIMITY RADAR or REAR PROXIMITY RADAR 87F REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the parking distance control switch onto the switch plate II FINAL OPERATION a Connect...

Page 2896: ...internal trim a Remove the rear parcel shelf trim see Rear parcel shelf trim Removal Refitting 71A Body inter nal trim a Remove the dashboard lower trim 1 see Dash board lower trim Removal Refitting...

Page 2897: ...istance control buzzer the parking distance control buzzer plastic rivets II FINAL OPERATION a Refit the right hand rear quarter panel trim see Quarter panel trim Removal Refitting 71A Body internal t...

Page 2898: ...the rear bumper see Rear bumper Re moval Refitting 55A Exterior protection a Unclip the front fog light trim pieces 1 a Remove the front bumper see Front bumper Re moval Refitting 55A Exterior protec...

Page 2899: ...emoval Refitting FRONT AND REAR PROXIMITY RADAR or REAR PROXIMITY RADAR 87F a Disconnect the connector 4 a Unclip the front side sensor at 5 a Remove the front side sensor FRONT AND REAR PROXIMITY RAD...

Page 2900: ...ont centre sensor REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip on the rear sensor a Connect the rear sensor connector a Clip on the front side sensor a Connect the front side sensor conne...

Page 2901: ...RADAR or REAR PROXIMITY RADAR 87F II FINAL OPERATION a Refit the rear bumper see Rear bumper Removal Refitting 55A Exterior protection a Clip on the front fog light trim piece a Refit the front bumper...

Page 2902: ...isconnect the connector 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the parking distance control computer con nector a Refit the parking distance control computer II FINAL OPERATION...

Page 2903: ...II LOCATION OF COMPONENTS 1 Max fuse box 2 Protection and Switching Unit To remove the cover of the UPC or the UPC refer to the procedure see 87G Engine compartment con nection unit Protection and Sw...

Page 2904: ...NED a Unlock the push button 1 by pulling it upwards a Unclip the cover of the Protection and Switching Unit by pressing at 2 on the push button the wiring clip 3 on the battery tray a Remove the Prot...

Page 2905: ...Protection and Switching Unit connec tors a a Clip in order the front section of the Protection and Switching Unit 7 the rear section of the Protection and Switching Unit 8 the Protection and Switchi...

Page 2906: ...y see 80A Battery Battery Re moval Refitting page 80A 4 a In the event of replacement apply the after repair procedure using the Diagnostic tool connect the Diagnostic tool select Protection and Switc...

Page 2907: ...raulic unit 5 an automatic transmission computer 6 an assisted parking brake control unit 7 a parking distance control computer 8 a multimedia network interface unit 9 a xenon headlight and additional...

Page 2908: ...88A 2 WIRING HARNESS Computers List and location of components 88A a 4 wheel drive computer 11 4 WHEEL STEERING...

Page 2909: ...ket List and location of components 88A LOCATION The diagnostic socket is located in the centre console storage compartment Open the centre console storage compartment Remove the lining of the centre...

Page 2910: ...s elec tronic earths To prevent water flowing into the connectors make a low point just on the wiring routing just before the con nector For connections between fixed and mobile compo nents secure the...

Page 2911: ...e Vehicle Towing and lifting 02A Lifting equipment a Remove the front bumper see Front bumper Re moval Refitting 55A Exterior protection a Disconnect the R 266 connector 1 125617 IMPORTANT Consult the...

Page 2912: ...on nectors see Connector Sealing and immobilisa tion Technical Note 6015A 88A Wiring II REFITTING OPERATION FOR PART CONCERNED a Refit the front bumper wiring a Clip on the front bumper wiring IMPORTA...

Page 2913: ...proximity sensor connectors a Connect the front fog light connectors III FINAL OPERATION a Refit the front bumper see Front bumper Remov al Refitting 55A Exterior protection a Connect the battery see...

Page 2914: ...and 6 SPEED AUTOMA TIC GEARBOX 125674 M9R and 6 SPEED AUTOMA TIC GEARBOX IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair see 88A Wiring...

Page 2915: ...ttery Battery Removal Refitting page 80A 4 a Remove the Protection and Switching Unit see 87G En gine compartment connection unit Protection and Switching Unit Removal Refitting page 87G 2 the air fil...

Page 2916: ...88A 10 WIRING HARNESS Engine wiring Connector access F4R or K4M or M4R 88A I LOCATION OF CONNECTORS a R 22 connector Connects engine wiring automatic gearbox F4R and 6 SPEED AUTOMA TIC GEARBOX 125663...

Page 2917: ...88A 11 WIRING HARNESS Engine wiring Connector access F4R or K4M or M4R 88A a R 262 connector Connects engine wiring passen ger compartment 125661...

Page 2918: ...88A 12 WIRING HARNESS Engine wiring Connector access F4R or K4M or M4R 88A a R 37 connector Connects engine wiring injection K4M 125656...

Page 2919: ...artment connection unit Protection and Switching Unit Removal Refitting page 87G 2 the air filter box see Air filter unit Removal Re fitting 12A Fuel mixture M4R 125654 IMPORTANT Consult the safety an...

Page 2920: ...g Connector access F4R or K4M or M4R 88A a Disconnect the R 22 connector 2 R 262 a Remove the detachable partition 1 from the battery tray a Disconnect the R 262 connector R 37 a Remove the front engi...

Page 2921: ...88A 15 WIRING HARNESS Engine wiring Connector access F4R or K4M or M4R 88A a Disconnect the R 37 connector R 179 a Remove the front engine cover a Disconnect the R 179 connectors 104240 M4R 123376...

Page 2922: ...emoval Re fitting 12A Fuel mixture the injection computer see Petrol injection com puter Removal Refitting 17B Petrol injection the engine undertray bolts the engine undertray the max fuse box cover a...

Page 2923: ...ide a Remove the bolts 4 on the crankshaft position sensor pro tector the crankshaft position sensor protector a Remove the bolts 5 on the intercooler outlet air pipe a Move the intercooler outlet air...

Page 2924: ...1 the camshaft position sensor connector 12 the coolant temperature sensor connector 13 the throttle valve connector 14 the air flowmeter connector 15 the upstream oxygen sensor connector 16 the downs...

Page 2925: ...88A 19 WIRING HARNESS Engine wiring Removal Refitting F4R or M4R 88A a Unclip the wiring at 24 125654...

Page 2926: ...nectors 33 the pinking sensor connector 34 the oil pressure sensor connector 35 the turbocharger pressure sensor connector 36 the oil level sensor connector 37 the air temperature sensor connector 38...

Page 2927: ...88A 21 WIRING HARNESS Engine wiring Removal Refitting F4R or M4R 88A a Unclip the wiring at 48 125663...

Page 2928: ...50 on the gearbox a Move aside the gearbox wiring channel a Remove the two earth nuts on the front left hand side member 51 a Disconnect the refrigerant pressure sensor connector 52 the engine coolin...

Page 2929: ...g REFITTING I REFITTING PREPARATION OPERATION a If replacing with more wiring lock the unused con nectors see Connectors Sealing and immobili sation Technical Note 6015A 88A Wiring II REFITTING OPERAT...

Page 2930: ...nsor connector the coolant temperature sensor connector the brake servo vacuum sensor connector the turbocharging pressure regulation solenoid valve connector the crankshaft position sensor connector...

Page 2931: ...or positive terminal nut 8 Nm a Refit the starter wiring the nut on the positive terminal of the starter 60 the nut on the excitation terminal of the starter 61 a Tighten to torque the nut on the posi...

Page 2932: ...y bolts a Refit the injection computer see Petrol injection com puter Removal Refitting 17B Petrol injection the air filter box see Air filter unit Removal Re fitting 12A Fuel mixture the engine cover...

Page 2933: ...itting 12A Fuel mixture the injection computer see Diesel injection com puter Removal Refitting 13B Diesel injec tion the engine undertray bolts the engine undertray the max fuse box cover a Remove th...

Page 2934: ...ve the bolt 3 from the max fuse box a Move the max fuse box to one side a Remove the injector rail protector see Injector rail protector Removal Refitting 13B Diesel injec tion a Loosen the clip 4 on...

Page 2935: ...ove the engine wiringaside a Remove the bolt 7 on the intercooler inlet air pipe the nut 8 on the intercooler inlet air pipe a Pull the clip 9 from the intercooler inlet air pipe a Disconnect the inte...

Page 2936: ...ector 18 the heater plug connectors 19 the damper valve connector 20 the turbocharger pump sensor connector 21 the camshaft position sensor connector 22 the rail pressure sensor connector 23 the exhau...

Page 2937: ...the heat insulating material around the oil level sensor 33 the heat insulating material around the crankshaft position sensor 34 a Disconnect the oil level sensor connector the TDC sensor connector a...

Page 2938: ...88A 32 WIRING HARNESS Engine wiring Removal Refitting K9K or M9R 88A a Remove the earth strap bolt 39 114998...

Page 2939: ...ir flowmeter connector 47 the turbocharging pressure regulation solenoid valve connector 48 the crankshaft position sensor connector 49 the alternator connectors 50 the air conditioning compressor con...

Page 2940: ...se a Remove the upper nuts 62 on the gearbox a Move aside the gearbox wiring channel a Remove the wiring bolts 63 on the front left hand side member a Disconnect the refrigerant pressure sensor connec...

Page 2941: ...ine cooling fan assembly resistor connec tor the refrigerant pressure sensor connector a Refit the two earth nuts on the front left hand side member a Torque tighten the two earth nuts on the front le...

Page 2942: ...engine a Connect the crankshaft position sensor connector the oil level sensor connector a Refit the heat insulating material around the crankshaft position sensor the heat insulating material around...

Page 2943: ...starter 73 a Tighten to torque the nut on the positive terminal of the starter 8 Nm the nut on the excitation terminal of the starter 5 Nm III FINAL OPERATION a Refit the injector rail protector cover...

Page 2944: ...n the bolt on the max fuse box a Refit the passenger compartment wiring harness in the max fuse box a Clip the fuse holders onto the max fuse box a Refit the max fuse box fuses the max fuse box cover...

Page 2945: ...access B91 or K91 88A I LOCATION OF CONNECTORS R 99 a R 99 connectors dashboard heating connection R 99 a R 99 connectors dashboard heating connection Special tooling required Car 1363 Set of trim re...

Page 2946: ...partment wiring Connector access B91 or K91 88A R 153 a R153 connector passenger compartment driver s door connection R 153 a R153 connector passenger compartment driver s door connection LEFT HAND DR...

Page 2947: ...tment wiring Connector access B91 or K91 88A R 154 a R 154 connector passenger compartment passen ger door connection R 154 a R 154 connector passenger compartment passen ger door connection LEFT HAND...

Page 2948: ...access B91 or K91 88A 1 R 155 a R 155 connector passenger compartment rear left hand door connection 2 R 156 a R 156 connector passenger compartment rear right hand door connection R 244 a R 244 conn...

Page 2949: ...access B91 or K91 88A 3 R 260 a R 260 connectors passenger compartment roof connection 4 R 265 a R265 connectors passenger compartment front end panel connection 5 R 266 a R 266 connector passenger co...

Page 2950: ...ring Connector access B91 or K91 88A R 292 a R 292 connector passenger compartment passen ger front airbag connection R 292 a R 292 connector passenger compartment passen ger front airbag connection L...

Page 2951: ...assenger compartment rear left connection R 315 a R 315 connector passenger compartment dis charge bulb corrector sensor connection 6 R 319 a R 319 connecter rear bumper rear connection 7 R 323 a R 32...

Page 2952: ...eat electrical func tions connection R 328 a R 328 connector passenger compartment passen ger compartment blower unit connection a R 328 connector passenger compartment passen ger compartment blower u...

Page 2953: ...d wiring parking brake electric unlocking connection 11 R 414 a R 414 connector passenger compartment wiring multimedia connection 12 R 415 a R 415 connector passenger compartment wiring multimedia 2...

Page 2954: ...rd see Dashboard Removal Refitting MR 416 57A Interior equipment a Disconnect the R 99 connectors 2 Access to the R 153 connector a Remove the front left hand door sill lining see Front door sill lini...

Page 2955: ...nclip the connector at 4 a Remove the R 154 connector 4 Access to the R 155 connector a Remove the rear left hand side door see Rear side door Removal Refitting MR 416 47A Side opening elements the le...

Page 2956: ...m see B pillar low er trim Removal Refitting MR 416 71A Body internal trim the front right hand door sill lining see Front door sill lining Removal Refitting MR 416 71A Body internal trim the rear rig...

Page 2957: ...88A a Disconnect the R 244 connector 6 Access to the R 260 connectors a Remove the A pillar trims see Windscreen pillar trim Removal Refitting MR 416 71A Body in ternal trim a Disconnect the R 260 con...

Page 2958: ...bumper see Front bumper Re moval Refitting MR 416 55A Exterior protec tion a Disconnect the R 266 connector 9 Access to the R 292 connector a Remove the glovebox see Glovebox Removal Refitting MR 416...

Page 2959: ...lip the R 297 connector from its support at 12 a Remove the R 297 connector support at 13 a Position the vehicle on a two post lift see Vehicle Towing and lifting MR 415 02A Lifting equip ment a Remov...

Page 2960: ...fting equip ment a Remove the rear bumper see Rear bumper Re moval Refitting MR 416 55A Exterior protec tion a Disconnect the R 319 connector 12 Access to the R 323 connector a Position the vehicle on...

Page 2961: ...at see Complete front seat Removal Refitting MR 416 75A Front seat frames and runners a R 324 connector 14 Access to the R 328 connector a Remove the glovebox see Glovebox Removal Refitting MR 416 57A...

Page 2962: ...a Disconnect the R 370 connector 17 Access to the R 414 connector a Remove the dashboard see Dashboard Removal Refitting MR 416 57A Interior equipment a Disconnect the R 414 connector 18 Access to th...

Page 2963: ...r a Remove the tailgate trim see Tailgate trim Re moval Refitting MR 416 73A Non side opening element trim a Disconnect the R 620 connector Access to the R 627 connector a Remove the rear bench seat b...

Page 2964: ...ecial tooling required Ele 1600 Spanner for removal refitting of the driver s position wiring locking ring Equipment required Diagnostic tool Tightening torquesm earth nut on the front left wing linin...

Page 2965: ...val Refitting 55A Exterior protection the scuttle panel grille see Scuttle panel grille Removal Refitting 56A Exterior equipment the scoop under the scuttle panel grille see Scoop under the scuttle pa...

Page 2966: ...r front panel see Centre console upper front panel Removal Refitting 57A Interior equipment the central console see Centre console Remov al Refitting 57A Interior equipment the dashboard lower trim se...

Page 2967: ...UCH see 87B Passenger compartment connection unit UCH Removal Refitting page 87B 1 the rear air distribution ducts see Rear air distri bution duct Removal Refitting 61A Heating the dashboard see Dashb...

Page 2968: ...t the R 244 connector a Unclip the R 244 connector at 8 a Disconnect the rear wheel speed sensor connector on both sides of the vehicle 9 a Unclip the wiring at 10 on both sides of the vehicle a Disco...

Page 2969: ...onnector 14 on both sides of the vehicle a Unclip the side curtain airbag wiring at 15 on both sides of the vehicle a Remove the rear light wiring at 16 on both sides of the vehicle a Disconnect the r...

Page 2970: ...l buzzer connector 20 the parking distance control computer connector 21 a Unclip the radio aerial connectors 22 a Disconnect the radio aerial connectors a Disconnect the fuel filler flap lock motor c...

Page 2971: ...ight hand seat belt stalk connector 25 a Disconnect the R 370 connector 26 a Unclip the wiring at 27 a Remove the plastic nuts 28 from the wiring chan nels a Unclip the wiring channels at 29 on both s...

Page 2972: ...ctors at 33 a Unclip the wiring at 34 on both sides of the vehicle a Unlock the airbag computer connector 35 a Disconnect the connectors 35 and 36 a Remove the earth nut 37 a Disconnect the lateral ac...

Page 2973: ...ctor mountings at 43 a Remove the R 323 and R 324 connector mountings 44 a Remove the plastic rivet 45 a Remove the wiring channel 46 a Unclip the wiring at 47 a Unclip the wiring at 48 a Remove the b...

Page 2974: ...B91 or K91 88A a Disconnect the R 339 connector 52 a Unclip the R 339 connector a Remove the earth nuts 53 a Unclip the wiring at 54 a Remove the earth nuts 55 a Disconnect the R 414 R 415 and R 416...

Page 2975: ...g distance control buzzer connector a Disconnect the electric steering column lock con nector 58 a Unclip the wiring at 59 a Disconnect the clutch pedal start and end of travel sensor con nectors 60 t...

Page 2976: ...K91 88A a Disconnect the accelerator pedal potentiometer connector 62 the brake light switch connector 63 a Disconnect the R 99 connectors 64 a Unclip the wiring at 65 the wiring channel at 66 a Remo...

Page 2977: ...connectors a Unclip the passenger compartment fuse and relay box upwards 70 a Disconnect the front wheel speed sensor connector 71 on both sides of the vehicle a Disconnect the headlight beam adjustm...

Page 2978: ...he braking computer connector 74 a Disconnect the braking computer connector a Remove the earth nut 75 a Unclip the wiring at 76 a Unclip the wiring at 77 a Disconnect the connector from the windscree...

Page 2979: ...bolts 81 a Unfasten the automatic transmission computer con nector 82 a Disconnect the automatic transmission connector a Unclip the wiring at 83 a Remove the earth bolt 84 the scoop rivet 86 see MR...

Page 2980: ...ox cover a Remove the fuses 89 from the max fuse box a Unclip the fuse holders at 90 a Remove the fuse holders a Detach the wiring from the max fuse box a Remove the bolt 91 from the max fuse box a Mo...

Page 2981: ...x a Clip the fuse holders onto the max fuse box a Refit the fuses in the max fuse box the max fuse box cover a Clip the wiring onto the left hand section of the bulk head a Refit the scoop the scoop r...

Page 2982: ...ustment front sensor connector a Connect the front wheel speed sensor connector on both sides of the vehicle a Clip on the R 260 connectors a Connect the R 260 connectors a Clip the wiring onto the le...

Page 2983: ...a Connect the automatic gear lever connector a Connect the lateral acceleration and yaw sensor connector a Torque tighten the tunnel earth nut 8 N m a Connect the airbag computer connectors a Lock th...

Page 2984: ...ear air distri bution duct Removal Refitting 61A Heating the UCH see 87B Passenger compartment connection unit UCH Removal Refitting page 87B 1 the A pillar air distribution ducts see Front foot well...

Page 2985: ...upper trims see B pillar upper trim Removal Refitting 71A Body internal trim the complete front seats see Complete front seat Removal Refitting 75A Front seat frames and runners the rear wheel arch t...

Page 2986: ...Removal Refitting 55A Exterior protec tion the front wheel arch liners see Front wheel arch liner Removal Refitting 55A Exterior protec tion the wheels see Wheel Removal Refitting 35A Wheels and tyres...

Page 2987: ...partment wiring Removal Refitting B91 or K91 88A select the Airbag computer go to repair mode display the Before after repair procedure of the selected computer carry out the operations described in t...

Page 2988: ...Side opening element mechanisms the side impact sensor on the front door see 88C Air bag and Pretensioners Side impact sensor Removal Refitting page 88C 27 a Disconnect the door mirror connector Equi...

Page 2989: ...ATION a If replacing with more wiring lock the unused con nectors see Connector Sealing and immobilisa tion Technical Note 6015A 88A Wiring II REFITTING OPERATION FOR PART CONCERNED a Refit the wiring...

Page 2990: ...ing page 88C 27 the front side door lock see Front side door lock Removal Refitting 51A Side opening element mechanisms the door sealing film see Door sealing film Re moval Refitting 65A Opening eleme...

Page 2991: ...1A Side opening element mechanisms the side impact sensor on the front door see 88C Air bag and Pretensioners Side impact sensor Removal Refitting page 88C 27 a Disconnect the door mirror connector Eq...

Page 2992: ...RATION a If replacing with more wiring lock the unused con nectors see Connector Sealing and immobilisa tion Technical Note 6015A 88A Wiring II REFITTING OPERATION FOR PART CONCERNED a Refit the wirin...

Page 2993: ...ting page 88C 27 the front side door lock see Front side door lock Removal Refitting 51A Side opening element mechanisms the door sealing film see Door sealing film Re moval Refitting 65A Opening elem...

Page 2994: ...moval Refitting page 80A 4 a Remove the tailgate trim see Tailgate trim Re moval Refitting 73A Non side opening ele ments trim 1 Access to the R 621 connector a Disconnect the R621 connector 125641 12...

Page 2995: ...88A 89 WIRING HARNESS Rear wiring Connector access K91 88A 2 Access to the R 401 connectors a Disconnect the R401 connectors 125641...

Page 2996: ...left rear connection a Disconnect the rear screen wiper motor connector 2 the R 621 connector on the left tailgate left tailgate intermediate connection 3 a Detach the rear wiring at 4 IMPORTANT Cons...

Page 2997: ...he R 401 connectors on the boot lid heated rear screen wiring connection the R 621 connector on the left tailgate left tailgate intermediate connection the rear screen wiper motor connector the R 244...

Page 2998: ...ting Rear wing light Removal Refitting page 81A 1 the rear bumper see Rear bumper Removal Refitting 55A Exterior protection a Disconnect the R 319 connector 1 125640 IMPORTANT Consult the safety and c...

Page 2999: ...Exterior protection II OPERATION FOR REMOVAL OF PART CONCERNED a a Disconnect the following connectors the number plate lights 1 the rear fog light 2 IMPORTANT Consult the safety and cleanliness advic...

Page 3000: ...ectors see Connector Sealing and immobilisa tion Technical Note 6015A 88A Wiring II REFITTING OPERATION FOR PART CONCERNED a Refit the rear bumper wiring a Clip the wiring onto the rear bumper a Conne...

Page 3001: ...ht for the number plate lights III FINAL OPERATION a Refit the rear bumper see Rear bumper Removal Refitting 55A Exterior protection the rear lights on the wing see 81A Rear lighting Rear wing light R...

Page 3002: ...sors an inhibitor switch front seat belt buckles rear seat belt buckles front side seat belts rear side seat belts anti submarining airbags the rear centre seat belt front seat lap belt pretensioners...

Page 3003: ...AND PRETENSIONERS Airbag and pretensioners List and location of components 88C Passenger front airbag Front chest level side airbag Curtain side airbag Curtain side airbag 124372 124770 B91 or K91 125...

Page 3004: ...rbag and pretensioners List and location of components 88C Side impact sensors One side impact sensor in each B pillar One side impact sensor in each front side door Inhibitor switch Front seat belt b...

Page 3005: ...D PRETENSIONERS Airbag and pretensioners List and location of components 88C Rear seat belt buckles Front side seat belt Front side seat belt Rear side seat belt 124018 B91 or K91 125383 D91 134380 B9...

Page 3006: ...ENSIONERS Airbag and pretensioners List and location of components 88C Rear side seat belt Anti submarining airbag Front seat belt lap belt pretensioner Rear centre seat belt D91 134402 D91 134389 B91...

Page 3007: ...ist and location of components 88C Rear side airbags chest level Positive battery terminal To remove the positive battery terminal see 80A Bat tery Battery terminals Removal Refitting page 80A 12 1233...

Page 3008: ...or indexing brackets etc Equipment required Diagnostic tool IMPORTANT All operations on airbag and pretensioner systems must be carried out by qualified trained personnel The airbags have a pyrotechn...

Page 3009: ...side airbag anti submarining airbag front seat lap belt pretensioner front side seat belt rear side seat belt pyrotechnic battery terminal automatic roll hoops Bodywork operation dent removal jacking...

Page 3010: ...act sensor Disconnection of passen ger compartment door con nection if the door is equipped with a side impact sensor Lock the airbag computer by applying the Before repair procedure using the Diagnos...

Page 3011: ...8C Air bag and Pretensioners Air bag and pretensioners Precautions for the repair page 88C 7 IMPORTANT To eliminate the risk of any accident do not reuse pyrotechnic components It is essential to dest...

Page 3012: ...e vehicle to be scrapped a Move the vehicle outside the workshop a Mark the adapter corresponding to the pyrotechnic component to be destroyed a Connect the destruction tool Ele 1287 to the adapter th...

Page 3013: ...ing page 80A 4 a Remove the centre console see Centre console Removal Refitting MR 416 57A Interior equipment the intermediate air distribution duct see C pillar intermediate air distribution duct Rem...

Page 3014: ...er protector a Clip the wiring on the airbag computer protector a Refit the soundproofing the intermediate air distribution duct see C pillar intermediate air distribution duct Removal Refitting MR 41...

Page 3015: ...ONCERNED a Insert a flat screwdriver into the aperture 1 located behind the steering wheel a Unclip the driver s front airbag by pushing in the di rection of the arrow 2 IMPORTANT Consult the safety a...

Page 3016: ...r the steering wheel the bolts to the covers under the steering wheel a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4 see 88C Air bag and Pretensioners Airbags and pretensi...

Page 3017: ...g page 86A 10 a Remove the central console see Centre console Remov al Refitting 57A Interior equipment the dashboard see Dashboard Removal Refit ting 57A Interior equipment Tightening torquesm passen...

Page 3018: ...dashboard cross member 4 N m a Refit the centre console see Centre console Re moval Refitting 57A Interior equipment a Refit the receiver see 86A Radio Receiver Removal Refitting page 86A 10 the centr...

Page 3019: ...moval Refitting page 86A 8 a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4 NAVIGATION AID 4 RADIO NO 01 or RADIO NO 02 or RADIO NO 03 WITHOUT NAVIGATION AID and VEHICLEWITH...

Page 3020: ...m II OPERATION FOR REMOVAL OF PART CONCERNED a Unlock the front side chest level airbag connector 1 at 2 a Disconnect the front side chest level airbag con nector a Unclip the front side chest level a...

Page 3021: ...connector III FINAL OPERATION a Refit the front seat back trim see Front seatback trim Removal Refitting 77A Front seat trim the front seat see Complete front seat Removal Refitting 75A Front seat fra...

Page 3022: ...ch seatback a Remove the side section at 1 and 2 a Remove the blanking covers 3 a Remove the rear chest level airbag bolts Tightening torquesm rear side chest level air bag bolts 4 Nm IMPORTANT Consul...

Page 3023: ...irbag a Connect the rear side chest level airbag connec tor a Lock the rear side chest level airbag connector III FINAL OPERATION a Refit the rear inner sill upper trim see Rear inner sill upper trim...

Page 3024: ...80A Battery Battery Re moval Refitting page 80A 4 see 88C Air bag and Pretensioners Airbags and pretensioners Recycling Destruction page 88C 10 IMPORTANT T o eliminate the risk of any accident do not...

Page 3025: ...OVAL OF PART CONCERNED a Unlock the connector 1 from the side curtain airbag at 2 a Disconnect the side curtain airbag connector a Remove the straps 3 the plastic rivet 4 Tightening torquesm side curt...

Page 3026: ...the brackets 8 the bolts 9 from the side curtain airbag generator a Remove the curtain airbag REFITTING I REFITTING PREPARATION OPERATION a a parts always to be replaced Curtain side airbag 31 02 01 4...

Page 3027: ...nector a Lock the side curtain airbag connector III FINAL OPERATION a Refit the headlining see Headlining Removal Refitting 71A Body internal trim a Refit the rear quarter panel trims see Quarter pan...

Page 3028: ...see Front side door trim Removal Refitting 72A Side opening elements trim 2 Central impact sensors a Remove the B pillar lower trim see B pillar lower trim Removal Refitting 71A Body internal trim II...

Page 3029: ...PERATION a parts always to be replaced Side impact sen sors 31 02 01 21 II REFITTING OPERATION FOR PART CONCERNED 1 Front impact sensors a Connect the impact sensor connector a Position the impact sen...

Page 3030: ...Refitting 71A Body internal trim 3 Final common operation a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4 a Unlock the airbag computer by applying the After repair procedur...

Page 3031: ...RNED a Unlock the anti submarining airbag connector at 1 a Disconnect the anti submarining airbag connector a Remove the bolt 2 from the anti submarining air bag bracket Tightening torquesm anti subma...

Page 3032: ...eat base trim see Front seat base trim Removal Refitting 77A Front seat trim the complete front seat see Complete front seat Removal Refitting 75A Front seat frames and runners a Connect the battery s...

Page 3033: ...d panel 1 on the dashboard a Disconnect inhibitor switch connector II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the inhibitor switch at 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Fi...

Page 3034: ...e front seat lap belt pretensioner 2 from the seat casing to disconnect its connector a Unlock 3 the connector 4 of the front seat lap belt pretensioner a Disconnect the connector of the front seat la...

Page 3035: ...s and runners a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4 IMPORTANT After a seat belt pyrotechnic component is trig gered it is essential to replace certain parts see 8...

Page 3036: ...Battery Battery Removal Refitting page 80A 4 a Remove the complete front seat see Complete front seat Removal Refitting 75A Front seat frames and runners II OPERATION FOR REMOVAL OF PART CONCERNED a...

Page 3037: ...ont seat belt buckle II REFITTING OPERATION FOR PART CONCERNED a Refit the front seat belt buckle using a new bolt a Torque tighten the front seat belt buckle bolt 35 N m a Clip on the connector III F...

Page 3038: ...of the rear seat belt buckles using a set of feeler gauges at 4 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the connector on the rear left hand buckle mounting a Connect the connectors o...

Page 3039: ...nclip the front side seat belt at 1 using a flat blade screwdriver a Remove the upper bolt 2 from the front side seat belt Tightening torquesm lower bolt for the front side seat belt 21 Nm upper bolt...

Page 3040: ...nt side seat belt connector a Lock the front side seat belt connector a Clip the front side seat belt into the front seat lap belt pretensioner a Refit the upper bolt of the front side seat belt using...

Page 3041: ...attery Battery Re moval Refitting page 80A 4 IMPORTANT T o eliminate the risk of any accident do not reuse pyrotechnic components It is essential to destroy pretensioners or airbags before scrapping a...

Page 3042: ...ng rail a Remove the cover according to 2 then 3 Tightening torquesm stiffness harness bolt 21 N m front side seat belt upper bolt21 N m front side seatbelt lower mounting runner bolts 21 N m IMPORTAN...

Page 3043: ...tia reel REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the front side seat belt inertia reel the stiffness harness a Torque tighten the stiffness harness bolt 21 N m a Connect the connect...

Page 3044: ...l trim see Rear panel lining Re moval Refitting 71A Body internal trim a Connect the battery see 80A Battery Battery Re moval Refitting page 80A 4 137761 IMPORTANT T o eliminate the risk of any accide...

Page 3045: ...ove the protective foam 1 from the rear side seat belt a Unlock at 2 the rear side seat belt connector 3 a Disconnect the rear side seat belt connector Tightening torquesm rear side seat belt bolt 21...

Page 3046: ...side seat belt bolt 21 N m a Refit a new bolt for the rear side seat belt fitting a Torque tighten the bolt of the rear side seat belt fitting 44 N m a Connect the rear side seat belt connector a Lock...

Page 3047: ...attery Battery Re moval Refitting page 80A 4 IMPORTANT T o eliminate the risk of any accident do not reuse pyrotechnic components It is essential to destroy pretensioners or airbags before scrapping a...

Page 3048: ...from the rear side seat belt fitting 1 a Pass the strap through the rear side seat belt return mechanism 2 a Remove the bolt 3 from the plastic cover the christmas tree pin 4 the plastic casing 5 a Un...

Page 3049: ...lt inertia reel connec tor a Lock the connector on the rear side seat belt inertia reel a Clip the strap a Refit the plastic cover a Pass the strap through the rear side seat belt return mechanism a T...

Page 3050: ...ry Battery Re moval Refitting page 80A 4 IMPORTANT T o eliminate the risk of any accident do not reuse pyrotechnic components It is essential to destroy pretensioners or airbags before scrapping a veh...

Page 3051: ...T CONCERNED a Remove the bolt 1 the rear centre seat belt guide 2 a Remove the rear centre seat belt inertia reel nut 3 the rear centre seat belt 4 REFITTING I REFITTING OPERATION FOR PART CONCERNED a...

Page 3052: ...seat belt strap through the rear bench seat base at 5 a Torque tighten the rear centre seat belt fitting nut 44 N m 6 a Make sure the strap is in the correct position II FINAL OPERATION a Refit the r...

Page 3053: ...MR 416 57A Interior equip ment a Unclip the centre console rear panel 1 a Disconnect the connectors a Remove the rear right hand parcel shelf trim see Rear parcel shelf trim Removal Refitting MR 416...

Page 3054: ...ATION a Refit the centre console see Centre console Re moval Refitting MR 416 57A Interior equip ment a Connect the connectors to the rear panel of the cen tre console a Clip on the centre console rea...

Page 3055: ...ont panel Removal Refit ting 57A Interior equipment II REMOVAL OPERATION FOR PART CONCERNED a Unclip the cigarette lighter REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the cigarette light...

Page 3056: ...s and accessories from which the vehicles are constructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering syste...

Page 3057: ...CTION Vehicle Precautions for the repair 01D 1 Tightening torques General information 01D 3 02A LIFTING EQUIPMENT Vehicle Towing and lifting 02A 1 03B COLLISION Vehicle involved in an impact Impact fa...

Page 3058: ...01A 1 VEHICLE MECHANICAL SPECIFICATIONS Vehicle Specifications B91 01A Dimensions in metres 123275 A 1 014 B 2 756 C 0 925 D 4 695 E 1 557 F unladen 1 445 G 1 512 H 1 811...

Page 3059: ...Euro 4 813 Euro 3 4 and 5 K4M 824 1598 TL4 016 019 Euro 3 and 4 K9K 780 1461 013 Euro 1 3 and 4 782 013 022 Euro 5 M4R 704 1997 017 020 Euro 3 and 4 726 Euro 5 M9R 742 1995 PK4 007 Euro 4 744 746 007...

Page 3060: ...01A 3 VEHICLE MECHANICAL SPECIFICATIONS Vehicle Specifications K91 01A Dimensions in metres 123276 A 1 014 B 2 758 C 1 031 D 4 776 E 1 557 F unladen 1 455 G 1 512 H 1 811...

Page 3061: ...018 Euro 4 813 Euro 3 and 4 K4M 824 1598 TL4 016 019 Euro 3 and 4 K9K 780 1461 013 Euro 4 782 013 022 Euro 5 M4R 704 1997 017 020 Euro 3 and 4 726 Euro 5 M9R 742 1995 PK4 007 Euro 4 744 746 007 009 7...

Page 3062: ...01A 5 VEHICLE MECHANICAL SPECIFICATIONS Vehicle Specifications D91 01A Dimensions in metres 141547 A 1 019 B 2 693 C 0 931 D 4 643 E 1 547 F unladen 1 401 G 1 542 H 2 082...

Page 3063: ...rbox suffix F4R 800 1998 PK4 008 Euro 4 802 Euro 5 811 AJ0 007 018 Euro 4 813 Euro 3 and 4 M9R 742 1995 PK4 007 Euro 4 744 748 007 009 Euro 3 and 4 754 800 012 Euro 4 802 007 009 Euro 4 and 5 803 AJ0...

Page 3064: ...1 Vehicle type mine and type num ber this information also appears on marking B 2 MGVW Maximum Gross Vehi cle Weight 3 GTW Gross train weight vehi cle under load with trailer 4 Maximum permissible fr...

Page 3065: ...EHICLE BODYWORK SPECIFICATIONS Vehicle Identification 01C IV COLD MARKING OF THE BODY Marking C 123656 Note If the complete body is being replaced it must be marked in compliance with the current regu...

Page 3066: ...ion 1 X1 1 5 mm 1 B91 or K91 124288 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respect to the o...

Page 3067: ...01C 4 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 2 X2 5 mm 2 Section 3 X3 4 mm 1 5 Section 4 X4 1 mm Section 5 X5 0 4 mm 0 4 124254 124256 124257 124253...

Page 3068: ...01C 5 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 6 X6 3 5 mm 1 2 Section 7 X7 4 5 mm 1 2 Section 8 X8 Plating Section 9 X9 4 mm 0 8 124258 124285 124287 124279...

Page 3069: ...01C 6 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 10 X10 4 5 mm 1 2 Section 11 X11 4 2 mm 1 2 Section 12 X12 4 7 mm 1 2 124286 124280 124282...

Page 3070: ...ction 13 X13 6 mm 0 2 B91 124289 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respect to the oppo...

Page 3071: ...C 8 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 14 X14 4 mm 1 9 Section 15 X15 4 mm 1 7 Section 16 X16 3 7 mm 1 25 Section 17 X17 1 mm 0 9 124277 124273 124278 1242...

Page 3072: ...01C 9 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 18 X18 1 mm Section 19 X19 2 mm 1 Section 20 X20 4 mm 0 8 Section 21 X21 4 5 mm 2 124276 124252 124281 124271...

Page 3073: ...01C 10 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 22 X22 4 mm 2 Section 23 X23 4 mm 1 6 Section 24 X24 2 mm 0 6 124270 124274 124283...

Page 3074: ...Section 25 X25 1 6 mm K91 124290 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respect to the oppo...

Page 3075: ...1C 12 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 26 X26 2 mm 1 Section 27 X27 4 2 mm 1 75 Section 28 X28 2 2 mm Section 29 X29 4 mm 1 7 124260 124259 124267 124265...

Page 3076: ...C 13 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 30 X30 1 mm 1 2 Section 31 X31 0 4 mm 0 4 Section 32 X32 1 mm 1 7 Section 33 X33 1 mm 1 7 124261 124264 124263 1242...

Page 3077: ...01C 14 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 34 X34 6 5 mm 2 4 124268 D91 134840...

Page 3078: ...ion 36 X36 4 mm 1 5 Section 37 X37 0 5 mm 0 5 WARNING The clearance values are given for information pur poses When adjusting clearances certain rules have to be followed maintain symmetry with respec...

Page 3079: ...16 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 38 X38 0 4 mm 0 4 Section 39 X39 3 5 mm 1 2 Section 40 X40 1 mm 0 9 Section 41 X41 4 5 mm 1 5 133295 133293 133300 13...

Page 3080: ...17 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 42 X42 4 mm 1 Section 43 X43 1 5 mm 0 9 Section 44 X44 4 5 mm 1 5 Section 45 X45 1 3 mm 1 2 133301 133292 133297 133...

Page 3081: ...01C 18 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 47 X47 4 mm 2 133307 134839...

Page 3082: ...LE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 48 X48 5 4 mm 1 5 Section 49 X49 a 1 mm 0 8 X49 b 1 mm 0 8 Section 50 X50 4 mm 1 5 Section 51 X51 0 4 mm 0 4 133313 133316 13...

Page 3083: ...01C 20 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 52 X52 4 mm 1 2 Section 53 X53 2 mm 0 7 Section 54 X54 4 mm 1 5 Section 55 X55 4 mm 1 133312 133310 133311 133302...

Page 3084: ...01C 21 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 56 X56 4 mm 2 Section 57 X57 4 mm 1 Section 58 X58 0 mm Section 59 X59 4 mm 1 133309 133303 133304 133305...

Page 3085: ...01C 22 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps Adjustment value 01C Section 60 X60 5 mm 0 5 133306...

Page 3086: ...be bonded threads stub axle splines to ensure proper adher ence protect the accessories and timing belts the electrical accessories starter blanking cover electric power assisted steering pump and th...

Page 3087: ...moke when working on vehicles use smoke extractors welding exhaust gases etc do not use harmful products in unventilated rooms do not overstrain yourself or attempt inappropriate work operations use a...

Page 3088: ...bly to prevent their separation or sliding when submitted to exterior forces Exterior forces The assembly is submitted to forces that are static and or dynamic simple e g simple traction multiple trac...

Page 3089: ...he friction coefficients from one assem bly to another and the uncertainty of the tightening pro cedures and methods 2 Angle tightening The principle consists of putting the parts of the assem bly in...

Page 3090: ...when using a click type torque wrench is 15 The instructions to be observed are Place the hand in the centre of the handle An incor rectly positioned hand on the handle will alter the trig ger thresh...

Page 3091: ...ening Using a universal joint will result in a difference between the set torque of the wrench and the actual torque applied Before storing the wrench loosen the adjustment spring completely A wrench...

Page 3092: ...ways pull in the direction of the rod s length in order to avoid breaking it Vehicles fitted with automatic transmission The vehicle should preferably be transported on a platform or towed by lifting...

Page 3093: ...he vehicle under the rear axle mechanism bearing at 6 and place the axle stand under the jacking point at 7 122657 IMPORTANT To prevent any accidents the trolley jack must only be used to lift and or...

Page 3094: ...Fitting the straps Fitting the safety strap s For safety reasons the safety strap s must always be in perfect condition replace them if they show signs of wear When fitting the safety strap s check th...

Page 3095: ...the jacking points 10 at the rear IMPORTANT Only the jacking points described in this section allow the vehicle to be raised in complete safety Do not raise the vehicle using points other than those...

Page 3096: ...1 COLLISION Vehicle involved in an impact Impact fault finding 03B I CHECKING THE SUBFRAME a Chronological order of checks Front impact Gd Ng Gg Nd Nd Hg Ng Hd Rear impact Gd Bg Gg Bd Bd Jg Bg Jd 124...

Page 3097: ...ct Impact fault finding 03B II DETAILED VIEW OF INSPECTION POINTS Points Ad Ag Points Bd Bg Rear axle guide Points Gd Gg Front side member rear guide Points Hg Hd Radiator cross member mounting on fro...

Page 3098: ...03B 3 COLLISION Vehicle involved in an impact Impact fault finding 03B Points Jd Jg Rear side member rear leader pin a 124333...

Page 3099: ...al impact Description 03B COMBINATIONS FOR REPLACING WELDED STRUCTURAL PARTS IN ACCORDANCE WITH IMPACT SUSTAINED 1st Degree 1 front end cross member mounting stiffener 2 front panel mounting bracket 3...

Page 3100: ...scription 03B 2nd Degree 4 front section of front right hand side member 5 scuttle side panel 6 battery tray bracket 7 front section of front left hand side member 8 front side member closure panel fr...

Page 3101: ...03B 6 COLLISION Vehicle involved in a frontal impact Description 03B 3rd Degree 10 front right hand half unit 11 upper linkage mounting 12 front left hand half unit 125028...

Page 3102: ...03B 7 COLLISION Vehicle involved in a side impact Description 03B 1st Degree B91 or K91 125037 B91 or K91 125038...

Page 3103: ...pper body 2 sill panel 3 body side closure panel 4 body side front section 2nd Degree 5 scuttle side panel 6 A pillar reinforcement 7 B pillar reinforcement 8 sill panel closure panel 9 sill panel rei...

Page 3104: ...reen aperture lower cross member 18 front wheel arch front section 19 front wheel arch rear section 20 centre floor front cross member 21 front cross member under front seat 22 rear cross member under...

Page 3105: ...03B 10 COLLISION Vehicle involved in a side impact Description 03B 1st Degree D91 134770 D91 134771...

Page 3106: ...n 03B 29 body side front section 30 body side closure panel front section 31 sill panel 2nd Degree 32 scuttle side panel reinforcement 33 A pillar reinforcement 34 windscreen pillar reinforcement 35 B...

Page 3107: ...involved in a side impact Description 03B 3rd Degree 37 roof 38 roof rear cross member 39 roof middle cross member 40 roof front cross member 41 A pillar lining 42 side floor 43 A pillar lining 44 sil...

Page 3108: ...03B 13 COLLISION Vehicle involved in a rear impact Description 03B B91 125034...

Page 3109: ...03B 14 COLLISION Vehicle involved in a rear impact Description 03B 1st Degree K91 125033 B91 128233...

Page 3110: ...COLLISION Vehicle involved in a rear impact Description 03B 1 rear end panel 2 rear wing panel 1st Degree 3 rear wing panel 4 cross member closure panel component 5 absorber mounting cross member K91...

Page 3111: ...16 COLLISION Vehicle involved in a rear impact Description 03B 2nd Degree 6 rear wheel arch 7 rear wing panel rain channel 8 rear side member 9 light mounting lining 10 rear floor rear section B91 125...

Page 3112: ...a rear impact Description 03B 2nd Degree 11 rear wheel arch 12 rear end pillar closure panel 13 rear side member 14 rear end panel 15 rear cross member rear section 16 rear floor rear section 17 rear...

Page 3113: ...impact Description 03B 3rd Degree 18 quarter panel reinforcement 19 shoulder harness reinforcement 20 rear wheel arch 21 side roof rail lining 22 grab handle fixed bridge piece 23 rear subframe assem...

Page 3114: ...scription 03B 3rd Degree 25 rear wheel arch 26 rear side member assembly 27 side roof rail lining rear section 28 rear subframe assembly 29 side roof rail lining front section 30 roof bar mounting rei...

Page 3115: ...03B 20 COLLISION Vehicle involved in a rear impact Description 03B 1st Degree D91 134769 D91 134774...

Page 3116: ...3B 21 COLLISION Vehicle involved in a rear impact Description 03B 32 body side rear section 33 rear end panel 2nd Degree 34 quarter panel lining 35 rear light mounting element upper section D91 134768...

Page 3117: ...2 COLLISION Vehicle involved in a rear impact Description 03B 3rd Degree 36 rear side parcel shelf 37 rear inner wheel arch 38 rear side rain channel 39 rear parcel shelf 40 body side extension D91 13...

Page 3118: ...23 369 SILICOJOINT 90 g tube 77 11 236 469 LOCTITE ADHESIVE 597 Sealing paste for PXX gearboxes Cartridge 77 11 219 705 RESIN ADHESIVE or SEALING RESIN Sealing resin for engine and gear box covers 25...

Page 3119: ...EANER 600 ml aerosol 77 11 422 413 150 ml aerosol 77 11 422 414 BIO BRAKE CLEANER 750 ml spray bottle 77 11 427 217 AIR CONDITIONING CLEANER 250 ml aerosol 77 11 230 498 CARBURETTOR CLEANER Aerosol 77...

Page 3120: ...ENAULT STANDARD 03 50 005 Authorised for vehicles without ESP 0 5 L container 77 11 172 381 5 L container 77 01 395 503 25 L container 77 11 171 926 DOT 4 Authorised for vehicles without ESP without c...

Page 3121: ...na III 1 L container PLANETELF PAG 488 250 ml container 77 11 172 668 SANDEN SP 10 Oil for air conditioning compressor 77 01 419 313 TYRES TYRE PASTE 1 kg pack 77 11 223 052 5 kg pack 77 11 223 053 TY...

Page 3122: ...BIPAC EVOLUTION ADHESIVE KIT 2 225 ml cartridges 77 11 421 434 LINT FREE CLOTH Box of 340 cloths 77 11 237 262 METAL PRIMER Bottle 77 11 419 599 WINDOW SEALING MASTIC 310 ml cartridge 77 11 170 222 SP...

Page 3123: ...container 77 11 420 288 FINISHING LIQUID 1 L container 77 11 420 289 MASTIC Universal mastic GALAXI 2 5 kg pack 77 11 172 238 OPTIMAX 1 23 l cartridge 77 11 172 239 EXCELLENCE For finishing plastic re...

Page 3124: ...rtridge 77 11 423 519 PLASTIC REPAIR CLOTH 90 m roller 77 11 423 520 PLASTIC REPAIR NOZZLES 12 nozzles 77 11 423 522 COMPOSITE MATERIAL REP AIR BY WELDING PLASTIC WELD REPAIR SET 77 11 425 742 PROTECT...

Page 3125: ...adhesion pro moter for thermoplastics 400 ml aerosol 77 11 423 734 PRIMARA BLACK adhesion pro moter primer for thermoplastics 1 L container 77 11 423 735 77 11 171 514 Activator PRIMARA adhesion prom...

Page 3126: ...onstructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering system is forbidden without the prior written author...

Page 3127: ...A 40 41A FRONT LOWER STRUCTURE Body Replacement 41A 1 Front impact cross member General description 41A 2 Front impact cross member Removal Refitting 41A 3 Front end side cross member General descript...

Page 3128: ...General description 41B 10 Rear cross member under front seat Description 41B 11 41A FRONT LOWER STRUCTURE 41C SIDE LOWER STRUCTURE Sill panel General description 41C 1 Sill panel Description 41C 4 Si...

Page 3129: ...43A 1 Windscreen pillar lining General description 43A 2 Windscreen pillar lining Description 43A 3 42A FRONT UPPER STRUCTURE B pillar reinforcement Description 43A 7 B pillar lining General descripti...

Page 3130: ...oof centre cross member General description 45A 9 Roof centre cross member Description 45A 10 44A REAR UPPER STRUCTURE Roof panel arch General description 45A 11 Roof panel arch Description 45A 12 Roo...

Page 3131: ...lock nut against the dashboard cross member nut while hold ing hexagon bolt a Unscrew the whole tool as far as the stop and tight en it gently during this operation the beam nut which has a left hand...

Page 3132: ...a Use this tool when replacing the windscreen remove the windscreen pillar trims position the protector to prevent damaging the dashboard USING THE TOOL FOR FITTING CRIMPED TYPE NUTS INTO BODY PANELS...

Page 3133: ...ses can arise if the rear of the vehicle is being rebuilt these two points alone may be used to align and support the front of the vehicle for a light frontal impact not requiring removal of the front...

Page 3134: ...is centred on the pilot hole B Use this situation for a rear impact with removal of the mechanical components IV SECONDARY REAR TRIM SETTING REFERENCE POINT The jig rests under the front side member...

Page 3135: ...k absorber front upper mount ing 2584 566 7 450 54 12 E2 Rear shock absorber rear upper mount ing 2655 2 566 7 455 5 14 5 F Front shock absorber upper mounting 52 89 589 47 676 41 42 6 F1 Front shock...

Page 3136: ...imen sion X mm Dimen sion Y mm Dimen sion Z mm Diameter mm Angle Ag Front left hand subframe rear mounting without mechanical components 384 5 337 61 17 26 8 M14 Ad Front right hand subframe rear moun...

Page 3137: ...ber left hand exterior mounting 592 16 620 7 370 2 M10 4 K4 Frontal impact cross member left hand interior mounting 700 518 238 M10 4 K3 Frontal impact cross member right hand exterior mounting 592 16...

Page 3138: ...40A 8 GENERAL INFORMATION Subframe Specifications 40A 124893...

Page 3139: ...40A 9 GENERAL INFORMATION Subframe Specifications 40A 124892...

Page 3140: ...40A 10 GENERAL INFORMATION Subframe Specifications 40A 124891...

Page 3141: ...40A 11 GENERAL INFORMATION Hollow section inserts List and location of components 40A A pillar insert 1 B pillar insert 2 121943 123796 121946...

Page 3142: ...40A 12 GENERAL INFORMATION Hollow section inserts List and location of components 40A Rear wheel arch insert 3 Quarter panel insert 4 Side roof rail lining insert 5 121947 123797 K91 121944...

Page 3143: ...3 GENERAL INFORMATION Hollow section inserts List and location of components 40A A pillar insert 1 A pillar insert 2 B pillar insert 5 B pillar insert 4 Rear wheel arch insert 3 121945 123795 121946 1...

Page 3144: ...40A 14 GENERAL INFORMATION Hollow section inserts List and location of components 40A Quarter panel front insert 6 Quarter panel rear insert 7 121948 D91 134262...

Page 3145: ...ts List and location of components 40A A pillar expanding insert 1 Windscreen pillar lining expanding insert 2 Windscreen pillar reinforcement expanding insert up per section 3 B pillar reinforcement...

Page 3146: ...N Hollow section inserts List and location of components 40A Rear quarter panel lining area expanding insert 5 Side roof rail rear reinforcement expanding insert 6 Rear tow eye mounting expanding inse...

Page 3147: ...sconnect the battery and the vehicle s electrical cir cuit earths located near the area to be welded see Battery Removal Refitting 80A Battery position the earth of the welding machine as close as pos...

Page 3148: ...40A 18 GENERAL INFORMATION Earths on body List and location of components 40A 122799...

Page 3149: ...Earths on body List and location of components 40A I DETAILED VIEW OF THE POSITION OF EARTHS ON THE VEHICLE Earth studs on the front left hand side member 1 Earth studs on the left hand scuttle side p...

Page 3150: ...d location of components 40A Earth studs on the front right hand side member 3 Earth stud on the centre floor tunnel 4 Earth studs on the rear end panel left hand side 5 Earth stud on the rear end pan...

Page 3151: ...40A 21 GENERAL INFORMATION Earths on body List and location of components 40A Earth studs on the tailgate 7 II SPECIAL FEATURE OF THE ESTATE 121953 K91 122800...

Page 3152: ...IEW OF THE POSITION OF EARTHS ON THE VEHICLE Earth studs on the rear end panel left hand side 8 Earth stud on the left hand rear quarter lining 9 Earth stud on the rear end panel right hand side 10 Ea...

Page 3153: ...structure Front wheel arch Description page 42A 25 Mild steel 2 5 3 Central floor front cross member see 41B Centre lower structure Centre floor front cross member Description page 41B 4 4 Front half...

Page 3154: ...cription page 42A 20 13 Scuttle side panel upper reinforcement see 42A Front upper structure Upper reinforce ment of scuttle side panel Description page 42A 23 14 Front end side cross member see 41A F...

Page 3155: ...ver see 41C Side lower struc ture Sill panel Description page 41C 4 Mild steel 0 65 3 Sill panel see 41C Side lower structure Sill panel Descrip tion page 41C 4 4 Body side front section see 43A Side...

Page 3156: ...0 Roof centre cross member see 45A Top of body Roof centre cross member Description page 45A 10 11 Roof rear cross member see 45A Top of body Roof rear cross member Description page 45A 14 12 Roof see...

Page 3157: ...t Description 3 Sill panel lining see 41C Side lower structure Sill panel closure panel Description page 41C 12 4 A pillar lining see 43A Side upper structure A pillar reinforce ment Description page...

Page 3158: ...nt section see 43A Side upper structure Body side front sec tion Description page 43A 17 10 Closure panel component front sec tion see 43A Side upper structure Body side front sec tion Description pag...

Page 3159: ...unit Description page 41A 28 4 Front side member centre section see 41A Front lower structure Front side member centre section Description page 41A 23 5 Sill panel closure panel see 41C Side lower st...

Page 3160: ...see 41B Centre lower structure Rear cross member under front seat Description page 41B 11 No Description Classification Type Thickness mm D91 134270 No Description Classification Type Thickness mm 1...

Page 3161: ...tion Description 40A 4 Roof front cross member see 45A Top of body Roof front cross member Description page 45A 8 5 Side floor see 41B Centre lower structure Centre floor side section Description page...

Page 3162: ...tion page 44A 15 Mild steel 1 2 Quarter panel upper section stiff ener see 4 4 A Rear upper structure Quarter panel reinforcement Descrip tion page 44A 41 Mild steel 0 9 3 Rear light mounting see 4 4...

Page 3163: ...D 6 8 Rear side member see 41D Rear lower structure Rear side member Description page 41D 9 9 Inner rear wheel arch see 44A Rear upper structure Inner rear wheel arch Description page 44A 28 10 Rear f...

Page 3164: ...end pillar closure panel see 44A Rear upper structure Rear end pillar clo sure panel Description page 44A 21 7 Rear floor rear cross member see 41D Rear lower structure Rear floor rear cross member De...

Page 3165: ...Rear end panel Description page 44A 50 3 Inner rear wheel arch see 44A Rear upper structure Inner rear wheel arch Description page 44A 28 4 Quarter panel lining see 44A Rear upper structure Quarter p...

Page 3166: ...ion Description 40A 7 Body side extension see 44A Rear upper structure Rear wheel arch extension Description page 44A 31 8 Rear wing panel see 44A Rear upper structure Rear wing panel Description page...

Page 3167: ...ont lower structure Front impact cross member Removal Refit ting page 41A 3 Aluminium 3 Front end panel see 42A Front upper structure Front end panel Removal Refitting page 42A 16 Polypropy lene 4 Bon...

Page 3168: ...Side opening elements Rear side door Removal Refitting page 47A 10 Steel 9 Rear side door K see 47A Side opening elements Rear side door Removal Refitting page 47A 10 Steel 10 Tailgate hatch see 48A N...

Page 3169: ...ntal impact cross member see 41A Front lower structure Front impact cross member Removal Refit ting page 41A 3 Aluminium 14 Front wing see 42A Front upper structure Front wing Removal Refitting page 4...

Page 3170: ...heel arch 2 Top tie bar mounting 3 Rear subframe assembly 4 Front side member rear part 5 Front side member centre section 6 Front panel mounting bracket 7 Front side member front section 8 Front half...

Page 3171: ...axle mounting It is used for replacing a rear side member assembly This point has a direct influence on the path angle of the vehicle 3 Front sub frame front mounting The jig rests under the front su...

Page 3172: ...t half unit This point has a direct influence on the pivot camber and castor angles 5 Engine mounting The jig rests on the engine mounting and is centred in engine mounting securing holes P1 and P2 It...

Page 3173: ...cen tred in the threaded hole H It is used when replacing the front side member completely or partially a front half unit 8 gearbox mounting The jig rests against the front side member and is cen tred...

Page 3174: ...ts under the rear side member and is cen tred in the square hole J It should be used with the mechanical components in place to realign a rear side member It is used with the mechanical components rem...

Page 3175: ...he centre floor side section see 41B Centre lower structure Centre floor side section Descrip tion page 41B 1 Note For standardisation purposes the Parts Depart ment only supplies one body type On veh...

Page 3176: ...de of aluminium Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading the following general infor...

Page 3177: ...ucture Front end panel Removal Refitting page 42A 16 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 1 the front impact cross member REFITTING I REFITTING OPERATION FOR PART CONCERNED a...

Page 3178: ...cles having the same design for this part Before reading the following general information make sure that there are no special notes associ ated with the vehicle These special notes are spec ified if...

Page 3179: ...CTRICAL EARTHS 124581 No Description Type Thick ness mm 1 Front end side cross member HEL 1 2 124631 Note For a detailed description of welded connections see MR 400 121951 WARNING To avoid damaging t...

Page 3180: ...LECTRICAL EARTHS 124606 No Description Type Thick ness mm 1 Front end cross member mount ing stiffener HEL 1 5 124626 Note For a detailed description of welded connections see MR 400 121954 WARNING To...

Page 3181: ...impact absorber radiator support Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading this gener...

Page 3182: ...the front wheel arch liners see Front wheel arch liner Removal Refitting MR 416 55A Exterior protection the front bumper see Front bumper Removal Refitting MR 416 55A Exterior protection a Remove the...

Page 3183: ...e mounting from the pump assembly return pipe a Unclip the return pipe 3 from the radiator mounting cross member pump assembly a Remove the two bolts 4 from the electric vacuum pump mounting II OPERAT...

Page 3184: ...mber the radiator mounting cross member bolts the radiator mounting cross member tie rod bolts a Tighten the radiator mounting cross member bolts the radiator mounting cross member tie rod bolts a Rem...

Page 3185: ...unit Removal Refitting MR 415 13C Preheat ing a Refit the front bumper see Front bumper Removal Refitting MR 416 55A Exterior protection the front wheel arch liners see Front wheel arch liner Removal...

Page 3186: ...CTRICAL EARTHS 124607 No Description Type Thick ness mm 1 Facade mount ing support HEL 1 5 124640 Note For a detailed description of welded connections see MR 400 121951 WARNING To avoid damaging the...

Page 3187: ...IMPORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assemblies Note The information contained in the following describes the general repair procedure for...

Page 3188: ...NT Only the connections which are specific to the partial replacement by cutting are indicated If there are other issues regarding access to mating faces the various replacement options are described...

Page 3189: ...the points and the geometry of the axle assemblies 124636 No Description Type Thick ness mm 1 Inner mounting plate of the unit HLE 1 5 2 Lower section cross member mounting HLE 1 5 3 Rear mounting rei...

Page 3190: ...l replacement of the front section Complete replacement III POSITIONING OF LOCAL ELECTRICAL EARTHS 124635 WARNING To maintain the mechanical properties of the vehi cle the position of the cut must be...

Page 3191: ...front section Description 41A WARNING To avoid damaging the vehicle s electrical and elec tronic components disconnect the earths of any wiring near the weld area Position the welding machine earth as...

Page 3192: ...cement by cutting are indicated IMPORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assemblies Note The information contained in the following describes t...

Page 3193: ...mating faces the various replacement options are described in the basic instructions for structural bodywork repair see MR 400 Line 3 on the drawing shows a butt weld by continu ous EGW welding WARNIN...

Page 3194: ...this part are as follows front section replacement complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 1 Front section replacement 122755 IMPORTANT Use a repair bench to ensure th...

Page 3195: ...ELECTRICAL EARTHS 122469 Note For a detailed description of welded connections see MR 400 121952 WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring ha...

Page 3196: ...llowing describes the general repair procedure for all vehi cles having the same design for this part Before reading the following general information make sure that there are no special notes associ...

Page 3197: ...ng of the points and the geometry of the axle assemblies 124612 No Description Type Thick ness mm 1 Front side mem ber centre sec tion Very high yield strengt h 4 124628 Note For a detailed descriptio...

Page 3198: ...rt cutting at A IMPORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assemblies B91 or K91 124613 No Description Type Thick ness mm 1 Front side mem ber re...

Page 3199: ...escription of welded connections see MR 400 D91 134274 Note For a detailed description of welded connections see MR 400 B91 or K91 121956 WARNING To avoid damaging the vehicles electric and elec troni...

Page 3200: ...ription 41A D91 134783 WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected Position the earth of the wel...

Page 3201: ...RICAL EARTHS 124614 No Description Type Thick ness mm 1 Battery tray sup port Mild steel 2 124639 Note For a detailed description of welded connections see MR 400 121951 WARNING To avoid damaging the...

Page 3202: ...F THE SPARE PART II PART IN POSITION 124615 IMPORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assemblies 124877 No Description Type Thick ness mm 1 Fron...

Page 3203: ...se a repair bench to ensure the positioning of the points and the geometry of the axle assemblies Note The information contained in the following describes the general repair procedure for all vehi cl...

Page 3204: ...the points and the geometry of the axle assemblies 124624 No Description Type Thick ness mm 1 Front end cross member mount ing stiffener HLE 2 5 2 Front wheel arch front section Mild steel High elast...

Page 3205: ...mem ber closure panel HLE 1 67 2 2 8 Front side mem ber front section VHEL 1 77 9 Lower section of upper cross member mount ing HLE 1 5 10 Battery tray sup port Mild steel 2 11 Front wheel arch front...

Page 3206: ...icle tool kit Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading this general information chec...

Page 3207: ...cement of the rear section complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION Partial replacement of the front section Partial replacement of the rear section 124604 No Descripti...

Page 3208: ...Note During partial or complete replacement of the rear section of the left hand side floor it is necessary to make two holes with a diameter of 5 2 mm in order to fit the neck support using two stee...

Page 3209: ...etry of the axle assemblies Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading the following g...

Page 3210: ...There is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART FITTED 124586 No Description Type Thick ness mm 1 Central floor front cross member Mild steel...

Page 3211: ...ench to ensure the positioning of the points and the geometry of the axle assemblies Note The information contained in the following describes the general repair procedure for all vehi cles having the...

Page 3212: ...placement I COMPOSITION OF THE SPARE PART II PART IN POSITION 124580 No Description Type Thick ness mm 1 Centre floor front side cross mem ber HLE 1 77 IMPORTANT Use a repair bench to ensure the posit...

Page 3213: ...a side impact Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading this general information chec...

Page 3214: ...s follows front partial replacement complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION Partial front replacement 124603 124880 No Description Type Thick ness mm 1 Front cross mem...

Page 3215: ...CAL EARTHS 124644 Note For a detailed description of welded connections see MR 400 121956 WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness ne...

Page 3216: ...side impact Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading this general information check...

Page 3217: ...only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 124601 No Description Type Thick ness mm 1 Rear cross mem ber under front seat Very high yi...

Page 3218: ...f the sill panel III AREA TO BE CUT FOR PARTIAL REPLACEMENT The lines 1 and 4 mark the areas for the partial re placement of the front of the sill panel Note The information contained in the following...

Page 3219: ...on under the door Previous cuts can be used to carry out more extensive partial replacements front partial replacement cut 1 2 and 5 Rear partial replacement cut 2 3 and 4 These operations allow you t...

Page 3220: ...escribed in the basic instructions for structural bodywork repair see MR 400 Lines 1 2 and 5 on the drawing show a butt weld by continuous EGW welding The welds described in this procedure are all ide...

Page 3221: ...follows front end replacement partial replacement under door front section replacement rear end section replacement rear section replacement complete replacement I COMPOSITION OF THE SPARE PART II PA...

Page 3222: ...al replacement under door Section C 122079 122447 122022 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffeners or acoustic inserts...

Page 3223: ...ed in accordance with the position of the inner stiffeners or acoustic inserts in order to pre vent damaging the parts inner stiffener and or acoustic insert 122466 122448 122021 WARNING Respect the p...

Page 3224: ...mined in accordance with the position of the inner stiffeners or acoustic inserts in order to pre vent damaging the parts inner stiffener and or acoustic insert 122077 WARNING Respect the position of...

Page 3225: ...LOCAL ELECTRICAL EARTHS 121956 IMPORTANT To avoid damaging the vehicle s electric and elec tronic components the battery and the earths of any wiring harness near the weld area must be dis connected T...

Page 3226: ...lacing this part are as follows partial replacement of the front section complete replacement I COMPOSITION OF THE SPARE PART II PART FITTED 1 Partial replacement of the front section Section A 134317...

Page 3227: ...ll panel Description D91 41C 2 Complete replacement 134319 Note For the connection of this joint see Electrical resistance spot welding connection with direct access Description MR 400 40B Electrical...

Page 3228: ...ctions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before re...

Page 3229: ...one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION Complete replacement 124602 No Description Type Thick ness mm 1 Sill panel closure panel Very hi...

Page 3230: ...lacement 134326 134327 No Description Type Thick ness mm 1 Sill panel closure panel THLE 1 2 2 Seat belt rail fixed bridge piece THLE 2 3 Seat belt rail fixed reinforce ment HLE 2 WARNING Respect the...

Page 3231: ...41C 14 SIDE LOWER STRUCTURE Sill panel closure panel Description D91 41C Section A 134329 134781...

Page 3232: ...41C 15 SIDE LOWER STRUCTURE Sill panel closure panel Description D91 41C 2 Complete replacement 134328 Note For a detailed description of welded connections see MR 400...

Page 3233: ...LACEMENT Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading this general information check tha...

Page 3234: ...lacement I COMPOSITION OF THE SPARE PART II PART IN POSITION Partial replacement of the front section Partial replacement of the rear section Complete replacement 124593 No Description Type Thick ness...

Page 3235: ...41C 18 SIDE LOWER STRUCTURE Sill panel reinforcement Description B91 or K91 41C Note For a detailed description of welded connections see MR 400...

Page 3236: ...he options for replacing this part are as follows partial front replacement complete replacement I COMPOSITION OF THE SPARE PART II PART FITTED Partial front replacement Detailed view A 134325 No Desc...

Page 3237: ...panel reinforcement Description D91 41C Complete replacement 134321 WARNING To preserve the mechanical specifications when partially replacing parts with a single structural component alter the weld l...

Page 3238: ...ssues regarding access to mating faces the various replacement options are described in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following...

Page 3239: ...41D 2 REAR LOWER STRUCTURE Rear floor rear section General description 41D Line 2 on the diagram shows a joint made by joggling connected with plug welds at regular intervals 123067...

Page 3240: ...COMPOSITION OF THE SPARE PART Adaptation 1 unsolder the bridge piece 3 battery mounting to be ordered additionally 4 battery wiring routing drilling 5 battery degassing pipe routing drilling 122758 1...

Page 3241: ...loor rear section Description 41D Cutting dimensions II PART IN POSITION 1 Partial replacement 2 Complete replacement 134786 V4Y or V9X 134314 B91 or K91 122449 122076 Note For a detailed description...

Page 3242: ...he earths of any wiring harness near the weld area must be disconnected Position the welding machine earth as close as possible to the weld zone see MR 400 134819 WARNING To avoid damaging the vehicle...

Page 3243: ...semblies 124651 No Description Type Thick ness mm 1 Rear axle assem bly mounting bridge piece Very high yield strengt h 4 2 Rear side mem ber front section HEL 1 77 3 Axle assembly mounting unit HEL 2...

Page 3244: ...41D 7 REAR LOWER STRUCTURE Rear side member assembly Description 41D II PART IN POSITION Complete replacement 124647 Note For a detailed description of welded connections see MR 400...

Page 3245: ...rk repair see MR 400 The line 2 on the drawing shows a butt weld made by continuous GMAW welding IMPORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assem...

Page 3246: ...PORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assemblies 124650 No Description Type Thick ness mm 1 Rear section of rear side member HEL 1 7 2 Suspens...

Page 3247: ...41D 10 REAR LOWER STRUCTURE Rear side member Description 41D Complete replacement 124649 Note For a detailed description of welded connections see MR 400...

Page 3248: ...following describes the general repair procedure for all vehi cles having the same design for this part Before reading this general information check that there are no special notes associated with th...

Page 3249: ...art beforehand I COMPOSITION OF THE SPARE PART II PART FITTED 122752 124652 No Description Type Thick ness mm 1 Lashing ring rein forcement HLE 1 5 2 Floor cross mem ber closure panel component Mild s...

Page 3250: ...tting back together the rear geometry of the vehicle s subframe It is carried out on a restructuring bench with geometric inspection body jig bench IMPORTANT Use a repair bench to ensure the positioni...

Page 3251: ...41D 14 REAR LOWER STRUCTURE Rear subframe assembly Description 41D There is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART 124619 124901...

Page 3252: ...nchor ing spacer HEL 1 47 7 Rear centre cross member HEL 1 17 8 Rear side mem ber assembly 9 Front section of rear floor Mild steel 0 67 10 Child baby seat central reinforce ment HEL 1 47 11 Floor sou...

Page 3253: ...ribes the general repair procedure for all vehi cles having the same design for this part Before reading the following general information make sure that there are no special notes associ ated with th...

Page 3254: ...PER STRUCTURE Front wing General description B91 or D91 or K91 42A Adjust the panel gaps and alignment with the front door using mountings 10 Adjust the alignment of the wing using mountings 21 122062...

Page 3255: ...eel arch liner Removal Refitting MR 416 55A Exterior protection the front bumper see Front bumper Removal Refitting MR 416 55A Exterior protection the headlight see Headlight Removal Refit ting MR 415...

Page 3256: ...a Refit the front wing the bolts II FINAL OPERATION a Refit the wing upper trim 4 the trim 3 the windscreen lower trim piece 2 the seal 1 the headlight see Headlight Removal Refit ting MR 415 80B Head...

Page 3257: ...Removal Refitting 55A Exterior protection the headlight on the side concerned see Head light Removal Refitting 80B Headlights the front side door seal on the side concerned see Front side door seal R...

Page 3258: ...N a Refit the front bumper support 5 the soundproofing 4 the wing upper trim 3 the windscreen lower trim piece 2 the seal 1 the front side door seal see Front side door seal Removal Refitting 65A Open...

Page 3259: ...d 4 a Symbols A B C and D show the adjustment op tions The black dot in the centre represents the body of the bolt The grey section represents the component to be adjusted The white section represents...

Page 3260: ...Loosen the mountings 5 and 6 a Refit the front wing the headlight a Adjust the front wing a Tighten the bolts 6 a Remove the front wing the headlight a Tighten the nuts 5 a Refit the front wing see 42...

Page 3261: ...ND FRONT DOOR a Remove the windscreen lower trim piece the wing upper trim a Adjust the panel gaps with the front door a Adjust the panel gaps with the front door and the sill panel a Refit the wing u...

Page 3262: ...42A 10 FRONT UPPER STRUCTURE Front wing Adjustment B91 or K91 42A the front wheel arch liner see Front wheel arch liner Removal Refitting 55A Exterior protec tion...

Page 3263: ...alue 01C Vehicle bodywork specifications ADJUSTMENT a There are three options for adjusting the front wing adjustment with the front door adjustment with the bonnet adjustment with the headlight and b...

Page 3264: ...Refitting 55A Exterior protec tion the front bumper see Front bumper Removal Refitting 55A Exterior protection II ADJUSTMENT WITH THE BONNET AND THE FRONT HEADLIGHT a a Remove the headlight on the sid...

Page 3265: ...see 42A Front upper structure Front wing Removal Refitting page 42A 3 the front headlight see Headlight Removal Re fitting 80B Front headlights a Adjust the panel gaps between the front bumper and the...

Page 3266: ...nt door and the sill panel a Refit the wing upper trim the windscreen lower trim piece IV FINAL OPERATION a Refit the front bumper see Front bumper Removal Refitting 55A Exterior protection the front...

Page 3267: ...d are bolted onto the vehicle Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading the following...

Page 3268: ...otection the headlights see Headlight Removal Refit ting MR 415 80B Headlights II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the windscreen washer bottle a Remove the front end panel central com...

Page 3269: ...element mechanisms the front end panel central component a Clip on the windscreen washer bottle II FINAL OPERATION a Refit the headlights see Headlight Removal Refit ting MR 415 80B Headlights the fro...

Page 3270: ...garding access to mating faces the various replacement options are described in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following describ...

Page 3271: ...19 FRONT UPPER STRUCTURE Scuttle side panel General description 42A Line 8 on the diagram shows the partial replacement and an EGW butt weld The weld must be made along the original butt weld line 124...

Page 3272: ...THE SPARE PART 124582 124883 No Description Type Thick ness mm 1 Scuttle side panel Mild steel 0 8 1 2 Windscreen wiper mounting side bridge piece Mild steel 1 5 3 Dashboard cross member mount ing Ver...

Page 3273: ...IONING OF LOCAL ELECTRICAL EARTHS 124654 124656 124655 Note For a detailed description of welded connections see MR 400 121951 WARNING To avoid damaging the vehicles electric and elec tronic component...

Page 3274: ...lly laser butt welded together prior to forming Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before rea...

Page 3275: ...nd panel mounting rein forcement Mild steel 1 3 2 Stay support bridge piece HEL 1 2 3 A pillar lining impact reinforce ment HEL 2 4 Cowl side panel upper reinforce ment HEL 0 7 1 2 124658 Note For a d...

Page 3276: ...ORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assemblies Note The information contained in the following describes the general repair procedure for all...

Page 3277: ...tion Type Thick ness mm 1 Frontal impact cross member mounting HEL 2 5 2 Side member clo sure panel com ponent HEL 1 67 2 2 3 Front end side cross member HEL 1 2 4 Wheel arch clo sure panel com ponent...

Page 3278: ...com ponent HEL 1 67 2 2 14 Front wheel arch closure panel component HEL 1 2 15 Front wheel arch front section Very high yield strengt h 1 8 16 Gearbox linkage support mount ing bridge piece Mild stee...

Page 3279: ...ECTRICAL EARTHS 124584 No Description Type Thick ness mm 1 Front wheel arch front section Mild steel 2 124662 Note For a detailed description of welded connections see MR 400 121954 WARNING To avoid d...

Page 3280: ...It can be replaced partially from the left hand side 1 Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Bef...

Page 3281: ...HE SPARE PART II PREPARATION OF THE REPLACEMENT PART For fitting stud rivets see Riveted connection De scription 134330 Note This part can be partially replaced in order to avoid repositioning the stu...

Page 3282: ...42A 30 FRONT UPPER STRUCTURE Windscreen aperture lower cross member Description 42A III PART IN POSITION 124663 Note For a detailed description of welded connections see MR 400...

Page 3283: ...bly a Unclip the passenger compartment fuse box a Disconnect the earths 1 a Remove the dashboard cross member flange bolts 2 the dashboard cross member flange nuts 3 the dashboard cross member flange...

Page 3284: ...side bolts 21 Nm a Refit the blanking covers 8 the dashboard cross member tie rod bolt 7 the dashboard cross member bolts 6 a Torque tighten the dashboard cross member tie rod bolt 21 Nm the dashboar...

Page 3285: ...see Windscreen Removal Refitting II AREA TO BE CUT FOR PARTIAL REPLACEMENT Cutting line 1 shows the area in which it is possible to carry out a partial replacement III ASSEMBLY INSTRUCTIONS FOR A PAR...

Page 3286: ...this part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION Section A 124589 No Description Type Thick ness mm 1 Bulkhead plate HEL 1 5 0 8 124664 Note To refit the bonding pro...

Page 3287: ...1 I COMPOSITION OF THE SPARE PART II PART IN POSITION 124590 K91 124665 No Description Type Thick ness mm 1 D o o r h i n g e mounting retainer Mild steel 0 8 2 Upper hinge mounting plate HEL 8 3 Uppe...

Page 3288: ...acement options are described in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cl...

Page 3289: ...he options for replacing this part are as follows front partial replacement Rear partial replacement complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 1 Partial front replacemen...

Page 3290: ...43A 4 SIDE UPPER STRUCTURE Windscreen pillar lining Description B91 or K91 43A 3 Complete replacement 124667 Note For a detailed description of welded connections see MR 400...

Page 3291: ...cation of components page 40A 11 the options for replacing this part are as follows partial front replacement without removal of the roof complete replacement with removal of the roof I COMPOSITION OF...

Page 3292: ...ar lining Description D91 43A Section A 2 Complete replacement 134793 134748 WARNING To preserve the mechanical specifications when partially replacing parts with a single structural component alter t...

Page 3293: ...ace this part also order the B pillar insert see 40A General information Hollow section inserts List and location of components page 40A 11 The options for replacing this part are as follows Complete...

Page 3294: ...oor upper hinge mounting retainer Mild steel 0 8 4 Door upper hinge mounting plate HLE 8 5 Airbag sensor mounting bridge piece Mild steel 2 6 B pillar reinforce ment lower sec tion HLE 1 8 7 B pillar...

Page 3295: ...ent as long as tabs 8 and 9 are folded in order to remove the lower part more quickly III POSITIONING OF LOCAL ELECTRICAL EARTHS 121956 IMPORTANT To avoid damaging the vehicle s electric and elec tron...

Page 3296: ...ist and location of components page 40A 11 The options for replacing this part are as follows Complete replacement lower section replacement COMPOSITION OF THE SPARE PART 134750 134751 No Description...

Page 3297: ...B pillar reinforcement Description D91 43A 1 Lower section replacement 134795 WARNING If the mating faces of the parts to be welded are not accessible perform GMAW plug welds instead of the original r...

Page 3298: ...A 2 Complete replacement 134794 WARNING If the mating faces of the parts to be welded are not accessible perform GMAW plug welds instead of the original resistance welding see MR 400 Note For detailed...

Page 3299: ...s the general repair procedure for all vehi cles having the same design for this part Before reading the following general information make sure that there are no special notes associ ated with the ve...

Page 3300: ...body side front section Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading the following gene...

Page 3301: ...e General description B91 or K91 D91 43A The special feature of the body side is that it is com prised of three distinct parts assembled by electric re sistance welding sill panel 1 rear wing panel 2...

Page 3302: ...an be replaced in several ways following an impact For detailed information about the body side front sec tion see 43A Side upper structure Body side front section Description page 43A 17 Note The inf...

Page 3303: ...tion replacement rear section replacement lower section replacement upper section replacement complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 1 Front section replacement Secti...

Page 3304: ...ar section replacement Section C Section D 122022 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffeners or acoustic inserts in orde...

Page 3305: ...this cut which has been determined in accordance with the position of the inner stiffeners or acoustic inserts in order to pre vent damaging the parts inner stiffener and or acoustic insert 122028 122...

Page 3306: ...H Section I 5 Complete replacement 122029 122017 122024 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffeners or acoustic inserts...

Page 3307: ...s to replace the original resistance welds see MR 400 Note For more detailed information on welded connec tions with three thicknesses see MR 400 121951 121956 IMPORTANT To avoid damaging the vehicle...

Page 3308: ...ttle side panel reinforcement sill lining replacement A pillar replacement A pillar lower section replacement without the scuttle side panel reinforcement I COMPOSITION OF THE SPARE PART II PART FITTE...

Page 3309: ...B 2 Sill lining replacement Section C 134764 134765 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffeners or acoustic inserts in o...

Page 3310: ...ar lower section replacement without the scuttle side panel reinforcement 134763 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffen...

Page 3311: ...SITIONING OF THE NEARBY ELECTRICAL EARTHS 134790 134783 WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnec...

Page 3312: ...he basic instructions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this...

Page 3313: ...43A 27 SIDE UPPER STRUCTURE Upper body General description B91 or K91 43A Lines 4 5 and 6 on the drawing show a butt weld by continuous EGW welding Weld 6 along the butt weld line 132023...

Page 3314: ...type compos elle remplit la fonc tion de doublure de brancard 1 et de renfort de coin sup rieur arri re 2 Note The information contained in the following describes the general repair procedure for al...

Page 3315: ...E UPPER STRUCTURE Side roof rail lining General description B91 or K91 43A Cette pi ce est de type compos elle remplit la fonc tion de doublure de brancard 1 et de renfort de fixa tion de ceinture de...

Page 3316: ...OMPOSITION OF THE SPARE PART II PART IN POSITION Complete replacement III POSITIONING OF LOCAL ELECTRICAL EARTHS 122765 122778 No Description Type Thick ness mm 1 Quarter panel lin ing Mild steel 1 5...

Page 3317: ...B91 43A IMPORTANT To avoid damaging the vehicle s electric and elec tronic components the battery and the earths of any wiring harness near the weld area must be dis connected Position the welding ma...

Page 3318: ...40A 11 must also be ordered The options for replacing this part are as follows partial replacement of the lower section partial replacement of the upper section complete replacement I COMPOSITION OF...

Page 3319: ...he upper section 3 Complete replacement 122072 122454 122452 WARNING If the mating faces of the parts to be welded are not accessible make EGW plug welds to replace the original resistance welds see M...

Page 3320: ...F LOCAL ELECTRICAL EARTHS 121955 IMPORTANT To avoid damaging the vehicle s electric and elec tronic components the battery and the earths of any wiring harness near the weld area must be dis connected...

Page 3321: ...on the lower section Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading the following general...

Page 3322: ...how the areas in which it is possible to carry out a partial replacement III ASSEMBLY METHOD FOR A PARTIAL REPLACEMENT Only the connections which are specific to the partial replacement by cutting are...

Page 3323: ...CTURE Rear wing panel General description B91 or D91 or K91 44A Lines 7 in the diagram show butt welding by continu ous EGW welding Lines 8 in the diagram show butt welding by continu ous EGW welding...

Page 3324: ...inserts List and location of components page 40A 11 The options for replacing this part are as follows lower section replacement central section replacement complete replacement I COMPOSITION OF THE S...

Page 3325: ...44A 5 REAR UPPER STRUCTURE Rear wing panel Description B91 44A Section C Section D 2 Central section replacement Section E 122460 122461 122474 122446...

Page 3326: ...e make EGW plug welds to replace the original resistance welds see MR 400 Note For more detailed information on welded connec tions with three thicknesses see MR 400 121955 IMPORTANT To avoid damaging...

Page 3327: ...s List and location of compo nents page 40A 11 The options for replacing this part are as follows lower section replacement upper section replacement rear end section replacement central section repla...

Page 3328: ...44A 8 REAR UPPER STRUCTURE Rear wing panel Description K91 44A II PART FITTED 1 Lower section replacement Section A Section B Section C 122472 122460 122072 122461...

Page 3329: ...44A 9 REAR UPPER STRUCTURE Rear wing panel Description K91 44A 2 Replacement of the upper section Section D 3 Rear end section replacement 4 Central section replacement 124671 122459 124673 124876...

Page 3330: ...UCTURE Rear wing panel Description K91 44A Section E 5 Complete replacement Section F III POSITIONING OF LOCAL ELECTRICAL EARTHS 122446 124875 122459 Note For a detailed description of welded connecti...

Page 3331: ...n K91 44A WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected The earth of the welding machine must be p...

Page 3332: ...SITION OF THE SPARE PART II POSITIONING OF LOCAL ELECTRICAL EARTHS 134741 134741 No Description Type Thick ness mm 1 Rear wing panel Mild steel 0 75 134742 Note For the connection of this joint see El...

Page 3333: ...ription D91 44A WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected Position the welding machine earth a...

Page 3334: ...ement options are described in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cles...

Page 3335: ...er section replacement complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION Lower section replacement Complete replacement 124594 No Description Type Thick ness mm 1 Rear wing pane...

Page 3336: ...or replacing this part are as follows lower section replacement complete replacement I COMPOSITION OF THE SPARE PART 1 Lower section replacement 134756 134757 No Description Type Thick ness mm 1 Lower...

Page 3337: ...ECTRICAL EARTHS 134760 Note For a detailed description of welded connections see MR 400 134819 WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harne...

Page 3338: ...acing this part complete replacement I COMPOSITION OF THE SPARE PART II PART FITTED III POSITIONING OF THE NEARBY ELECTRICAL EARTHS 134738 134738 No Description Type Thick ness mm 1 Lights support lin...

Page 3339: ...escription D91 44A WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected Position the welding machine eart...

Page 3340: ...There is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 124890 No Description Type Thick ness mm 1 Lights support lining Mild steel 0 7 12...

Page 3341: ...placing this part complete replacement I COMPOSITION OF THE PART II PART IN POSITION 124889 124676 No Description Type Thick ness mm 1 Rear end pillar closure panel Mild steel 1 2 Opening control moun...

Page 3342: ...TIONING OF LOCAL ELECTRICAL EARTHS 121955 WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected The earth...

Page 3343: ...es regarding access to mating faces the various replacement options are described in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following de...

Page 3344: ...24 REAR UPPER STRUCTURE Outer rear wheel arch General description B91 or D91 or K91 44A Line 2 on the diagram shows partial replacement and a weld by joggling with plug welds at regular intervals 110...

Page 3345: ...this part partial replacement I COMPOSITION OF THE SPARE PART II PART FITTED Partial replacement III POSITIONING OF LOCAL ELECTRICAL EARTHS 124595 No Description Type Thick ness mm 1 Outer rear wheel...

Page 3346: ...iption 44A WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected The earth of the welding machine must be...

Page 3347: ...structural bodywork repair see MR 400 IMPORTANT Use a repair bench to ensure the positioning of the points and the geometry of the axle assemblies Note The information contained in the following descr...

Page 3348: ...Thick ness mm 1 Inner rear wheel arch Mild steel 0 8 2 Shock absorber mounting rein forcement HLE 1 5 3 Shock absorber mounting yoke HLE 2 4 Inert i a r e e l mounting rein forcement HLE 2 5 Backrest...

Page 3349: ...III POSITIONING OF LOCAL ELECTRICAL EARTHS 122802 WARNING To avoid damaging the vehicle s electrical and elec tronic components disconnect the earths of any wiring near the weld area Position the weld...

Page 3350: ...134736 No Description Type Thick ness mm 1 Inner rear wheel arch Mild steel 0 8 2 Frame lower mounting bridge piece HLE 1 5 3 Shock absorber mounting rein forcement HLE 1 5 4 Shock absorber mounting y...

Page 3351: ...COMPOSITION OF THE SPARE PART II PART FITTED 1 Lower section replacement 134730 134731 No Description Type Thick ness mm 1 Body side exten sion Mild steel 0 75 2 Rear light mount ing element lower se...

Page 3352: ...44A 32 REAR UPPER STRUCTURE Rear wheel arch extension Description D91 44A 2 Complete replacement III POSITIONING OF LOCAL ELECTRICAL EARTHS 134732 122802...

Page 3353: ...ons for replacing this part are as follows replacement of outer wheel arch replacement of front section B pillar lining replacement of rear section wheel arch extension replacement of lower section wi...

Page 3354: ...el 1 3 5 Quarter panel outer rear stiff ener Mild steel 0 8 6 Luggage com partment lid hinge mounting reinforcement Mild steel 1 5 7 Roof drip mould ing rear rein forcement Mild steel 1 8 Seat opening...

Page 3355: ...arch 2 Replacement of front section B pillar lining 134804 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffeners or acoustic insert...

Page 3356: ...ng 3 Replacement of rear section wheel arch extension 134802 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffeners or acoustic inse...

Page 3357: ...ch extension 4 Complete replacement without roof 134799 WARNING Respect the position of this cut which has been determined in accordance with the position of the inner stiffeners or acoustic inserts i...

Page 3358: ...44A 38 REAR UPPER STRUCTURE Quarter panel lining Description D91 44A Complete without roof Section F Section B 134801 134806 134807...

Page 3359: ...STRUCTURE Quarter panel lining Description D91 44A 5 Complete replacement Complete with roof 134798 Note To preserve the mechanical specifications when making a partial replacement respect the positio...

Page 3360: ...is in addition to the replacement of the roof This is a basic part it serves as the quarter panel rein forcement Note The information contained in the following describes the general repair procedure...

Page 3361: ...nt of lower section I COMPOSITION OF THE SPARE PART II PART IN POSITION Partial replacement of lower section 124597 124679 No Description Type Thick ness mm 1 Quarter panel lower section stiffener Mil...

Page 3362: ...There is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 124591 No Description Type Thick ness mm 1 Quarter panel reinforcement Mild steel...

Page 3363: ...ART II PART FITTED 134719 134720 No Description Type Thickness mm 1 Centre cross member Mild steel 0 65 2 Rear parcel shelf centre cross member Mild steel 0 75 3 Rear screen lower cross member Mild st...

Page 3364: ...44A 44 REAR UPPER STRUCTURE Rear parcel shelf Description D91 44A III POSITIONING OF LOCAL ELECTRICAL EARTHS 134812...

Page 3365: ...complete unit Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading this general information che...

Page 3366: ...44A 46 REAR UPPER STRUCTURE Rear end panel assembly Description B91 44A There is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART 122754 122003...

Page 3367: ...val No Description Type Thick ness mm 1 Rear end panel lining HEL 1 2 Boot lid striker panel mounting Mild steel 1 2 3 Rear end panel cross member HEL 1 4 Rear end panel Mild steel 0 7 5 Rear end cros...

Page 3368: ...OF LOCAL ELECTRICAL EARTHS 121955 IMPORTANT To avoid damaging the vehicle s electric and elec tronic components the battery and the earths of any wiring harness near the weld area must be dis connecte...

Page 3369: ...tructions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before...

Page 3370: ...44A 50 REAR UPPER STRUCTURE Rear end panel Description B91 or D91 44A There is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART 122754 122003...

Page 3371: ...HLE 1 4 Striker plate sup port Mild steel 1 2 5 Rear end panel lining HLE 1 122005 WARNING If the mating faces of the parts to be welded are not accessible make EGW plug welds to replace the original...

Page 3372: ...ption Type Thick ness mm 1 Rear side parcel shelf Mild steel 1 2 2 Rear inertia reel mounting rein forcement Mild steel 1 5 3 Rear seat belt shoulder har ness reinforce ment Mild steel 1 2 4 Rear seat...

Page 3373: ...A III POSITION OF LOCAL ELECTRICAL EARTHS 134819 WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected Pos...

Page 3374: ...mating faces the various replacement options are described in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following describes the general re...

Page 3375: ...part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 1 Dismantling a Cutting Cut the part around each laser bead see MR 400 Remove the damaged part Special tooling required C...

Page 3376: ...cle Gently sand the internal mating faces at the bonding zones on the vehicle with P320 dry sand paper or with a red abrasive pad without removing the galvanised protection Prepare the remaining matin...

Page 3377: ...sitioned on the shims passing the straps through the door windows safety strap s to position it in accordance with the markings made previously see MR 400 c Making the other joints Make the rest of th...

Page 3378: ...te replacement This operation only affects versions fitted with a sun roof I COMPOSITION OF THE SPARE PART II PART IN POSITION Complete replacement 122747 No Description Type Thick ness mm 1 Front sec...

Page 3379: ...EARTHS 124598 No Description Type Thick ness mm 1 Roof rear section Mild steel 0 85 124882 Note For a detailed description of welded connections see MR 400 121953 WARNING To avoid damaging the vehicl...

Page 3380: ...scribed in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cles having the same des...

Page 3381: ...nly one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 122777 No Description Type Thick ness mm 1 Roof front cross member Mild steel 0 95 122443 No...

Page 3382: ...structions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Befor...

Page 3383: ...is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART IN POSITION 122769 No Description Type Thick ness mm 1 Roof centre cross member UHLE 1 3 122442 Note...

Page 3384: ...The information contained in the following describes the general repair procedure for all vehi cles having the same design for this part Before reading the following general information make sure tha...

Page 3385: ...e is only one way of replacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART FITTED 122745 No Description Type Thick ness mm 1 Roof centre cross member HEL 1 122445 Note For a...

Page 3386: ...described in the basic instructions for structural bodywork repair see MR 400 Note The information contained in the following describes the general repair procedure for all vehi cles having the same d...

Page 3387: ...LOCAL ELECTRICAL EARTHS 122770 No Description Type Thick ness mm 1 Roof rear cross member Mild steel 0 7 122444 Note For a detailed description of the welded connec tions see MR 400 121955 WARNING To...

Page 3388: ...eplacing this part complete replacement I COMPOSITION OF THE SPARE PART II PART FITTED III POSITIONING OF LOCAL ELECTRICAL EARTHS 134712 No Description Type Thick ness mm 1 Roof rear cross member Mild...

Page 3389: ...iption D91 45A WARNING To avoid damaging the vehicles electric and elec tronic components the earths of any wiring harness near the weld area must be disconnected Position the welding machine earth as...

Page 3390: ...door nuts 3 the front side door II REFITTING WITHOUT HINGES 1 OPERATION FOR REFITTING PART CONCERNED a a Refit the front side door the front side door nuts 3 a Adjust the front side door clearances a...

Page 3391: ...t side door hinge bolts 4 the front side door hinge nuts 5 the front side door IV REFITTING WITH HINGES 1 OPERATION FOR REFITTING PART CONCERNED a Refit the front side door the front side door hinge n...

Page 3392: ...n channel Removal Refit ting MR 416 66A Window sealing the window winder motor see Electric window motor Removal Refitting MR 415 87D Elec tric windows Sunroof the front side door sliding window see F...

Page 3393: ...ide door sliding window Removal Refitting MR 416 54A Windows the window winder motor see Electric window motor Removal Refitting MR 415 87D Elec tric windows Sunroof the front side door glass run chan...

Page 3394: ...indow mechanism Removal Refitting 51A Side opening element mechanisms the front side door lock barrel see Front side door lock barrel Removal Refitting 51A Side opening element mechanisms the front si...

Page 3395: ...86A Radio the front side door sliding window see Front side door sliding window Removal Refitting 54A Windows the window motor see Electric window motor Removal Refitting 87D Electric windows Sunroof...

Page 3396: ...wing needs to be removed for this operation a Observe the adjustment sequence a I ADJUSTMENT OF OPENING CLEARANCES WITH THE FRONT WING AND THE REAR DOOR 1 PREPARATION FOR ADJUSTING THE FLUSH FITTING...

Page 3397: ...dard nuts with a hammer with an 8 mm minimum and 150 mm long minimum cylindrical hammer 6 a Remove the standard nuts 6 a Refit the original front side door box section nuts 6 without tightening them 2...

Page 3398: ...nt wing see 42A Front upper structure Front wing Removal Refitting page 42A 3 a Replace the original indexing studs 9 with bolts 10 available from the Parts Department to en able the flush fitting to...

Page 3399: ...m the rear side door wiring harness a Remove the rear side door check strap bolt 1 2 OPERATION FOR REMOVAL OF PART CONCERNED a Remove the rear side door nuts 2 the rear side door II REMOVAL WITH HINGE...

Page 3400: ...earances and flush fit tings see 47A Side opening elements Rear side door Adjustment page 47A 14 2 FINAL OPERATION a Connect the supply connector to the rear side door wiring harness II REFITTING WITH...

Page 3401: ...Refitting MR 416 51A Side opening element mechanisms the rear side door lock see Rear side door lock Removal Refitting MR 416 51A Side opening element mechanisms the rear side door check strap see Rea...

Page 3402: ...or trim see Rear side door pillar exterior trim Removal Refitting MR 416 56A Exterior equipment the rear side door glass run channel see Rear side door window run channel Removal Refit ting MR 416 66A...

Page 3403: ...two options for adjusting the door by means of the mountings on the door box section opening clearance adjustment by means of the mountings on the B pillar panel gap adjustment a Observe the adjustme...

Page 3404: ...Undo the nuts 4 a Remove the rear side door mounting plates by tap ping the nuts with a hammer using an 8 mm mini mum and 150 mm long minimum cylindrical hammer 3 a Remove the standard nuts 3 a Refit...

Page 3405: ...II ADJUSTMENT OF SHUT LINES WITH THE FRONT DOOR AND THE REAR WING a Replace the original indexing studs 6 with bolts 7 available from the Parts Department to enable the flush fitting to be adjusted a...

Page 3406: ...A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Press the two sides of the fuel filler flap cover at 1 a Unclip the fuel filler flap cover in the direction shown 2 REFITTING REFITTING OPERATION FO...

Page 3407: ...pening elements Bonnet Ad justment page 48A 3 2 FINAL OPERATION a Clip on the pipe at 2 a Connect the pipe 1 III REMOVAL BY MEANS OF THE BONNET HINGE BOLTS 1 REMOVAL PREPARATION OPERATION a Remove the...

Page 3408: ...A Non side opening elements Bonnet Ad justment page 48A 3 2 FINAL OPERATION a Clip on the pipe at 2 a Connect the pipe 1 a Refit the front wing upper mounting supports the front wing see 42A Front upp...

Page 3409: ...et mounting bolts by means of the bonnet hinge mounting bolts this operation requires the removal of the front wing and the front wing upper mounting bracket The bonnet striker must be adjusted in add...

Page 3410: ...ng bracket the front wing a Adjust the bonnet shut lines a Remove the front wing the front wing mounting bracket a Refit the front wing upper mounting bracket the front wing see 42A Front upper struct...

Page 3411: ...II REMOVAL OF PART CONCERNED a Remove the bolts 2 the boot lid REFITTING a Refit the boot lid a Adjust the panel gaps and flush fittings see 48A Non side opening elements Luggage compart ment lid Adju...

Page 3412: ...lid exterior handle 1 a Remove the tailgate lights see Rear opening ele ment light Removal Refitting 81A Rear light ing a Remove the wiring 2 REBUILDING a Refit the wiring of the boot lid 2 the tailga...

Page 3413: ...specifications ADJUSTMENT a The boot lid can be adjusted in two ways by adjusting the boot lid bolts by adjusting the boot lid hinge bolts This operation requires the quarter panel trim to be removed...

Page 3414: ...LID BOLTS a Loosen the boot lid bolts a Adjust the panel gaps and flush fitting of the boot lid a Tighten the boot lid bolts II ADJUSTMENT BY MEANS OF THE BOOT LID HINGE BOLTS a Remove the rear quarte...

Page 3415: ...e Luggage compartment lid lock Removal Refitting 52A Non side opening element mechanisms a Adjust the panel gaps and flush fittings of the boot lid see Vehicle panel gaps Adjustment value 01C Vehicle...

Page 3416: ...screen wiper motor the tailgate lock for the boot lid opening control the heated rear screen the high level brake light a Disconnect the earths the aerial connectors the tailgate lights a Disconnect t...

Page 3417: ...ted rear screen the high level brake light a Disconnect the earths the aerial connectors the tailgate lights a Disconnect the number plate light connectors a Remove the tailgate wiring the tailgate wa...

Page 3418: ...he tailgate lights a Connect the number plate light connectors a Connect the electrical connectors to the rear screen wiper motor the tailgate lock for the boot lid opening control the heated rear scr...

Page 3419: ...strip see Tailgate strip 55A Exterior protection the number plate lights a Remove the tailgate wiring REBUILDING I PREPARATION FOR REBUILDING a Always replace the rear badge a Order a tailgate fitting...

Page 3420: ...ipping Rebuilding 48A the tailgate exterior opening control see Tailgate exterior opening control Removal Refitting 52A Non side opening element mechanisms the tailgate trim see Tailgate trim Removal...

Page 3421: ...le panel gaps Adjustment value MR 416 01C Vehicle bodywork specifications ADJUSTMENT a There are two options for adjusting the tailgate using the tailgate bolts using the tailgate hinge nuts operation...

Page 3422: ...each side of the vehi cle a Adjust the clearances at the top of zones 1 and 2 on the tailgate 109496 Note Symbols A B C and D show the adjustment options The black dot in the centre represents the bo...

Page 3423: ...rtially remove the rear section of the headlining see Headlining Removal Refitting MR 416 71A Body internal trim a Undo the hinge nut 7 on both sides of the vehicle a Adjust the tailgate edge clearanc...

Page 3424: ...ssories from which the vehicles are constructed All rights reserved by Renault Copying or translating in part or in full of this document or use of the service part reference numbering system is forbi...

Page 3425: ...Refitting 51A 17 52A NON SIDE OPENING ELEMENT MECHANISMS Bonnet lock Removal Refitting 52A 1 Bonnet release cable Removal Refitting 52A 4 Tailgate lock Removal Refitting 52A 7 Tailgate strut Removal R...

Page 3426: ...Rear wheel arch liner Removal Refitting 55A 28 Body side trim Removal Refitting 55A 29 54A WINDOWS Front side door pillar exterior trim Removal Refitting 55A 35 Rear side door pillar exterior trim Re...

Page 3427: ...6 Grab handle Removal Refitting 57A 17 Rear side door sun visor Removal Refitting 57A 19 Front side door trim decoration Removal Refitting 57A 21 59A SAFETY ACCESSORIES Door airbag module Removal Refi...

Page 3428: ...CERNED a Remove the bolt 1 the bolts 2 the front side door check strap seal 3 the front side door check strap from inside the front side door box section REFITTING I REFITTING OPERATION FOR PART CONCE...

Page 3429: ...vent any acci dental damage card and adhesive a Remove the front side door lock barrel see 51A Side opening element mechanisms Front side door lock barrel Removal Refitting page 51A 5 or the dummy loc...

Page 3430: ...level a Unclip the front side door lock cable from the front side exterior door handle module REFITTING I REFITTING PREPARATION OPERATION a Always replace the front side door module rivet II REFITTING...

Page 3431: ...ock a new rivet 1 the front side exterior door handle see 51A Side opening element mechanisms Exterior door handle Removal Refitting page 51A 6 a Connect the battery see Battery Removal Refit ting 80A...

Page 3432: ...D a Loosen the locking bolt completely without removing it a Remove the front side door lock barrel REFITTING I REFITTING OPERATION FOR PART CONCERNED a Position the front side door lock barrel a Torq...

Page 3433: ...ilm see Door sealing film Re moval Refitting 65A Opening element seal ing the front side door lock barrel see 51A Side opening element mechanisms Front side door lock barrel Removal Refitting page 51A...

Page 3434: ...vehicle a Refit the front side door lock barrel see 51A Side opening element mechanisms Front side door lock barrel Removal Refitting page 51A 5 or the dummy lock a Carry out a function test III FINA...

Page 3435: ...NCERNED a Unclip the front side door electric window mecha nism a Remove the nuts 1 the front side door electric window mechanism REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the front s...

Page 3436: ...oor sliding window see 54A Win dows Front side door sliding window Removal Refitting page 54A 9 the electric window motor see Electric window motor Removal Refitting 87D Electric win dows Sunroof a Re...

Page 3437: ...AL OF PART CONCERNED a Unclip the front side door electric window mecha nism 4 and the mechanism cables inside the front side door box section a Remove the nuts 5 and 6 the rear section and then the f...

Page 3438: ...n channel see Front side door window run channel Removal Refit ting 66A Window sealing the door mirror see 56A Exterior equipment Door mirror Removal Refitting page 56A 7 a Connect the battery see Bat...

Page 3439: ...ing bolt of the dummy lock a Loosen the locking bolt completely without removing it a Remove the dummy lock the exterior door handle see 51A Side opening element mechanisms Exterior door handle Remova...

Page 3440: ...uip ment level a Unclip the rear side door lock cable from the rear side exterior door handle module REFITTING I REFITTING PREPARATION OPERATION a Always replace the rear side door module rivet II REF...

Page 3441: ...the access blanking cover to the locking bolt of the dummy lock a Refit a new rivet 1 the rear side exterior door handle see 51A Side opening element mechanisms Exterior door handle Removal Refitting...

Page 3442: ...N FOR REMOVAL OF PART CONCERNED a Unclip the rear side door electric window winder mechanism a Remove the nuts 1 the rear side door electric window mechanism REFITTING REFITTING OPERATION FOR PART CON...

Page 3443: ...odule II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the rear side door manual window mecha nism at 2 a Remove the nuts 3 the rear side door manual window mechanism REFITTING I REFITTING OPERATIO...

Page 3444: ...F PART CONCERNED a Remove the bolt 1 the bolts 2 the rear side door check strap seal 3 the rear side door check strap from inside the rear side door box section REFITTING I REFITTING OPERATION FOR PAR...

Page 3445: ...g 52A REMOVAL I REMOVAL PREPARATION OPERATION a Remove the bolts 1 the clips 2 a Lift the trim at 3 a Unclip the trim at 4 a Remove the trim 5 a Remove the bolts 6 a Remove the upper section of the co...

Page 3446: ...nose pliers a Remove the bonnet catch REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the bonnet opening cable 9 onto the bonnet catch a Refit the bonnet catch the bolts 8 of the bonnet catc...

Page 3447: ...MENT MECHANISMS Bonnet lock Removal Refitting 52A II FINAL OPERATION a When refitting the tamperproof cover check that the lugs are correctly positioned at 9 a Refit the tamperproof cover 7 the cover...

Page 3448: ...he bonnet catch see 52A Non side opening el ement mechanisms Bonnet lock Removal Refitting page 52A 1 the front sill panel trim see Front door sill lining Removal Refitting 71A Body internal trim a Re...

Page 3449: ...l a Note the route of the bonnet release cable a Remove the bonnet release cable from inside the vehicle REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the bonnet release cable a Clip on t...

Page 3450: ...ter nal trim a Refit the front door sill lining see Front door sill lining Removal Refitting 71A Body internal trim the bonnet catch see 52A Non side opening el ement mechanisms Bonnet lock Removal Re...

Page 3451: ...le ments trim II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the tailgate lock bolts 1 the tailgate lock a Disconnect the connector REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect th...

Page 3452: ...tailgate strut 2 while holding the tail gate REFITTING I REFITTING PREPARATIONS OPERATION a Position the clips 1 on the tailgate strut II REFITTING OPERATION FOR PART CONCERNED a Refit the tailgate s...

Page 3453: ...t management II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 1 the boot lid lock partially a Disconnect the connector 2 a Remove the boot lid lock REFITTING I REFITTING OPERATION FOR PAR...

Page 3454: ...e 54A 30 the sunroof s mobile panel see 52A Non side opening element mechanisms Sunroof mobile panel Removal Refitting page 52A 13 a Disconnect the battery see Battery Removal Re fitting 80A Battery a...

Page 3455: ...d bonding see Technical Note 560A a Always replace the positioning shims a Position the indexing guides on the sunroof operating mechanism new positioning shims on the sunroof operating mechanism a Re...

Page 3456: ...chanisms Sunroof mobile panel Removal Refitting page 52A 13 III FINAL OPERATION a Torque tighten the curtain airbag bolts see Side curtain airbag Removal Refitting 88C Airbags and pretensioners a Conn...

Page 3457: ...unroof mobile panel this operation requires two people REFITTING I REFITTING PREPARATION OPERATION a Equipment required Diagnostic tool Tightening torquesm front sunroof mobile panel bolts 6 N m rear...

Page 3458: ...n sumables Products II REFITTING OPERATION FOR PART CONCERNED a Refit the sunroof mobile panel this operation re quires two people a Adjust the sunroof mobile panel The upper section of the sunroof mo...

Page 3459: ...EMOVAL I REMOVAL PREPARATION OPERATION a Open the sunroof mobile panel II OPERATION FOR REMOVAL OF PART CONCERNED a Remove bolts 1 and 2 whilst holding the sunroof deflec tor the sunroof deflector Equ...

Page 3460: ...ables Products a Using a fine brush grease the area 4 with OPEN ING ELEMENT GREASE see Vehicle Parts and consumables for the repair 04B Consumables Products III FINAL OPERATION a Apply the after repai...

Page 3461: ...oval Refitting 71A Body internal trim II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the clips 1 a Remove the sunroof sun visor at 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the...

Page 3462: ...bead see Technical Note 560A REFITTING I REFITTING PREPARATION OPERATION a Always replace the shims the rain and light sensor adhesive base the safety labels a For preparation and bonding see Technica...

Page 3463: ...view mirror see 57A Interior equipment Interior rear view mirror Removal Refitting page 57A 14 the windscreen pillar trims see Windscreen pillar trim Removal Refitting 71A Body internal trim the scut...

Page 3464: ...e door trim Removal Refitting 72A Side opening elements trim a Remove the blanking covers 1 a Manually lock the front side door lock check that the window raises a Loosen the bolts of the front side d...

Page 3465: ...and draw two lines at the dimen sions shown X1 6 mm X2 10 mm a Position a suction cup on the front side door sliding window a Unlock the front side door lock using the exterior door handle check that...

Page 3466: ...ot tight enough push the front side door sliding window backwards a Check the alignment of the front side door sliding window in relation to the rear quarter panel window 2 Next simultaneously adjust...

Page 3467: ...ese actions causes the front side door sliding window to become misaligned in relation to the rear quarter panel window Window too high towards the front Turn the bolt 5 anticlockwise 1 turn 1 mm Wind...

Page 3468: ...3 a Undo the nuts a Fit a shim 7 between the front side door and the rear wing panel a Rest the front side door on the shim a Measure the dimension X4 and X5 of the front side door sliding window a T...

Page 3469: ...ont side door sliding window fully a Close the front side door again a Check that the front side door sliding window is in the right position a Refit the blanking covers 3 a Remove the masking tape fr...

Page 3470: ...t the side impact sensor to prevent any acci dental damage card and adhesive a Remove the clips 1 a Remove the front side sliding door window 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Ref...

Page 3471: ...tting 72A Side opening element trim the door sealing films see Door sealing film Re moval Refitting 65A Opening elements seal ing a Remove the front side door interior weatherstrip clip 1 a Remove the...

Page 3472: ...ntal damage card and adhesive a Remove the blanking covers 4 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolt 5 from the front side door electric window mechanism rear slider a Loosen the...

Page 3473: ...hile taking care to place the window correctly in the channel 9 and while pushing the front side door sliding window to wards the front of the vehicle at 10 without tightening the front and rear bolts...

Page 3474: ...k that the front side door sliding window lowers a Adjust the front side door sliding window at X and Z see 54A Windows Side windows Adjustment page 54A 3 a If necessary adjust the front side door sli...

Page 3475: ...ar lower bolts II OPERATION FOR REMOVAL OF PART CONCERNED a Remove clip 1 a Remove the sliding window from the rear side door REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the rear side s...

Page 3476: ...masking tape II OPERATION FOR REMOVAL OF PART CONCERNED a Cut the cement bead see Technical Note 560A a Remove the rear quarter panel window REFITTING I REFITTING PREPARATION OPERATION a Refit the rea...

Page 3477: ...al Refitting K91 54A III FINAL OPERATION a Refit the rear quarter panel trim see Quarter panel trim Removal Refitting 71A Body internal trim the rear parcel shelf side trim see Rear parcel shelf side...

Page 3478: ...ge 55A 29 55A Exterior protection a Protect the area around the rear quarter panel win dow with masking tape II OPERATION FOR REMOVAL OF PART CONCERNED a Cut the cement bead see Technical Note 560A a...

Page 3479: ...Re moval Refitting 71A Body internal trim the rear bench seat base see Rear bench seat base Removal Refitting 76A Rear seat frames and runners the rear quarter panel trim see Quarter panel trim Remova...

Page 3480: ...ety accesso ries Door airbag module Removal Refitting page 59A 1 a Wind the rear side door sliding window down to the bottom of the door box section see 54A Windows Rear side door sliding window Remov...

Page 3481: ...ries Door airbag module Removal Refitting page 59A 1 the rear side door exterior weatherstrip see Rear side door exterior weatherstrip Removal Re fitting 65 Opening elements sealing the interior weath...

Page 3482: ...I REFITTING PREPARATIONS OPERATION a Protect the rear wing panel with masking tape II REFITTING OPERATION FOR PART CONCERNED a Refit the rear quarter panel window trim piece by sliding it into its hou...

Page 3483: ...emoval Refitting 85A Washing Wiping the high level brake light see 3rd brake light Re moval Refitting 81A Rear lighting a Disconnect the heated rear screen wiring harness a Disconnect the aerial ampli...

Page 3484: ...motor Removal Refitting 85A Wiping Washing a Refit the side seals 2 II REFITTING OPERATION FOR PART CONCERNED a Bond the rear screen this operation requires two people a Equal out the clearances and...

Page 3485: ...two people REFITTING I REFITTING PREPARATION OPERATION a For preparation and bonding see Technical Note 560A a parts always to be replaced Rear screen adjust ing shim 50 04 12 03 II REFITTING OPERATI...

Page 3486: ...een Removal Refitting D91 54A the rear quarter panel trims see Quarter panel trim Removal Refitting 71A Body internal trim a Refit the rear screen lower seal starting at 4 a Carry out a function test...

Page 3487: ...heated rear screen the high level brake light connector 3 a Remove the high level brake light see 3rd brake light Removal Refitting 81A Rear lighting a Unclip the clips 4 of the opening rear screen s...

Page 3488: ...two people are re quired for this operation a Close the opening rear screen a Check the clearances and flush fitting see Vehicle panel gaps Adjustment value 01C Vehicle bodywork specifications III FI...

Page 3489: ...cal Note 560A a Position new positioning shims on the sunroof oper ating mechanism a Refit the central seal the sunroof side trim pieces see 54A Windows Sunroof side trim Removal Refitting page 54A 30...

Page 3490: ...d window Removal Refitting B91 or K91 54A a Note If the sunroof fixed window is cracked refit the headlining see Headlining Removal Refitting 71A Body internal trim connect the battery see Battery Rem...

Page 3491: ...im at 1 and at 2 a Unclip the front and rear trims 3 using the Car 1363 REFITTING I REFITTING PREPARATION OPERATION a Check the condition of the clipsand replace them if necessary II REFITTING OPERATI...

Page 3492: ...owing and lifting 02A Lifting equipment a Partially remove the front wheel arch liners see 55A Exterior protection Front wheel arch liner Removal Refitting page 55A 26 II OPERATION FOR REMOVAL OF PART...

Page 3493: ...t bumper this operation requires two people REFITTING I REFITTING PREPARATION OPERATION a Connect the headlight washer jet supply depending on the equipment level the various connectors depending on t...

Page 3494: ...washer jets see Headlight washer jet Removal Refitting 85A Wiping Washing a Remove the front bumper wiring see Front bumper wiring Removal Refitting 88A Wiring a Remove the proximity radars see Proxi...

Page 3495: ...per Stripping Rebuilding B91 or K91 55A a Remove the headlight washer pipes 3 a Drill out the rivets 4 a Cut the plastic welds 5 a Remove the side mounting supports 6 a Unclip the diffuser 7 DISCHARGE...

Page 3496: ...1 55A a Unclip the side trims a Cut the clips 8 a Remove the spoiler 9 a Unclip the centre absorber 10 a Cut the mountings 11 a Unclip the centre grille 12 EQUIPMENT LEVEL EAG and SPORT LOOK FEATURE 1...

Page 3497: ...ing Rebuilding B91 or K91 55A a Remove the headlight washer jet mountings 13 a Unclip the absorbers 14 DISCHARGE LAMPS 125016 EQUIPMENT LEVEL EA1 or EQUIPMENT LEVEL EA2 or EQUIPMENT LEVEL EA3 or EQUIP...

Page 3498: ...DING I REBUILDING PREPARATION OPERATION a parts always to be replaced Front bumper clip 50 05 02 17 a parts always to be replaced front bumper rivet 50 05 02 18 a Always replace the mountings 11 EQUIP...

Page 3499: ...sher pipes 3 a Clip on the deflectors 2 a Clip on the blanking covers 1 a Refit the front fog lights see Front fog light Re moval Refitting 80B Headlights a Refit the proximity radars see Proximity ra...

Page 3500: ...r wiring Removal Refitting 88A Wiring a Refit the headlight washer jets see Headlight washer jet Removal Refitting 85A Wiping Washing III FINAL OPERATION a Refit the front bumper see 55A Exterior prot...

Page 3501: ...ng page 55A 1 II STRIPPING OPERATION FOR PART CONCERNED a Remove the headlight washer jets see Headlight washer jet Removal Refitting 85A Wiping Washing a Remove the front bumper wiring see Front bump...

Page 3502: ...TION Front bumper Stripping Rebuilding D91 55A a Remove the diffuser 4 a Cut the clips 5 a Remove the bolts 6 a Unclip the centre grille 7 a Cut the clips 8 a Remove the side mounting supports 9 12501...

Page 3503: ...supports 9 new clips 8 the centre grille 7 new clips 5 the diffuser 4 the headlight washer supports 3 new rivets 2 the headlight washer supply pipes 1 a Refit the proximity radars see Proximity radar...

Page 3504: ...g a small file a a Cut the connections 2 a Discard the deflectors 3 B91 or K91 and HEADLIGHT WASHERS WITH BLADE Note When a front bumper is replaced the replace ment part needs to be modified before i...

Page 3505: ...e connection on the left hand side 2 a Discard the deflector 3 a D91 and V9X 124291 B91 or K91 and V9X and FRONT AND REAR PROXIMITY RADAR Note When replacing the front bumper centre grille it is neces...

Page 3506: ...55A 15 EXTERIOR PROTECTION Front bumper Conversion 55A a Fit the proximity radar supports 4 and 5 a Secure the proximity radar supports with clips part number 77 03 076 037 144227 144228 144226...

Page 3507: ...fting equipment a Remove the rear wing lights see Rear wing light Remov al Refitting 81A Rear lighting the rear wheel arch liners see 55A Exterior pro tection Rear wheel arch liner Removal Refit ting...

Page 3508: ...OTECTION Rear bumper Removal Refitting 55A a Remove the side bolts 2 a Remove the clips 3 a Unclip the rear bumper at 4 a Remove the clips 3 a Unclip the rear bumper at 4 D91 133799 B91 or K91 122916...

Page 3509: ...s connectors depending on equipment level II REFITTING OPERATION FOR PART CONCERNED a Refit the rear bumper this operation requires two people a Clip on the rear bumper 4 a Refit the clips 3 the side...

Page 3510: ...rear bumper wiring see Rear bumper wiring Removal Refitting 88A Wiring a Remove the proximity radars see Proximity radar Removal Refitting 87F Parking distance con trol a Remove the number plate light...

Page 3511: ...TECTION Rear bumper Stripping Rebuilding 55A a Unclip the reflectors 2 a Cut the clips 3 a Unclip the rear bumper end panel 4 a Cut the clips 2 a Unclip the rear bumper end panel 3 133786 133788 B91 o...

Page 3512: ...ts see Number plate light Removal Refitting 81A Rear lighting the absorber 1 a Refit the rear bumper end panel 4 new clips 3 the reflectors 2 the absorbers 1 the number plate lights see Number plate l...

Page 3513: ...NCERNED a Remove the nuts 1 a Disconnect the connectors depending on equip ment level a Remove the tailgate strip REFITTING I REFITTING PREPARATION OPERATION a Connect the connectors depending on equi...

Page 3514: ...PERATION a Remove the blanking cover 1 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolt 2 a Remove the front side door protective strip at 3 REFITTING I REFITTING OPERATION FOR PART CONCER...

Page 3515: ...strip Removal Refitting B91 or K91 55A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolt 1 a Remove the door protective strip at 2 REFITTING REFITTING OPERATION FOR PART CONCERNED a Re...

Page 3516: ...MOVAL OF PART CONCERNED a Carefully remove the roof protection strip using the Car 1363 REFITTING REFITTING OPERATION FOR PART CONCERNED a Mark the roof protection strip front section 1 a Refit the ro...

Page 3517: ...t lift see Vehicle Towing and lifting 02A Lifting equipment a Remove the front wheel see Wheel Removal Re fitting 35A Wheels and tyres II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the clips 1 t...

Page 3518: ...eplace the plastic nuts and clips if necessary II REFITTING OPERATION FOR PART CONCERNED a Refit the front wheel arch liner the bolts 7 the clips 6 the bolt 5 the plastic nuts 4 the clips 3 a Refit th...

Page 3519: ...I OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 1 the plastic nuts 2 a Remove the plastic nuts 3 clip 4 the rear wheel arch liner REFITTING I REFITTING PREPARATION OPERATION a Replace the...

Page 3520: ...OVAL I REMOVAL PREPARATION OPERATION a Remove the trim 1 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the body side trim piece at 2 and 3 using tool Car 1363 this operation requires two people...

Page 3521: ...g a body side trim piece a II REFITTING OPERATION FOR PART CONCERNED a Refit the body side trim piece this operation re quires two people III FINAL OPERATION a Refit the trim 1 K91 122926 K91 122926 N...

Page 3522: ...A REMOVAL I REMOVAL PREPARATION OPERATION a Protect the front upper section of the front side door and the front wing using masking tape a Remove the bolts from the front section of the body side trim...

Page 3523: ...side trim Removal Refitting D91 55A II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the front section of the body side trim gently and gradually starting from the front towards the rear this opera...

Page 3524: ...trim 1 gently and gradually one clip at a time REFITTING I REFITTING PREPARATION OPERATION a Replace the clips on the body side trim if necessary 135121 Note T ake care with the clips located behind t...

Page 3525: ...on of the body side trim a Partially refit the body side trim along its entire length a Gently clip on the body side trim one clip at a time by pressing on each clip on the body side trim III FINAL OP...

Page 3526: ...tting 66A Window sealing a Detach the seal 1 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 2 a Remove the front side door pillar exterior trim 3 REFITTING I REFITTING OPERATION FOR PAR...

Page 3527: ...side door exterior weatherstrip Removal Re fitting 66A Window sealing the door sealing film see Door sealing film Re moval Refitting 65A Opening element seal ing the door airbag module see 59A Safety...

Page 3528: ...illar exterior trim a Remove the bolts 4 the rear side door pillar exterior trim Rear section of rear side door pillar exterior trim a Remove the bolts 5 the rear side door pillar exterior trim REFITT...

Page 3529: ...airbag module see 59A Safety accesso ries Door airbag module Removal Refitting page 59A 1 the door sealing film see Door sealing film Re moval Refitting 65A Opening element seal ing a Carry out a seal...

Page 3530: ...windscreen wiper arms see Wind screen wiper arm Removal Refitting 85A Wip ing Washing a Remove the seal 1 a Remove the clips 2 the front wing trims a Remove the clips 3 the windscreen lower trims 4 II...

Page 3531: ...ttle panel grille before refitting the scuttle panel grille II REFITTING OPERATION FOR PART CONCERNED a Refit the scuttle panel grille 6 the clips 5 III FINAL OPERATION a Refit the windscreen lower tr...

Page 3532: ...REMOVAL OF THE PART CONCERNED a Remove the nuts 1 a Remove the bolts 2 the tailgate spoiler REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the tailgate spoiler II FINAL OPERATION a Check...

Page 3533: ...ting 85A Wip ing Washing a Remove the trims 1 the scuttle panel grille see 56A Exterior equip ment Scuttle panel grille Removal Refitting page 56A 1 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove...

Page 3534: ...4 the scoop under the scuttle panel grille REFITTING I REFITTING PREPARATION OPERATION a The strips of sealing foam must be systematically re placed II REFITTING OPERATION FOR PART CONCERNED a Refit...

Page 3535: ...e reinforcement tie rod 2 respecting the posi tion of the reinforcement tie rod bolts according to their length III FINAL OPERATION a Refit the trims 1 the scuttle panel grille see 56A Exterior equip...

Page 3536: ...prevent the bolt from being lost II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 4 a Remove the bolts 5 the door mirror REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit...

Page 3537: ...e the front side door trim see Front side door trim Removal Refitting 72A Side opening elements trim II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector 1 a Remove the door mirror bo...

Page 3538: ...ting D91 56A a Refit the door mirror bolts in order 3 4 and 5 a Connect the connector 1 a Carry out a function test II FINAL OPERATION a Refit the front side door trim see Front side door trim Removal...

Page 3539: ...I OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the door mirror casing at 1 a Remove the door mirror casing REFITTING I REFITTING OPERATION FOR PART CONCERNED a Position the door mirror casing at 2...

Page 3540: ...using the Car 1363 a Disconnect the connectors depending on equip ment level REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the connectors depending on equipment level a Clip the exterio...

Page 3541: ...using the tool Car 1363 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 3 the roof bar 4 REFITTING I REFITTING PREPARATION OPERATION a Always replace the sealing components of the roof...

Page 3542: ...Use HEPTANE see Vehicle Parts and consum ables for the repair 04B Consumables Prod ucts to degrease the bonding area and the roof bar trim a Prime the bonding area a Apply adhesive using the MONOPAC E...

Page 3543: ...1 II VEHICLE BADGE FITTING a FITTING PREPARATION OPERATION a Clean the adhesive surface of the vehicle badge us ing a LINT FREE CLOTH soaked in HEPTANE see Vehicle Parts and consumables for the re pai...

Page 3544: ...ting 56A LAGUNA badge a Position the template badge assembly LAGUNA badge a Position the template badge assembly a Remove the protective paper from the back of the vehicle badge a Stick on the vehicle...

Page 3545: ...l Refitting MR 415 83C On board telematics system depending on equip ment level the glovebox depending on equipment level the centre front panel see 57A Interior equip ment Centre front panel Removal...

Page 3546: ...ERATION FOR PART CONCERNED a Partially refit the dashboard this operation requires two people a Position the wiring a Refit the dashboard this operation requires two people the dashboard bolts 2 II FI...

Page 3547: ...A Interior equip ment Centre front panel Removal Refitting page 57A 7 the radionavigation system see Radio naviga tion Removal Refitting MR 415 83C On board telematics system depending on equip ment l...

Page 3548: ...e connectors from the switch side plate II REMOVAL OPERATION FOR PART CONCERNED a Remove the bolt 3 a Unclip the dashboard lower trim at 4 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip on...

Page 3549: ...the battery see Battery Removal Re fitting MR 415 80A Battery a Remove the dashboard see 57A Interior equip ment Dashboard Removal Refitting page 57A 1 a Remove the air duct 1 II REMOVAL OPERATION FO...

Page 3550: ...ION FOR PART CONCERNED a Clip on the dashboard air vent trim a Refit the dashboard air vent the bolts 2 II FINAL OPERATION a Refit air duct 1 the dashboard see 57A Interior equipment Dashboard Removal...

Page 3551: ...emove the bolts 1 a Unclip the centre front panel using the Car 1363 a Disconnect the centre front panel connectors REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the centre front panel...

Page 3552: ...omputer Removal Refitting MR 415 83C On board telematics system II REMOVAL OPERATION FOR PART CONCERNED a Remove the bolts 2 the glovebox REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the...

Page 3553: ...57A 9 INTERIOR EQUIPMENT Glovebox Removal Refitting 57A a Refit the inhibitor switch see Inhibitor switch Re moval Refitting MR 415 88C Airbags and pre tensioners LEFT HAND DRIVE...

Page 3554: ...ATION a Apply the parking brake 1 a Unclip the gear lever gaiter 2 a Unclip the parking brake lever gaiter 3 a Put the selector in position R a Rotate the ring clockwise a Remove the gear lever knob F...

Page 3555: ...nel a Remove the centre console upper front panel REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the centre console upper front panel con nectors a Clip on the centre console upper front...

Page 3556: ...er front panel see 57A Interior equipment Centre console upper front panel Removal Refitting page 57A 10 a Move the front seats forward II REMOVAL OPERATION FOR PART CONCERNED a Remove the bolts 2 a P...

Page 3557: ...tre console connectors a Refit the centre console the bolts 3 a Move the front seats forward a Refit the bolts 2 II FINAL OPERATION a Push the front seats back a Refit the centre console upper front p...

Page 3558: ...over 1 depending on equipment level a Unclip the lower cover 2 depending on equipment level a Disconnect the connectors depending on equip ment level a Remove interior rear view mirror at 4 120791 120...

Page 3559: ...mirror Removal Refitting 57A REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit interior rear view mirror a Connect the connectors 3 depending on equip ment level a Depending on the equipment le...

Page 3560: ...or mounting at 2 using the Car 1363 II REMOVAL OPERATION FOR PART CONCERNED a Unclip the sun visor at 3 a Disconnect the connector REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the conn...

Page 3561: ...he upper section of the handle 2 using a flat blade screwdriver a Remove the upper section of the handle II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the retaining handle 3 using a flat blade s...

Page 3562: ...e the lower section of the handle REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the grab handle a Clip on the grab handle 3 a Refit the lower section of the handle a Clip on the lower sec...

Page 3563: ...OPERATION FOR REMOVAL OF PART CONCERNED a Remove the plastic welds 1 a Remove the rear side door sun visor from the plastic welds at 2 a Carefully unclip the rear side door sun visor clips 3 a Remove...

Page 3564: ...rs onto the pins 4 part no 77 03 080 006 a Carry out a function test III FINAL OPERATION a Refit the rear side door trim see Rear side door trim Removal Refitting 72A Side opening ele ment trim 21675...

Page 3565: ...im Removal Refitting 72A Side opening elements trim II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts 1 the front side door trim decoration REFITTING I REFITTING OPERATION FOR PART CONCERN...

Page 3566: ...ment seal ing II OPERATION FOR REMOVAL OF PART CONCERNED a Loosen the bolts 1 a Remove the door airbag module at 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the door airbag module a T...

Page 3567: ...OPERATION FOR REMOVAL OF PART CONCERNED a a Make a note of the harness routing a Unclip the wiring a Unclip the runner switch 1 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip the runner sw...

Page 3568: ...seat pad see Heated seat pad Removal Refitting MR 416 79A Seat compo nents II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the passenger presence sensor cover connector 1 IMPORTANT Consult th...

Page 3569: ...eat pad see Heated seat pad Removal Refitting MR 416 79A Seat compo nents a Refit the front seat base trim see Front seat base trim Removal Refitting MR 416 77A Front seat trim the front seat lower ca...

Page 3570: ...onnect the battery see Battery Removal Refit ting see Airbags and pretensioners Recycling De struction IMPORTANT T o eliminate the risk of any accident do not reuse pyrotechnic components It is essent...

Page 3571: ...on of the various component units and accessories from which his vehicles are constructed All copyrights reserved by Renault The reproduction or translation in part of whole of the present document as...

Page 3572: ...moval Refitting 65A 8 66A WINDOW SEALING Front side door glass run channel Removal Refitting 66A 1 Front door side exterior weather strip Removal Refitting 66A 6 Rear side door exterior weather strip...

Page 3573: ...m see Front side door trim Removal Refitting 72A Side opening elements trim a or remove the rear side door trim see Rear side door trim Removal Refitting 72A Side opening elements trim II OPERATION FO...

Page 3574: ...gun set to approximately 100 C held approximately 20 cm away from the sealing film to ease its removal Note Remove the adhesive residue from the door box section by applying wide masking tape over the...

Page 3575: ...t bringing it into contact with the areas shown 2 a Offer up the sealing film without forcing it bringing it into contact with the areas shown 2 a Position the sealing film correctly around the outsid...

Page 3576: ...ATION a Carry out a sealing test see Technical Note 653A a Refit the rear side door trim see Rear side door trim Removal Refitting 72A Side opening ele ments trim or a Refit the front side door trim s...

Page 3577: ...m a Unclip the dashboard side panel 1 a Remove the blanking cover 2 using the tool Car 1363 the rear wing panel trim bolt II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolts in the front sec...

Page 3578: ...the tool Car 1363 to fit the front side door seal under the B pillar upper trim a Position the front side door seal in its index in the front section 6 a Fit the front side door seal starting with the...

Page 3579: ...RATION a Check the positioning of the front side door seal in relation to the front side door sliding window a Refit the rear wing panel trim bolt the blanking cover 2 the dashboard side panel 1 the f...

Page 3580: ...ED a Position the sunroof seal joint at the rear central sec tion 1 a Bond the sunroof seal using special adhesive for windows see Vehicle Parts and ingredients for the repairwork 04B Consumables Prod...

Page 3581: ...side exterior wea ther strip Removal Refitting page 66A 6 the front side door pillar exterior trim see Front side door pillar exterior trim Removal Refit ting 56A Exterior equipment II OPERATION FOR...

Page 3582: ...or trim see Front side door pillar exterior trim Removal Refitting 56A Exterior equipment a Refit the front side door exterior weatherstrip see 66A Window sealing Front door side exterior wea ther str...

Page 3583: ...ont side door Removal Refitting 54A Windows the door mirror see Door mirror Removal Re fitting 57A Interior equipment the front side exterior door weatherstrip see 66A Window sealing Front door side e...

Page 3584: ...nnel using a clean and dry LINT FREE CLOTH II REFITTING OPERATION FOR PART CONCERNED a Partially refit the front side door window run channel by guiding the slider in the rail of the front side door e...

Page 3585: ...e exterior wea ther strip Removal Refitting page 66A 6 the door mirror see Door mirror Removal Re fitting 57A Interior equipment the front side door sliding window see Sliding window in front side doo...

Page 3586: ...a Remove the front side exterior door weatherstrip clip 1 a Carefully remove the front side exterior door wea therstrip 2 using the Car 1363 a Carefully remove the front side exterior door wea therst...

Page 3587: ...PERATION FOR PART CONCERNED a Refit the front side exterior door weatherstrip at 2 and 3 a Check that the front side exterior door weatherstrip is correctly aligned a Refit the front side exterior doo...

Page 3588: ...ior door wea therstrip 1 using the Car 1363 REFITTING I REFITTING PREPARATIONS OPERATION a Index the rear side exterior door weatherstrip II REFITTING OPERATION FOR PART CONCERNED a Refit the rear sid...

Page 3589: ...t sealing Door sealing film Removal Refitting page 65A 1 the door airbag module see Seat base lever Re moval Refitting 59A Safety equipment a Wind the rear side door sliding window down to the bottom...

Page 3590: ...oor airbag module see Seat base lever Re moval Refitting 59A Safety equipment the rear side door exterior weatherstrip see 66A Window sealing Rear side door exterior wea ther strip Removal Refitting p...

Page 3591: ...MOVAL OF PART CONCERNED a Remove the clips 1 using an unclipping tool the bonnet soundproofing REFITTING I REFITTING PREPARATION OPERATION a Replace the clips 1 if necessary II REFITTING OPERATION FOR...

Page 3592: ...cture the distribution unit see Air distribution unit Re moval Refitting MR 416 61A Heating system the front door sill linings see Front door sill lining Removal Refitting MR 416 71A Body internal tri...

Page 3593: ...trim the distribution unit see Air distribution unit Re moval Refitting MR 416 61A Heating system the dashboard cross member see Dashboard cross member Removal Refitting MR 416 42A Upper front structu...

Page 3594: ...are constructed All copyrights reserved by Renault The reproduction or translation in part of whole of the present document as well as the use of the spare parts reference numbering system are prohib...

Page 3595: ...Refitting 71A 30 Rear panel trim Removal Refitting 71A 31 Rear parcel shelf side trim Removal Refitting 71A 34 Door sill Removal Refitting 71A 37 Rear end panel lining Removal Refitting 71A 40 72A SI...

Page 3596: ...e Conversion 76A 5 Rear bench seat mechanism Removal Refitting 76A 6 77A FRONT SEAT TRIM Front seat base trim Removal Refitting 77A 1 Front seatback trim Removal Refitting 77A 3 Front seatback casing...

Page 3597: ...B pillar upper trim Removal Refitting page 71A 22 the B pillar lower trims see 71A Body internal trim B pillar lower trim Removal Refitting page 71A 15 a Remove the bolts 1 of the front side seat bel...

Page 3598: ...I REFITTING OPERATION FOR PART CONCERNED a Refit the floor carpet a Refit the floor carpet bolt 4 the floor carpet clips 2 and 3 II FINAL OPERATION a Refit the rear inner sill upper trims see 71A Body...

Page 3599: ...illar upper trims see 71A Body internal trim B pillar upper trim Removal Refitting page 71A 22 a Refit the front door sill linings see 71A Body internal trim Front door sill lining Removal Refitting p...

Page 3600: ...age compartment carpet Removal Refitting 71A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Remove the luggage compartment carpet 1 REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit the lugg...

Page 3601: ...ve the side door seals a Remove the windscreen pillar trims see 71A Body inter nal trim A pillar trim Removal Refitting page 71A 21 the B pillar upper trims see 71A Body internal trim B pillar upper t...

Page 3602: ...ve the finishing seals 2 depending on the equipment level a Remove the high level brake light see Third brake light Removal Refitting 81A Rear lighting a Disconnect the headlining wiring connectors 1...

Page 3603: ...BODY INTERNAL TRIM Headlining Removal Refitting 71A a Remove the airbag pins 3 with the clips 4 a Remove the central rear clip 5 134060 134053 Note The clips are destroyed once they have been removed...

Page 3604: ...Car 1597 a Remove the headlining clips 5 the headlining through the rear of the vehicle this operation requires two people B91 or K91 124062 Note When detaching the central part of the headli ning tak...

Page 3605: ...M Headlining Removal Refitting 71A Front mounting Central mounting a Unclip the front section of the headlining 6 then the central section 7 a Pass the headlining 8 through the passenger side D91 1340...

Page 3606: ...adlining front section a Position the headlining rear section a Refit the headlining clips 5 a Bond the headlining central section a Position the headlining in the passenger compart ment this operatio...

Page 3607: ...inter nal trim A pillar trim Removal Refitting page 71A 21 a Refit the high level brake light see Third brake light Removal Refitting 81A Rear lighting the rear panel trims see 71A Body internal trim...

Page 3608: ...B pillar upper trim Removal Refitting page 71A 22 the B pillar lower trim see 71A Body internal trim B pillar lower trim Removal Refitting page 71A 15 II OPERATION FOR REMOVAL OF PART CONCERNED a Remo...

Page 3609: ...e front door sill lining at 1 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the rear section of the front door sill lining trim the front section of the front door sill lining trim the bo...

Page 3610: ...l Refitting 71A II FINAL OPERATION a Refit the B pillar lower trim see 71A Body internal trim B pillar lower trim Removal Refitting page 71A 15 the B pillar upper trim see 71A Body internal trim B pil...

Page 3611: ...rim B pillar upper trim Removal Refit ting page 71A 22 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the B pillar lower trim at 1 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the B...

Page 3612: ...mechanisms Rear bench seat base Removal Refitting page 76A 3 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the rear door sill lining as shown 1 REFITTING I REFITTING OPERATION FOR PART CONCERNED...

Page 3613: ...ear door upper sill trim see 71A Body internal trim Rear door sill upper lining Remo val Refitting page 71A 25 a Remove the rear end panel trim see 71A Body in ternal trim Rear end panel lining Remova...

Page 3614: ...lining Removal Refitting 71A a Remove the storage compartment flap 4 a Remove the rear parcel shelf trim see Rear parcel shelf trim Removal Refitting a Remove the bolt the rear bench seatback unlockin...

Page 3615: ...rear wheel arch trim a Refit clips II FINAL OPERATION a Refit the rear bench seatback unlocking control the bolt a Refit the rear parcel shelf trim see Rear parcel shelf trim Removal Refitting a Refit...

Page 3616: ...l trim Rear door sill upper lining Removal Refitting page 71A 25 a Connect the battery see Battery Removal Refit ting 80A Battery a Refit the luggage compartment carpet see 71A Body internal trim Lugg...

Page 3617: ...eal II OPERATION FOR REMOVAL OF PART CONCERNED a Partially remove the windscreen pillar trim at 1 and 2 a Unclip the windscreen pillar trim at 3 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Cl...

Page 3618: ...lt II OPERATION FOR REMOVAL OF PART CONCERNED a a Carefully unclip the B pillar upper trim at 1 and 2 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Clip on the B pillar upper trim II FINAL OPER...

Page 3619: ...m see 71A Body inter nal trim Rear quarter panel trim Removal Re fitting page 71A 27 the rear panel trim see 71A Body internal trim Rear panel trim Removal Refitting page 71A 31 a Remove the trim 1 fr...

Page 3620: ...efit the trim 1 of the front side seat belt return mecha nism the rear panel trim see 71A Body internal trim Rear panel trim Removal Refitting page 71A 31 the rear quarter panel trim see 71A Body inte...

Page 3621: ...t base Removal Refitting page 76A 3 a Tilt the rear bench seatback a Remove the side section at 1 and 2 II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the rear inner sill upper trim at 3 a Unclip...

Page 3622: ...trim II FINAL OPERATION a Refit the side section a Tilt the rear bench seatback a Refit the rear bench seat base see 76A Rear seat frames and mechanisms Rear bench seat base Removal Refitting page 76...

Page 3623: ...71A 34 the rear inner sill upper trim see 71A Body inter nal trim Rear door sill upper lining Removal Refitting page 71A 25 II OPERATION FOR REMOVAL OF PART CONCERNED a a Remove the bolt 1 a Carefull...

Page 3624: ...t section of the rear quarter panel trim 4 the bolt 3 the rear section of the rear quarter panel trim 2 the bolt 1 a Refit the rear quarter panel trim 2 the bolt 1 II FINAL OPERATION a Refit the rear...

Page 3625: ...er panel trim Removal Refitting D91 71A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Remove the rear quarter panel trim at 1 2 and 3 REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit the r...

Page 3626: ...71A 27 a Remove the bolt 1 the clip 2 the trim 3 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the clips 4 the rear parcel shelf lining 5 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Ref...

Page 3627: ...efitting page 71A 12 the rear bench seat base see 76A Rear seat fra mes and mechanisms Rear bench seat base Removal Refitting page 76A 3 the rear quarter panel trim see 71A Body inter nal trim Rear qu...

Page 3628: ...71A 32 BODY INTERNAL TRIM Rear panel trim Removal Refitting D91 71A a Remove the bolt 5 a Remove the bolt 6 a Remove clip 7 133971 133972 133973...

Page 3629: ...a Refit the trim 3 the clip 2 the bolt 1 the rear quarter panel trim see 71A Body inter nal trim Rear quarter panel trim Removal Re fitting page 71A 27 the rear bench seat base see 76A Rear seat fra...

Page 3630: ...l side trim 1 see 71A Body internal trim Rear end panel lining Removal Refitting page 71A 40 a Remove the luggage cover the side section see 76A Rear seat frames and mechanisms 1 3 and 2 3 rear bench...

Page 3631: ...shelf side trim at 7 a Disconnect the connector 8 a Remove the rear parcel shelf side trim REFITTING I REFITTING OPERATION FOR PART CONCERNED a Connect the connector 4 a Refit the rear parcel shelf s...

Page 3632: ...see 76A Rear seat frames and mechanisms 1 3 and 2 3 rear bench seatback Removal Refitting page 76A 1 the luggage cover a Refit the rear end panel side trim 1 see 71A Body in ternal trim Rear end pane...

Page 3633: ...71A 37 BODY INTERNAL TRIM Door sill Removal Refitting D91 71A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the door sill partially at 1 135094...

Page 3634: ...71A 38 BODY INTERNAL TRIM Door sill Removal Refitting D91 71A a Unclip the door sill at 2 135091...

Page 3635: ...71A 39 BODY INTERNAL TRIM Door sill Removal Refitting D91 71A REFITTING REFITTING OPERATION FOR PART CONCERNED a Check the condition of the clips a Refit the door sill a Clip on the door sill 135092...

Page 3636: ...emove the luggage compartment carpet see 71A Body internal trim Luggage compartment car pet Removal Refitting page 71A 4 II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the bolt 1 a Unclip the rea...

Page 3637: ...lts 7 the towing rings a Unclip the rear end panel trim at 8 a Remove the rear end panel trim REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the rear end panel trim a Clip on the rear end...

Page 3638: ...end panel trim side sections at 5 a Refit the towing rings 4 the bolts 3 the rear end panel trim centre section the bolt 1 II FINAL OPERATION a Refit the luggage compartment carpet see 71A Body inter...

Page 3639: ...er s door Removal Refitting 87D Elec tric windows Sunroof or the front window winder switch plate on the passenger door see Front elec tric window switch on the passenger door Re moval Refitting 87D E...

Page 3640: ...A a Unclip the trim of the front side door interior handle using a flat blade screwdriver a Remove bolts 3 and 4 a Remove the front side door trim partially at 5 one clip at a time using the tool Car...

Page 3641: ...EFITTING PREPARATION OPERATION a Always replace the clips on the front side door trim a Clip the cable 7 of the front side door light the front side door interior opening release cable a Connect the f...

Page 3642: ...EMENT TRIM Front side door trim Removal Refitting 72A switch plate on the passenger door see Front elec tric window switch on the passenger door Re moval Refitting 87D Electric windows Sunroof a Carry...

Page 3643: ...inder switch plate see Rear electric window switch Removal Refit ting 87D Electric windows Sunroof a Remove the window winder handle 1 the interior handle 2 II OPERATION FOR REMOVAL OF PART CONCERNED...

Page 3644: ...I REFITTING PREPARATION OPERATION a Always replace the clips on the rear side door trim a Connect the various connectors depending on equi pment level a Clip on the rear side door interior opening re...

Page 3645: ...dow winder switch plate see Front electric window switch Removal Refitting 87D Electric windows Sunroof the front door trim see 72A Side opening ele ment trim Front side door trim Removal Re fitting p...

Page 3646: ...ERATION FOR PART CONCERNED a Refit the front side door frame interior trim starting with the upper section 4 the bolt 2 the trim 1 III FINAL OPERATION a Refit the front door trim see 72A Side opening...

Page 3647: ...ar side door trim see 72A Side opening element trim Rear side door trim Removal Refitting page 72A 5 II OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the interior trim 1 from the rear side door win...

Page 3648: ...ior trim 1 to the rear side door fixed win dow pillar III FINAL OPERATION a Refit the rear side door trim see 72A Side opening element trim Rear side door trim Removal Refitting page 72A 5 the rear wi...

Page 3649: ...91 73A REMOVAL I REMOVAL PREPARATION OPERATION a Remove the rear parcel shelf cords II OPERATION FOR REMOVAL OF PART CONCERNED a Remove the tailgate central trim 1 a Remove the tailgate side trim pane...

Page 3650: ...Remove the bolts 7 the tailgate lower trim 8 a Remove the bolts 9 the tailgate upper trim 10 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the tailgate lower trim 6 the bolts 5 the bolts...

Page 3651: ...DE OPENING ELEMENTS TRIM Tailgate lining Removal Refitting B91 or K91 73A the bolts 7 a Refit the tailgate side trim panels 2 the tailgate central trim 1 II FINAL OPERATION a Refit the rear parcel she...

Page 3652: ...MOVAL OF PART CONCERNED a Remove the bolt 2 of the interior handle the clips 3 using the tool Car 1363 the boot lid trim REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the boot lid trim th...

Page 3653: ...seat belt buckle Removal Refitting 88C Airbags and pretensioners a Remove the front seat slide motor see 75A Front seat frames and mechanisms Front seat sliding motor Removal Refitting page 75A 10 a...

Page 3654: ...r Removal Re fitting a Refit the front seat base trim see 77A Front seat trim Front seat base trim Removal Refitting page 77A 1 a Refit the front seat slide motor see 75A Front seat frames and mechani...

Page 3655: ...REMOVAL OF PART CONCERNED a Remove the bolts 1 the front seatback frame 2 REFITTING I REFITTING PREPARATION OPERATION Replacement of the front seatback frame a When replacing the front seatback frame...

Page 3656: ...ont seat trim Front seat lower cover Removal Refitting page 77A 8 the front seatback trim see 77A Front seat trim Front seatback trim Removal Refitting page 77A 3 the entire front seat see 75A Front s...

Page 3657: ...fitting page 75A 15 the front seat lower cover exterior part see 77A Front seat trim Front seat lower cover Remo val Refitting page 77A 8 the front seat belt stalk see Front seat belt stalk Removal Re...

Page 3658: ...f the left hand and right hand runners of front seat a Torque tighten new front seat runner nuts 27 N m a Clip the front seat connector mounting 1 III FINAL OPERATION a Connect the connector of the fr...

Page 3659: ...repair mode display the before after repair procedure for the computer selected select instrumented front motor for driver s seat cushion height adjustment or instrumented rear motor for driver s seat...

Page 3660: ...15 80A Battery a Remove the compete front seat see 75A Front seat fra mes and mechanisms Complete front seat Re moval Refitting page 75A 15 the front seatback trim see 77A Front seat trim Front seatba...

Page 3661: ...a Refit the front seat lumbar adjustment mechanism new rivets 4 a Clip on the cable 3 a Carry out a function test III FINAL OPERATION a Refit the lumbar support the front seatback trim see 77A Front s...

Page 3662: ...tery II OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connectors 1 a Unclip the sheath 2 at 3 a Remove the front seat slide motor sheath assembly 4 and 2 the cable 5 REFITTING I REFITTING P...

Page 3663: ...difference between the two runners use the cable 6 in order to manually synchronise the ri ght hand and left hand runners of the front seat Correct Incorrect a 134063 Note Dimension X1 must be identic...

Page 3664: ...g 80A Battery a Apply the after repair procedure using the diagnos tic tool connect the diagnostic tool select driver s seat position control and storage keypad go to repair mode display the before af...

Page 3665: ...te front seat Re moval Refitting page 75A 15 the lower seat covers see 77A Front seat trim Front seat lower cover Removal Refitting page 77A 8 the front seat cushion trim see 77A Front seat trim Front...

Page 3666: ...t trim Front seat lower cover Removal Refitting page 77A 8 the entire front seat see 75A Front seat frames and mechanisms Complete front seat Remo val Refitting page 75A 15 a Connect the battery see B...

Page 3667: ...sten the front seat belt from its buckle 1 a Adjust the steering wheel to the top position and push it in the front seatback to the vertical position the front seat on the runners to a central positio...

Page 3668: ...TING PREPARATIONS OPERATION a Always replace the front seat nuts II REFITTING OPERATION FOR PART CONCERNED a Refit the complete front seat this operation requires two people a Torque tighten the new f...

Page 3669: ...and mechanisms Rear bench seat base Removal Refitting page 76A 3 a Tilt the 1 3 and 2 3 rear bench seatbacks a Unclip the trim 1 a Unclip the side frames at 2 and 3 II OPERATION FOR REMOVAL OF PART CO...

Page 3670: ...TION FOR PART CONCERNED a Refit the 1 3 and 2 3 rear bench seatbacks this opera tion requires two people new bolts 4 a Tighten to torque the 1 3 and 2 3 rear bench seat back bolts 44 Nm III FINAL OPER...

Page 3671: ...he rear bench seat base REFITTING I REFITTING PREPARATION OPERATION a Always replace the rear centre seat belt nut 1 a Pass the rear centre seat belt through the rear bench seat base a Refit the rear...

Page 3672: ...bench seat mechanism see 76A Rear seat frames and mechanisms Rear bench seat mechanism Removal Refitting page 76A 6 a Remove the 1 3 and 2 3 rear bench seatback frame REFITTING I REFITTING OPERATION...

Page 3673: ...ed on Laguna Hatch and Laguna Sport Tourer These frames are equipped with a central headrest guide frame a central seat belt return mechanism frame a central seat belt inertia reel bolt The 2 3 seatba...

Page 3674: ...e 71A 17 a Remove the 1 3 and 2 3 rear bench seat seatback trim see 78A Rear seat trim 1 3 and 2 3 rear bench seat seatback trim Removal Refitting page 78A 1 a Remove the rear parcel shelf trim see Re...

Page 3675: ...rear bench seatbacks a Remove the centre hinge 3 from the rear bench seatback a Remove the nuts 4 from the rear bench seatback locking mechanism a Partially remove the rear bench seatback locking mech...

Page 3676: ...king control 2 a Clip the rear bench seatback unlocking control 6 the linkage 5 a Refit the rear bench seatback locking mechanism new nuts 4 to the rear bench seatback locking mechanism a Torque tight...

Page 3677: ...ear wheel arch trim see 71A Body internal trim Rear wheel arch lining Removal Refit ting page 71A 17 the rear parcel shelf trim see Rear parcel shelf trim Removal Refitting a Refit the 1 3 and 2 3 rea...

Page 3678: ...emove the compete front seat see 75A Front seat fra mes and mechanisms Complete front seat Re moval Refitting page 75A 15 the lower seat covers see 77A Front seat trim Front seat lower cover Removal R...

Page 3679: ...l a Refit the retaining sections 2 a Refit the elastic band 1 III FINAL OPERATION a Refit the lower seat covers see 77A Front seat trim Front seat lower cover Removal Refitting page 77A 8 the entire f...

Page 3680: ...y a Remove the compete front seat see 75A Front seat fra mes and mechanisms Complete front seat Re moval Refitting page 75A 15 the front headrest see Front headrest Removal Refitting the front seatbac...

Page 3681: ...seatback trim Removal Refitting 77A a Remove the lower trim 2 a Remove the retaining sections 3 a Remove the front headrest guides see Front seat headrest guide Removal Refitting a Disconnect the conn...

Page 3682: ...the front headrest guides see Front seat hea drest guide Removal Refitting the retaining sections 3 the lower trim 2 the elastic strap 1 III FINAL OPERATION a Refit the front seatback angle control s...

Page 3683: ...asing Removal Refitting D91 77A REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Pull the casing away at 2 while holding the casing at 1 135058 Note It is essential to hold the upper section of the c...

Page 3684: ...77A 7 FRONT SEAT TRIM Front seatback casing Removal Refitting D91 77A a Remove the casing at 3 135061...

Page 3685: ...MR 415 02A Lifting equip ment a Disconnect the battery see Battery Removal Refitting MR 415 80A Battery a Remove the complete front seat see 75A Front seat frames and mechanisms Complete front seat R...

Page 3686: ...ove the bolt 4 the clip 5 a Partially remove the lower casing outer section a Disconnect the connectors depending on equip ment level a Remove the seat outer casing 2 Seat with manual adjustment a Rem...

Page 3687: ...g outer section the clip 5 the bolt 4 a Clip on the seat lower casing inner section a Refit the bolts 2 the elastic strap 1 2 Seat with manual adjustment a Refit the front seat lower casing outer sect...

Page 3688: ...see 76A Rear seat frames and mechanisms 1 3 and 2 3 rear bench seatback Removal Refitting page 76A 1 a Rotate 1 4 of a turn 1 a Separate the 1 3 and 2 3 rear bench seatbacks 2 II OPERATION FOR REMOVA...

Page 3689: ...bench seat seatback trim Removal Refitting 78A a Remove the 1 3 rear bench seat seatback rear trim 5 a Remove the retaining sections 6 from the 1 3 rear bench seatback trim a Remove the clips from the...

Page 3690: ...ing a Unclip the rear bench seatback unlocking mecha nism guide at 8 a Remove the 1 3 rear bench seatback trim foam assembly a Remove the headrest guides 9 a Remove the 1 3 rear bench seat seatback tr...

Page 3691: ...m Removal Refitting 78A a Remove the bolt 10 the rear centre seat belt loop a Remove the headrests see Rear headrest Remo val Refitting a Remove the bolt 11 the trim 12 a Remove the side hinge nut 13...

Page 3692: ...Tilt the centre hinge opposite the foolproofing devi ce a Remove the centre hinge 15 a Remove the rear trim 16 from the 2 3 rear bench seatback a Unclip the centre armrest casing at 17 a Remove the lo...

Page 3693: ...bench seatback a Partially remove the 2 3 rear bench seatback trim foam assembly a Unclip the head rest guides see Rear seat hea drest guide Removal Refitting a Unclip the rear bench seatback unlockin...

Page 3694: ...6 of the 1 3 rear bench seatback the rear trim 5 of the 1 3 rear bench seatback the side hinge 4 a new side hinge nut 3 a Torque tighten the side hinge nut 25 N m a Refit the trim 2 the bolt 1 a Refit...

Page 3695: ...e side hinge 14 a new side hinge nut 13 a Torque tighten the side hinge nut 25 N m a Refit the trim 12 the bolt 11 a Refit the rear centre seat belt loop the bolt 10 a Refit the headrest see Rear head...

Page 3696: ...e rear bench seat base trim REFITTING I REFITTING PREPARATIONS OPERATION a II REFITTING OPERATION FOR PART CONCERNED a Refit the rear bench seat base trim on the foam the rear bench seat base foam tri...

Page 3697: ...Front seat fra mes and mechanisms Complete front seat Re moval Refitting page 75A 15 the front seat lower covers see 77A Front seat trim Front seat lower cover Removal Refit ting page 77A 8 the front...

Page 3698: ...Remove the front seat see 75A Front seat frames and mechanisms Complete front seat Removal Refitting page 75A 15 a Refit the front seatback trim see 77A Front seat trim Front seatback trim Removal Re...

Page 3699: ...it fold bench seatback 1 3 II REMOVAL OPERATION FOR PART CONCERNED a Remove the clip 1 the rear central armrest at 2 and 3 REFITTING I REFITTING OPERATION FOR PART CONCERNED a Refit the rear central a...

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