3
Chassis
30A
GENERAL INFORMATION
31A
FRONT AXLE COMPONENTS
33A
REAR AXLE COMPONENTS
35A
WHEELS AND TYRES
35B
TYRE PRESSURE MONITOR
36A
STEERING ASSEMBLY
36B
POWER ASSISTED STEERING
37A
MECHANICAL COMPONENT CONTROLS
38C
ANTI-LOCK BRAKING SYSTEM
X84, and B84 or C84 or E84 or G84 or K84 or L84 or S84
77 11 318 062
APRIL 2009
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
All copyrights reserved by Renault.
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 prohibited without the prior written
consent of Renault.
© Renault s.a.s 2008
Mégane II - Section 3
Mégane II - Section 3ContentsPage
Contents
Page
30A
GENERAL INFORMATION
31A
FRONT AXLE COMPONENTS
Brake circuit Operating
diagram
30A-1
Front brake pads: Removal Refitting
31A-1
Brake circuit Precautions for
repair
30A-2
Front brake hose: Removal Refitting
31A-7
Brake circuit Bleeding
30A-4
Front brake calliper: Removal
- Refitting
31A-11
Front brake calliper support:
Removal - Refitting
31A-15
Brake circuit Tightening
torque
30A-6
Rigid brake pipe: Repair
30A-8
Brake fluid: Specifications
30A-13
Front brake disc: Removal Refitting
31A-17
Brake: Specifications
30A-14
Front brake disc: Description
31A-20
Steering: Tightening torque
30A-17
Axle assemblies: Check
30A-18
Front driveshaft hub carrier:
Removal - Refitting
31A-21
Underbody height:
Adjustment values
30A-19
Front hub carrier bearing:
Removal - Refitting
31A-26
Front axle: Tightening torque
30A-22
Spring and front shock
absorber: Removal - Refitting
31A-29
Front axle: Adjustment
values
30A-26
Front driveshaft lower arm:
Removal - Refitting
31A-39
Front axle: Adjusting
30A-32
Rear axle: Tightening torque
30A-33
Front driveshaft lower arm
ball joint: Check
31A-45
Rear axle: Adjustment values
30A-36
Front axle sub-frame:
Removal - Refitting
31A-46
Front anti-roll bar: Removal Refitting
31A-57
Front anti-roll bars:
Specifications
Rear anti-roll bar:
Specifications
30A-40
30A-41
Contents
33A
REAR AXLE COMPONENTS
TYRE PRESSURE MONITOR
Rear brake pads: Removal Refitting
33A-1
SSPP: List and location of
components
35B-1
Rear brake caliper: Removal
- Refitting
33A-3
Pressure sensor: Removal Refitting
35B-2
Rear brake calliper
mounting: Removal Refitting
33A-5
Rear brake disc shield:
Removal - Refitting
33A-7
Rear brake disc: Removal Refitting
Rear brake disc: Description
Shock absorber: Removal Refitting
Rear suspension spring:
Removal - Refitting
Rear disc brake bearing:
Removal - Refitting
Rear axle rubber bearing:
Removal - Refitting
Complete rear axle: Removal
- Refitting
35A
35B
36A
33A-8
33A-14
33A-15
33A-17
33A-19
33A-21
33A-24
36B
WHEELS AND TYRES
Wheel: Removal - Refitting
35A-1
Wheel: Balancing
35A-4
Tyres: Identification
35A-7
Tyres: Removal - Refitting
35A-8
37A
Tyre inflation pressure:
Identification
35A-10
Wheel rim: Identification
35A-16
STEERING ASSEMBLY
Steering rack: Removal Refitting
36A-1
Track rod: Removal Refitting
36A-3
Axial ball joint linkage:
Removal - Refitting
36A-4
Steering column: Removal Refitting
36A-7
Steering rack gaiter:
Removal - Refitting
36A-12
Bulkhead seal: Removal Refitting
36A-13
Steering wheel: Removal Refitting
36A-14
POWER ASSISTED STEERING
Steering column: List and
location of components
36B-1
Intermediate shaft
36B-2
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal Refitting
37A-1
Brake servo non-return
valve: Removal - Refitting
37A-7
Brake servo: Removal Refitting
37A-12
Vacuum pump: Removal Refitting
37A-25
Contents
37A
MECHANICAL COMPONENT CONTROLS
Accelerator pedal: Removal Refitting
37A-29
Brake pedal: Removal Refitting
37A-30
Brake pedal bell crank rod:
Removal - Refitting
38C
37A-35
Brake pedal switch: Removal
- Refitting
37A-36
Parking brake lever: Removal
- Refitting
37A-38
Parking brake lever:
Adjusting
37A-44
Clutch pedal: Removal Refitting
37A-45
Clutch circuit: Bleeding
37A-50
Clutch master cylinder:
Removal - Refitting
37A-56
Clutch circuit: Removal Refitting
37A-61
Manual gearbox selector
cable: Removal - Refitting
37A-66
Parking brake cables:
Removal - Refitting
37A-67
Clutch control: Description
37A-73
External gear control:
Description
37A-77
External gear control:
Removal - Refitting
37A-78
Gearbox lever unit Removal Refitting
37A-84
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly:
List and location of
components
38C-1
Brake hydraulic assembly:
Removal - Refitting
38C-2
38C
ANTI-LOCK BRAKING SYSTEM
Wheel speed sensor:
Removal - Refitting
38C-20
Yaw speed and transversal
acceleration sensor:
Removal - Refitting
38C-22
Braking computer: Removal Refitting
38C-23
GENERAL INFORMATION
Brake circuit Operating diagram
« 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 vehicle's braking circuit, always mark the pipes before
removing them.
30A-1
30A
GENERAL INFORMATION
Brake circuit Precautions for repair
30A
I - SAFETY
III - GENERAL RECOMMENDATIONS
1 - Advice to be followed before any operation
When replacing brake pads, always replace the pads
on the other side as well.
For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).
The brake regulation circuit must be free of all hydraulic and electrical faults.
When replacing a disc, always replace the disc on the
opposite side.
When replacing brake discs, you must replace the brake pads.
In case of incorrect handling, the brake fluid can cause
serious injury and damage. Follow the manufacturer's
instructions for brake fluid.
WARNING
In order not to damage the brake hose:
To prevent dust from entering the master cylinder reservoir and the brake circuit, the plug must be removed
just before filling and closed immediately afterwards,
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding
components.
2 - Instructions to be followed during the operation
Do not press on the brake pedal during work on the
brake system.
If, during work on the brake system, any damage on
any part is observed, it must be repaired before driving
the vehicle again.
Brake fluid is highly corrosive. Ensure any brake fluid
spilt on parts of the vehicle is cleaned off.
Use brake fluids that comply with the Renault standard
(see Precautions for repair) .
Check the brake fluid levels in the braking circuit and
the bleeding device.
Check that the pressure of the bleeding device is
between 1.5 bar and 2 bar.
IMPORTANT
To avoid any accident, bring the pistons, brake pads
and brake discs into contact by depressing the
brake pad several times.
Always replace the rigid brake pipe clips.
Reminder:
- The pipes between the master cylinder, callipers and
the hydraulic assembly are connected using threaded
unions with a metric thread.
- Therefore, only parts specified in the Parts Catalogue
for this vehicle should be used.
II - CLEANLINESS
1 - Advice to be followed before any operation
Protect any bodywork components that risk being damaged by brake fluid with a cover.
2 - Instructions to be followed during the operation
Clean around the braking system with BRAKE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products).
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
Do not allow friction materials to come into contact with
grease, oil or other lubricants and cleaning products
which are mineral oil based.
30A-2
78491
GENERAL INFORMATION
Brake circuit Precautions for repair
Parts identification:
- shape of steel or copper pipe end piece (A),
- shape of connecting points on components (B),
- shape of unions (C): 11 mm hexagonal.
Precautions to be taken before and during the brake
circuit bleeding operation:
- use brake fluid which conforms to the Renault standard (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products),
- check the brake fluid levels in the brake circuit and the
bleeding device,
- the braking regulation circuit must be free from all hydraulic and electrical faults,
- check that the pressure of the bleeding device is
between 1.5 bars and 2 bars.
30A-3
30A
GENERAL INFORMATION
Brake circuit Bleeding
30A
Essential equipment
pedal press
brake circuit bleeding device
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and operation recommendations before carrying out any
repair (see 30A, General information, Brake circuit Precautions for repair, page 30A-2) .
This procedure must be applied after one of the following components has been removed or replaced:
- the master cylinder,
- the brake fluid,
- the hydraulic unit,
- a rigid pipe,
- a hose,
115993
a Use locally produced containers to collect the used
brake fluid.
- the reservoir,
Front and rear callipers:
- a calliper.
- 2 washer fluid containers (1) (1 litre),
- 4 mm diameter transparent pipes (2) ,
WARNING
- 4 pipettes (3) (part no: 00 00 081 501),
Switch off the vehicle ignition so as not to activate
the hydraulic unit solenoid valves when bleeding the
brake circuit.
- 2 T-unions (4) .
Note:
WARNING
The new hydraulic unit is pre-filled.
The level must be between the « MIN » and
« MAX » markings on the reservoir.
When working on one of the following components, position a pedal press to limit the outflow
of brake fluid and prevent any air from entering
the master cylinder and the circuits downstream
of the master cylinder:
- hydraulic unit,
- pipes between the hydraulic unit and brake callipers,
- brake hoses,
- brake calliper.
Remove the pedal press before carrying out the
braking system bleeding procedure.
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Switch off the vehicle ignition.
30A-4
GENERAL INFORMATION
Brake circuit Bleeding
a Connect the brake circuit bleeding device (after
having received Renault approval) to the master cylinder reservoir (see the instructions for the equipment).
a Pressurise the brake circuit.
a Adjust the pressure to between 1.5 bar < P < 2 bar
for 3 minutes to stabilise it in the braking circuit.
30A
a Remove the brake circuit bleeding device from
the master cylinder reservoir.
a Check pedal travel and resistance. If it is not correct,
finish bleeding the brake circuit with the help of a second operator. Start the bleed operation by bleeding
the calliper that is the furthest away from the master
cylinder:
- hold down the brake pedal,
a Close the circuit between the bleed screw and brake
fluid reservoir without dumping the pressure.
- open the circuit bleed screw to release the air from
the brake circuit,
- close the circuit bleed screw,
Note:
- release the brake pedal.
The circuit between the bleed screw and brake
fluid reservoir is closed in different ways depending on the type of equipment used:
a Top up the brake fluid level in the reservoir, if necessary. Check the sealing of the front and rear bleed
screws and ensure that the sealing covers are in place (see 30A, General information, Brake circuit
Tightening torque, page 30A-6) .
- valve,
- switch.
a Fit the bleed containers to the four bleed screws of
the callipers.
a Undo the calliper bleed screws:
- front left-hand,
a During a road test, trigger braking regulation to confirm that the brake pedal travel is correct.
a Clean off any traces of brake fluid on the vehicle
using BRAKE CLEANING PRODUCT (see Vehicle: Parts and ingredients for the repairwork)
- front right-hand,
- rear left-hand,
- rear right-hand.
a Open the circuit between the bleed screw and brake
fluid reservoir and allow the liquid to run until all the
air bubbles have been released.
a Tighten the bleed screws in the following order:
- front left-hand,
- front right-hand,
- rear left-hand,
- rear right-hand.
a Undo the calliper bleed screw:
- front left-hand,
- allow the fluid to run until all the air bubbles have
been released,
- tighten the bleed screw on the calliper.
a Carry out the previous operation on the callipers:
- front right-hand,
- rear left-hand,
- rear right-hand.
a Close the bleed screw to dump the pressure in the
brake circuit.
30A-5
GENERAL INFORMATION
Brake circuit Tightening torque
30A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
I - FRONT AND REAR BRAKES
Description
Tightening
torque
(N.m)
Front calliper bleed screw
6.5
Rear calliper bleed screw
14
Calliper inlet brake pipe
17
Front brake guide pin bolt
32
Calliper support bolt
105
Rear brake guide pin bolt
36
Disc mounting bolt
15
II - BRAKE CONTROL
Description
Tightening
torque
(N.m)
Brake servo mounting nuts
21
TRW master cylinder mounting
nuts
50
BOSCH master cylinder mounting
nuts
21
Master cylinder outlet pipe
17
Hydraulic unit mounting bolt
8
Hydraulic unit pipe unions
17
Parking brake control mounting
nuts
8
Bolts mounting hydraulic unit support on vehicle body
6.5
30A-6
GENERAL INFORMATION
Brake circuit Tightening torque
B84 or C84, and EQT LEVEL SPORT
I - FRONT AND REAR BRAKES
Description
Tightening
torque
(N.m)
Front calliper bleed screw
15
Rear calliper bleed screw
15
Front brake hose on calliper
27
Front brake hose on rigid brake
pipe
14
Rear hybrid brake pipe on calliper
14
Rear hybrid brake pipe on hose
14
Front calliper mounting bolt
175
Rear calliper support bolt
105
Rear brake guide pin bolt
36
Disc mounting bolt
21
II - BRAKE CONTROL
Description
Tightening
torque
(N.m)
Brake servo mounting nuts
21
Master cylinder mounting nuts
50
Master cylinder outlet pipe
17
Hydraulic unit mounting bolt
8
Hydraulic unit pipe unions
17
Parking brake control mounting
nuts
8
Bolts mounting hydraulic unit support on vehicle body
6.5
30A-7
30A
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
Essential equipment
compressed air nozzle
Tightening torquesm
brake pipe bolts
underbody
(female/male)
8 N.m
unions
6 N.m
This procedure applies to copper pipes diameter 4.7
mm.
128666
Note:
This procedure does not apply to:
- hybrid pipes (pipe + hose),
- pipes with diameters 6 mm and 8 mm.
REPAIR
I - PIPE PREPARATION OPERATION
a
WARNING
128643
To avoid causing a breakdown in hydraulic brake
circuit , do not squash or bend the rigid pipe
when cutting.
a Cut the pipe to the recommended length using a
tube cutter (see Garage equipment catalogue).
128665
a Put the nuts or bolts on the pipe before forming the
rivets.
II - MAKING THE RIVETS
a
Note:
To make the rivets, fit the rivet press in a vice.
30A-8
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
a Fit the pipe in the rivet press (see Garage Equipment Catalogue).
a Adjust the length of the pipe to be shaped.
a Torque tighten the press end piece(40 N.m).
III - CHECKING THE RIVETS
128668
a Visually check that the internal diameter of the pipe
is not oval-shaped.
128667
128645
a Check that the diameter of the end panel is not oval
shaped using a sliding calliper.
128669
Correct diameter if (X1) = (X2)
a Visually inspect:
- the uniformity of the rivets' diameter,
- the rivet centring in relation to the pipe shaft.
IV - PREPARATION OF THE PIPE BEFORE
BENDING
a
Note:
Impurities may spread inside the pipe while the
rivets are being made.
a Blow inside the pipe in both directions using a compressed air nozzle.
a Put plugs on the bolts or nuts at the ends of the pipe.
a Put the original pipe on a flat base plate that is the
length of the pipe.
30A-9
GENERAL INFORMATION
Rigid brake pipe: Repair
128659
a Measure the dimensions (X3) (in mm) curve after
curve, between each curve radius « centre » (1) of
the old pipe.
30A-10
30A
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
128814
a
WARNING
To avoid weakening 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 then unbended alternatively to reach the correct curve radius.
Note:
During the bending operation, the required angle
should be passed slightly in order to compensate
for material elasticity.
a Shape the pipe using a bender, curve after curve,
while respecting the original shape of the pipe.
30A-11
GENERAL INFORMATION
Rigid brake pipe: Repair
V - CHECKING BENDING
30A
VI - REFITTING THE PIPE
a
Note:
When refitting the rigid brake pipe:
- respect the original routing as much as possible,
- adjust the pipe routing by hand when fitting
inside the clips.
WARNING
Contact points between the rigid brake pipe and
the surrounding components could cause
damage to the pipe. In order to avoid these contacts, adjust the pipe routing by hand.
128664
128670
a Check the out-of-roundness of the outer diameter at
the centre of the curve radius (2) using a sliding calliper (the out-of-roundness of the outer diameter is
correct if it is less than 10% flattening):
128644
a Torque tighten the brake pipe bolts (8 N.m).
- nominal diameter of the pipe: 4.75 mm,
- minimum diameter after bending: 4.30 mm.
128646
a Torque tighten the underbody unions (female/male) (6 N.m).
30A-12
GENERAL INFORMATION
Brake fluid: Specifications
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc brakes (hollow pistons which conduct little heat, have a
low volume of fluid in the cylinder, sliding callipers avoiding the need for a fluid reserve in the least cooled
area of the wheel), has allowed us to prevent the risk of
« vapour lock » as far as possible, even with heavy
braking (mountainous area). However, current brake
fluids are subject to minor deterioration during the first
months of use due to slight humidity intake. This is why
it is recommended that you change the brake fluid: see
maintenance booklet for the vehicle.
1 - Topping up the level
Wear of the brake pads will result in a gradual drop in
the fluid level in the reservoir.
Do not top up the fluid, as the level will rise again when
the pads are next changed. The brake fluid level must
not fall below the minimum mark.
2 - Approved brake fluid
Mixing two incompatible brake fluids in the brake circuit
may lead to:
- serious risk of leakage due mainly to deterioration of
the cups,
- deterioration in the operation of the ESP system.
To prevent such risks, it is essential to use only brake
fluids that comply with the RENAULT standard (see
Vehicle: Parts and ingredients for the repairwork) .
30A-13
30A
GENERAL INFORMATION
Brake: Specifications
30A
B84 or C84 or E84 or G84 or L84 or S84
Engine
K4J
K9K, K4M, F9Q,
F4R, M9R
Piston diameter
54
54
Disc diameter
260
280
Disc thickness
22
24
Minimum disc thickness (1)
19.8
21.8
Maximum disc run-out
0.07
0.07
Brake pad thickness (including backplate)
18
18
Minimum brake pad thickness (including backplate)
6
6
Front brakes (mm)
Rear brakes (mm)
Piston diameter
34
Disc diameter
240
Disc thickness
8
Minimum disc thickness (1)
6.5
Maximum disc run-out
0.07
Brake pad thickness (including backplate)
16
Minimum brake pad thickness (including backplate)
6
Master cylinder (mm)
Diameter
23.8
Stroke
36
K84
Engines of all types
FRONT BRAKE (mm)
Piston diameter
54
Disc diameter
280
Disc thickness
24
30A-14
GENERAL INFORMATION
Brake: Specifications
30A
Engines of all types
Minimum disc thickness (1)
21.8
Maximum disc run-out
0.07
Brake pad thickness (including backplate)
18
Minimum brake pad thickness (including backplate)
6
REAR BRAKE (mm)
Piston diameter
34
Disc diameter
270
Disc thickness
10
Minimum disc thickness (1)
6.5
Maximum disc run-out
0.07
Brake pad thickness (including backplate)
16
Minimum brake pad thickness (including backplate)
6
MASTER CYLINDER (mm)
Diameter
23.8
Stroke
36
EQT LEVEL SPORT
FRONT BRAKE (mm)
Piston diameter
40
Disc diameter
312
Disc thickness
28
Minimum disc thickness (1)
26
Maximum disc run-out
0.07
Brake pad thickness (including backplate)
15.2
Minimum brake pad thickness (including backplate)
6.5
REAR BRAKE (mm)
Piston diameter
38
Disc diameter
300
Disc thickness
11
Minimum disc thickness (1)
8.5
30A-15
GENERAL INFORMATION
Brake: Specifications
30A
Maximum disc run-out
0.07
Brake pad thickness (including backplate)
16.6
Minimum brake pad thickness (including backplate)
8
MASTER CYLINDER (mm)
Diameter X Stroke
23.8 x 36
(1) Brake discs cannot be reground. If they are too heavily worn or scratched they must be replaced.
30A-16
GENERAL INFORMATION
Steering: Tightening torque
30A
Description
Tightening torques (N.m)
Steering wheel mounting bolt
44
Description
Tightening torques (N.m)
Universal joint bolt
26
Description
Tightening torques (N.m)
Intermediate shaft mounting bolt on steering column
44
Axial ball joint
80
Track rod nut
37
Wheel alignment adjustment lock nut
53
Steering column nut
21
Steering box bolt on the subframe
105
30A-17
GENERAL INFORMATION
Axle assemblies: Check
a Lock the slip plates of the lift.
a Position the vehicle on a lift (see Vehicle: Towing
and lifting) .
a Check the condition of the following components:
- track rods,
- axial ball joint linkages,
- subframe,
- lower arm rubber bushes,
- lower arm ball joints (see 31A, Front axle components, Front driveshaft lower arm ball joint:
Check, page 31A-45) ,
- shock absorbers,
- tyres,
a Check:
- the tyre size (see 35A, Wheels and tyres, Tyres:
Identification, page 35A-7) ,
- the tyre inflation pressure (see 35A, Wheels and
tyres, Tyre inflation pressure: Identification,
page 35A-10) .
a Put the vehicle in the VODM position (vehicle in running order) (see 30A, General information, Underbody height: Adjustment values, page 30A-19) :
- tank full,
- vehicle empty (without luggage, etc.).
a Consult:
- the front axle geometry values (see 30A, General
information, Front axle: Adjustment values,
page 30A-26) ,
- the rear axle geometry values (see 30A, General
information, Rear axle: Adjustment values,
page 30A-36) .
a Refer to the user manual for the geometry tester.
a Check the geometry using the geometry tester.
a If there is an inconsistency between the manufacturer's values and the measured values:
a Adjust the front axle (see 30A, General information, Front axle: Adjusting, page 30A-32)
30A-18
30A
GENERAL INFORMATION
Underbody height: Adjustment values
30A
I - MEASURING POINTS
101937
Radius under load:
- (R1) : Distance between the ground and the front
wheel centre line
- (R2) : Height between the ground and the rear wheel
centre line
139129
(W1) : Height between the ground and the rear cross
member bolt head.
1 - Front height (W1)
2 - Rear height (W2)
102312
102246
30A-19
GENERAL INFORMATION
Underbody height: Adjustment values
30A
1 - Plate higher than the lift:
126087
Measure the heights (1) , (2) and (3) .
Example: (1) = 13 cm, (2) = 8 cm, (3) = 10 cm
139128
(W2) : Height between the ground and the shaft of the
rubber bush on the bearing.
II - MEASURING METHODS
Calculate the height Wx:
Wx = height (1) + height (3) - height (2)
Wx = 15 cm
2 - Plate lower than the lift:
Note:
For measurements (W1) and (W2) , take into
account the height difference between the plates
and the lift.
Measure the heights:
- R1,
- R2,
- W1 right-hand and left-hand,
- W2 right-hand and left-hand.
126088
Note:
Measure the heights (1) , (2) and (3) .
The value of Wx to be entered into the geometry
bench is the average of the W1 heights, right-hand
and left-hand and of the W2 heights, right-hand and
left-hand.
Example: (1) = 8 cm, (2) = 10 cm, (3) = 4 cm
Special cases:
Note:
If the measuring points are located in empty space
(between the rails of the lift), use a bar.
Fit a bar across the lift.
Calculate the height Wx:
Wx = height (1) + height (2) + height (3)
Wx = 22 cm
III - VEHICLE IN RUNNING ORDER POSITION
VODM (Vehicle in working order) position:
- tank full,
- vehicle empty (without luggage, etc.).
30A-20
GENERAL INFORMATION
Underbody height: Adjustment values
B84 or C84, and EQT LEVEL SPORT
(w1) = 154 mm
(w2) = 232.4 mm
Note:
The position of the vehicle varies according to:
- the weight of the engine,
- the springs and shock absorbers,
- the tyres,
- the amount of fuel in the tank.
30A-21
30A
GENERAL INFORMATION
Front axle: Tightening torque
30A
101232
No.
Description
Tightening torque
(N.m)
(1)
"Spring and shock absorber" assembly bolt on body
21
B84 or C84 or G84 or K84 or L84 or S84
No.
Description
Tightening torque
(N.m)
(2)
Lower arm rear bolt
70
E84
No.
Description
Tightening torque
(N.m)
(2)
Lower arm rear bolt
105
30A-22
GENERAL INFORMATION
Front axle: Tightening torque
30A
No.
Description
Tightening torque
(N.m)
(3)
Lower arm front bolt
70
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT
LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4 or EQT LEVEL EA5 or EQT LEVEL EA6 or
EQT LEVEL EAG
No.
Description
Tightening torque
(N.m)
(4)
Sub-frame stud bolt
105
B84 or C84, and EQT LEVEL SPORT
No.
Description
Tightening torque
(N.m)
(4)
Sub-frame stud bolt
110
No.
Description
Tightening torque
(N.m)
(5)
Rear cross member bolt
62
(6)
Anti-roll bar bolt on the subframe
21
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT
LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4 or EQT LEVEL EA5 or EQT LEVEL EA6 or
EQT LEVEL EAG
No.
Description
Tightening torque
(N.m)
(7)
Radiator cross member front bolt
105
30A-23
GENERAL INFORMATION
Front axle: Tightening torque
30A
B84 or C84, and EQT LEVEL SPORT
No.
Description
Tightening
(N.m)
torque
(7)
Radiator cross member front bolt
110
No.
Description
Tightening torque
(N.m)
(8)
Radiator cross member rear nut
21
101231
No.
Description
Tightening torque
(N.m)
(9)
Shock absorber nut
62
(10)
Anti-roll bar tie-rod ball joint nut
44
(11)
Shock absorber base bolts
105
30A-24
GENERAL INFORMATION
Front axle: Tightening torque
30A
No.
Description
Tightening torque
(N.m)
(12)
Subframe tie-rod bolt
105
(13)
Lower arm ball joint bolt
62
(14)
Driveshaft nut
280
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT
LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4 or EQT LEVEL EA5 or EQT LEVEL EA6 or
EQT LEVEL EAG
No.
Description
Tightening
(N.m)
(15)
Wheel bolts
110
torque
EQT LEVEL SPORT
No.
Description
Tightening torque
(N.m)
(15)
Wheel bolts
145
No.
Description
Tightening
(N.m)
(16)
Track rod end nut
37
30A-25
torque
GENERAL INFORMATION
Front axle: Adjustment values
30A
B84 or C84 or G84 or S84, and EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL
EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
I - CASTOR ANGLE
Not adjustable.
Value
Position of front
axle (mm)
+ 0˚ 02’ ± 30’
R1 - W1 = 127
- 0˚ 12’ ± 30’
R1 - W1 = 146
- 0˚ 15’ ± 30’
R1 - W1 = 152
Maximum right/left difference = 0˚ 30’
III - PIVOT
Not adjustable.
93012
Value
Position of front
axle (mm)
+ 5˚ 00’ ± 30’
W2 - W1 = 79
+ 5˚ 20’ ± 30’
W2 - W1 = 71
+ 6˚ 06’ ± 30’
W2 - W1 = 49
+ 6˚ 30’ ± 30’
W2 - W1 = 40
Maximum right/left difference
= 0˚ 30’
93014
II - CAMBER
Value
Position of front
axle (mm)
+ 10˚ 54’ ± 30’
R1 - W1 = 127
+ 11˚ 24’ ± 30’
R1 - W1 = 146
+ 11˚ 30’ ± 30’
R1 - W1 = 152
Not adjustable.
Maximum left - right difference = 30’
IV - WHEEL ALIGNMENT: MEANING OF SYMBOLS
WARNING
Symbols used by RENAULT:
93013
- toe-out: - toe-in: +
30A-26
GENERAL INFORMATION
Front axle: Adjustment values
30A
B84 or C84 or G84 or S84, and EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL
EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
V - WHEEL ALIGNMENT
93011
Value (for two wheels)
Position of
vehicle
- 0˚ 10’ ± 10’
Vehicle
running
order
in
30A-27
GENERAL INFORMATION
Front axle: Adjustment values
30A
B84 or C84, and EQT LEVEL SPORT
I - CASTOR ANGLE
Sport version
Not adjustable.
Value
Position of front
axle (mm)
+ 0˚ 47’ ± 30’
R1 - W1 = 151.6
Maximum right/left difference = 0˚ 30’
III - PIVOT
Not adjustable.
93012
Sport version
Value
Position of front
axle (mm)
+ 5˚ 16’ ± 30’
W2 - W1 = 78.4
Maximum right/left difference
= 0˚ 30’
93014
II - CAMBER
Sport version
Not adjustable.
Value
Position of front
axle (mm)
+ 9˚ 05’ ± 30’
R1 - W1 = 151.6
Maximum left - right difference = 30’
IV - WHEEL ALIGNMENT: MEANING OF SYMBOLS
WARNING
Symbols used by RENAULT:
- toe-out: 93013
30A-28
- toe-in: +
GENERAL INFORMATION
Front axle: Adjustment values
B84 or C84, and EQT LEVEL SPORT
V - WHEEL ALIGNMENT
93011
Value (for two wheels)
Position of
vehicle
- 0˚ 10’ ± 10’
Vehicle
running
order
in
30A-29
30A
GENERAL INFORMATION
Front axle: Adjustment values
30A
E84 or K84 or L84
I - CASTOR ANGLE
II - CAMBER
Not adjustable.
Not adjustable.
93012
E84
93013
E84
Value
Position of front
axle (mm)
Value
Position of front
axle (mm)
+ 5˚ 12’ ± 30’
W2 - W1 = 70
0˚ 00’ ± 30’
R1 - W1 = 124
+ 5˚ 30’ ± 30’
W2 - W1 = 63
- 0˚ 05’ ± 30’
R1 - W1 = 132
+ 5˚ 48’ ± 30’
W2 - W1 = 56
- 0˚ 12’ ± 30’
R1 - W1 = 147
+ 6˚ 06’ ± 30’
W2 - W1 = 49
- 0˚ 14’ ±30’
R1 - W1 = 153
Maximum right/left difference
= 0˚ 30’
Maximum right/left difference = 0˚ 30’
K84 or L84
K84 or L84
Value
Position of front
axle (mm)
Value
Position of front
axle (mm)
+ 4˚ 30’ ± 30’
W2 - W1 = 94
+ 0˚ 38’ ± 30’
R1 - W1 = 118
+ 5˚ 06’ ± 30’
W2 - W1 = 75
+ 0˚ 01’ ± 30’
R1 - W1 = 125
+ 5˚ 42’ ± 30’
W2 - W1 = 62
- 0˚ 12’ ± 30’
R1 - W1 = 146
+ 6˚ 18’ ± 30’
W2 - W1 = 46
- 0˚ 16’ ± 30’
R1 - W1 = 158
Maximum right/left difference
= 0˚ 30’
Maximum right/left difference = 0˚ 30’
30A-30
GENERAL INFORMATION
Front axle: Adjustment values
30A
E84 or K84 or L84
III - PIVOT
IV - WHEEL ALIGNMENT: MEANING OF SYMBOLS
Not adjustable.
WARNING
Symbols used by RENAULT:
- toe-out: - toe-in: +
V - WHEEL ALIGNMENT
93014
E84
Value
Position of front
axle (mm)
+ 10˚ 02’ ± 30’
R1 - W1 = 124
+ 11˚ 14’ ± 30’
R1 - W1 = 132
+ 11˚ 32’ ± 30’
R1 - W1 = 147
+ 11˚ 40’ ± 30’
R1 - W1 = 153
Maximum right/left difference = 0˚ 30’
93011
Value (for two wheels)
Position of
vehicle
- 0˚ 10’ ± 10’
Vehicle
running
order
K84 or L84
Value
Position of front
axle (mm)
+ 10˚ 59’ ± 30’
R1 - W1 = 118
+ 11˚ 06’ ± 30’
R1 - W1 = 125
+ 11˚ 32’ ± 30’
R1 - W1 = 146
+ 11˚ 45’ ± 30’
R1 - W1 = 158
Maximum right/left difference = 0˚ 30’
30A-31
in
GENERAL INFORMATION
Front axle: Adjusting
30A
Essential equipment
steering wheel lock
Tightening torquesm
wheel alignment adjustment lock nuts
53 N.m
I - ADJUSTMENT PREPARATION STAGE
a
Note:
Throughout the axle assembly checking and
adjustment process:
- the Renault Card must remain in the reader,
- do not press the « START » button.
121364
a Check the geometry (see 30A, General information, Axle assemblies: Check, page 30A-18) .
a Loosen the wheel alignment adjustment lock nut (1)
.
a Turn the track rod sleeve (2) to the required value.
a After adjustment, torque tighten the wheel alignment adjustment lock nuts (53 N.m).
II - ADJUSTMENT OPERATION
1 - Wheel alignment
2 - Castor angle
a Set the wheels straight ahead.
a Lock the steering wheel using a steering wheel
lock.
a Adjust the wheel alignment by rotating the track rod
sleeves.
a Not adjustable.
3 - Camber
a Not adjustable.
4 - Pivot
a Not adjustable.
30A-32
GENERAL INFORMATION
Rear axle: Tightening torque
30A
B84 or C84 or E84 or G84 or L84 or S84, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4 or EQT LEVEL EAG
101900
No.
Description
Tightening torque
(Nm)
(1)
Stub-axle nut
175
(2)
Calliper support bolt
105
(3)
Guide pin bolt
36
(4)
Bearing bolt
62
Shock absorber lower bolt
105
Shock absorber upper bolt
62
(6)
Brake pipe nut
14
(7)
Bearing - rear axle mounting bolt nut
125
Bolt on guard under rear axle
8
(5)
30A-33
GENERAL INFORMATION
Rear axle: Tightening torque
30A
K84
101900
No.
Description
Tightening torque
(Nm)
(1)
Stub-axle nut
220
(2)
Calliper support bolt
105
(3)
Guide pin bolt
36
(4)
Bearing bolt
62
Shock absorber lower bolt
105
Shock absorber upper bolt
62
(6)
Brake pipe nut
14
(7)
Bearing - rear axle mounting bolt nut
125
Bolt on guard under rear axle
8
(5)
30A-34
GENERAL INFORMATION
Rear axle: Tightening torque
30A
B84 or C84, and EQT LEVEL SPORT
101900
No.
Description
Tightening torque
(N.m)
(1)
Stub axle nut
220
(2)
Calliper support bolt
105
(3)
Guide pin bolt
36
(4)
Bearing bolt
62
Shock absorber lower bolt
105
Shock absorber upper bolt
62
(6)
Brake pipe nut
14
(7)
Bearing - rear axle mounting bolt nut
125
Bolt on guard under rear axle
8
(5)
30A-35
GENERAL INFORMATION
Rear axle: Adjustment values
30A
B84 or C84 or G84 or S84, and EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL
EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
I - CAMBER
Not adjustable.
Axle
p a rt
number
Value
Position
vehicle
77 01 474 558
+ 0˚40’ ± 25’
77 01 474 559
77 01 476 337
+ 0˚35’ ± 25’
of
Vehicle in running order
77 01 476 338
NORMAL SUSPENSION – EQT LEVEL E3 PLUS
or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT
LEVEL EA3 or EQT LEVEL EA4, and DOCUMENT
PHASE 2
93013-1
Value
Position of vehicle
-1˚25’ ± 20’
Vehicle in running order
II - WHEEL ALIGNMENT: MEANING OF SYMBOLS
Value
Position of vehicle
+ 0˚32’ ± 30’
Vehicle in running order
ADJUSTED SUSPENSION
WARNING
Meaning of symbols used in this document,
Value
Position of vehicle
+ 0˚24’ ± 25’
Vehicle in running order
-: toe-out
+: toe-in
III - WHEEL ALIGNMENT
B84 or C84, and EQT LEVEL EAG
Not adjustable.
93011-1
30A-36
Value
Position of vehicle
+ 0˚36’ ± 20’
Vehicle in running order
GENERAL INFORMATION
Rear axle: Adjustment values
30A
E84 or K84 or L84
I - CAMBER
Not adjustable.
E84
Axle part number
Value
77 01 475 265
+ 0˚40’ ± 25’
Position
vehicle
of
77 01 475 266
77 01 476 342
+ 0˚35’ ± 25’
77 01 476 343
77 01 476 510
+ 0˚34’ ± 25’
Vehicle in running order
77 01 476 511
93013-1
77 01 477 075
77 01 477 076
Value
Position of vehicle
- 1˚ 25’ ± 20’
Vehicle in running order
II - WHEEL ALIGNMENT: MEANING OF SYMBOLS
K84
WARNING
Meaning of symbols used in this document,
-: toe-out
+: toe-in
Axle part number
Value
77 01 475 283
+ 0˚40’ ± 25’
77 01 475 149
III - WHEEL ALIGNMENT
77 01 476 340
Not adjustable.
77 01 476 341
+ 0˚35’ ± 25’
Position
vehicle
of
Vehicle in running order
K84, and ADJUSTED SUSPENSION
Axle part number
Value
Position
vehicle
77 01 476 508
+ 0˚23’ ± 23’
Vehicle in running order
77 01 476 509
77 01 477 072
93011-1
77 01 477 073
30A-37
of
GENERAL INFORMATION
Rear axle: Adjustment values
30A
E84 or K84 or L84
K84, and NORMAL SUSPENSION
L84, and NORMAL SUSPENSION
Axle part number
Value
Position
vehicle
77 01 476 508
+ 0˚28’ ± 25’
Vehicle in running order
77 01 476 509
of
Axle part number
Value
Position
vehicle
77 01 476 514
+ 0˚30’ ± 30’
Vehicle in running order
77 01 476 515
77 01 477 072
77 01 477 081
77 01 477 073
77 01 477 082
77 01 477 423
77 01 477 424
L84
Axle part number
Value
77 01 474 962
+ 0˚40’ ± 25’
77 01 474 963
77 01 475 919
+ 0˚35’ ± 25’
Position
vehicle
of
Vehicle in running order
77 01 475 920
L84, and ADJUSTED SUSPENSION
Axle part number
Value
Position
vehicle
77 01 476 514
+ 0˚23’ ± 23’
Vehicle in running order
77 01 476 515
of
77 01 477 081
77 01 477 082
77 01 477 423
77 01 477 424
30A-38
of
GENERAL INFORMATION
Rear axle: Adjustment values
30A
B84 or C84, and EQT LEVEL SPORT
I - CAMBER
Toe-in: plus symbol
Not adjustable.
93011-1
93013-1
III - WHEEL ALIGNMENT
Not adjustable.
Value
Position of vehicle
- 1˚ 30’ ± 30’
Vehicle in running order
II - WHEEL ALIGNMENT: MEANING OF SYMBOLS
WARNING
Meaning of symbols used in this document,
-: toe-out
+: toe-in
Toe-out: minus sign
93011-1
Value (for
wheels)
+ 0˚ 40’ ± 10’
93011
30A-39
two
Position of vehicle
Vehicle in running order
GENERAL INFORMATION
Front anti-roll bars: Specifications
FRONT AXLE
Bar diameter (mm)
Marking
19
White
20
Yellow
21
Orange
22
Green
30A-40
30A
GENERAL INFORMATION
Rear anti-roll bar: Specifications
B84 or C84 or G84 or S84
REAR AXLE
105839
F4R or F9Q or K9K or M9R, and DP0
Bar size (mm)
(X) : 15.7
(Y) : 41.3
K4J or K4M or K9K
Bar size (mm)
(X) : 15.9
(Y) : 38
30A-41
30A
GENERAL INFORMATION
Rear anti-roll bar: Specifications
E84
REAR AXLE
105839
F4R or F9Q or K9K, and DP0
Bar size (mm)
(X) : 15.7
(Y) : 35
K4J or K4M or K9K
Bar size (mm)
(X) : 17.9
(Y) : 28.3
M9R
Bar size (mm)
(X) : 15.7
(Y) : 41.3
30A-42
30A
GENERAL INFORMATION
Rear anti-roll bar: Specifications
L84
REAR AXLE
105839
F4R or F9Q or K9K, and DP0
Bar size (mm)
(X) : 15.9
(Y) : 38
K4J or K4M or K9K
Bar size (mm)
(X) : 15.7
(Y) : 35
M9R
Bar size (mm)
(X) : 15.7
(Y) : 41.3
30A-43
30A
GENERAL INFORMATION
Rear anti-roll bar: Specifications
K84
REAR AXLE
105839
F4R or F9Q or K9K, and DP0
Bar size (mm)
(X) : 15.7
(Y) : 41.3
K4J or K4M or K9K
Bar size (mm)
(X) : 15.9
(Y) : 38
M9R
Bar size (mm)
(X) : 17.1
(Y) : 40.7
30A-44
30A
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
This procedure concerns BOSCH type brake pads.
When replacing brake pads or a disc, it is essential to
replace the pads and disc on the opposite side.
REMOVAL
a Position the vehicle on a two-post lift.
119215
a Unclip the brake hose (2) from the shock absorber.
a Rotate the calliper upwards.
a Remove the pads.
a Check the condition of the braking components.
a Replace any faulty parts.
101214
101212
a Remove:
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the lower pillar bolt (1) .
31A-1
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
a Push the piston.
REFITTING
a Fit the new pads, starting from the inside.
WARNING
In order not to damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding components.
a Proceed in the reverse order to removal.
a Torque tighten the guide pin bolts (see 30A, General information, Brake circuit Tightening torque,
page 30A-6) .
IMPORTANT
103115
117348
a Clean the calliper mountings and callipers using the
cleaning station.
31A-2
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
When replacing brake pads, be sure to replace the
pads on the opposite side.
REFITTING
REMOVAL
a Position the vehicle on a two-post lift.
a Remove:
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the lower pillar bolt.
117348
a Clean the brake callipers using the cleaning station.
105892
a Remove:
- the brake pad retaining pins (1) ,
- the spring (2) ,
- the brake pads.
a Check the condition of the braking components.
a Replace any faulty parts.
31A-3
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting
B84 or C84, and EQT LEVEL SPORT
106080
a Push the pistons back until they are at the end of
their bores.
a Fit the new brake pads, starting from the inside.
WARNING
In order to not damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding components.
a Proceed in the reverse order to removal.
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
31A-4
31A
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
Essential special tooling
Fre. 1190-01
Brake calliper piston return
tool.
This procedure concerns TEVES type brake pads.
WARNING
In order not to damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding
components.
REMOVAL
127486
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the guide pin bolt caps (2) ,
a Remove the front wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
- the calliper guide pin bolts (2) ,
- the calliper (3) from its support.
a Attach the calliper (3) to the shock absorber spring.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Remove the brake pads.
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the guide pin bolts.
a Measure the thickness of the pads and then compare them to the minimum values (see 30A, General
information, Brake: Specifications, page 30A-14)
.
a Do not allow friction materials to come into contact
with grease, oil or other lubricants and cleaning products which are mineral oil based.
a Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products):
127487
- the calliper supports,
a Unclip the brake hose from the shock absorber.
a Remove the retaining spring (1) from the brake calliper using a flat-blade screwdriver.
- the callipers.
a Push the piston with the tool (Fre. 1190-01).
31A-5
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the brake pads,
- the brake calliper,
- the calliper retaining spring.
a Torque tighten the bolts of the calliper guide pins
(see 30A, General information, Brake circuit Tightening torque, page 30A-6) .
a Refit the guide pin bolt caps.
a Attach the brake hose to the shock absorber.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
III - FINAL OPERATION
a Refit the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
31A-6
FRONT AXLE COMPONENTS
Front brake hose: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
II - REMOVAL OPERATION FOR PART
CONCERNED
Essential equipment
pedal press
Tightening torquesm
brake hose on the calliper
17 Nm
brake hose on the union
17 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
101709
a Unscrew:
- the pipe union (1) ,
- the calliper hose.
REFITTING
101707
a Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
I - REFITTING OPERATION FOR PART
CONCERNED
a
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
WARNING
In order to not damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding components.
Note:
The hoses supplied as spare parts are encased
in a spring to prevent them from being twisted
during fitting.
a Refit the brake hose at the calliper end.
a Torque tighten:
- the brake hose on the calliper (17 Nm),
- the brake hose on the union (17 Nm),
31A-7
FRONT AXLE COMPONENTS
Front brake hose: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
a Position the female end of the brake hose on the retaining bracket without straining it by twisting.
a Make sure that the end piece engages freely into the
bracket splines.
a Fit:
- the spring,
- the rigid pipe on the brake hose, making sure that
the hose does not twist when screwing on the rigid
pipe.
II - FINAL OPERATION.
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Refit the wheel (see 3 5 A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
31A-8
FRONT AXLE COMPONENTS
Front brake hose: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
Essential equipment
pedal press
Tightening torquesm
brake hose on the calliper
27 N.m
lower mounting of the
shock absorber
105 N.m
rigid brake pipe union
on the hose
14 N.m
REMOVAL
a Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1)
106081
a Unscrew:
- the lower mounting of the shock absorber to release the hose support bracket (1) ,
- the rigid pipe union on the brake hose (2) ,
- the hose union on the calliper (3) .
a Remove:
- the hose of the support bracket,
- the support bracket.
REFITTING
106079
a
a
WARNING
WARNING
In order not to damage the brake hose:
Prepare for the flow of fluid, and protect the surrounding components.
- do not tension the hose,
- do not twist the hose,
Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
- check that there is no contact with the surrounding components.
a Open the bleed screws.
Note:
The pipe supplied as spare parts are encased in
a spr ing to prevent them from being twisted
during fitting.
a Systematically replace the union seals when they
are removed.
a Refit the brake hose at the calliper end.
31A-9
FRONT AXLE COMPONENTS
Front brake hose: Removal - Refitting
B84 or C84, and EQT LEVEL SPORT
a Tighten to torque:
- the brake hose on the calliper (27 N.m),
a Position the rubber section of the hose in the lug of
the support bracket (without fitting it in fully),
a Refit the support bracket,
a Torque tighten:
- the lower mounting of the shock absorber (105
N.m), ensuring the correct positioning of the support bracket
a Position the brake hose fully in the lug of the support
bracket.
a Refit the other end of the hose (body side) without
straining it by twisting.
a Check that the end piece engages freely in the retaining bracket splines.
a Fit:
- the staple,
- the rigid brake pipe on the hose, making sure that
the hose does not twist when screwing on the rigid
pipe union.
a Torque tighten:
- the rigid brake pipe union on the hose (14 N.m),
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Refit the wheel (see 3 5 A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
31A-10
31A
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
Essential equipment
pedal press
Tightening torquesm
guide pin bolts
32 Nm
brake hose
17 Nm
When replacing brake pads or a disc, be sure to replace the pads or disc on the opposite side.
Note:
The callipers supplied as replacement parts are
pre-filled.
101214
REMOVAL
a Position the vehicle on a two-post lift.
a Remove the front wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Fit the pedal press to the brake pedal to reduce the
amount of brake fluid running out.
a Release the brake hose from the brake calliper.
a Remove:
- the guide pin bolt (1) (brake calliper mountings),
- the brake calliper,
- the brake pads.
a Check the condition of the braking components.
a Replace any faulty parts.
31A-11
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
REFITTING
117348
a Clean the calliper mountings and callipers using the
cleaning station.
103115
a Push the piston back until it is at the end of its bore.
a Fit the pads, starting from the inside.
a Refit:
- the calliper,
- the guide pin bolt.
a Torque tighten:
- the guide pin bolts (32 Nm),
- the brake hose (17 Nm).
WARNING
In order to not damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding components.
a Refit the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Bleed the brake circuit partially if the compensation
reservoir is not completely emptied during the procedure. If necessary, bleed the circuit completely (see
30A, General information, Brake circuit Bleeding, page 30A-4) .
a Check the brake fluid level.
31A-12
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
Essential equipment
pedal press
Note:
The callipers supplied as replacement parts are
pre-filled.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) .
a Fit the pedal press to the brake pedal to reduce the
amount of brake fluid running out.
a Remove the front wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
105892
a
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
a Open the bleed screws.
a Remove:
- the brake hose (1) from the calliper,
- the calliper bolts (2) ,
- the brake pads.
a Check the condition of the braking components.
a Replace any faulty parts.
31A-13
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
REFITTING
117348
a Clean the callipers using the cleaning station.
106080
a Push the pistons back until they are at the end of
their bores.
a Fit the pads, starting from the inside.
a Refit the calliper.
a Torque tighten the bolts of the brake calliper (see
30A, General information, Brake circuit Tightening torque, page 30A-6) .
a Torque tighten the brake hose (see 30A, General
information, Brake circuit Tightening torque,
page 30A-6) .
a
WARNING
In order not to damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding components.
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Partially bleed the braking circuit if the compensation reservoir has not been completely emptied during the operation. If necessary, bleed the circuit
completely (see 30A, General information, Brake
circuit Bleeding, page 30A-4) .
a Check the brake fluid level.
31A-14
FRONT AXLE COMPONENTS
Front brake calliper support: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EA6 or EQT LEVEL EAG
REMOVAL
Essential special tooling
Fre. 1190-01
Brake calliper piston return
tool.
Tightening torquesm
calliper mounting bolts
105 Nm
When replacing brake pads or a disc, be sure to replace the pads or disc on the opposite side.
101215
a Position the vehicle on a two-post lift.
a Remove:
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the guide pin bolts (1) ,
- the calliper (see 31A, Front axle components,
Front brake calliper: Removal - Refitting, page
31A-11)
a Hang the brake calliper from the suspension spring.
a Remove:
- the two calliper mounting bolts (2) ,
- the calliper mounting.
a Check the condition of the braking components.
a Replace any faulty parts.
a Clean the calliper mountings and callipers using the
cleaning station.
31A-15
FRONT AXLE COMPONENTS
Front brake calliper support: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EA6 or EQT LEVEL EAG
REFITTING
Wheel: Removal - Refitting, page 35A-1) .
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
103115
a Push the piston back using the (Fre. 1190-01) until it
is at the end of its housing.
The calliper mounting bolts must be coated with a
product such as FRENBLOC before they are fitted.
a Refit:
- the calliper mounting,
- the calliper mounting bolts.
a Torque tighten the calliper mounting bolts (105
Nm).
a Fit the pads, starting from the inside.
a Refit:
- the calliper (see 31A, Front axle components,
Front brake calliper: Removal - Refitting, page
31A-11) ,
- the guide pin bolts.
WARNING
In order to not damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding components.
a Check the brake fluid level.
a Refit the wheel (see 3 5 A, Wheels and tyres,
31A-16
FRONT AXLE COMPONENTS
Front brake disc: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
REFITTING
a To refit, proceed in the reverse order of removal.
Tightening torquesm
disc bolts
15 Nm
WARNING
When replacing the pads or disc, the pads and disc on
the opposite side must also be replaced.
In order to not damage the brake hose:
- do not tension the hose,
REMOVAL
- do not twist the hose,
- check that there is no contact with the surrounding components.
101212
a Position the vehicle on a two-post lift.
a Remove:
117348
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
a Clean the calliper mountings and callipers using the
cleaning station.
- the calliper (see 31A, Front axle components,
Front brake calliper: Removal - Refitting, page
31A-11) .
a Tighten to torque the disc bolts (15 Nm)
a
a Hang the calliper on the suspension spring.
IMPORTANT
a Remove:
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
- the calliper mounting (see 31A, Front axle components, Front brake calliper: Removal - Refitting, page 31A-11) ,
- the two disc bolts (1),
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
- the disc.
31A-17
FRONT AXLE COMPONENTS
Front brake disc: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
Tightening torquesm
disc bolts
21 Nm
REMOVAL
a Position the vehicle on a two-post lift.
a Remove the front wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
106081
a Remove:
- the two disc mounting bolts (2) ,
- the disc.
REFITTING
a Proceed in the reverse order to removal.
105892
a Remove the calliper (see 31A, Front axle components, Front brake calliper: Removal - Refitting,
page 31A-11) .
WARNING
In order to not damage the brake hose:
- do not tension the hose,
- do not twist the hose,
a Hang the calliper on the suspension spring.
- check that there is no contact with the surrounding components.
31A-18
FRONT AXLE COMPONENTS
Front brake disc: Removal - Refitting
B84 or C84, and EQT LEVEL SPORT
117348
a Clean the callipers using the cleaning station.
a Torque tighten the disc bolts (21 Nm).
a
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
31A-19
31A
FRONT AXLE COMPONENTS
Front brake disc: Description
31A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
II - CHECKING OPERATION FOR PART
CONCERNED
Note:
Use a Palmer type tool to check the thickness of the
disc.
88310
Measure the thickness of the disc at 4 points in order
(90˚ apart).
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-14) .
III - FINAL OPERATION
Replace the discs if necessary (see 31A, Front axle
components, Front brake disc: Removal - Refitting,
page 31A-17) .
Refit the wheel (see 35A, Wheels and tyres, Wheel:
Removal - Refitting, page 35A-1) .
117057
Position the Palmer tool (1) to measure the disc thickness.
31A-20
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
Essential special tooling
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
Sus. 1731
Front shock absorber removal
tool.
WARNING
In order to prevent irreversible damage to the front
hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
101215
a Remove the calliper (see 31A, Front axle components, Front brake calliper: Removal - Refitting,
page 31A-11) .
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Hang the calliper on the suspension spring.
a Remove:
- the calliper mounting,
a Unclip:
- the track rod end nut (2) ,
- the wheel speed sensor from the hub carrier,
- the lower ball joint nut (3) ,
- the xenon bulb sensor (if fitted).
- the lower bolt (4) from the shock absorber.
31A-21
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
101212
a Remove:
112078
a Position the (Sus. 1731).
- the disc (see 31A, Front axle components, Front
brake disc: Removal - Refitting, page 31A-17) ,
a Tighten the bolt (8) of the (Sus. 1731) to remove the
hub carrier while holding it.
- the hub nut (6) using the (Rou. 604-01),
a Take care not to drop the hub carrier.
- the anti-roll bar tie-rod upper nut (7) ,
a Check that the part (9) of the tool (Sus. 1731) is in
contact with the shock absorber base.
- the anti-roll bar tie-rod.
a Extract the ball joints using the (Tav. 476).
a Separate the driveshaft from the hub carrier taking
care not to dislocate the driveshaft.
REFITTING
a Proceed in the reverse order to removal.
Note:
The calliper mounting bolts must be coated with
a product such as HIGH RESISTANCE THREAD
LOCK before being refitted.
a Torque tighten (see 30A, General information,
Front axle: Tightening torque, page 30A-22) :
- the shock absorber lower bolt,
- the lower ball joint nut.
a Torque tighten the track rod end nut (see 30A, General information, Steering: Tightening torque,
page 30A-17) .
31A-22
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
a Torque tighten the hub nut (see 30A, General information, Front axle: Tightening torque, page 30A22) .
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
a Adjust the axle assemblies (see 30A, General information, Axle assemblies: Check, page 30A-18) .
31A-23
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
WARNING
In order to prevent irreversible damage to the front
hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
REMOVAL
a Position the vehicle on a two-post lift.
a Disconnect the battery starting with the negative terminal (see Battery : Removal - Refitting) (MR 364,
80A, Battery).
106095
For the hub carrier to be removed, the spring/shock
absorber assembly must also be removed (see 31A,
Front axle components, Spring and front shock
absorber: Removal - Refitting, page 31A-29) .
a Tighten the hub and its pivot in the vice with jaws.
107158
a Remove the ring (2) using a puller.
107161
a Remove the hub mounting bolts (1) .
31A-24
FRONT AXLE COMPONENTS
Front driveshaft hub carrier: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
107159
106581
a Refit the ring and the hub centring axis using a shaft.
a Torque tighten the shock absorber base nut (see
30A, General information, Front axle: Tightening
torque, page 30A-22) .
107160
a Remove the centring axis (3) using a shaft.
a Remove the pivot hub.
REFITTING
a Proceed in the reverse order to removal.
31A-25
FRONT AXLE COMPONENTS
Front hub carrier bearing: Removal - Refitting
31A
WARNING
To ensure that the wheel speed sensor works properly, do not mark the sensor target on the bearing.
WARNING
In order to prevent irreversible damage to the front
hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
REMOVAL
20787
a Remove the stub-axle carrier (see 31A, Front axle
components, Front driveshaft hub carrier: Removal - Refitting, page 31A-21) .
a Remove the internal bush from the hub, applying
pressure with a 41 mm diameter tube.
F4R or K4J or K4M
F9Q or K9K
20786
20786
a Remove:
a Remove:
- the hub using the press, applying pressure with a
36 mm diameter tube,
- the stub-axle carrier external bearing bush by applying pressure with a tube of the same diameter
as that of the external bush,
31A-26
- the hub, with the press, applying pressure with a 41
mm diameter tube,
FRONT AXLE COMPONENTS
Front hub carrier bearing: Removal - Refitting
31A
- the stub-axle carrier external bearing bush by applying pressure with a pipe of the same diameter as
that of the external bush.
101934
a Refit the sensor holder.
20787
a Remove the internal ring from the hub, applying
pressure with a 46 mm diameter tube.
− 5˚ from the
a Position the sensor holder at= 35˚ +/−
vertical. This position corresponds to the centre of
the housing.
F4R or K4J or K4M
REFITTING
a It is essential to check the condition of the hub surface and the stub axle carrier bore before refitting the
bearing.
a Replace the stub axle carrier if it is faulty.
a Clean:
- the inner and outer surfaces of the new bearing, in
contact with the stub axle carrier and the hub,
- the stub axle carrier surfaces in contact with the
new bearing,
- the hub surfaces in contact with the new bearing.
a
WARNING
Do not press the bearing's inner bush so as to
avoid damaging the bearing (very high shrink-fitting force).
20788
a Apply pressure to the external bush with a tube with
an outer diameter of 72 mm and a bore diameter of
65 mm.
31A-27
FRONT AXLE COMPONENTS
Front hub carrier bearing: Removal - Refitting
31A
101933
a Refit the circlip.
101933
a Refit the circlip.
a Check the circlip is correctly positioned.
a Check the circlip is correctly positioned.
F9Q or K9K
20789
20788
a Refit:
a Apply pressure to the external bush with a tube with
an outer diameter of 77 mm and a bore diameter of
70 mm.
31A-28
- the hub,
- the « stub-axle carrier - bearing - hub » (see 31A,
Front axle components, Front driveshaft hub
carrier: Removal - Refitting, page 31A-21) assembly.
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
Essential special tooling
Sus. 1731
Front shock absorber removal
tool.
Essential equipment
spring compressor
spanner for shock absorber rod nut
Tightening torquesm
shock absorber rod nut
62 N.m
WARNING
To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle.
101210
a Remove the seal (1) .
a Cut the flap at (2) .
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove:
- the flap plastic rivets,
- the anti-roll bar linkage upper nut.
a Remove the front wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Unclip the brake hose from the shock absorber and
the wheel speed sensor cable.
101215
a Remove:
- the shock absorber base mounting bolt (3) ,
- the front brake calliper mounting bolt (4) .
a Suspend the « front brake calliper mounting calliper » assembly.
31A-29
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
a Place the appropriate cups on the spring compressor and position the assembly on the spring.
a Detach the spring from the cups by compressing the
spring.
112078
a Position the (Sus. 1731).
a Tighten the bolt (5) of the (Sus. 1731) to separate
the shock absorber base from the hub carrier.
96049
a Check that part (6) of the (Sus. 1731) is in contact
with the shock absorber strut.
a Remove the shock absorber rod nut using the spanner for shock absorber rod nut.
a Suspend the hub carrier.
a Separate the various components which make up
the « spring/shock absorber » assembly.
REFITTING
a Place the spring compressor tool in a vice.
101211
a Remove:
- the shock absorber turret mounting bolts (7) ,
- the « spring - shock absorber » assembly.
31A-30
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
95435
a
Note:
When replacing the spring for easier fitting,
ensure that the positioning and orientation of the
spring and the tool cups are correct.
31A-31
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
102201
a Position the spring in the cup groove, smooth sheath
above, and grooved sheath below.
31A-32
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
a Remove the spring compressor.
101939
a Respect the order and direction of fitting for the
constituent parts.
101211
a Fit the index bolt (8) in its housing.
a Proceed in the reverse order to removal.
Note:
WARNING
Make sure that the rotary stop is correctly oriented to facilitate refitting above and below.
In order not to damage the brake hose:
- do not tension the hose,
- do not twist the hose,
- check that there is no contact with the surrounding components.
a Torque tighten (see 30A, General information,
Front axle: Tightening torque, page 30A-22) :
- the shock absorber turret mounting bolts,
- the shock absorber mounting bolt,
- the mounting nut of the anti-roll bar tie-rod ball joint.
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Adjust the xenon bulb system (if fitted to the vehicle)
(see Xenon headlights: Adjustment) (MR 364,
80C, Xenon bulb).
96049
a The shock absorber rod nut must be replaced.
a Torque tighten the shock absorber rod nut (62
N.m).
a Decompress the spring.
31A-33
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
Essential special tooling
Rou. 604-01
Hub locking tool.
Tav. 476
Ball joint extractor.
WARNING
To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Disconnect the battery (see Battery: Removal - Refitting) (MR 364, 80A, Battery).
a Remove the front wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
105891
a Remove:
- the driveshaft nut (1) using the (Rou. 604-01),
- the track rod end nut (2) ,
- the track rod end using the (Tav. 476),
- the anti-roll bar tie-rod upper nut (3) ,
- the anti-roll bar tie-rod ball joint using the (Tav.
476).
a Unclip the brake hose from the shock absorber and
the wheel speed sensor wiring.
105892
a Remove the calliper bolts (4) .
31A-34
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
106115
a Suspend the brake calliper on the sub-frame.
106114
a Compress the driveshaft by 10 cm.
a Extract the ball joint from the lower linkage using the
(Tav. 476).
a Remove the three bolts (6) from the pivot support.
a Relax the driveshaft by raising the lift by 50 cm.
105893
a Remove the lower linkage nut (5) .
106245
a Remove the pivot from its support (7) using a hammer.
31A-35
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
101210
a Remove the seal (8) from the scuttle panel.
106126
a In place of the bolt (10) , tighten an M8 x 30 bolt, allowing the head to protrude by 20 mm.
a Cut the flap at (9) .
a Remove the two other bolts (11) from the shock absorber turret.
a Remove the plastic rivets from the flap.
101211
a Remove the bolt (10) from the shock absorber turret.
31A-36
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
B84 or C84, and EQT LEVEL SPORT
106641
a Move aside the « spring, shock absorber and pivot »
assembly.
a Extract the driveshaft from the hub, the driveshaft
stays on the vehicle.
a Remove the « spring, shock absorber and pivot »
assembly.
a Extract the pivot spring and shock absorber assembly on the workbench.
31A-37
31A
FRONT AXLE COMPONENTS
Spring and front shock absorber: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
REFITTING
Front axle: Tightening torque, page 30A-22) .
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Connect the battery (see Battery: Removal - Refitting) (MR 364, 80A, Battery).
101211
a Proceed in the reverse order to removal.
a Fit the index bolt (12) in its housing.
a Refasten the brake hose and wheel speed sensor
wiring if they have been unclipped.
a Do not twist the brake hose.
a Torque tighten:
- the shock absorber base nut (see 30A, General information, Front axle: Tightening torque, page
30A-22) ,
- the "spring and shock absorber" assembly bolts on
the body (see 30A, General information, Front
axle: Tightening torque, page 30A-22) ,
- the pivot support bolts (see 30A, General information, Front axle: Tightening torque, page 30A22) ,
- the lower linkage nut (see 30A, General information, Front axle: Tightening torque, page 30A22) ,
- the brake calliper bolts (see 30A, General information, Brake circuit Tightening torque, page
30A-6) ,
- the anti-roll bar tie-rod ball joint nut (see 30A, General information, Brake circuit Tightening torque, page 30A-6) ,
- the track rod end nut (see 30A, General information, Steering: Tightening torque, page 30A-17)
,
- the driveshaft nut (see 30A, General information,
31A-38
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
Essential equipment
component jack
Tightening torquesm
bolts mounting the lower
arm on the subframe
70 Nm
track rod end nut
37 Nm
anti-roll bar return tierod ball joint nut
44 Nm
lower ball joint bolt
62 Nm
radiator cross member
front mounting bolts
105 Nm
radiator cross member
rear mounting bolts
21 Nm
side stiffener lower bolts
21 Nm
WARNING
To prevent any damage, do not use the lower arm
as support for the lifting system.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Strap the radiator to the radiator grille.
31A-39
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
- the lower arm ball joint,
- the height sensor ball joint (if fitted to the vehicle).
a Remove:
- the lower arm front and rear mounting bolts (4) ,
- the lower arm.
REFITTING
a Proceed in the reverse order to removal.
101212
103114
a
WARNING
To tighten the rubber bushes freely, position the
lower arm below the head of the rear bolt on the
subframe (H) = 10 mm.
101213
a Remove:
- the front wheel concerned (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
- the wheel arch protectors,
a Lower the component jack by (H = 10 mm).
- the engine undertray,
a Rest the lower arm ball joint (6) on the component
jack without adjusting the settings.
- the side stiffener lower bolts (1) ,
a Torque tighten the bolts mounting the lower arm
on the subframe (70 Nm) in this position.
- the radiator cross member bolts (2) ,
- the radiator cross member rear mounting nuts,
a Remove the component jack.
- the radiator cross member.
a Refit the lower ball joint into the hub carrier.
a Unclip the wheel sensor wiring.
a Disconnect the wheel sensor connector in the wheel
arch.
a Remove the lower ball joint bolt (3) .
a Extract the ball joint:
a Place the component jack against the subframe
rear bolt head (5) .
a The sub-frame and arm mountings must be replaced
with new mountings.
a A 10mm shim must be placed between the radiator
cross member and the subframe to tighten the radiator cross member mountings to torque.
31A-40
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting
31A
EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT LEVEL EAG
a Refit and tighten to torque:
- the track rod end nut (37 Nm),
- the anti-roll bar return tie-rod ball joint nut (44
Nm).
- the lower ball joint bolt (62 Nm),
- the radiator cross member and the radiator cross
member front mounting bolts (105 Nm),
- the radiator cross member rear mounting bolts
(21 Nm),
- the side stiffener lower bolts (21 Nm),
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Adjust the axle assemblies (see 30A, General information, Front axle: Adjusting, page 30A-32) .
31A-41
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting
B84 or C84, and EQT LEVEL SPORT
Essential equipment
component jack
Tightening torquesm
side reinforcement lower
bolts
21 N.m
WARNING
To prevent any damage, do not use the lower arm
as support for the lifting system.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Strap the radiator to the radiator grille.
31A-42
31A
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
- the anti-roll bar tie-rod ball joint nut.
a Extract the height sensor ball joint.
a Remove:
- the lower arm front and rear mounting bolts (4) ,
- the lower arm.
REFITTING
a Proceed in the reverse order to removal.
106077
106634
a Remove:
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the wheel arch protectors,
- the engine undertray,
- the side reinforcement lower bolts (1) ,
- the radiator cross member front bolts,
- the radiator cross member rear mounting nuts (2) ,
- the radiator cross member.
a Detach the wiring from the wheel speed sensor.
a Disconnect the wheel sensor connector in the wheel
arch.
a Remove:
- the lower ball joint bolt (3) ,
31A-43
FRONT AXLE COMPONENTS
Front driveshaft lower arm: Removal - Refitting
31A
B84 or C84, and EQT LEVEL SPORT
- the lower ball joint bolt,
- the radiator cross member and the front bolts of the
radiator cross member,
- the rear bolts of the radiator cross member
a Tighten the side reinforcement lower bolts (21
N.m).
a Adjust the axle assemblies (see 30A, General information, Axle assemblies: Check, page 30A-18) .
103114
a
WARNING
To tighten the rubber bushes freely, position the
lower arm below the head of the rear bolt on the
subframe (H) = XX mm.
a Place the component jack against the subframe
rear bolt head (5) .
a Lower the component jack by (H = 55mm) .
a Rest the lower arm ball joint (6) on the component
jack without adjusting the settings.
a Torque tighten the bolts mounting the lower arm on
the subframe (see 30A, General information,
Front axle: Tightening torque, page 30A-22) in
this position.
a Remove the component jack.
a Refit the lower ball joint into the stub axle carrier.
a The subframe and arm mountings must be replaced
with new mountings.
a Be sure to place a 10 mm thick shim between the radiator cross member and the sub-frame to torque tighten the radiator cross member mountings.
a Refit and tighten to torque:
- the track rod end nut (see 30A, General information, Steering: Tightening torque, page 30A-17)
.
a Torque tighten (see 30A, General information,
Front axle: Tightening torque, page 30A-22) :
- the anti-roll bar tie-rod ball joint nut,
31A-44
FRONT AXLE COMPONENTS
Front driveshaft lower arm ball joint: Check
CHECKING
Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
31A
III - CHECKING THE LOWER ARM BALL JOINT
PLAY
I - CHECKING THE CONDITION OF THE LOWER
ARM BALL JOINT GAITER
a Check:
- that the gaiter is not torn,
- that retaining rings are present.
If the lower arm ball joint is in poor condition, replace
the lower arm ball joint (see 31A, Front axle components, Front driveshaft lower arm: Removal Refitting, page 31A-39)
II - CHECK THE FITTING OF THE LOWER ARM
BALL JOINT
117494
a Check that there is no play in the lower arm ball joint:
- from a position underneath the vehicle,
- using both hands, hold the lower arm as close as
possible to the ball joint,
- push downwards several times.
If there is play in the lower arm ball joint, replace the
lower arm ball joint (see 31A, Front axle components, Front driveshaft lower arm: Removal - Refitting, page 31A-39) .
113735
a Check:
- that the lower arm ball joint - lower arm front bolt hub carrier assembly is correctly positioned,
- that the ring (1) on the lower arm ball joint is correctly positioned,
- the tightening torque (see 30A, General information, Front axle: Adjustment values, page 30A26) .
If the lower arm ball joint is not fitted correctly, replace the lower arm ball joint (see 31A, Front axle
components, Front driveshaft lower arm: Removal - Refitting, page 31A-39) .
31A-45
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EAG
Essential equipment
steering wheel lock
component jack
safety strap(s)
Tightening torquesm
engine tie-bar bolts on
the engine mountings (F
or M engines)
180 N.m
engine tie-bar bolts on
the engine (K engines)
105 N.m
engine tie-bar bolts on
the subframe
105 N.m
side reinforcement bolts
21 N.m
104020
a Discard the cover (do not keep it).
a Remove the universal joint bolt and nut.
a Position the steering wheel lock.
a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
a Strap the radiator to the radiator grille.
WARNING
To prevent any damage, do not use the lower arm
as support for the lifting system.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Set the wheels straight ahead.
a Centre the steering wheel.
a Lift the floor carpet to access the universal joint.
31A-46
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EAG
a Remove:
- the track rod end nuts (3) ,
- the lower ball joint bolts (4) ,
- the upper ball joint nuts (5) from the anti-roll bar tie
bars.
a Take out the ball joints.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
K4J or K4M or K9K
101212
101208
101213
a Remove the engine tie-bar bolt (6) on the engine.
a Remove:
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection),
- the engine undertray,
- the side reinforcement lower bolts (1) ,
- the radiator cross member front bolts (2) ,
- the radiator cross member rear nuts,
- the radiator cross member.
a Unclip the wheel speed sensors wiring.
a Disconnect the wheel speed sensor connector from
the wheel arch.
31A-47
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EAG
F9Q
M9R
102313
a Remove the engine tie-bar bolt (7) on the engine.
114650
a Remove the engine tie-bar bolt (8) on the engine.
a Fit the component jack underneath the sub-frame.
a Strap the sub-frame to the component jack.
a Remove the lower arm ball joints.
a Remove:
- the wheel speed sensor wiring mounting,
- the rear cross member bolts,
- the subframe bolts on the body,
- the rear cross member,
- the subframe.
31A-48
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EAG
101209
a Remove the sub-frame fittings.
a Refit:
- the sub-frame,
REFITTING
- the rear cross member,
- the wheel speed sensor wiring mounting,
I - REFITTING PREPARATION OPERATION
- the lower arm ball joints,
a Degrease the body surfaces that make contact with
the sub-frame and cross member using SURFACE
CLEANER (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Products).
- the engine tie-bar.
a Torque tighten (see 30A, General information,
Front axle: Tightening torque, page 30A-22) :
- the subframe stud bolts,
a Always replace the subframe and arm mountings.
- the rear cross member bolts on the subframe,
a A shim 10 mm thick must be placed between the radiator cross member and the sub-frame.
- the lower ball joint bolts,
a Set the wheels straight, centre the steering wheel.
- the subframe tie rod bolts.
a
Torque tighten:
II - REFITTING OPERATION FOR PART
CONCERNED
- the engine tie-bar bolts on the engine mountings (F or M engines) (180 N.m),
a Refit the subframe equipment.
- the engine tie-bar bolts on the engine (K engines) (105 N.m),
a Strap the sub-frame onto the component jack.
31A-49
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EAG
- the engine tie-bar bolts on the subframe (105
N.m).
a Remove the safety strap(s) from the subframe.
III - FINAL OPERATION
a Refit the ball joints.
a Torque tighten (see 30A, General information,
Front axle: Tightening torque, page 30A-22) :
- the anti-roll bar tie rod ball joint nuts,
- the track rod end nuts.
a Connect the wheel speed sensor connector.
a Clip the wheel speed sensor wiring.
a Refit the radiator cross member.
a Torque tighten:
- the front bolts of the radiator cross member (see
30A, General information, Front axle: Tightening torque, page 30A-22) ,
116021
- the side reinforcement bolts (21 N.m).
a Refit:
- the engine undertray,
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection),
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Remove the safety strap(s) from the radiator.
a Refit the universal joint.
116022
a Check that the universal joint is in the correct position.
a Torque tighten the universal joint bolt (see 30A, General information, Steering: Tightening torque,
page 30A-17) .
a Refit the floor carpet.
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
a Check the front axle assemblies (see 30A, General
information, Axle assemblies: Check, page 30A18) .
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
31A-50
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EAG
a Initialise the xenon bulb system (if fitted to the vehicle) (see Fault finding - Configurations and programming)(80C, Xenon bulbs).
31A-51
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL SPORT
Essential special tooling
Tav. 476
Ball joint extractor.
Essential equipment
steering wheel lock
component jack
safety strap(s)
Tightening torquesm
subframe bracket bolts
62 N.m
engine tie-bar bolts on
the engine
180 N.m
engine tie-bar bolts on
the subframe
105 N.m
side panel bolts
106077
a Remove:
21 N.m
- the side panels (1) ,
- the radiator cross member front bolts (2) ,
REMOVAL
- the radiator cross member rear nuts (3) ,
I - REMOVAL PREPARATION OPERATION
- the radiator cross member.
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Set the wheels straight ahead.
a Extract the height sensor ball joint.
a Unclip the wheel speed sensors wiring.
a Disconnect the wheel speed sensor connector from
the wheel arch.
a Centre the steering wheel.
a Position the steering wheel lock.
a In the passenger compartment, remove the steering
column universal joint bolt and nut.
a Strap the radiator to the radiator grille.
a Remove:
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection),
- the engine undertray.
31A-52
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL SPORT
105891
106114
a Compress the driveshaft by approximately 10 cm.
a Remove:
- the track rod end nuts (4) ,
a Remove the three bolts (7) from the pivot support.
- the upper ball joint nuts (5) from the anti-roll bar tierods.
a Relax the driveshaft by raising the lift by 50 cm.
106085
a Remove the sub-frame reinforcement strut (8) .
105893
a Remove the lower tie-bar nuts (6) .
a Extract the ball joints using the (Tav. 476).
31A-53
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL SPORT
II - OPERATION FOR REMOVAL OF PART
CONCERNED:
107161
102313
a Remove the engine tie-bar (11) .
a Fit the component jack underneath the sub-frame.
a Strap the sub-frame to the component jack.
106245
a Remove the pivots (9) from their support (10) using
a hammer.
106085
a Remove:
- the bolts (12) from the subframe bracket,
- the bracket.
31A-54
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL SPORT
106086
a Remove:
- the subframe tie-rod bolts (13) ,
- the subframe.
a Remove the sub-frame fittings.
REFITTING
I - REFITTING PREPARATION OPERATION
a Degrease the body surfaces that make contact with
the sub-frame and cross member using SURFACE
CLEANER (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Products).
a Always replace the subframe and arm mountings.
102313
a A shim 10 mm thick must be placed between the radiator cross member and the sub-frame.
a Set the wheels straight ahead; centre the steering
wheel.
31A-55
FRONT AXLE COMPONENTS
Front axle sub-frame: Removal - Refitting
31A
EQT LEVEL SPORT
a Torque tighten (see 30A, General information,
Front axle: Tightening torque, page 30A-22) :
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit the subframe equipment.
- the radiator cross member front bolts,
a Strap the sub-frame onto the component jack.
- the rear nuts of the radiator cross member.
a Refit:
a Torque tighten:
- the sub-frame,
- the side panel bolts (21 N.m)
a Refit:
- the bracket,
- the engine tie-bar .
- the engine undertray,
a Tighten to torque (see 30A, General information,
Front axle: Tightening torque, page 30A-22)
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protection),
- the sub-frame tie rod bolts,
- the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
a Torque tighten:
- the universal joint.
- the subframe bracket bolts (62 N.m),
- the engine tie-bar bolts on the engine (180 N.m),
- the engine tie-bar bolts on the subframe (105
N.m).
III - FINAL OPERATION
a Torque tighten the universal joint bolt (see 30A, General information, Steering: Tightening torque,
page 30A-17) .
a Remove the safety strap(s) from the radiator.
a Adjust the axle assemblies (see 30A, General information, Axle assemblies: Check, page 30A-18) .
a Refit:
- the pivots on their support,
- the subframe reinforcement strut,
- the anti-roll bar tie bars,
- the ball joints.
a Torque tighten (see 30A, General information,
Front axle: Tightening torque, page 30A-22) :
- the pivot bolts,
- the subframe reinforcement strut bolts,
- the anti-roll bar tie-rod nuts,
- the lower ball joint nuts.
- the track rod end nuts.
a Torque tighten (see 30A, General information,
Steering: Tightening torque, page 30A-17) :
- the track rod end nuts.
a Connect the wheel speed sensor connector.
a Clip the wheel speed sensor wiring.
a Refit:
- the height sensor ball joint,
- the radiator cross member,
- the side panels.
31A-56
FRONT AXLE COMPONENTS
Front anti-roll bar: Removal - Refitting
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove:
- the front axle sub-frame (see 31A, Front axle
components, Front axle sub-frame: Removal Refitting, page 31A-46) ,
- the steering box (see 36A, Steering assembly,
Steering rack: Removal - Refitting, page 36A-1) ,
- the bolts mounting the anti-roll bar on the subframe,
- the anti-roll bar.
REFITTING
a Proceed in the reverse order to removal.
a Make sure the anti-roll bar mounting bracket lugs
are correctly positioned in the sub-frame apertures.
a Torque tighten the anti-roll bar bolts on the subframe
(see 30A, General information, Front axle: Tightening torque, page 30A-22)
a Refit the steering box (see 36A, Steering assembly, Steering rack: Removal - Refitting, page 36A1)
31A-57
31A
REAR AXLE COMPONENTS
Rear brake pads: Removal - Refitting
33A
Essential special tooling
Fre. 1190-01
Brake calliper piston return
tool.
Tightening torquesm
calliper guide pin lower
bolt
36 Nm
When replacing brake pads, be sure to replace the
pads on the opposite side.
WARNING
To avoid damaging the parking brake cable protectors and causing premature wear of the system, do
not handle the cables with a tool.
101702
REMOVAL
a Tilt the calliper upwards.
a Remove the brake pads.
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Release the parking brake.
a Remove the rear wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Unclip the parking brake cable.
a Remove the calliper guide pin lower bolt (discard it).
REFITTING
I - REFITTING PREPARATION OPERATION
a Measure the thickness of the brake pads and compare them with the minimum values (see 30A, General information, Brake: Specifications, page
30A-14) .
a Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products):
- the calliper supports,
- the callipers.
a Always replace the brake calliper guide pin bolts.
33A-1
REAR AXLE COMPONENTS
Rear brake pads: Removal - Refitting
33A
a Refit the parking brake cable.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
a Operate the parking brake control several times to
activate the locking and unlocking function and the
calliper self-adjustment.
III - FINAL OPERATION.
a Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
18931
a Push the calliper piston back using the (Fre. 119001) until it reaches the end of its bore.
127485
a Remove the protective film from the brake pad.
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the new brake pads,
- the brake calliper.
a Torque tighten the calliper guide pin lower bolt (36
Nm).
33A-2
REAR AXLE COMPONENTS
Rear brake caliper: Removal - Refitting
33A
Essential special tooling
Fre. 1190-01
Brake calliper piston return
tool.
Tightening torquesm
guide pin bolts
36 Nm
brake hose
17 Nm
When replacing brake pads or a disc, be sure to replace the pads or disc on the opposite side.
Note:
The callipers supplied as spare parts are supplied
pre-filled.
117348
a Clean the calliper mounting and calliper using the
cleaning station.
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Release the parking brake.
a Remove the rear wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Detach the parking brake cable.
a Memorise the parking brake cable routing for refitting.
a Undo the brake hose.
a Remove:
- the guide pin bolts (discard them),
- the calliper (see 33A, Rear axle components,
Rear brake caliper: Removal - Refitting, page
33A-3) ,
- the brake pads.
a Cap the hose.
a Check the condition of the braking components.
a Replace any faulty parts (see 30A, General information, Brake: Specifications, page 30A-14) .
33A-3
REAR AXLE COMPONENTS
Rear brake caliper: Removal - Refitting
33A
REFITTING
101306
18931
a Refit the parking brake cable.
a Push the calliper piston back using the (Fre. 119001) until it reaches the end of its bore.
a Check that the parking brake cable stop is properly
engaged in its housing.
a Refit:
- the brake pads,
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
- the calliper,
a Check the brake fluid level.
- the new guide pin bolts.
IMPORTANT
a Torque tighten the guide pin bolts (36 Nm).
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
a Torque tighten the brake hose (17 Nm).
a Apply the parking brake control several times to activate the locking - unlocking function and to activate
the calliper automatic play compensation.
a Refit the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
33A-4
REAR AXLE COMPONENTS
Rear brake calliper mounting: Removal - Refitting
33A
Essential special tooling
Fre. 1190-01
Brake calliper piston return
tool.
Tightening torquesm
calliper mounting bolts
guide pin bolts
105 Nm
36 Nm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Release the parking brake.
a Remove the rear wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
117348
a Clean the calliper and calliper mounting using the
cleaning station.
a Detach the parking brake cable.
a Remove:
- the guide pin bolts (discard them),
REFITTING
- the calliper (see 33A, Rear axle components,
Rear brake caliper: Removal - Refitting, page
33A-3) .
a Refit:
- the calliper mounting,
- the calliper mounting bolts.
a Hang the calliper on the suspension springs.
a Torque tighten the calliper mounting bolts (105
Nm).
a Remove:
- the brake pads,
- the calliper mounting bolts,
- the calliper mounting.
a Check the condition of the braking components (replace the faulty parts (see 30A, General information, Brake: Specifications, page 30A-14) ).
33A-5
REAR AXLE COMPONENTS
Rear brake calliper mounting: Removal - Refitting
33A
18931
101301
a Push the calliper piston back using the (Fre. 119001) until it reaches the end of its bore.
a Check that the parking brake cable stop is properly
engaged in its housing.
a Refit:
IMPORTANT
- the brake pads (see 33A, Rear axle components,
Rear brake pads: Removal - Refitting, page 33A1) ,
- the calliper (see 33A, Rear axle components,
Rear brake caliper: Removal - Refitting, page
33A-3) ,
- the new guide pin bolts.
a Torque tighten the guide pin bolts (36 Nm).
a Refit the parking brake cable (see 37A, Mechanical
component controls, Parking brake cables: Removal - Refitting, page 37A-67) .
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
a Apply the parking brake control several times to activate the locking and unlocking function and to activate the calliper automatic play compensation.
a Refit the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
33A-6
REAR AXLE COMPONENTS
Rear brake disc shield: Removal - Refitting
33A
REMOVAL
REFITTING
I - REMOVAL PREPARATION OPERATION
I - REFITTING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove:
- the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the rear brake calliper and suspend it from the
shock absorber (see 33A, Rear axle components,
Rear brake caliper: Removal - Refitting, page
33A-3) ,
- the rear brake pads (see 33A, Rear axle components, Rear brake pads: Removal - Refitting,
page 33A-1) ,
- the rear brake calliper mounting (see 33A, Rear
axle components, Rear brake calliper mounting: Removal - Refitting, page 33A-5) ,
117348
- the rear brake disc (see 33A, Rear axle components, Rear brake disc: Removal - Refitting,
page 33A-8) .
a Remove the filing deposits caused during drilling,
using the cleaning station.
II - REFITTING OPERATION FOR PART
CONCERNED
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Refit:
- the rivets using a rivet gun,
- the rear brake disc protector.
III - FINAL OPERATION.
a Refit:
- the rear brake disc (see 33A, Rear axle components, Rear brake disc: Removal - Refitting,
page 33A-8) ,
- the rear brake calliper mounting (see 33A, Rear
axle components, Rear brake calliper mounting: Removal - Refitting, page 33A-5) ,
- the rear brake pads (see 33A, Rear axle components, Rear brake pads: Removal - Refitting,
page 33A-1) ,
119908
a Drill out the rivets (1) .
- the rear brake calliper (see 33A, Rear axle components, Rear brake caliper: Removal - Refitting, page 33A-3) ,
- the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Remove the rear brake disc protector (2) .
33A-7
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting
33A
B84 or C84 or E84 or G84 or L84 or S84
Essential special tooling
Fre. 1190-01
Brake calliper piston return
tool.
Tightening torquesm
stub axle nuts
175 Nm
calliper mounting bolts
105 Nm
(new) guide pin bolts
36 Nm
Brake discs cannot be reground. If there is excessive
wear or scoring, the brake discs must be replaced (see
30A, General information, Brake: Specifications,
page 30A-14) .
When replacing a brake disc, be sure to replace the
disc on the opposite side.
101306
When replacing brake discs, you must replace the brake pads.
a Remove:
- the guide pin bolts (2) ,
The discs are supplied with fitted bearings.
a Hang the callipers on the shock absorbers.
a Remove:
REMOVAL
- the brake pads (see 31A, Front axle components, Front brake pads: Removal - Refitting,
page 31A-1) ,
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
- the calliper mounting bolts (3) ,
a Remove the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
- the calliper mountings (see 33A, Rear axle components, Rear brake calliper mounting: Removal - Refitting, page 33A-5) ,
- the hub caps,
- the stub-axle nuts,
- the « disc - bearing » assemblies.
a Check the condition of the braking components.
a Replace any faulty parts.
101301
a Release the parking brake cables (1) .
33A-8
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting
33A
B84 or C84 or E84 or G84 or L84 or S84
117348
18931
a Clean the calliper mountings and callipers using the
cleaning station.
a Push the calliper piston back using the (Fre. 119001) until it reaches the end of its bore.
REFITTING
a Refit the brake pads (see 33A, Rear axle components, Rear brake pads: Removal - Refitting,
page 33A-1) .
a Refit the « disc - bearing » assemblies.
a Fit the callipers.
a Refit the stub-axle nuts.
a Torque tighten the (new) guide pin bolts (36 Nm).
a Torque tighten the stub axle nuts (175 Nm).
a Refit the hub caps.
a Refit the calliper mountings (see 33A, Rear axle
components, Rear brake calliper mounting: Removal - Refitting, page 33A-5)
a Torque tighten the calliper mounting bolts (105
Nm).
101306
a Refit the parking brake cables. (4)
33A-9
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting
B84 or C84 or E84 or G84 or L84 or S84
a Check that the parking brake cable stops are properly engaged in their housing.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
a Check the brake fluid level.
a Operate the parking brake control several times to
activate the locking and unlocking function and to
activate the calliper automatic play compensation.
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
33A-10
33A
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting
33A
B84 or C84, and EQT LEVEL SPORT – K84
Essential special tooling
Fre. 1190-01
Brake calliper piston return
tool.
Tightening torquesm
stub axle nuts
220 Nm
calliper mounting bolts
105 Nm
(new) guide pin bolts
36 Nm
Brake discs cannot be reground. If there is excessive
wear or scoring, the brake discs must be replaced (see
30A, General information, Brake: Specifications,
page 30A-14) .
When replacing a brake disc, be sure to replace the
disc on the opposite side.
101306
When replacing brake discs, you must replace the brake pads.
a Remove:
- the guide pin bolts (2) (discard them),
The discs are supplied with fitted bearings.
a Hang the callipers on the shock absorbers.
a Remove:
REMOVAL
- the brake pads (see 31A, Front axle components, Front brake pads: Removal - Refitting,
page 31A-1) ,
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
- the calliper mounting bolts (3) ,
a Remove the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
- the calliper supports (see 31A, Front axle components, Front brake calliper support: Removal Refitting, page 31A-15) ,
- the hub caps,
- the stub-axle nuts,
- the « disc - bearing » assemblies.
a Check the condition of the braking components.
a Replace any faulty parts.
101301
a Unclip the parking brake cables (1) .
33A-11
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting
33A
B84 or C84, and EQT LEVEL SPORT – K84
117348
18931
a Clean the calliper mountings and callipers using the
cleaning station.
a Push back the calliper pistons using the (Fre. 119001) until they reach the end of their bore.
REFITTING
a Refit the brake pads (see 33A, Rear axle components, Rear brake pads: Removal - Refitting,
page 33A-1)
a Refit the « disc - bearing » assemblies.
a Fit the callipers.
a Refit the stub-axle nuts.
a Torque tighten the (new) guide pin bolts (36 Nm).
a Torque tighten the stub axle nuts (220 Nm).
a Refit the hub caps.
a Refit the calliper mountings (see 33A, Rear axle
components, Rear brake calliper mounting: Removal - Refitting, page 33A-5) .
a Torque tighten the calliper mounting bolts (105
Nm).
33A-12
REAR AXLE COMPONENTS
Rear brake disc: Removal - Refitting
B84 or C84, and EQT LEVEL SPORT – K84
101306
a Refit the parking brake cables (4) .
a Check that the parking brake cable stops are properly engaged in their housing.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
a Check the brake fluid level.
a Operate the parking brake application control several times to activate the locking and unlocking function and the calliper set self-adjustment.
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
33A-13
33A
REAR AXLE COMPONENTS
Rear brake disc: Description
33A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
Remove the rear wheel concerned (see 35A, Wheels
and tyres, Wheel: Removal - Refitting, page 35A-1) .
II - CHECKING OPERATION FOR PART
CONCERNED
Note:
Use a Palmer type tool to check the thickness of the
disc.
99582
Measure the thickness of the disc at 4 points in order
(90˚ apart).
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-14) .
III - FINAL OPERATION
Replace the discs if necessary (see 33A, Rear axle
components, Rear brake disc: Removal - Refitting,
page 33A-8) .
Refit the rear wheel concerned (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
117058
Position the Palmer tool (1) to measure the disc thickness.
33A-14
REAR AXLE COMPONENTS
Shock absorber: Removal - Refitting
33A
Tightening torquesm
shock absorber upper
bolts
62 Nm
shock absorber lower
bolts
105 Nm
bolts mounting the protection under the rear
axle
8 Nm
During removal, note the colours of the shock absorbers and springs to be sure that the parts for refitting
are compliant.
WARNING
To prevent any damage, do not use the rear axle as
support for the lifting system.
101302
a Remove the shock absorber head upper mounting
bolt (1) .
WARNING
a Raise the lift.
To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle.
a Remove:
- the protective fairing cover clip,
REMOVAL
- the shock absorber lower mounting nut,
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
- the shock absorber.
a Lift up the carpet in the boot.
REFITTING
a Refit:
- the shock absorber,
- the shock absorber lower mounting.
a Pretighten the shock absorber lower mounting.
Note:
The shock absorber mountings are only to be
tightened with the vehicle wheels on the ground
a Cut the retaining wire.
a Position the shock absorber head in its housing.
a Lower the lift until the wheels touch the ground.
a Align the shock absorber head with the drill hole in
the boot.
a Refit the shock absorber upper mounting bolt.
a Pretighten the shock absorber upper mounting bolt.
a Repeat the operation on the opposite side.
33A-15
REAR AXLE COMPONENTS
Shock absorber: Removal - Refitting
a Torque tighten:
- the shock absorber upper bolts (62 Nm),
- the shock absorber lower bolts (105 Nm) whilst
holding the bolt head.
a Refit the rear axle under-protector, replacing any damaged plastic clips.
a Torque tighten the bolts mounting the protection
under the rear axle (8 Nm).
33A-16
33A
REAR AXLE COMPONENTS
Rear suspension spring: Removal - Refitting
33A
I - LEFT SIDE
Essential equipment
component jack
Tightening torquesm
shock absorber lower
bolts
105 Nm
rear axle under-protector bolts
8 Nm
During removal, note the colours of the shock absorbers and springs to be sure that the parts for refitting
are compliant.
WARNING
To prevent any damage, do not use the rear axle as
support for the lifting system.
101304
a Fit the component jack, with a shim, under the left
spring cup.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR364, 02A, Lifting equipment).
a Remove the rear wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Remove:
a Mark the position where the left spring is fitted.
a Remove the left shock absorber lower mounting (1)
using a long socket.
a Release the left shock absorber lower mounting.
a Remove the component jack.
- the rear axle protective fairing bolts,
- the clips from the rear axle protective fairing using
unclipping pliers,
- the rear axle protective cowling.
33A-17
REAR AXLE COMPONENTS
Rear suspension spring: Removal - Refitting
33A
a Pre-tighten the shock absorber lower mounting.
Note:
The shock absorber mountings are only to be
tightened with the vehicle wheels on the ground.
a Remove the component jack.
II - RIGHT-HAND SIDE
a Repeat these operations on the right side of the vehicle.
a Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Lower the lift until the wheels touch the ground.
a Torque tighten the shock absorber lower bolts
(105 Nm).
a Raise the lift again.
101307
a Remove the left spring with its lower support.
a Refit the rear axle under-protector, replacing any damaged plastic clips.
a Torque tighten the rear axle under-protector bolts
(8 Nm).
Note:
If the upper support is unclipped, replace it with a
new one.
II - RIGHT-HAND SIDE
a Repeat these operations on the right side of the vehicle.
a Leave the rear axle suspended.
REFITTING
a Refit both spring supports.
a Refit the springs in their housing.
a Mount the bump stops on the axle assembly, with
the marking towards the rear and in the longitudinal
axis of the vehicle.
I - LEFT SIDE
a Mount the component jack tool, with a shim, under
the spring cup.
a Compress the rear axle.
a Refit the shock absorber lower mounting.
33A-18
REAR AXLE COMPONENTS
Rear disc brake bearing: Removal - Refitting
33A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Remove the brake disc (see 33A, Rear axle components, Rear brake disc: Removal - Refitting,
page 33A-8) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
104396
a Remove the bearing, with a press, applying pressure with a pipe, diameter (49 mm) .
REFITTING
I - REFITTING PREPARATIONS OPERATION
a Clean:
- the internal and external surfaces of the new bearing in contact with the hub carrier and the stubaxle,
- the hub carrier surfaces in contact with the new
bearing,
- the stub-axle surfaces in contact with the new bearing,
104528
a Remove the rubber ring (1) .
II - REFITTING OPERATION FOR PARTS
CONCERNED
a
WARNING
Do not press the bearing's inner bush so as to
avoid damaging the bearing (very high shrink-fitting force).
33A-19
REAR AXLE COMPONENTS
Rear disc brake bearing: Removal - Refitting
104395
a Refit the bearing, with a press, applying pressure
with a pipe, diameter (49 mm) .
a Refit the rubber ring (1) .
III - FINAL OPERATION.
a Refit the brake disc (see 33A, Rear axle components, Rear brake disc: Removal - Refitting, page
33A-8)
a Refit the wheel (see 3 5 A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1)
33A-20
33A
REAR AXLE COMPONENTS
Rear axle rubber bearing: Removal - Refitting
II - REMOVAL OPERATION FOR PART
CONCERNED
Essential special tooling
Tar. 1838
33A
Tool for removing and refitting rear axle rubber bushes
Tightening torquesm
the nut on cover B
new rubber bearing nuts
16 Nm
120 Nm
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Rear axle assemblies: Precautions
for repair) .
REMOVAL
125483
I - REFITTING PREPARATIONS OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the bolt (1) from the bearings,
a Remove:
- the bearings (2) .
- the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the rear axle (see 33A, Rear axle components,
Complete rear axle: Removal - Refitting, page
33A-24) .
126257
a Mark the position of the rubber bush on the rear
axle. Use the notch (3) on the rubber bush as a
mark.
a Make a mark on the rear axle in alignment with the
notch.
33A-21
REAR AXLE COMPONENTS
Rear axle rubber bearing: Removal - Refitting
33A
122816
a Remove the rubber bushes by striking with a hammer and articulation castor of the (Tar. 1838).
122817
a Fit:
- the covers (A) and (B) of the (Tar. 1838),
- the threaded rod (C) of the (Tar. 1838),
REFITTING
- the washer (D) of the (Tar. 1838),
I - REFITTING PREPARATIONS OPERATION
- the nut (E) of the (Tar. 1838).
a Always replace:
- the rubber bushes,
- the rear axle rubber bearing nuts,
- the rear axle bolts.
II - REFITTING OPERATION FOR PART
CONCERNED
a Position the rubber bush so that the mark on the new
rubber bush and the mark previously made on the
rear axle are aligned.
122815
a Tighten the rod of the (Tar. 1838) until the cover is
fully fitted onto the rear axle.
a Check that the notch is still aligned with the mark.
a Torque tighten the nut on cover B (16 Nm).
a Remove the (Tar. 1838).
33A-22
REAR AXLE COMPONENTS
Rear axle rubber bearing: Removal - Refitting
a Refit the bearings.
a Torque tighten the new rubber bearing nuts (120
Nm).
III - FINAL OPERATION.
a Refit:
- the rear axle (see 33A, Rear axle components,
Complete rear axle: Removal - Refitting, page
33A-24) ,
- the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Adjust the rear axle (see Rear axle: Adjusting) .
33A-23
33A
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting
33A
Essential special tooling
Mot. 1390
Support for removing/refitting
the engine - gearbox assembly.
Essential equipment
pedal press
component jack
Tightening torquesm
bearing bolts
62 Nm
brake hose bolts
14 Nm
shock absorber lower
mountings
105 Nm
rear axle under-protector bolts
8 Nm
101303
a Undo the brake hose nuts (1) .
a Disconnect the wheel speed sensor connectors on
each side member.
a Remove:
WARNING
To prevent any damage, do not use the rear axle as
support for the lifting system.
- the rear axle protective fairing bolts.
- the clips from the rear axle protective fairing using
unclipping pliers,
REMOVAL
- the rear axle protector.
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
a Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Unclip the parking brake cables.
33A-24
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting
33A
1 - Left side
101307
a Remove the left spring with its lower support (3) .
101304
a Fit the component jack with a shim, under the left
spring cup.
Note:
If the upper spring support is unclipped, replace
it.
a Mark the position where the left spring is fitted.
a Remove the left shock absorber lower mounting (2)
using a long socket.
a Release the left shock absorber lower mounting.
a Remove the component jack.
2 - Right-hand side
a Repeat these operations on the right side of the vehicle.
101300
a Fit the (Mot. 1390) on the rear axle jacking points.
33A-25
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting
101303
a Loosen the bearing bolts (4) .
a Position the pads of the (Mot. 1390) in contact with
the rear axle.
a Strap the rear axle.
a Remove the bearing bolts (4) .
a Raise the vehicle.
33A-26
33A
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting
33A
101305
a Remove the rear axle equipment, if necessary.
REFITTING
a Refit the rear axle equipment.
a Strap the rear axle onto tool (Mot. 1390) ;.
a Position the axle under the vehicle.
33A-27
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting
33A
101300
a Lower the lift.
a Position the bearing locators opposite the centring
holes.
a Refit the mountings, starting with the left-hand bearing.
a Insert the brake pipes into their housing.
a Remove the strap.
a Raise the lift.
a Remove tool (Mot. 1390) ;.
101706
a Check that the parking brake cable stops are properly engaged in their housing.
a Refit the spring supports.
a Refit the springs in their housing (see 33A, Rear
axle components, Rear suspension spring: Removal - Refitting, page 33A-17) .
a Mount the bump stops on the axle assembly, with
the marking towards the rear and in the longitudinal
axis of the vehicle.
a Torque tighten:
- the bearing bolts (62 Nm),
- the brake hose bolts (14 Nm).
a Connect the wheel speed sensor connectors.
a Refit the parking brake cables.
1 - Left side
a Fit the component jack with a shim, under the
spring cup.
a Compress the rear axle.
a Refit the shock absorber lower mounting.
a Remove the component jack.
2 - Right-hand side
a Fit the component jack with a shim, under the
spring cup.
a Check the position of the bump stop on the axle assembly.
a Compress the rear axle.
a Refit the shock absorber lower mounting.
a Remove the component jack.
33A-28
REAR AXLE COMPONENTS
Complete rear axle: Removal - Refitting
a Torque tighten the shock absorber lower mountings (105 Nm).
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Refit the rear axle under-protector, replacing any damaged plastic clips.
a Torque tighten the rear axle under-protector bolts
(8 Nm).
a Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
33A-29
33A
WHEELS AND TYRES
Wheel: Removal - Refitting
35A
The removal - refitting procedure is the same for all
wheels.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Release the parking brake.
a Remove the trim.
a Position the wheel so that the valve is at the top.
a Mark the position of the wheel on the hub.
Note:
100682
a Strike around the edge of the tyre walls (1) several
times using a mallet on the inner and outer surfaces
of the wheel to detach the wheel.
This mark is required in order to:
- Note the original position of the wheel on the
hub,
a Remove:
- perform the balancing operation.
- the wheel bolts,
- the wheel.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Loosen the wheel bolts with the wheel on the
ground.
Note:
Use sockets with protective sheaths in order to
avoid scratching the alloy wheel rims.
a Raise the lift.
a Remove:
- the wheel bolts,
- the wheel.
If the wheel cannot be removed after the bolt has
been undone:
a Position all the wheel bolts.
a Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.
a Undo the wheel bolts by one turn.
35A-1
WHEELS AND TYRES
Wheel: Removal - Refitting
35A
If this procedure does not work:
124750
106089
a Strike the inner surface of the wheel (2) using a mallet and a wooden block to detach it.
a Coat the wheel-mating face (3) with COPPER ANTISEIZE AGENT (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables Products).
Note:
a Align the mark on the wheel with the mark made on
the hub when it was removed.
Do not strike the surface of the wheel using
excessive force as this may damage it.
a Fit the wheel to the vehicle, positioning the valve at
the top.
a Insert the wheel bolts.
a Remove:
- the wheel bolts,
- the wheel.
REFITTING
I - REFITTING PREPARATION OPERATION
a Clean the hub carrier using a wire brush.
Note:
there are two types of wheel bolts for alloy and
steel wheel rims; do not swap them.
a Check the condition of the tyre.
a Do not move or remove the balance weights.
II - REFITTING OPERATION FOR PART
CONCERNED
a Clean the mating surfaces between the wheel and
the hub carrier using a wire brush.
35A-2
WHEELS AND TYRES
Wheel: Removal - Refitting
35A
EQT LEVEL SPORT – M9R
F4R or F9Q or K4M or K9K, and EQT LEVEL E3
PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or
EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EA6 or EQT LEVEL
EAG
100682
a Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.
113180
a Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.
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 position.
a Position the vehicle on its wheels.
Note:
Use sockets with protective sheaths in order to
avoid scratching the alloy wheel rims.
a Torque tighten the wheel bolts in order (see 30A,
General information, Front axle: Tightening torque, page 30A-22) (30A, General information).
a Refit the trim piece.
35A-3
WHEELS AND TYRES
Wheel: Balancing
35A
I - PREREQUISITES FOR WHEEL BALANCING
a Wheel balancing is a measurement operation.
Several conditions must be met to achieve a reliable
result in a single operation.
The wheel balancer must be installed in accordance
with the manufacturer's instructions.
It is essential to calibrate the balancer according to
the frequency recommended by the manufacturer.
Do not grease the threaded shaft.
Check the condition of the supports, centring components and mountings.
Replace any faulty parts (see manufacturer's instructions).
The wheel and the wheel balancer must be clean.
Driver's perception
a If the wheels are not correctly balanced this causes
the steering wheel and/or the vehicle floor to vibrate.
105870
a
These vibrations appear between 54 mph (90 km/h)
and 90 mph (150 km/h).
Note:
The ring is available from the supplier of the
equipment used.
II - BALANCING PREPARATION OPERATION
a Adjust the tyre pressure (see 35A, Wheels and tyres, Tyre inflation pressure: Identification, page
35A-10) .
a Always carry out a road test for a minimum distance
of 1 mile (2 km) before balancing the wheels, in order to remove any flat spots on the tread caused by
the vehicle being immobilised.
To reproduce the exact vehicle wheel assembly, use
a ring (1) of diameter:
a 60 mm
a There are three types of weight:
a Actions to be carried out immediately after the test
drive:
- Position the vehicle on a two-post vehicle lift (see
Vehicle: Towing and lifting) ,
- raise the vehicle,
- leave the four wheels hanging free,
- release the parking brake.
35A-4
WHEELS AND TYRES
Wheel: Balancing
35A
113742
(2)
Steel wheel with flange
(3)
Alloy wheel with flange
(4)
Alloy wheel without flange
105871
a The wheel is fitted on the wheel balancer as follows:
- (5) ring,
- (6) wheel balancer back-plate,
- (7) wheel tightening device (certain alloy wheels
require a device 200 mm in diameter to ensure that
the wheel has been correctly tightened),
a In some countries, the use of lead weights is forbidden; in this case it is recommended to use ZAMAK
weights instead.
- (8) outer wheel plane,
Only use weights provided by the Parts Department.
- (9) wheel.
a Remove the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Always clean the wheel, disc, and hub bearing surfaces.
III - PROCEDURE FOR BALANCING THE WHEEL IN
QUESTION
a Make sure that the wheel balancer bearing surface
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.
100681
a Place the wheel on the wheel balancer, with the valve at the top, then lock the wheel in place.
a Remove any stones trapped in the tyre tread.
35A-5
WHEELS AND TYRES
Wheel: Balancing
a Enter the specific wheel parameters when starting
the wheel balancer.
a Start the wheel balancer and check the wheel balance, which should be 0 g on each plane of the wheel.
a If this is not the case, remove the old wheel balancing weights and repeat the wheel balancing procedure, checking that the wheel balance equals 0 on
each wheel plane.
WARNING
To avoid detachment of the balance weights, use
only weights which correspond to the vehicle
wheel rims.
IV - FINAL OPERATION
a Refit the wheel (see 3 5 A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
35A-6
35A
WHEELS AND TYRES
Tyres: Identification
Example of a tyre identification 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
35A
35A-7
Code
Maximum
speed
in
mph (km/h)
R
170
S
180
T
190
U
200
H
210
V
240
ZR
above 240
W
270
Y
300
WHEELS AND TYRES
Tyres: Removal - Refitting
35A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the wheel in question (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the balance weights,
- the valve mechanism.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
TYRE PRESSURE SENS.
18885
a
a Position the tyre lever approximately 15 cm from the
valve on the outside of the wheel rim in order to remove the exterior bead from the tyre.
WARNING
To avoid any damage to the sensor, make sure
the tyre bead never presses on the sensor.
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 remove the bead from inside the tyre.
a Remove the interior bead of the tyre, finishing at the
valve.
REFITTING
I - REFITTING PREPARATION OPERATION
WITHOUT TYRE PRESSURE SENS.
a parts always to be replaced: Tyre valve (13,05,
02,02)
18884
a Lubricate the two tyre beads correctly using the
TYRE PASTE (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables Products).
a Detach:
- the bead from the outside of the tyre, starting with
the side opposite the valve,
- the bead from the inside of the tyre.
II - REFITTING OPERATION FOR PART
CONCERNED
a Engage the lower tyre bead approximately 15 cm after the valve.
35A-8
WHEELS AND TYRES
Tyres: Removal - Refitting
a Finish fitting the tyre at the valve.
a Fit the exterior bead approximately 15 cm after the
valve using the tyre lever.
a Inflate the tyre to 3.5 bar to press the tyre beads
against the wheel rim.
III - FINAL OPERATION
a Refit the valve mechanism.
a Inflate the tyre to the recommended pressure (see
35A, Wheels and tyres, Tyre inflation pressure:
Identification, page 35A-10) .
Note:
It is not necessary to drive the vehicle before and
after a new wheel is balanced.
a Balance the wheel (see 35A, Wheels and tyres,
Wheel: Balancing, page 35A-4) .
a Refit the wheel in question (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
35A-9
35A
WHEELS AND TYRES
Tyre inflation pressure: Identification
35A
B84 or C84 or G84 or S84
I - INFLATION
WARNING
If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
Engine
Wheel
Tyre
Tyre inflation pressure when cold (bar)
Front
Rear
emergency
spare wheel
6.5 J 15
195/65 R 15 T
2.2
2
2.2
6.5 J 16*
205/55 R16H
2.2
2
2.2
6.5 J 16*
205/55 R16 V
2.2
2
2.2
6.5 J 17*
205/50 R17V
2.2
2
2.2
6.5 J 15
195/65 R 15 T
2.3
2
2.3
6.5 J 15
195/65R15H
2.3
2
2.3
6.5 J 16*
205/55 R16H
2.3
2
2.3
6.5 J 16*
205/55 R16 V
2.3
2
2.3
6.5 J 17*
205/50 R17V
2.4
2
2.4
6.5 J 15
195/65 R 15 T
2.3
2
2.3
6.5 J 16*
205/55 R16H
2.3
2
2.3
6.5 J 16*
205/55 R16 V
2.3
2
2.3
6.5 J 17*
205/50 R17V
2.4
2
2.4
6.5 J 16*
205/55 R16H
2.4
2
2.4
6.5 J 16*
205/55 R16 V
2.4
2
2.4
6.5 J 17*
205/50 R17V
2.5
2
2.5
6.5 J 15
195/65R15H
2.4
2
2.4
6.5 J 16*
205/55 R16H
2.4
2
2.4
6.5 J 16*
205/55 R16 V
2.4
2
2.4
6.5 J 17*
205/50 R17V
2.5
2
2.5
6.5 J 16*
205/55 R16 V
2.6
2
2.6
6.5 J 17*
205/50 R17V
2.8
2.1
2.8
K4J
K4M
K9K
F4R
F4RT
and
F9Q
M9R
* Alloy wheel rim
II - CONFORMITY CHECK AND ADJUSTMENT
The pressure values given are « motorway » pressures.
Wheel offset:
- steel wheel rim: 45 mm,
35A-10
WHEELS AND TYRES
Tyre inflation pressure: Identification
B84 or C84 or G84 or S84
- alloy wheel rim: 49 mm.
For information on fitting chains, see « Driver's
handbook » .
35A-11
35A
WHEELS AND TYRES
Tyre inflation pressure: Identification
35A
K84 or L84
I - INFLATION
WARNING
If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
Engine
Wheel
Tyre
Tyre inflation pressure when cold (bar)
Front
Rear
emergency
spare wheel
6.5 J 15
195/65 R 15 T
2.2
2
2.2
6.5 J 16*
205/55 R16H
2.2
2
2.2
6.5 J 16*
205/55 R16 V
2.2
2
2.2
6.5 J 17*
205/50 R17V
2.2
2
2.2
6.5 J 15
195/65 R 15 T
2.3
2
2.3
6.5 J 15
195/65R15H
2.3
2
2.3
6.5 J 16*
205/55 R16H
2.3
2
2.3
6.5 J 16*
205/55 R16 V
2.3
2
2.3
6.5 J 17*
205/50 R17V
2.4
2
2.4
6.5 J 15
195/65 R 15 T
2.3
2
2.3
6.5 J 16*
205/55 R16H
2.3
2
2.3
6.5 J 16*
205/55 R16 V
2.3
2
2.3
6.5 J 17*
205/50 R17V
2.4
2
2.4
6.5 J 16*
205/55 R16H
2.4
2
2.4
6.5 J 16*
205/55 R16 V
2.4
2
2.4
6.5 J 17*
205/50 R17V
2.5
2
2.5
6.5 J 15
195/65R15H
2.4
2
2.4
6.5 J 16*
205/55 R16H
2.4
2
2.4
6.5 J 16*
205/55 R16 V
2.4
2
2.4
6.5 J 17*
205/50 R17V
2.5
2
2.5
6.5 J 16*
205/55 R16 V
2.6
2.2
2.6
6.5 J 17*
205/50 R17V
2.8
2.2
2.8
K4J
K4M
K9K
F4R
F4RT
and
F9Q
M9R
* Alloy wheel rim
II - CONFORMITY CHECK AND ADJUSTMENT
The pressure values given are « motorway » pressures.
Wheel offset:
- steel wheel rim: 45 mm,
35A-12
WHEELS AND TYRES
Tyre inflation pressure: Identification
K84 or L84
- alloy wheel rim: 49 mm.
For information on fitting chains, see « Driver's
handbook » .
35A-13
35A
WHEELS AND TYRES
Tyre inflation pressure: Identification
35A
E84
I - INFLATION
WARNING
If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
Engine
Wheel
Tyre
Tyre inflation pressure when cold (bar)
Front
Rear
emergency
spare wheel
6.5 J 15
195/65R15H
2.3
2.2
2.3
6.5 J 16*
205/55 R16H
2.3
2.2
2.3
6.5 J 16*
205/55 R16 V
2.3
2.2
2.3
6.5 J 17*
205/50 R17V
2.4
2.2
2.4
6.5 J 16*
205/55 R16H
2.4
2.2
2.4
6.5 J 16*
205/55 R16 V
2.4
2.2
2.4
6.5 J 17*
205/50 R17V
2.5
2.2
2.5
6.5 J 15
195/65R15H
2.4
2.2
2.4
6.5 J 16*
205/55 R16H
2.4
2.2
2.4
6.5 J 16*
205/55 R16 V
2.4
2.2
2.4
6.5 J 17*
205/50 R17V
2.6
2.2
2.5
6.5 J 16*
205/55 R16 V
2.6
2.2
2.6
6.5 J 17*
205/50 R17V
2.8
2.2
2.8
K4M
F4R
F4RT
and
F9Q
M9R
* Alloy wheel rim
The pressure values given are « motorway » pressures.
II - CONFORMITY CHECK AND ADJUSTMENT
Wheel offset:
- steel wheel rim: 45 mm,
- alloy wheel rim: 49 mm.
For information on fitting chains, see « Driver's
handbook » .
35A-14
WHEELS AND TYRES
Tyre inflation pressure: Identification
35A
B84 or C84, and EQT LEVEL SPORT
I - INFLATION
Inflation pressure when cold (in bar), during fully loaded use and/or on motorway.
WARNING
If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
Inflation pressure when cold
Assembly
Wheel
Tyre
Front
Rear
7.5J x 18
225/40 R18 Y
2.5 bar
2.3 bar
8.0J x 18
235/40 R 18 Y
2.3 bar
2.1 bar
Winter
7.5J x 18
225/40 R18 V
2.5 bar
2.3 bar
Chain
7.0J x 17
215/45 R17 W
2.5 bar
2.3 bar
Emergency spare
wheel
7.0J x 17
225/45 R17 W
2.5 bar
2.3 bar
Standard
Wheel offset:
- alloy wheel rim: 49 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 » tyres, if the programming has already been carried out, the
« summer » or « winter » mode is automatically detected.
35A-15
WHEELS AND TYRES
Wheel rim: Identification
IDENTIFICATION
35A
2 - Installation diameter for the wheel bolts
1 - Marking
There are two types of identification marking on the
wheel rims:
- engraved marking for steel wheel rims,
The wheel bolts are positioned with a pitch circle diameter of:
- 5 holes: 108 mm,
- 4 holes: 100 mm.
- cast marking for alloy wheel rims.
The marking gives the main dimensional specifications
of the wheel rim.
3 - Rim run-out
This marking may be:
The maximum run-out is measured at the wheel rim
edge (7) .
- complete, for example 6 J 15 5 CH 36,
Steel wheel rims: 0.8 mm
- simplified, for example 6 J 15.
Alloy wheel rims: 0.3 mm
4 - Out-of-roundness
Wheel type
6 J 15
1
Width (in inches)
6
The maximum out-of-round value is measured on the
tyre bead bearing surface.
2
Rim edge profile
J
0.7 mm
3
Nominal diameter (in inches)
15
4
Number of holes
5
5
Anchorage profile of the tyre
CH
6
Offset (in mm)
36
100988
There are 3 types of wheel rim edges (2) :
- those with two flat edges,
- those with two raised edges,
- those with one flat edge and one raised edge.
35A-16
TYRE PRESSURE MONITOR
SSPP: List and location of components
35B
102413
The system consists of:
- four pressure sensors (1) built into the valves (one per
wheel); the sensors transmit a radio signal,
- a computer (2) which collects, decodes and processes sensor signals, and then determines which message to display,
- a display (3) integrated to the instrument panel.
Note:
Each sensor is identified by a coloured marking
around the valve:
- green = front left,
- yellow = front right,
- red = rear left-hand,
- black = rear right-hand.
35B-1
TYRE PRESSURE MONITOR
Pressure sensor: Removal - Refitting
35B
– B84 or C84, and EQT LEVEL SPORT
I - RIGID TYRE PRESSURE MONITOR VALVE
Essential equipment
diagnostic tool
Tightening torquesm
tyre pressure monitor
rigid sensor retaining
nut
7.5 Nm
tyre pressure monitor
hinged sensor retaining
nut
8.5 Nm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove:
18887
a The following parts must be replaced:
- the wheels (see 35A, Wheels and tyres, Wheel:
Removal - Refitting, page 35A-1) ,
- the seal (3) ,
- the tyres (see 35A, Wheels and tyres, Tyres: Removal - Refitting, page 35A-8) .
- the cap (5) ,
- the mechanism (4) ,
- the retaining nut (6) .
a If necessary, replace:
- the coloured marker (7) .
112627
a Remove:
- the retaining nut (1) , holding the pressure sensor
(2) on the wheel,
- the pressure sensor (2) .
35B-2
TYRE PRESSURE MONITOR
Pressure sensor: Removal - Refitting
35B
– B84 or C84, and EQT LEVEL SPORT
II - HINGED TYRE PRESSURE MONITOR VALVE
III - ALL TYPES
115168
a The following parts must be replaced:
- the seal with the metal ring (8) ,
102242
a Make sure that the sensor is correctly positioned on
the wheel rim:
- the mechanism (9) ,
- figure 1 = fitted incorrectly,
- the retaining nut (10) ,
- figure 2 = fitted correctly.
- the cap (11) .
a If necessary, replace:
- the coloured marker (12) .
a Position the sensor in the valve opening, checking
that the seal is attached all around the edge of the
opening.
Note:
After using a tyre repair aerosol, remove the product residue from the valve with a dry cloth or air
gun before refitting it on the wheel rim.
a Manually tighten the retaining nut, holding the pressure sensor in contact with the rim.
a For hinged tyre pressure monitor valves, gently
press the cap towards the centre of the wheel, keeping the sensor support on the rim to modify the valve/sensor angle to the rim profile.
Tighten the nut manually.
a Tighten to the following torques:
- the tyre pressure monitor rigid sensor retaining
nut (7.5 Nm),
- the tyre pressure monitor hinged sensor retaining nut (8.5 Nm).
a Refit the tyres (see 35A, Wheels and tyres, Tyres:
Removal - Refitting, page 35A-8) .
35B-3
TYRE PRESSURE MONITOR
Pressure sensor: Removal - Refitting
– B84 or C84, and EQT LEVEL SPORT
a Balance the wheels (see 35A, Wheels and tyres,
Wheel: Balancing, page 35A-4) .
a Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
B84 or C84 or E84 or G84 or K84 or L84 or S84
a If replacing a pressure sensor, carry out the necessary operations using the diagnostic tool (see MR
366 Fault finding, 35B, Tyre pressure monitor,
Replacement of components).
35B-4
35B
STEERING ASSEMBLY
Steering rack: Removal - Refitting
36A
II - REFITTING OPERATION FOR PART
CONCERNED
Essential equipment
a Refit:
steering wheel lock
- the steering box on the subframe,
- the steering box bolts on the subframe.
Tightening torquesm
steering box bolts on the
subframe
105 N.m
cam nut for the universal joint
24 N.m
a Torque tighten the steering box bolts on the subframe (105 N.m).
III - FINAL OPERATION
a Refit the subframe (see 31A, Front axle components, Front axle sub-frame: Removal - Refitting,
page 31A-46) .
REMOVAL
a Refit the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
I - REMOVAL PREPARATION OPERATION
a Remove the steering wheel lock.
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a In the passenger compartment, refit:
a Set the wheels straight ahead.
- the cam nut to the universal joint,
- the universal joint bolt.
a In the passenger compartment, remove:
- the universal joint bolt ,
- the cam nut from the universal joint.
a Position the steering wheel lock.
a Remove the front wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
a Remove the sub-frame (see 31A, Front axle components, Front axle sub-frame: Removal - Refitting, page 31A-46) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Remove:
- the two steering box bolts,
- the steering box.
REFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Steering rack bolt
(13,04,03,05).
36A-1
STEERING ASSEMBLY
Steering rack: Removal - Refitting
116021
116022
a Check that the universal joint is in the correct position.
a Torque tighten the cam nut for the universal joint
(24 N.m).
a Refit the floor carpet.
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
a Check the axle assembly geometry (see 30A, General information, Axle assemblies: Check, page
30A-18)
a If necessary, adjust the geometry of the axle assemblies (see 30A, General information, Front axle:
Adjusting, page 30A-32) .
36A-2
36A
STEERING ASSEMBLY
Track rod: Removal - Refitting
36A
Essential special tooling
Tav. 476
Ball joint extractor.
Tightening torquesm
track rod ball joint nut
37 N.m
wheel alignment adjusting lock nut
53 N.m
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Steering: Precautions for repair) .
REMOVAL
122713
I - REMOVAL PREPARATION OPERATION
a Extract the ball joint using (3) (Tav. 476).
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Unscrew the track rod anti-clockwise and note the
number of turns for refitting.
a Remove the front wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Remove the track rod.
REFITTING
II - OPERATION FOR REMOVAL OF PART
CONCERNED
I - REFITTING OPERATION FOR PART
CONCERNED
a Screw the track rod back in place by the number of
turns noted during removal.
a Fit the track rod end in the hub carrier.
a Refit the 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: Removal - Refitting, page 35A-1) .
122722
a Loosen the wheel alignment adjustment lock nut (1)
.
a Remove the track rod ball joint nut (2) .
a Check the axle geometry (see 30A, General information, Axle assemblies: Check, page 30A-18) .
a If necessary, adjust the geometry of the axle assemblies (see 30A, General information, Front axle:
Adjusting, page 30A-32) .
36A-3
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting
36A
EQT LEVEL E3 PLUS or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4 or EQT
LEVEL EA5 or EQT LEVEL EA6 or EQT LEVEL EAG
REFITTING
Essential special tooling
Dir. 1306-04
Tool for locking steering rack.
I - REFITTING PREPARATION OPERATION
Dir. 1305-01
Tool for removing/refitting 35
mm to 41 mm diameter axial
ball joints.
a parts always to be replaced: Steering axial ball
joint washer (13,04,02,04)
II - REFITTING OPERATION FOR PART
CONCERNED
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) .
a Remove the front wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Remove the track rod (see 36A, Steering assembly, Track rod: Removal - Refitting, page 36A-3) .
a Remove the steering rack gaiter (see 36A, Steering
assembly, Steering rack gaiter: Removal - Refitting, page 36A-12) .
a Unlock the steering column.
101355
a Refit:
Note:
- a new washer (3) ,
During this operation, the steering rack must be
in place on the vehicle.
- the axial ball joint (4) .
a Torque tighten the axial ball joint (see 30A, General
information, Steering: Tightening torque, page
30A-17) using the tool (Dir. 1305-01).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Coat with SILICONE GREASE (see Vehicle: Parts
and ingredients for the repairwork) :
- the steering rack,
- the axial ball joint.
III - FINAL OPERATION
a Refit the steering box gaiter (see 36A, Steering assembly, Steering rack gaiter: Removal - Refitting, page 36A-12) .
a Refit the track rod (see 36A, Steering assembly,
Track rod: Removal - Refitting, page 36A-3) .
102206
a Set up the (Dir. 1306-04) (1) on the steering rack, at
the pinion end.
a Unlock the axial ball joint using tool (Dir. 1305-01)
(2) .
a Remove the axial ball joint.
a Refit the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Check the axle geometry (see 30A, General information, Axle assemblies: Check, page 30A-18) .
a If necessary, adjust the geometry of the axle assemblies (see 30A, General information, Front axle:
Adjusting, page 30A-32) .
36A-4
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting
36A
EQT LEVEL SPORT
Essential special tooling
Tav. 476
Ball joint extractor.
Dir. 1306-04
Tool for locking steering rack.
Dir. 1305-01
Tool for removing/refitting 35
mm to 41 mm diameter axial
ball joints.
Essential equipment
diagnostic tool
REMOVAL
102206
a Position the vehicle on a two-post lift.
a Unlock the steering column lock using the diagnostic tool.
a Set up the (Dir. 1306-04) (1) on the steering rack, at
the pinion end.
a Unlock the axial ball joint using tool (Dir. 1305-01)
(2) .
Note:
During this operation, the steering rack must be
in place on the vehicle.
a Disconnect the battery, starting with the negative
terminal.
a Extract the track rod end using the (Tav. 476).
a Loosen the wheel alignment adjusting lock nut.
a Remember the number of thread turns made in order to preset the wheel alignment when refitting.
a Remove:
- the ball joint housing,
- the lock nut,
- the gaiter retaining clips,
- the gaiter.
WARNING
Be careful not to damage the gaiters: risk of irreversible damage.
36A-5
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting
36A
EQT LEVEL SPORT
REFITTING
30A, General information, Axle assemblies:
Check, page 30A-18) .
a If necessary, adjust the geometry of the axle assemblies (see 30A, General information, Front axle:
Adjusting, page 30A-32) .
101355
a Always replace washer (3) with a new one.
a Refit:
- the stop (3) (13 mm thick),
- the axial ball joint (4) (specific length: 230 mm).
a Torque tighten the axial ball joint (see 30A, General
information, Steering: Tightening torque, page
30A-17) using the tool (Dir. 1305-01).
a Coat the following parts with lithium grease:
- the steering rack,
- the axial ball joint.
a Refit:
- the gaiter,
- the metal clip,
- the new plastic clip, the same as the original fitting,
- the lock nut,
- the ball joint housing.
a Retighten the track rod end housing by the number
of rotations noted during removal.
a Refit the track rod end.
a Torque tighten:
- the wheel alignment adjustment lock nut (see 30A,
General information, Steering: Tightening torque, page 30A-17) ,
- the track rod end nut (see 30A, General information, Steering: Tightening torque, page 30A-17)
,
- the wheel mounting bolts (see 30A, General information, Front axle: Tightening torque, page
30A-22) .
a Check the geometry of the axle assemblies (see
36A-6
STEERING ASSEMBLY
Steering column: Removal - Refitting
36A
Essential equipment
diagnostic tool
Tightening torquesm
electric lock bolt
8 N.m
cover bolts
2 N.m
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
101194
These operations do not require a lift.
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
101196
REMOVAL
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(MR 366, 88C, Airbag and pretensioner).
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
101197
a Unclip:
- the lower cover access flap,
- the side panel,
- the headlight adjustment control.
a Remove the bolts (1) .
a Disconnect the remote adjustment control connectors.
36A-7
STEERING ASSEMBLY
Steering column: Removal - Refitting
36A
102211
101204
a Unclip the air duct (3) at (4) .
a Remove both bolts (7) .
a Fold the air duct (3) downwards at (5) .
a Unclip both upper clips (8) .
a Lift the air duct at (6) .
a Remove:
a Remove:
- the second lower cover, partially,
- the air distribution duct (3)
- the driver's front airbag (see Driver's front airbag:
Removal - Refitting) (MR 364, 88C, Airbags and
seat belt pretensioners).
a Set the wheels straight ahead.
a Disconnect the connectors in the steering wheel.
a Remove:
- the steering wheel (see 36A, Steering assembly,
Steering wheel: Removal - Refitting, page 36A14) ,
- the steering column switch assembly (see Steering wheel controls assembly: Removal - Refitting) (MR 364, 84A, Control - Signals).
36A-8
- the instrument panel (see Instrument panel: Removal - Refitting) (MR 364, 83A, Instrument panel),
- the carpet on the driver's side, partially.
STEERING ASSEMBLY
Steering column: Removal - Refitting
36A
104020
a Discard the cover (9) (do not keep it).
a Remove the universal joint bolt (do not keep),
a Disconnect:
- the steering column lock connector,
101353
- the electric power-assisted steering computer
power connector using a 4 mm wide and 0,5 mm
thick screwdriver,
- the electric power-assisted steering computer signal connector using a 4 mm wide and 0,5 mm
thick screwdriver.
a Remove the two nuts (11) from the steering column.
B84 or C84 or G84 or S84, and RIGHT-HAND
DRIVE
Special note for right-hand drive
a Unclip the rotary switch wiring harness from the
steering column.
102202
a Access the steering column front nuts through the
instrument panel openings (12) .
101350
a Access the nuts (10) from behind the steering column, between the steering column intermediate shaft
and the brake pedal.
a Unclip the locator.
a Remove the steering column.
a Remove the nuts.
36A-9
STEERING ASSEMBLY
Steering column: Removal - Refitting
36A
a
Note:
- If the steering column is being replaced,
remove the column lock.
- The column lock is attached by a bolt with a lefthanded thread.
a Remove:
- the adjustment handle,
- the two steering column front nuts.
a Unclip the locator.
104020
Note:
a Respect the direction of fitting for the universal joint
cam bolt and nut.
Remove the locator if it is damaged when the
steering column is removed.
a Refit the universal joint.
a Remove the steering column.
a Refit the cam nut and the fork bolt.
a Finger tighten the cam nut and the yoke bolt.
REFITTING
a Immobilise the cam nut in its housing (on the universal joint).
a Torque tighten the electric lock bolt (8 N.m).
a The universal joint cam nut and bolt and the steering
wheel bolt must be replaced.
a Pretighten the universal joint nut and bolt.
a Proceed in the reverse order to removal.
Note:
- If replacing the electric lock (see Fault finding Replacement of components) (MR 366 Fault
finding, 36B, Electric power-assisted steering).
- Remove the locator if it is damaged when the
steering column is removed. Do not replace it
when refitting the steering column.
- Do not refit the cover (13) .
- On a new steering column, the universal joint
cam nut is pre-fitted.
a Push and pull on the electric power-assisted steering computer power and signal connectors to check
that they are properly secured (risk of loss of assistance).
36A-10
STEERING ASSEMBLY
Steering column: Removal - Refitting
36A
a Refit the floor carpet.
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
a Refit the lower section of the dashboard and the casing.
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (MR 366, 88C, Airbag and pretensioners).
116021
116022
a Check that the universal joint is in the correct position.
a Proceed in the reverse order to removal.
a Torque tighten:
- the steering column nuts,
- the universal joint bolt,
- the steering wheel bolt.
a Tighten the cover bolts (2 N.m).
Note:
Take care to route the remote adjustment control
wiring harness above the air duct.
a Lock the steering column in the high position.
36A-11
STEERING ASSEMBLY
Steering rack gaiter: Removal - Refitting
REMOVAL
36A
REFITTING
I - REMOVAL PREPARATION OPERATION
I - REFITTING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Always replace:
a Remove:
- the steering box gaiter,
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the track rod, (see 3 6 A, Steering assembly,
Track rod: Removal - Refitting, page 36A-3)
- the wheel alignment adjusting lock nut.
- the retaining clips.
a Clean the contact surfaces between the steering box
and the gaiter using SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) .
a Coat the gaiter bearing face on the axial ball joint
with SILICONE LUBRICANT (see Vehicle: Parts
and ingredients for the repairwork) to prevent the
gaiter from twisting.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Note:
Be sure to centre the steering to ensure the air in
the gaiters is equalised.
Note:
Be careful not to damage the gaiters: risk of irreversible damage.
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- a new steering box gaiter,
- new retaining clips.
105678
a
Note:
III - FINAL OPERATION.
When removing the steering gaiter, blast the gaiter surfaces with compressed air to eliminate any
impurities that could enter the steering box.
a Refit:
- the wheel alignment adjustment lock nut,
a Remove the gaiter retaining clip (1)
- the track rod, (see 3 6 A, Steering assembly,
Track rod: Removal - Refitting, page 36A-3)
a Cut the gaiter retaining clip (2) .
a Remove the gaiter (3) .
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
a Check the axle geometry (see 30A, General information, Axle assemblies: Check, page 30A-18) .
a If necessary, adjust the axle assemblies' geometry
(see 30A, General information, Front axle: Adjusting, page 30A-32) .
36A-12
STEERING ASSEMBLY
Bulkhead seal: Removal - Refitting
36A
REFITTING
a Clip the bulkhead seal onto the steering box.
Essential equipment
a Refit the subframe (see 31A, Front axle components, Front axle sub-frame: Removal - Refitting,
page 31A-46) .
steering wheel lock
REMOVAL
a Refit the front wheels. (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1)
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Fill the power-assisted steering fluid reservoir.
a Set the wheels straight ahead.
a With the engine running, bleed the power-assisted
steering circuit turning the steering wheel from lock
to lock (left to right).
a Check the axle geometry (see 30A, General information, Underbody height: Adjustment values,
page 30A-19) .
a In the passenger compartment, remove:
- the universal joint bolt,
- the cam nut from the universal joint.
a Position the steering wheel lock.
a Remove the battery cover.
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
a Remove the front wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Remove the sub-frame (see 31A, Front axle components, Front axle sub-frame: Removal - Refitting, page 31A-46) .
108823
a Unclip the bulkhead seal by pressing on the clips (1)
, using a screwdriver.
36A-13
STEERING ASSEMBLY
Steering wheel: Removal - Refitting
36A
Essential equipment
diagnostic tool
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
IMPORTANT
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
101201
a Set the wheels straight ahead.
REMOVAL
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(MR 366, 88C, Airbag and pretensioner).
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
a Remove the driver's front airbag (see Driver's front
airbag: Removal - Refitting) (MR 364, 88C, Airbags and seat belt pretensioners).
a Disconnect the connectors (depending on equipment level).
a Remove the steering wheel bolt (1) .
a Remove the steering wheel carefully to avoid disconnecting the rotary switch connectors.
REFITTING
a The steering wheel bolt must be replaced with a new
one whenever it is removed.
a Proceed in the reverse order to removal.
a Push and pull on the electric power-assisted steering computer power and signal connectors to check
that they are properly secured (risk of loss of assistance).
WARNING
In order not to damage the steering wheel or
steering column, the steering wheel-column foolproofing devices must be aligned.
a Torque tighten the steering wheel bolt (see 30A, General information, Steering: Tightening torque,
page 30A-17) .
a Refit the driver's front airbag (see Driver's front airbag: Removal - Refitting) (MR 364, 88C, Airbags
and seat belt pretensioners).
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
36A-14
STEERING ASSEMBLY
Steering wheel: Removal - Refitting
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (MR 366, 88C, Airbag and pretensioners).
36A-15
36A
STEERING ASSEMBLY
Steering wheel: Removal - Refitting
36A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
new steering wheel bolt
44 N.m
IMPORTANT
Consult the safety and cleanliness advice and operation recommendations before carrying out any
repair (see Steering: Precautions for repair) .
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Apply the procedure for deactivating the safety systems. (see Airbag and Pretensioners: Precautions for repair)
a
122730
WARNING
a Remove the steering wheel bolt (1) .
Incorrect wheel alignment may damage the
rotary switch.
WARNING
a Remove the driver's front airbag (see Driver's front
airbag: Removal - Refitting) .
To ensure that the electronic systems operate
correctly, do not damage the locking systems of
the connectors.
a Set the wheels straight ahead.
a Disconnect the connectors.
a Remove the steering wheel.
a
WARNING
To prevent damaging the rotary switch, do not
turn the mobile section of the rotary switch.
REFITTING
I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Steering wheel bolt
(13,04,01,09).
36A-16
STEERING ASSEMBLY
Steering wheel: Removal - Refitting
II - REFITTING OPERATION FOR PART
CONCERNED
105327
a
WARNING
In order not to damage the steering wheel or
steering column, the steering wheel-column foolproofing devices must be aligned.
a Refit the steering wheel.
a Connect the connectors.
a Refit the new steering wheel bolt.
a Torque tighten the new steering wheel bolt (44
N.m).
III - FINAL OPERATION
a Refit the driver's front airbag (see Driver's front airbag: Removal - Refitting) .
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 it stops,
- check that there are no faults on the instrument panel.
36A-17
36A
POWER ASSISTED STEERING
Steering column: List and location of components
36B
101938
(1)
Electrical power assisted steering computer fitted with a torque and angle sensor
(2)
Electric stepper motor with
worm screw
(3)
Reducer pinion
(4)
Intermediate shaft
(5)
Universal joint in the passenger
compartment
The assistance varies according to the speed.
36B-1
POWER ASSISTED STEERING
Intermediate shaft
36B
B84 or C84 or G84 or S84
CHECKING
a These vehicles are fitted with a non-removable
« intermediate shaft / steering wheel shaft / steering
column » assembly. If it is not possible to fit the universal joint eccentric bolt, or after an impact, check
that the length of the shaft is correct.
If the length of the intermediate shaft is incorrect, replace the steering column assembly, (see 36A,
Steering assembly, Steering column: Removal Refitting, page 36A-7) .
WARNING
Never pull the intermediate shaft (after an
impact).
92218
a Check that: L = 269.35 +/- 1 mm
36B-2
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
37A
F9Q or K4J or K4M or K9K or M9R
F9Q or M9R
Tightening torquesm
master cylinder reservoir bolt
8.5 N.m
TRW master cylinder
nuts
50 N.m
BOSCH master cylinder nuts
21 N.m
brake pipe nuts
17 N.m
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
a Remove the injection computer (depending on the
version):
- (see Diesel injection computer: Removal - Refitting) (MR 364, 13B, Diesel injection),
- (see Petrol injection computer: Removal - Refitting) (MR 364, 17B, Petrol injection).
101889
a Unclip the turbocharger regulation solenoid valve (1)
.
a Disconnect the air flowmeter connector.
a Remove the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture).
a Remove the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery).
37A-1
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
37A
F9Q or K4J or K4M or K9K or M9R
REFITTING
101700
a Disconnect the electrical connector (2) from the
master cylinder reservoir.
a Drain the master cylinder reservoir with a syringe.
101704
a The master cylinder seals (7) must be replaced.
a Clip the master cylinder reservoir onto the master
cylinder correctly.
a Remove:
a Refit the bolt securing the master cylinder reservoir
to the master cylinder.
- the heat shield clip,
- the clutch master cylinder pipe (3) ,
a Torque tighten the master cylinder reservoir bolt
(8.5 N.m).
- the brake pipes (4) on the master cylinder,
- the master cylinder nuts (5) on the brake servo,
- the master cylinder assembly and the master cylinder reservoir,
- the master cylinder reservoir bolt (6) on the master
cylinder,
- the master cylinder reservoir.
37A-2
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
F9Q or K4J or K4M or K9K or M9R
101711
a Line up the master cylinder with the brake servo so
that the pushrod goes into the master cylinder housing.
a When refitting the master cylinder, be sure the cup is
centred in the brake servo.
a Refit the master cylinder nuts to the brake servo.
a Torque tighten:
- the TRW master cylinder nuts (50 N.m) on the
brake servo,
- the BOSCH master cylinder nuts (21 N.m) on the
brake servo.
a Proceed in the reverse order to removal.
a Torque tighten the brake pipe nuts (17 N.m) on the
master cylinder.
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
37A-3
37A
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
37A
F4R
OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
brake fluid reservoir bolt
on the master cylinder
8.5 N.m
TRW master cylinder
nuts
50 N.m
BOSCH master cylinder nuts
21 N.m
brake pipe nuts
17 N.m
WARNING
Prepare for brake fluid outflow, to prevent damage
to the mechanical parts and bodywork around the
braking system.
REMOVAL
101700
a Disconnect:
REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove:
- the brake fluid level sensor connector (1) on the
brake fluid reservoir,
- the vacuum pipe from the brake servo (2) .
a Drain the brake fluid reservoir with a syringe.
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery),
Note:
- the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery),
Remove the pipe and clip from the clutch master
cylinder by carefully pressing on the brake fluid
reser voir.
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture),
- the air filter box air outlet pipe,
a Remove:
- the clutch master cylinder pipe (3) on the brake
fluid reservoir side,
- the engine cover.
- the brake pipes (4) on the master cylinder.
37A-4
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
37A
F4R
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
119990
119989
a
WARNING
Always replace the master cylinder seals (9)
when refitting the master cylinder reservoir.
a Clip the brake fluid reservoir onto the master cylinder.
a Refit the brake fluid reservoir bolt on the master cylinder.
a Torque tighten the brake fluid reservoir bolt on
the master cylinder (8.5 N.m).
119989
a Remove:
- the master cylinder nuts on the brake servo (5) ,
- the master cylinder and reservoir assembly (6) ,
- the brake fluid reservoir bolt on the master cylinder
(7) ,
- the brake fluid reservoir (8) .
37A-5
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
37A
F4R
II - FINAL OPERATION
a Refit:
- the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery),
- the air filter box air outlet pipe,
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture),
- the engine cover.
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Refit the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
119990
a Line up the master cylinder with the brake servo so
that the pushrod (10) goes into the master cylinder
housing.
WARNING
When refitting the master cylinder, be sure the
cup is centred in the brake servo.
a Refit the master cylinder nuts to the brake servo.
a Torque tighten:
- the TRW master cylinder nuts (50 N.m) on the
brake servo,
- the BOSCH master cylinder nuts (21 N.m) on the
brake servo.
a Refit:
- the clutch master cylinder pipe on the brake fluid
reservoir side,
- the brake pipes to the master cylinder.
a Torque tighten the brake pipe nuts (17 N.m) on the
master cylinder.
a Connect:
- brake servo vacuum pipe ,
- the brake fluid level sensor connector on the brake
fluid reservoir.
37A-6
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting
37A
B84 or C84 or G84 or S84, and M9R, and LEFT-HAND DRIVE
REMOVAL
a Remove the front engine cover.
115383
a Unclip:
- the turbocharger regulation solenoid valve (3) ,
115384
- the vacuum pipe (4) from the air inlet duct.
a Disconnect the non-return valve (8) at the brake servo.
a Disconnect:
- the air flow sensor connector (5) ,
a Pull and turn the non-return valve to release it from
the rubber sealing washer.
- the oil vapour rebreathing pipe (6) .
a Disconnect the non-return valve (9) at the vacuum
pump.
a Remove the non-return valve.
REFITTING
115382
a Undo the retaining clips (7) on the air inlet duct.
a Remove the air inlet duct.
74883
a Check the condition of the sealing washer and the
non-return valve.
a Replace any faulty parts.
a Proceed in the reverse order to removal.
37A-7
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting
37A
F4R or K4J
II - REMOVAL OPERATION FOR PART
CONCERNED
Tightening torquesm
air duct clips
5.5 Nm
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Remove the engine covers.
103492
a Disconnect the vacuum pipe on the brake servo side
(3) .
101807
a Undo the air duct clips (1) .
a Pull and turn the non-return valve to release it from
the rubber sealing washer.
a Remove the air duct (2) .
Note:
Ensure that the vacuum pipe on the inlet manifold is not damaged, otherwise the inlet manifold
will need replacing.
a Disconnect the vacuum pipe on the inlet manifold
side (4) .
REFITTING
I - REFITTING PREPARATION 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 Connect the vacuum pipe on the intake distributor side.
a Refit the rubber sealing washer.
a Connect the vacuum pipe on the brake servo side.
37A-8
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting
F4R or K4J
III - FINAL OPERATION.
a Refit the air duct.
a Torque tighten the air duct clips (5.5 Nm).
a Refit the engine covers.
37A-9
37A
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting
37A
F9Q or K9K
REMOVAL
F9Q
I - REMOVAL PREPARATION OPERATION
a Remove:
- the engine covers,
- the air duct from the air filter box.
II - REMOVAL OPERATION FOR PART
CONCERNED
K9K
103567
a Disconnect the vacuum pipe on the brake servo side
(1) .
a Pull and turn the non-return valve to release it from
the rubber sealing washer.
a Disconnect the vacuum pipe at the vacuum pump
end (2) .
103564
a Disconnect the vacuum pipe on the brake servo side
(1) .
a Pull and turn the non-return valve to release it from
the rubber sealing washer.
a Disconnect the vacuum pipe at the vacuum pump
end (2) .
REFITTING
I - REFITTING PREPARATIONS OPERATION
a Check the condition of:
- the sealing washer,
- the return valve.
a Replace any faulty parts.
II - REFITTING OPERATION FOR PART
CONCERNED
a Connect the vacuum pipe at the vacuum pump end.
a Refit the rubber sealing washer.
a Connect the vacuum pipe on the brake servo side.
37A-10
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting
F9Q or K9K
III - FINAL OPERATION.
a Refit:
- the air duct on the air filter box,
- the engine covers.
37A-11
37A
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
Tightening torquesm
brake servo bolts
21 Nm
This procedure is for the TRW brake servo.
Note:
It is impossible to remove the brake servo pushrod.
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
101698
a Remove:
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
a Remove:
- the engine cover,
- the upper ball joint (1) from the gearbox control
(see 37A, Mechanical component controls, Manual gearbox selector cable: Removal - Refitting, page 37A-66) ,
- the gearbox control cable sleeve stop at (2) .
- the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) .
Note:
Do not touch the system of adjustment on the
ND gearbox selector cables, as this would alter
the length of the cable and consequently the
movement of the gear lever.
37A-12
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
REFITTING
102245
a Remove the brake pedal clevis pin (3) from the brake servo pushrod in the passenger compartment.
91101
a Check the following dimension before refitting:
- for left-hand drive vehicles: (X1) = 163.7 mm,
- for right-hand drive vehicles: (X1) = 133.2 mm.
a Proceed in the reverse order to removal.
a Torque tighten the brake servo bolts (21 Nm).
a Check that the brake servo pushrod-brake pedal
connecting shaft is locked in place.
a Refit the master cylinder (see 37A, Mechanical
component controls, Master cylinder: Removal Refitting, page 37A-1) .
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
a Adjust the brake pedal position switch (see 37A, Mechanical component controls, Brake pedal
switch: Removal - Refitting, page 37A-36) .
101698
a Remove:
- the clips (4) from the scuttle panel partition,
- the brake servo bolts (5) .
37A-13
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and F9Q, and DOCUMENT PHASE 2
Tightening torquesm
height adjuster nuts
21 Nm
gear lever sleeve stop
mounting bolts
21 Nm
This procedure deals with the BOSCH brake servo.
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
I - REMOVAL PREPARATION OPERATION.
a Position the vehicle on a two-post lift (see 02A, Lifting equipment: Underbody lift).
a Remove:
121475
a Remove:
- The non-return valve (1) from the brake servo,
- the battery (see 80A, Battery, Battery: Removal Refitting),
- the gear lever ball joints, (see 37A, Mechanical
component controls, Manual gearbox selector
cable: Removal - Refitting, page 37A-66) ,
- the engine cover,
- the injection computer (see 13B, Diesel injection,
Diesel injection computer: Removal - Refitting),
- the sleeve stop mounting bolts,
- the battery tray (see 80A, Battery, Battery tray:
Removal-Refitting),
- the clips (2) from the brake servo soundproofing.
- the air filter box (see 12A, Fuel mixture, Air filter
box: Removal-Refitting),
- the sleeve stop mounting,
a Remove the brake servo soundproofing.
- the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) .
37A-14
Note:
Do not touch the adjustment system on the ND
gearbox selector cable, as this would alter the
length of the cable and consequently the movement of the gear lever.
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and F9Q, and DOCUMENT PHASE 2
121474
a Remove the brake washer (3) from the securing pin.
a Unclip the securing pin (4) by pushing it downwards.
121472
a Remove the brake servo from the height adjuster.
a Remove:
- the nuts (6) from the height adjuster,
a Remove the securing pin.
- the "height adjuster - brake servo" assembly.
REFITTING
II - OPERATION FOR REMOVAL OF PART
CONCERNED
I - REFITTING PREPARATION OPERATION
a
WARNING
To avoid damaging the braking assistance system, do not attempt to arm the brake servo height adjuster system.
Always replace a height adjuster when the system is disarmed.
121471
a Using a flat-blade screwdriver, press on the bayonet
(5) and turn the brake servo in a clockwise direction
to unlock it.
37A-15
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and F9Q, and DOCUMENT PHASE 2
121473
a Check that the plastic ring is positioned correctly.
Note:
The arrows must face the spigots.
121470
a Position the opening of the non-return valve (7) on
the brake servo so that it is vertically aligned with the
pushrod axis.
a Check the positioning of the pushrod and the brake
pedal in the passenger compartment.
II - REFITTING OPERATION FOR PART
CONCERNED
a Fit the "height adjuster - brake servo" assembly.
a Refit the height adjuster nuts.
a Torque tighten the height adjuster nuts (21 Nm).
121469
a Press and turn the brake servo in an anti-clockwise
direction until a beep sounds from the height adjustment system and bayonet.
a Refit:
- the securing pin,
- the new brake washer on the securing pin,
37A-16
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
B84 or C84, and F9Q, and DOCUMENT PHASE 2
- the brake servo soundproofing,
- the non-return valve on the brake servo.
III - FINAL OPERATION.
a Refit the sleeve stop mounting.
a Torque tighten the gear lever sleeve stop mounting bolts (21 Nm).
a Refit:
- the gear lever ball joints, (see 37A, Mechanical
component controls, Manual gearbox selector
cable: Removal - Refitting, page 37A-66)
- the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) ,
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting),
- the battery tray (see 80A, Battery, Battery tray:
Removal-Refitting),
- the injection computer (see 13B, Diesel injection,
Diesel injection computer: Removal - Refitting),
- the engine cover.
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Refit the battery (see 80A, Battery, Battery: Removal - Refitting).
a Adjust the brake light switch (see 37A, Mechanical
component controls, Brake pedal switch: Removal - Refitting, page 37A-36) .
37A-17
37A
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and M9R, and DOCUMENT PHASE 2
Tightening torquesm
height adjuster nuts
21 Nm
This procedure deals with the BOSCH brake servo.
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
115165
I - REMOVAL PREPARATION OPERATION.
a Position the vehicle on a two-post lift (see 02A, Lifting equipment: Underbody lift).
a Remove:
- the battery (see 80A, Battery, Battery: Removal Refitting),
a Unclip the vacuum pipe (1) from the air inlet duct.
a Disconnect the oil vapour rebreathing pipe (2) .
a Undo the clip (3) securing the air inlet duct on the
turbocharger.
a Remove:
- the engine cover,
- the air inlet duct,
- the injection computer (see 13B, Diesel injection,
Diesel injection computer: Removal - Refitting),
- the brake servo non-return valve,
- the clip (4) from the brake servo soundproofing,
- the battery tray (see 80A, Battery, Battery tray:
Removal-Refitting),
- the brake servo soundproofing.
- the air filter box (see 12A, Fuel mixture, Air filter
box: Removal-Refitting),
- the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) .
121474
a Remove the brake washer (5) from the securing pin.
a Unclip the securing pin (6) by pushing it downwards.
a Remove the securing pin.
37A-18
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and M9R, and DOCUMENT PHASE 2
REFITTING
II - OPERATION FOR REMOVAL OF PART
CONCERNED
I - REFITTING PREPARATION OPERATION
a
WARNING
To avoid damaging the braking assistance system, do not attempt to arm the brake servo height adjuster system.
Always replace a height adjuster when the system is disarmed.
121471
a Using a flat-blade screwdriver, press on the bayonet
(7) and turn the brake servo in a clockwise direction
to unlock it.
121473
a Check that the plastic ring is positioned correctly.
Note:
The arrows must face the spigots.
II - REFITTING OPERATION FOR PART
CONCERNED
a Fit the "height adjuster - brake servo" assembly.
a Refit the height adjuster nuts.
a Torque tighten the height adjuster nuts (21 Nm).
121472
a Remove the brake servo from the height adjuster.
a Remove:
- the nuts (8) from the height adjuster,
- the "height adjuster - brake servo" assembly.
37A-19
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and M9R, and DOCUMENT PHASE 2
- the brake servo soundproofing,
- the non-return valve on the brake servo.
III - FINAL OPERATION.
a Refit:
- the air inlet duct,
- the oil vapour rebreathing pipe,
- the air inlet manifold vacuum pipe,
- the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) ,
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting),
- the battery tray (see 80A, Battery, Battery tray:
Removal-Refitting),
- the injection computer (see 13B, Diesel injection,
Diesel injection computer: Removal - Refitting),
121470
a Position the opening of the non-return valve (9) on
the brake servo so that it is vertically aligned with the
pushrod axis.
a Check the positioning of the pushrod and the brake
pedal in the passenger compartment.
- the engine cover.
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Refit the battery (see 80A, Battery, Battery: Removal - Refitting).
a Adjust the brake light switch (see 37A, Mechanical
component controls, Brake pedal switch: Removal - Refitting, page 37A-36) .
121469
a Press and turn the brake servo in an anti-clockwise
direction until a beep sounds from the height adjustment system and bayonet.
a Refit:
- the securing pin,
- the new brake washer on the securing pin,
37A-20
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and F4R or K4J or K4M or K9K, and DOCUMENT PHASE 2
Tightening torquesm
height adjuster nuts
21 Nm
This procedure deals with the BOSCH brake servo.
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
I - REMOVAL PREPARATION OPERATION.
a Position the vehicle on a two-post lift (see 02A, Lifting equipment: Underbody lift).
a Remove the battery (see 80A, Battery, Battery: Removal - Refitting).
101698
a Remove:
- the upper ball joint (1) from the gear lever, (see
37A, Mechanical component controls, Manual
gearbox selector cable: Removal - Refitting,
page 37A-66) ,
K9K
- the gearbox control cable sleeve stop at (2) .
a Remove the diesel injection computer (see 13B,
Diesel injection, Diesel injection computer: Removal - Refitting).
Note:
Do not touch the adjustment system on the ND
gearbox selector cable, as this would alter the
length of the cable and consequently the movement of the gear lever.
F4R or K4J or K4M
a Remove:
a Remove the petrol injection computer (see 17B, Petrol injection, Petrol injection computer: Removal - Refitting).
a Remove:
- the battery tray (see 80A, Battery, Battery tray:
Removal-Refitting),
- the air filter box (see 12A, Fuel mixture, Air filter
box: Removal-Refitting),
- the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) .
- the non-return valve on the brake servo,
37A-21
- the clips from the brake servo soundproofing,
- the brake servo soundproofing.
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and F4R or K4J or K4M or K9K, and DOCUMENT PHASE 2
121474
a Remove the brake washer (3) from the securing pin.
a Unclip the securing pin (4) by pushing it downwards.
121472
a Remove the brake servo from the height adjuster.
a Remove:
- the nuts (6) from the height adjuster,
a Remove the securing pin.
- the "height adjuster - brake servo" assembly.
REFITTING
II - OPERATION FOR REMOVAL OF PART
CONCERNED
I - REFITTING PREPARATION OPERATION
a
WARNING
To avoid damaging the braking assistance system, do not attempt to arm the brake servo height adjuster system.
Always replace a height adjuster when the system is disarmed.
121471
a Using a flat-blade screwdriver, press on the bayonet
(5) and turn the brake servo in a clockwise direction
to unlock it.
37A-22
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
37A
B84 or C84, and F4R or K4J or K4M or K9K, and DOCUMENT PHASE 2
121473
a Check that the plastic ring is positioned correctly.
Note:
The arrows must face the spigots.
121470
a Position the opening of the non-return valve (7) on
the brake servo so that it is vertically aligned with the
pushrod axis.
a Check the positioning of the pushrod and the brake
pedal in the passenger compartment.
II - REFITTING OPERATION FOR PART
CONCERNED
a Fit the "height adjuster - brake servo" assembly.
a Refit the height adjuster nuts.
a Torque tighten the height adjuster nuts (21 Nm).
121469
a Press and turn the brake servo in an anti-clockwise
direction until a beep sounds from the height adjustment system and bayonet.
a Refit:
- the securing pin,
- the new brake washer on the securing pin,
37A-23
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
B84 or C84, and F4R or K4J or K4M or K9K, and DOCUMENT PHASE 2
- the brake servo soundproofing,
- the non-return valve on the brake servo.
III - FINAL OPERATION.
a Refit:
- the cable sleeve stop on the gearbox control cable,
- the gearbox control upper ball joint, (see 37A, Mechanical component controls, Manual gearbox
selector cable: Removal - Refitting, page 37A66)
- the master cylinder (see 37A, Mechanical component controls, Master cylinder: Removal - Refitting, page 37A-1) ,
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting),
- the battery tray (see 80A, Battery, Battery tray:
Removal - Refitting).
K9K
a Refit the diesel injection computer (see 13B, Diesel
injection, Diesel injection computer: Removal Refitting).
F4R or K4J or K4M
a Refit the petrol injection computer (see 17B, Petrol
injection, Petrol injection computer: Removal Refitting).
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Refit the battery (see 80A, Battery, Battery: Removal - Refitting).
a Adjust the brake light switch (see 37A, Mechanical
component controls, Brake pedal switch: Removal - Refitting, page 37A-36) .
37A-24
37A
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting
K9K
Tightening torquesm
vacuum pump bolts
21 Nm
REMOVAL
a Remove the engine covers.
103565
a Remove:
- the hose connected to the brake servo,
- the vacuum pump bolts (1) ,
- the vacuum pump.
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the vacuum pump bolts (21 Nm).
37A-25
37A
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting
F9Q
Tightening torquesm
vacuum pump bolts
21 Nm
inlet manifold bolts
8 Nm
REMOVAL
a Remove the engine covers.
103566
a Remove:
- the inlet manifold bolts,
- the inlet duct,
- the hose connected to the brake servo,
- the vacuum pump bolts (1) ,
- the vacuum pump.
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten:
- the vacuum pump bolts (21 Nm),
- the inlet manifold bolts (8 Nm).
37A-26
37A
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting
37A
M9R
a Move the wiring harness to one side.
a Remove the battery tray with the injection computer
support.
Tightening torquesm
vacuum pump bolts
21 Nm
diesel pipe retaining
bracket bolt
14 Nm
battery tray bolts
21 Nm
REMOVAL
a Remove:
- the engine cover,
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery).
115167
a Disconnect:
- the vacuum pipe (5) ,
- the non-return valve (6) .
a Remove:
- the bolt (7) from the diesel pipe retaining bracket,
- the diesel pipe retaining bracket,
- the vacuum pump bolt (8) .
112659
a Disconnect:
- the computer connectors (1) ,
- the air flowmeter connector.
a Unclip:
- the wiring harness (2) from the computer connector,
- the wiring harness to the battery negative terminal,
- the air filter unit turbocharger regulation solenoid
valve,
- the wiring harness.
a Remove:
- the battery tray bolts (3) ,
- the nut (4) from the wiring harness.
37A-27
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting
37A
M9R
a Refit:
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery),
- the engine cover.
115166
a Unclip the harness at (9) .
a Remove:
- the vacuum pump bolts (10) ,
- the vacuum pump.
REFITTING
a Be sure to replace the vacuum pump seal.
a Proceed in the reverse order to removal.
a Torque tighten:
- the vacuum pump bolts (21 Nm),
- the diesel pipe retaining bracket bolt (14 Nm).
a Refit the battery tray with the injection computer support.
a Fit the wiring harness.
a Refit:
- the wiring harness nut,
- the battery tray bolts,
a Tighten to torque the battery tray bolts (21 Nm).
a Fit the wiring harness.
a Refit the turbocharger regulation solenoid valve on
the air filter unit.
a Fit:
- the wiring harness to the battery negative terminal,
- the wiring harness for the computer connector.
a Connect the injection computer connectors.
37A-28
MECHANICAL COMPONENT CONTROLS
Accelerator pedal: Removal - Refitting
Tightening torquesm
accelerator pedal nuts
8 Nm
REMOVAL
a Switch off the vehicle ignition.
116018
a Disconnect the accelerator pedal potentiometer connector (1) .
a Remove:
- the accelerator pedal nuts (2) ,
- the accelerator pedal.
REFITTING
a Proceed in the reverse order to removal.
a Torque tighten the accelerator pedal nuts (8 Nm).
37A-29
37A
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
LEFT-HAND DRIVE
Tightening torquesm
brake pedal clevis nuts
21 Nm
REMOVAL
a Pull back the carpet on the driver's side.
102203
a Remove:
- the brake light switch (1) from the brake pedal (see
37A, Mechanical component controls, Brake
pedal switch: Removal - Refitting, page 37A-36)
,
- the brake pedal clevis from the brake servo push
rod,
- the brake pedal clevis nuts (2) ,
- the brake pedal,
- the accelerator pedal nuts,
- the accelerator pedal.
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the brake pedal clevis nuts (21
Nm).
37A-30
37A
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
37A
RIGHT-HAND DRIVE
- the dashboard cross member (see Dashboard
cross member: Removal - Refitting) (MR 365,
42A, Upper front structure).
Essential special tooling
Fre. 1752
Safety pin
Essential equipment
diagnostic tool
Tightening torquesm
brake pedal clevis nuts
21 Nm
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
103831
a Disconnect the accelerator pedal potentiometer connector (1) .
IMPORTANT
a Remove:
Never handle the pyrotechnic systems (pretensioners or airbags) near to a source of heat or naked
flame - they may be triggered.
- the accelerator pedal bolts (2) ,
- the accelerator pedal.
Note:
When the brake pedal is replaced, the pedal is supplied fitted with a pin. (Fre. 1752).
If removing or refitting (without replacing the brake
pedal), it is essential to fit the pin (Fre. 1752) during
the removal and refitting procedure.
REMOVAL
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components)
(MR 366, 88C, Airbag and pretensioner).
a Remove:
- the dashboard (see Dashboard: Removal - Refitting) (MR 365, 57A, Interior equipment),
- the steering column (see 36A, Steering assembly, Steering column: Removal - Refitting, page
36A-7) ,
37A-31
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
37A
RIGHT-HAND DRIVE
- the brake pedal mounting, by turning it until it is released from the idler bar.
103829
a Disconnect the clutch pedal switch.
104823
a Remove the clutch pedal bolts (3) .
a Cut pin (6) (Fre. 1752).
a Remove the clutch pedal mounting from its housing
without removing the master cylinder pipes.
103830
a Remove the connecting shaft (4) from the « brake
pedal and idler bar » assembly.
a Remove:
- the brake pedal switch,
- the brake pedal bolts (5) ,
104825
a Insert the pin (Fre. 1752) moving from left to right
(when not replacing the pedal).
37A-32
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
37A
RIGHT-HAND DRIVE
REFITTING
104825
104824
a
a Cut the pin according to the dotted line (do not remove the pedal pin).
IMPORTANT
In order not to trigger the brake pedal collapse
system, do not damage the restraint system (7) .
Note:
Do not remove the pin before refitting and tightening the pedal assembly.
37A-33
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
RIGHT-HAND DRIVE
103858
a
Note:
Always check the fuse board (8) , it must not be
damaged. If there is any deformation on the fuse
board, the brake pedal assembly must be replaced.
a Proceed in the reverse order to removal.
a Torque tighten the brake pedal clevis nuts (21
Nm).
a Remove the pin.
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of components) (MR 366, 88C, Airbag and pretensioners).
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
37A-34
37A
MECHANICAL COMPONENT CONTROLS
Brake pedal bell crank rod: Removal - Refitting
B84 or C84 or G84 or S84, and RIGHT-HAND DRIVE
REMOVAL
a Remove the brake pedal (see 37A, Mechanical
component controls, Brake pedal: Removal - Refitting, page 37A-30) .
103828
a Remove:
- the brake light switch (1) (see 37A, Mechanical
component controls, Brake pedal switch: Removal - Refitting, page 37A-36) ,
- the two nuts from the idler bar retaining ring (2) ,
- idler bar retaining ring,
- the shaft (3) connecting the « brake servo pushrod
and idler bar » assembly.
a Remove the idler bar to the driver's side.
REFITTING
a To refit, proceed in the reverse order of removal.
37A-35
37A
MECHANICAL COMPONENT CONTROLS
Brake pedal switch: Removal - Refitting
REMOVAL
37A
REFITTING
WHEN REMOVING AND REFITTING OR
REPLACING THE BRAKE LIGHT SWITCH
108436
109201
a
a Disconnect the brake light switch connector (1) .
WARNING
a Turn the brake light switch (2) a quarter of a turn
anti-clockwise.
Handle the switch (3) with care.
Only operate the piston (4) to adjust the dimension (X) .
a Remove the brake light switch.
The switch must be replaced:
- if the piston (4) is separated from the switch (3)
,
- if more than three adjustments to dimension (X)
are necessary during the operation.
a Measure dimension (X) of the piston (4) . If dimension (X) is less than 17 mm, carefully pull on the end
of the piston to adjust the dimension (X) between the
values: minimum 17 mm and maximum 18 mm.
a Depress the brake pedal by hand.
a Position the brake light switch on the pedal assembly.
a Lock the brake light switch by turning it a quarter of
a turn clockwise.
a Carefully follow the return of the brake pedal.
Note:
The brake pedal switch has an automatic adjustment which adapts to the pedal position.
The automatic adjustment makes a clicking noise
when in operation.
a Connect the connector.
37A-36
MECHANICAL COMPONENT CONTROLS
Brake pedal switch: Removal - Refitting
a Check that the brake light switch is operating correctly:
- depress the brake pedal to switch on the lights,
- release the brake pedal to switch off the lights.
37A-37
37A
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting
37A
B84 or C84 or G84 or S84
REFITTING
Tightening torquesm
parking brake lever nuts
a Always replace the nut (3) .
8 Nm
a Refit:
REMOVAL
- the parking brake lever,
a Remove the centre console (see Centre console:
Removal - Refitting) (MR 365, 57A, Interior equipment).
- the parking brake lever nuts.
a Torque tighten the parking brake lever nuts (8
Nm).
a Refit the parking brake wiring harness clip.
a Connect the parking brake connector.
a Refit:
- the parking brake cables on the parking brake lever
side,
- the nut.
a Ensure that the handbrake cable stops are fully inserted in their housing.
a Tighten the nut so that (X) = 21 mm if the cable sleeve stop bracket is black, and (X) = 16 mm if the cable sleeve stop bracket is gold.
101927
a Operate the parking brake to activate the compensation.
a Remove the nut (3) .
a Remove the parking brake cables from their housing
(1) .
a Remove:
- the parking brake lever nuts (2) ,
- the parking brake lever.
a Disconnect the parking brake connector.
24316
a Check whether control lever (4) detaches from its
stop (play should be equal to 1 mm).
37A-38
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting
B84 or C84 or G84 or S84
a Check the lever stroke.
a With the handbrake released, check that the wheels
rotate freely.
a Refit the centre console (see Centre console: Removal - Refitting) (MR 365, 57A, Interior equipment).
37A-39
37A
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting
37A
E84
REFITTING
Tightening torquesm
parking brake lever nuts
I - REFITTING OPERATION FOR PART
CONCERNED
8 Nm
a Always replace the nut (1) .
REMOVAL
a Refit:
I - REMOVAL PREPARATION OPERATION
- the parking brake lever,
a Remove the centre console (see Centre console:
Removal - Refitting) (MR 365, 57A, Interior equipment).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
- the parking brake lever nuts.
a Torque tighten the parking brake lever nuts (8
Nm).
a Refit the parking brake wiring harness clip.
a Connect the parking brake connector.
a Refit:
- the parking brake cables on the parking brake lever
side,
- the nut.
a Ensure that the handbrake cable stops are fully inserted in their housing.
a Tighten the nut to obtain a dimension of (X1) 15
mm.
a Operate the parking brake to activate the compensation.
101927
a Remove the nut (1) .
a Remove the parking brake cables from their housing
(2) .
a Remove:
- the parking brake lever nuts (3) ,
- the parking brake lever.
a Disconnect the parking brake connector.
24316
a Check that the control lever (4) detaches from its
stop (play should be equal to 1 mm).
37A-40
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting
E84
II - FINAL OPERATION.
a Check:
- the lever travel,
- that the wheels turn freely with the handbrake released.
a Refit the centre console (see Centre console: Removal - Refitting) (MR 365, 57A, Interior equipment).
37A-41
37A
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting
37A
K84 or L84
REFITTING
Tightening torquesm
parking brake lever nuts
I - REFITTING OPERATION FOR PART
CONCERNED
8 Nm
a Always replace the nut (1) .
REMOVAL
a Refit:
I - REMOVAL PREPARATION OPERATION
- the parking brake lever,
a Remove the centre console (see Centre console:
Removal - Refitting) (MR 365, 57A, Interior equipment).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
- the parking brake lever nuts.
a Torque tighten the parking brake lever nuts (8
Nm).
a Refit the parking brake wiring harness clip.
a Connect the parking brake connector.
a Refit:
- the parking brake cables on the parking brake lever
side,
- the nut.
a Ensure that the handbrake cable stops are fully inserted in their housing.
a Tighten the nut to obtain a dimension of (X1) 17
mm.
a Operate the parking brake to activate the compensation.
101927
a Remove the nut (1) .
a Remove the parking brake cables from their housing
(2) .
a Remove:
- the parking brake lever nuts (3) ,
- the parking brake lever.
a Disconnect the parking brake connector.
24316
a Check whether control lever (4) detaches from its
stop (play should be equal to 1 mm).
37A-42
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Removal - Refitting
K84 or L84
II - FINAL OPERATION.
a Check:
- the lever travel,
- that the wheels turn freely with the handbrake released.
a Refit the centre console (see Centre console: Removal - Refitting) (MR 365, 57A, Interior equipment).
37A-43
37A
MECHANICAL COMPONENT CONTROLS
Parking brake lever: Adjusting
A poorly adjusted parking brake:
- prevents correct operation of the automatic compensation system for the brake shoes,
37A
II - OPERATION FOR ADJUSTMENT OF PART
CONCERNED
- causes premature wear of brake shoes.
ADJUSTMENT
I - ADJUSTMENT PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) .
a Apply the parking brake five times to condition the
cables for normal use.
a Put the parking brake lever into the released position.
a Check that the rear wheels turn freely. If they do not,
check the following components and if necessary repair:
- the parking brake cables,
101927
- the calliper piston,
- the automatic compensation system,
a Loosen the nut (3) to release the cables.
- calliper
a Position the parking brake lever at the 2nd notch.
a Remove the rear wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
a Remove the centre console (see Centre console:
Removal - Refitting) .
a Move the adjustment nut until the disc or drum can
no longer be turned by hand.
a Pull the brake lever several times.
a Put the parking brake lever into the released position.
a The disc or the drum must be able to turn freely. If
not, move the nut gradually until the disc or drum
can turn freely.
a Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
37A-44
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting
37A
LEFT-HAND DRIVE
Tightening torquesm
clutch pedal plate nuts
21 Nm
REMOVAL
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
101899
a Disconnect the sensor connector (3) .
101193
a Remove:
- the left-hand lower cover (see Dashboard: Removal - Refitting) (MR 365, 57A, Interior equipment),
- the UCH (1) (see UCH: Removal - Refitting) (MR
364,87B, Passenger compartment connection
unit),
- the left-hand air duct (2) .
a Remove the grey start of travel sensor (3) (see
Clutch pedal position sensor: Removal - Refitting) .
a Disconnect the sensor connector (4) .
a Remove the green end of travel sensor (4) (see
Clutch pedal position sensor: Removal - Refitting) .
a Unclip the clutch pedal master cylinder ball joint (5) .
a Remove:
- the three clutch pedal nuts (6) ,
- the clutch pedal.
REFITTING
a To refit, proceed in the reverse order of removal.
a Torque tighten the clutch pedal plate nuts (21
Nm).
a It is essential to pull the ends of the clutch pedal sensors to set them at the minimum position.
The clutch pedal position sensors have an automatic
adjustment function which adjusts according to the
position of the clutch pedal.
37A-45
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting
LEFT-HAND DRIVE
102205
a Refit the clutch pedal sensors (see Clutch pedal
position sensor: Removal - Refitting) .
a Connect:
- the clutch pedal sensor connectors,
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery).
37A-46
37A
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting
37A
RIGHT-HAND DRIVE
JH3 or JR5
Tightening torquesm
clutch pedal plate nuts
21 Nm
REMOVAL
a
Note:
The clutch master cylinder is mounted on the
clutch pedal assembly. Remove the « pedal master cylinder » assembly to extract the pedal
or master cylinder.
a Drain the brake fluid reservoir until the level is below
the master cylinder supply port.
a Remove:
- the engine covers,
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery),
- the battery tray (see Battery tray: Removal - Refitting) (MR 364, 80A, Battery).
101701
a Lift up the clip (1) .
a Pull out the master cylinder control pipe by one
notch.
a Remove the injection computer (depending on the
version):
- (see Petrol injection computer: Removal - Refitting) (MR 364, 17B, Petrol injection),
- (see Diesel injection computer: Removal - Refitting) (MR 364, 13B, Diesel injection).
a Remove the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture).
a Drain the brake fluid reservoir until the level is below
the master cylinder supply port.
a Place a cloth under the bleed hole.
a Depress the clutch pedal using your hand to drain
the master cylinder and the pipe.
a Lift up the clip (2) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
37A-47
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting
37A
RIGHT-HAND DRIVE
In the passenger compartment
ND0
101741
102513
a Apply pressure to the clip (3) manually, whilst pulling
on the pipe.
a Remove the grey start of travel sensor (4) (see
Clutch pedal position sensor: Removal - Refitting) .
a Disconnect the sensor connector (4) .
a Remove the green end of travel sensor (5) (see
Clutch pedal position sensor: Removal - Refitting) .
Note:
Do not pull the clip. If it is incorrectly handled in
any way, the pipe will need to be replaced.
a Disconnect the sensor connector (5) .
a Pull out the master cylinder control pipe by one
notch.
a Place a cloth under the bleed hole.
a Depress the clutch pedal using your hand (to drain
the master cylinder and the pipe).
a Place a cloth under the master cylinder.
a Remove the union clips from the master cylinder (6)
.
a Disconnect the pipes.
a Fit plugs into the openings.
a Remove the clip (3) .
a Extract the clutch pedal master cylinder ball joint.
a Disconnect the pipes from the slave cylinder.
a Remove the four nuts from the clutch pedal plate.
a Fit plugs into the openings.
a Extract the « pedal - master cylinder » assembly.
a Remove the master cylinder from the pedal assembly by turning it clockwise a quarter of a turn (bayonet type mounting).
37A-48
MECHANICAL COMPONENT CONTROLS
Clutch pedal: Removal - Refitting
RIGHT-HAND DRIVE
REFITTING
a Check the condition of the seals.
a To refit, proceed in the reverse order of removal.
a Torque tighten the clutch pedal plate nuts (21
Nm).
a It is essential that the sensors are pulled to the end
stop so that they are in the minimum position.
The clutch pedal position sensors have an automatic
adjustment function which adjusts according to the
position of the clutch pedal.
102205
a Refit the clutch pedal sensors (see Clutch pedal
position sensor: Removal - Refitting) .
a Connect the clutch pedal sensor connectors.
a Bleed the clutch control (see 3 7 A, Mechanical
component controls, Clutch circuit: Bleeding,
page 37A-50) .
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
37A-49
37A
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding
37A
JH3 or JR5 or ND0 or PK4 or TL4
There are two types of equipment used to bleed the
clutch circuit:
Essential equipment
a ARC50 via the brake fluid reservoir.
brake circuit bleeding device
a Syringe via the bleed hole located on the clutch slave cylinder.
hydraulic circuit bleed syringe
Bleed in the event of:
There are two procedures used to bleed the clutch
circuit:
- dead travel,
a If no parts of the clutch hydraulic circuit are removed:
- pedal at mid-travel,
- pedal to the floor,
- Carry out the bleed operation using the ARC50 via
the brake fluid reservoir or using a new syringe via
the bleed hole located on the clutch slave cylinder.
- poor gear changing.
a If no parts of the clutch hydraulic circuit are removed:
I - PRECAUTIONS DURING REPAIR
- Only carry out the bleed operation using a new syringe by injecting the brake fluid via the bleed hole
on the clutch slave cylinder.
Risks relating to contamination.
a The hydraulic clutch system is very sensitive to contamination. The risks caused by contamination are:
- impossible to change gears,
Note:
- damage to or destruction of the clutch system,
- Even the tiniest air bubble in the circuit can
cause faulty operation (pedal failing to return
properly, crunching sound when changing gear,
etc.).
- leaks on the hydraulic circuit.
All the operations on the hydraulic clutch circuit system must be carried out under excellent cleanliness
conditions. This ensures that no impurities enter the
hydraulic circuit during the operation.
The cleanliness principles apply to all components
of the hydraulic clutch circuit.
Items causing contamination are:
- Incorrect bleeding can lead to incorrect detection of faults and unnecessary part replacements.
Consumables required for the repair:
a Bleed the clutch circuit using approved (see Vehicle: Parts and ingredients for the repairwork)
brake fluid (04B, consumables - products).
- metal or plastic swarf,
- fibres:
• cardboard,
II - PREPARATION STAGE
• brushes,
• paper,
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
• clothing,
a Remove the engine undertray.
• cloth,
• dust and particles in the air,
• etc.
Cleaning cloths.
a Use lint-free cleaning cloths (see Recommended
products for repairwork) (04B, Consumables Products).
Each cloth must only be used once.
37A-50
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding
37A
JH3 or JR5 or ND0 or PK4 or TL4
There are several versions of bleed screw:
Bleed screw with a clip.
Screw type bleed screw.
112868
113919
a To open the bleed screw, hold the plastic union (1)
using a ring spanner and undo the bleed screw (2) .
a To open the bleed screw, press and hold the clip (4)
while pulling by one notch.
Bleed screw with a clip.
Half-turn bleed screw.
107280
114335
a To open the bleed screw, lift the clip (5) while pulling
by one notch.
a To open the bleed screw, fully turn the bleed screw
(3) by hand.
37A-51
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding
37A
JH3 or JR5 or ND0 or PK4 or TL4
a Connect the brake circuit bleeding device (after
having received Renault approval) to the master cylinder reservoir (see the instructions for the equipment).
Bleed screw with two clips.
a Remove the bleed plug from the clutch slave cylinder.
a Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
a Open the bleed screw.
a Open the circuit between the bleeding device and
the brake fluid reservoir.
a Let the brake fluid run until all air bubbles have been
released.
a Stop the bleeding device to dump the pressure in the
clutch circuit.
a Close the bleed screw.
a Remove the transparent pipe from the bleed hole.
113732
a To open the bleed screw, lower the clip (6) and lift
the clip (7) while pulling by one notch.
a Refit the bleed plug.
a Top up the brake fluid level in the master cylinder reservoir after disconnecting the bleed device.
a Disengage and engage the clutch quickly around
twenty times.
III - BLEED PROCEDURE IF NO PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED
a Check that the clutch system is operating correctly.
1 - Bleed using the ARC50.
a Repeat the bleed operation if necessary.
a Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure continuity of the hydraulic circuit during the bleed operation.
a Check the adjustment of the switch. (see Clutch pedal switch: Removal - Refitting) (37A, mechanical
control elements).
Note:
Take care not to disrupt the adjustment of the
clutch start of travel switch.
37A-52
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding
37A
JH3 or JR5 or ND0 or PK4 or TL4
2 - Bleed using a new syringe.
a Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure continuity of the hydraulic circuit during the bleed operation.
IV - BLEED PROCEDURE IF PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED.
a
Note:
WARNING
The master cylinder pipe must be disconnected
from its take-off point on the brake fluid reservoir,
to avoid any foreign matter penetrating inside the
brake system hydraulic circuit.
Take care not to disrupt the adjustment of the
clutch start of travel switch.
WARNING
a Remove the bleed plug from the clutch slave cylinder.
Prepare for the flow of fluid and protect the surrounding components.
a Connect a transparent pipe of sufficient length to the
bleed hole (at least thirty centimeters) in order to place it at the same height as the reservoir.
Note:
a Open the bleed screw.
a Fill the brake fluid master cylinder reservoir until brake fluid flows out of the bleed screw.
Note:
The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.
a Connect a new hydraulic circuit bleed syringe
filled with a useful volume of 60 ml of approved 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 air from the top section of the syringe.
a Close the bleed screw.
a Remove the transparent pipe from the bleed hole.
a Refit the bleed plug.
a Top up the brake fluid level in the master cylinder reservoir.
a Disengage and engage the clutch quickly around
twenty times.
a Check that the clutch system is operating correctly.
a Repeat the bleed operation if necessary.
a Check the adjustment of the switch. (see Clutch pedal switch: Removal - Refitting) (37A, mechanical
control elements).
37A-53
Prefill the hydraulic circuit pipe equipped with a
filter.
Position the filter head facing downwards to
ensure that it fills.
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding
37A
JH3 or JR5 or ND0 or PK4 or TL4
There are several versions of pipe with and without
a filter:
Filling position for pipe with filter.
Pipe without filter.
141810
Filling position for pipe with filter.
141812
Filling position for pipe with filter.
141813
a Prefill the clutch pipe using the syringe.
141811
a Plug the prefilled pipe on the master cylinder end to
stop any brake fluid from escaping.
37A-54
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleeding
37A
JH3 or JR5 or ND0 or PK4 or TL4
V - BLEED PROCEDURE AFTER A REMOVING A
COMPONENT OF THE HYDRAULIC CIRCUIT.
a Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure continuity of the hydraulic circuit during the bleed operation.
Note:
Take care not to disrupt the adjustment of the
clutch start of travel switch.
a Remove the bleed plug from the clutch slave cylinder.
a Connect a transparent pipe of sufficient length to the
bleed hole (at least thirty centimeters) in order to place it at the same height as the reservoir.
a Open the bleed screw.
141809
a Prefill the hydraulic tappet using the new syringe (by
gravity).
a Fill the brake fluid master cylinder reservoir until brake fluid flows out of the bleed screw.
Note:
a Refit the part(s) concerned.
The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.
a Connect a new syringe containing 60 ml of approved 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 air from the top section of the syringe.
a Close the bleed screw.
a Remove the transparent pipe from the bleed hole.
a Refit the bleed plug.
a Top up the brake fluid level in the master cylinder reservoir.
a Disengage and engage the clutch quickly around
twenty times.
a Check that the clutch system is operating correctly.
a Repeat the bleed operation if necessary.
a Check the adjustment of the switch. (see Clutch pedal switch: Removal - Refitting) (37A, mechanical
control elements).
VI - FINAL OPERATION
a Refit the engine undertray.
a Remove the vehicle from the two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
37A-55
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting
37A
B84 or C84 or G84 or S84
Essential special tooling
JH3 or JR5
Emb. 1797
24 mm socket for removing
and refitting clutch master
cylinder
Tightening torquesm
clutch pedal plate nuts
21 Nm
REMOVAL
M9R
a Position the vehicle on a lift (see Vehicle: Towing
and lifting) (MR 364, 02A, Lifting equipment).
a Disconnect the battery, starting with the negative
terminal (see Battery : Removal - Refitting) (MR
364, 80A, Battery).
101701
a Remove the bleed plug.
a Place a cloth under the bleed hole.
F4R or F9Q or K4M or K9K or M9R
a Lift up the clip (1) .
a Remove:
a Pull out the master cylinder control pipe by one position.
- the engine cover,
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery),
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture).
a Drain the brake fluid reservoir using a syringe until
the level is below the master cylinder supply orifice.
37A-56
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting
37A
B84 or C84 or G84 or S84
ND0
PK4
102513
115170
a Remove:
a Remove the bleed plug.
a Place a cloth under the bleed hole.
- the engine undertray,
a Apply pressure to the clip (2) manually, whilst pulling
on the pipe.
- the bleed plug (3) .
a Turn the end (4) of the calliper piston anti-clockwise
as far as it will go.
WARNING
Do not pull the clip. If it is incorrectly handled in
any way, the pipe will need to be replaced.
a Pull out the master cylinder control pipe by one position.
a Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
a Depress the pedal using your hand (to drain the
master cylinder and the pipe).
37A-57
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting
37A
B84 or C84 or G84 or S84
LEFT-HAND DRIVE
19399
a Remove the master cylinder from the bulkhead in
the engine compartment by turning it a quarter turn
clockwise (bayonet type mounting) using the (Emb.
1797).
101740
RIGHT-HAND DRIVE
a Place a cloth under the master cylinder.
a
a Disconnect the brake fluid reservoir pipe.
a Fit plugs into the openings.
Note:
a Place a cloth under the master cylinder.
The clutch master cylinder is mounted on the
clutch pedal assembly. Remove the pedal - master cylinder assembly to extract the pedal and the
master cylinder.
a Remove the union clip on the master cylinder (5) .
a Disconnect the pipes.
a Place plugs in each opening.
a Disconnect the master cylinder ball joint from the
clutch pedal in the passenger compartment.
37A-58
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting
37A
B84 or C84 or G84 or S84
REFITTING
LEFT-HAND DRIVE
101741
a Remove the grey start of travel switch (6) by turning
it a quarter of a turn (see Clutch pedal position
sensor: Removal - Refitting) .
19148
a Check the condition of the seals.
a Disconnect the connector from the switch (6) .
a Proceed in the reverse order to removal.
a Remove the green end of travel switch (7) by turning
it a quarter of a turn (see 37A, Mechanical component controls, Brake pedal switch: Removal - Refitting, page 37A-36) .
Note:
a Disconnect the switch connector (7) .
- Lubricate both ends of the supply pipe with
brake fluid to facilitate fitting on the brake fluid
reservoir take-off pipe.
a Place a cloth under the master cylinder.
- The master cylinder has a foolproofing device, it
only fits in one position.
a Remove the union clips from the master cylinder (8)
.
WARNING
a Disconnect the pipes.
Do not use the take-off pipes as a support when
fitting.
a Fit plugs into the openings.
a Extract the clutch master cylinder ball joint from the
pedal.
a Connect the master cylinder ball joint to the clutch
pedal.
a Remove the four nuts from the « pedal » assembly.
a Extract the « pedal - master cylinder » assembly.
a Remove the master cylinder from the bulkhead by
turning it a quarter turn clockwise (bayonet type
mounting) using the (Emb. 1797).
37A-59
MECHANICAL COMPONENT CONTROLS
Clutch master cylinder: Removal - Refitting
B84 or C84 or G84 or S84
RIGHT-HAND DRIVE
a Check the condition of the seals.
a Refit the « pedal - master cylinder » assembly.
a Torque tighten the clutch pedal plate nuts (21
Nm).
a Proceed in the reverse order to removal.
a Bleed the clutch control (see 3 7 A, Mechanical
component controls, Clutch circuit: Bleeding,
page 37A-50) .
a Check that the clutch system is operating correctly.
a Adjust and refit:
- the brake switch (see 37A, Mechanical component controls, Brake pedal switch: Removal Refitting, page 37A-36) ,
- the clutch switch (see Clutch pedal position sensor: Removal - Refitting) .
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
37A-60
37A
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting
37A
B84 or C84 or G84 or S84
REMOVAL
JH3 or JR5
M9R
a Position the vehicle on a lift (see Vehicle: Towing
and lifting) (MR 364, 02A, Lifting equipment).
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
F4R or F9Q or K4M or K9K or M9R
a Remove:
- the engine cover,
- the battery (see Battery : Removal - Refitting)
(MR 364, 80A, Battery),
- the battery tray with the injection computer,
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture).
101701
a Lift up the clip (1) .
a Drain the brake fluid reservoir using a syringe until
the level is below the master cylinder supply orifice.
a Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
a Pull out the master cylinder control pipe by one
notch.
a Place a cloth under the bleed hole.
a Operate the pedal by hand to empty the master cylinder and the pipe.
a Lift up the clip (2) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
37A-61
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting
37A
B84 or C84 or G84 or S84
PK4
ND0
102513
a Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
a Apply pressure to the clip (3) manually, whilst pulling
on the pipe.
WARNING
115170
a Remove:
- the engine undertray,
- the bleed plug (4) .
a Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
a Turn the end (5) of the calliper piston anti-clockwise
as far as it will go.
Do not pull the clip. If there are any errors when
handling the pipe it will need to be replaced.
a Pull out the master cylinder control pipe by one
notch.
a Depress the pedal using your hand (to drain the
master cylinder and the pipe).
a Place a cloth under the bleed hole.
a Depress the pedal using your hand (to drain the
master cylinder and the pipe).
a Press the clip (3) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
37A-62
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting
37A
B84 or C84 or G84 or S84
LEFT-HAND DRIVE
PK4
115169
a Lift up the clip (6) .
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
a Unclip the pipe at (7) .
101739
a Place a cloth under the master cylinder.
a Remove the clip (8) from the union on the master cylinder return.
a Disconnect the pipes from the slave cylinder.
a Fit plugs into the openings.
a Withdraw the slave cylinder supply pipe.
RIGHT-HAND DRIVE
a Remove:
- the left-hand glove compartment,
- the left-hand air duct.
37A-63
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting
37A
B84 or C84 or G84 or S84
102212
101741
a Place a cloth under the pipe unions.
a Place a cloth under the master cylinder.
a Remove the clip (9) from the master cylinder supply
union on the master cylinder return.
a Remove the clip (11) from the master cylinder supply union on the master cylinder return.
a Disconnect the pipes.
a Disconnect the pipes.
a Fit plugs into the openings.
a Fit plugs into the openings.
a Remove the clip (10) from the slave cylinder supply
union on the master cylinder return.
a Withdraw the master cylinder supply pipe from the
left-hand side.
a Disconnect the pipes.
a Remove the clip (12) from the slave cylinder supply
union on the master cylinder return.
a Fit plugs into the openings.
a Disconnect the pipes.
a Fit plugs into the openings.
a Withdraw the slave cylinder supply pipe from the
left-hand side.
37A-64
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Removal - Refitting
B84 or C84 or G84 or S84
101739
a Place a cloth under the hole (13) .
a Remove the brake fluid reservoir pipe.
a Fit plugs into the openings.
a Remove the master cylinder return (14) from the
bulkhead by turning it a quarter of a turn clockwise
(bayonet type mounting)
REFITTING
a Check the condition of the seals.
a Proceed in the reverse order to removal.
a Bleed the clutch control (see 3 7 A, Mechanical
component controls, Clutch circuit: Bleeding,
page 37A-50) .
a Check that the clutch system is operating correctly.
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
37A-65
37A
MECHANICAL COMPONENT CONTROLS
Manual gearbox selector cable: Removal - Refitting
37A
AJ0 or DP0 or JH3 or JR5 or ND0 or PK4 or TL4
I - REMOVAL
II - REFITTING
a Precautions to be taken when removing and refitting
the gear cable end pieces to avoid tearing the plastic
guide tube and damaging the ball joints.
121257
a To remove the gear control cables from their ball
joints, use an open-ended spanner as shown above.
This prevents the control cables from being damaged.
121258
121259
a To refit, use pliers to clip the gear control cables to
the ball joints.
a Perform rapid gearchanges for all gears for 20 seconds.
Check that the cables are not unclipped.
37A-66
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting
37A
B84 or C84 or G84 or S84
REMOVAL
REFITTING
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Always replace the nut (1) .
a Refit the parking brake cables into their housing.
a Remove the centre console (see Centre console:
Removal - Refitting) (MR 365, 57A, Interior equipment).
Note:
When replacing the sleeves of the parking brake
cables, pull the parking brake lever several times
before adjusting the dimension (X) = 21 mm if
the sleeve stop bracket is black, and (X) = 16
mm if the sleeve stop bracket is gold.
a Check that the handbrake cable stops are correctly
positioned on the body side.
a Refit the parking brake cables:
- brake calliper side (see 33A, Rear axle components, Rear brake caliper: Removal - Refitting,
page 33A-3) ,
- at the parking brake lever end (see 37A, Mechanical component controls, Parking brake lever:
Removal - Refitting, page 37A-38) .
a Refit the nut.
a Ensure that the handbrake cable stops are fully inserted in their housing.
101927
a Remove the nut (1) .
a Remove the parking brake cables:
- at the parking brake lever end (see 37A, Mechanical component controls, Parking brake lever:
Removal - Refitting, page 37A-38) ,
a Tighten the nut so that (X) = 21 mm if the cable sleeve stop bracket is black, and (X) = 16 mm if the cable sleeve stop bracket is gold.
a Operate the parking brake to activate the compensation.
- brake calliper side (see 33A, Rear axle components, Rear brake caliper: Removal - Refitting,
page 33A-3) .
a Remove the parking brake cables from their housing.
37A-67
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting
B84 or C84 or G84 or S84
24316
a Check:
- that the control lever (2) detaches from its stop
(play should be equal to 1 mm),
- the lever travel,
- that the wheels turn freely with the handbrake released.
a Refit the centre console (see Centre console: Removal - Refitting) (MR 365, 57A, Interior equipment).
37A-68
37A
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting
37A
E84
REMOVAL
REFITTING
I - REMOVAL PREPARATION OPERATION
I - REFITTING OPERATION FOR PART
CONCERNED
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove the centre console (see Centre console:
Removal - Refitting) (MR 365, 57A, Interior equipment).
a Always replace the nut (1) .
a Refit the parking brake cables into their housing.
Note:
When replacing the parking brake cable sleeves,
pull the parking brake lever several times before
adjusting the dimension to (X1) 15 mm.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Check the handbrake cable stops are correctly positioned at the body side.
a Refit the parking brake cables:
- brake calliper side (see 33A, Rear axle components, Rear brake caliper: Removal - Refitting,
page 33A-3) ,
- at the parking brake lever end (see 37A, Mechanical component controls, Parking brake lever:
Removal - Refitting, page 37A-38) .
a Refit the nut.
a Ensure that the handbrake cable stops are fully inserted in their housing.
a Tighten the nut to obtain a dimension of (X1) 15
mm.
a Operate the parking brake to activate the compensation.
101927
a Remove the nut (1) .
a Remove the parking brake cables:
- at the parking brake lever end (see 37A, Mechanical component controls, Parking brake lever:
Removal - Refitting, page 37A-38) ,
- brake calliper side (see 33A, Rear axle components, Rear brake caliper: Removal - Refitting,
page 33A-3) .
a Remove the parking brake cables from their housing.
37A-69
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting
E84
24316
a Check:
- that the control lever (2) detaches from its stop
(play should be equal to 1 mm),
- the lever travel,
- that the wheels turn freely with the handbrake released.
II - FINAL OPERATION.
a Refit the centre console (see Centre console: Removal - Refitting) (MR 365, 57A, Interior equipment).
37A-70
37A
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting
37A
K84 or L84
REMOVAL
REFITTING
I - REMOVAL PREPARATION OPERATION
I - REFITTING OPERATION FOR PART
CONCERNED
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove the centre console (see Centre console:
Removal - Refitting) (MR 365, 57A, Interior equipment).
a Always replace the nut (1) .
a Refit the parking brake cables into their housing.
Note:
When replacing the parking brake cable sleeves,
pull the parking brake lever several times before
adjusting the dimension to (X1) 17 mm.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Check the handbrake cable stops are correctly positioned at the body side.
a Refit the parking brake cables:
- brake calliper side (see 33A, Rear axle components, Rear brake caliper: Removal - Refitting,
page 33A-3) ,
- at the parking brake lever end (see 37A, Mechanical component controls, Parking brake lever:
Removal - Refitting, page 37A-38) .
a Refit the nut.
a Ensure that the handbrake cable stops are fully inserted in their housing.
a Tighten the nut to obtain a dimension of (X1) 17
mm.
a Operate the parking brake to activate the compensation.
101927
a Remove the nut (1) .
a Remove the parking brake cables:
- at the parking brake lever end (see 37A, Mechanical component controls, Parking brake lever:
Removal - Refitting, page 37A-38) ,
- brake calliper side (see 33A, Rear axle components, Rear brake caliper: Removal - Refitting,
page 33A-3) .
a Remove the parking brake cables from their housing.
37A-71
MECHANICAL COMPONENT CONTROLS
Parking brake cables: Removal - Refitting
K84 or L84
24316
a Check:
- that the control lever (2) detaches from its stop
(play should be equal to 1 mm),
- the lever travel,
- that the wheels turn freely with the handbrake released.
II - FINAL OPERATION.
a Refit the centre console (see Centre console: Removal - Refitting) (MR 365, 57A, Interior equipment).
37A-72
37A
MECHANICAL COMPONENT CONTROLS
Clutch control: Description
37A
B84 or C84 or G84 or S84
LEFT-HAND DRIVE
102207
(1)
Master cylinder supply pipe
(engine compartment)
(2)
Master cylinder (engine compartment - passenger compartment connection)
(3)
Slave cylinder supply pipe
(engine compartment)
37A-73
MECHANICAL COMPONENT CONTROLS
Clutch control: Description
B84 or C84 or G84 or S84
RIGHT-HAND DRIVE
37A-74
37A
MECHANICAL COMPONENT CONTROLS
Clutch control: Description
B84 or C84 or G84 or S84
37A-75
37A
MECHANICAL COMPONENT CONTROLS
Clutch control: Description
37A
B84 or C84 or G84 or S84
102208
(1)
Master cylinder supply pipe
(engine compartment)
(2)
Master cylinder return (engine
compartment - passenger compartment connection)
(3)
Master cylinder supply pipe
(passenger compartment)
(4)
Master cylinder (passenger
compartment)
(5)
Slave cylinder supply pipe (passenger compartment)
(6)
Slave cylinder supply pipe
(engine compartment)
37A-76
MECHANICAL COMPONENT CONTROLS
External gear control: Description
B84 or C84 or G84 or S84
JH3 or JR5
102326
(1)
Gear selection cable
(2)
Gear change cable
ND0 or PK4
102325
Note:
The ND - PK4 external control has the same specifications as the JH - JR except for the adjustment
system (3) on the selection cable.
37A-77
37A
MECHANICAL COMPONENT CONTROLS
External gear control: Removal - Refitting
37A
JH3 or JR5 or ND0 or PK4
Tightening torquesm
control unit mounting
bolts
21 Nm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
101743
a Remove the gear levers.
a Clip type:
- press the clips at (A) and uncouple the control lever
cable from the gearbox,
- pull the pin at (B) ,
- detach the cable from the cable sleeve stop, lifting
at (C) .
101742
a Remove:
- the battery tray with the injection computer,
- the air filter box, if necessary (see Air filter unit:
Removal - Refitting) (MR 364, 12A, Fuel mixture).
a Select third gear.
37A-78
MECHANICAL COMPONENT CONTROLS
External gear control: Removal - Refitting
37A
JH3 or JR5 or ND0 or PK4
PK4
121257
109149
a Remove the gear control cables from the gearbox
ball joints using an open-ended spanner in order to
avoid damaging the control cables.
a Pushrod type:
- press the pushrod at (D) and detach the cable end
piece by hand,
a Remove:
- Press the lugs at (E) to detach the cable from the
cable sleeve stop,
- the gear lever knob by lifting it,
- the gear lever gaiter.
Note:
Do not remove the cable end piece by levering
underneath it, to avoid damaging the cable and
the lever ball joint.
101320
a Unclip the centre console upper trims.
a Remove the bolts (3) from the centre console.
a Remove the centre console.
37A-79
MECHANICAL COMPONENT CONTROLS
External gear control: Removal - Refitting
37A
JH3 or JR5 or ND0 or PK4
101328
101793
a Cut the carpet between the airbag computer and the
gear lever unit.
a Remove the mounting nuts (6) from the exhaust
bracket.
a Remove the soundproofing covering the airbag
computer and the gear lever unit.
101898
a Remove the four mounting bolts (4) from the control
unit.
a Press the four tabs (5) to release the control unit.
a Remove the engine undertray.
37A-80
MECHANICAL COMPONENT CONTROLS
External gear control: Removal - Refitting
37A
JH3 or JR5 or ND0 or PK4
109405
a Remove:
- the heat shield mountings
- the heat shield (8) .
102116
101897
102117
a Remove the mounting bolts (7) from the exhaust
pipe rubber mounting bush.
a Let the exhaust pipe rest on the rear axle.
a Remove the gear lever unit.
REFITTING
a Refit:
- the control unit,
- the heat shield,
- the heat shield mountings.
a Torque tighten the control unit mounting bolts (21
Nm).
37A-81
MECHANICAL COMPONENT CONTROLS
External gear control: Removal - Refitting
37A
JH3 or JR5 or ND0 or PK4
CLIP TYPE
PK4
103113
a Press the clip tabs together.
a Press the insert to fit the clip.
121258
121259
a Clip the gear control cables onto the gearbox ball
joints using pliers.
a Adjust the gearbox cables.
a Rapidly shift through all the gears for 20 seconds.
a Check that the cables are not unclipped.
a Proceed in the reverse order to removal.
a Refit the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
37A-82
MECHANICAL COMPONENT CONTROLS
External gear control: Removal - Refitting
37A
JH3 or JR5 or ND0 or PK4
a Immobilise the lever against the shim in 3rd gear engaged position using a strap.
I - ADJUSTING THE GEARBOX CABLES
JH3 or JR5
2 - Engine compartment
a Refit the cables in their respective sleeve stops.
a Position the gear lever on the gearbox in 3rd gear
engaged position.
a Fit the cables into their respective ball joints.
a Check that all the gears engage correctly before
starting the engine.
a Refit the cables into their respective sleeve stops.
a Fit the selector cable on the lever ball joint.
Note:
a Loosen the clip (using a screwdriver) on the selection cable.
- There is no cable adjustment system.
a Adjust the length of the cable accordingly.
- The external control unit and the control levers
on the gearbox must be in third gear when the
cables are attached to the levers.
a Fit the selector cable on the gear lever ball joint.
II - ADJUSTING THE GEARBOX CABLES
ND0 or PK4
a Refit the control unit.
1 - Passenger compartment
102429
a Lock the clip by pressing down on (10) and stop its
movement by sliding the catch (11) .
WARNING
The shim must be removed from the gear lever
after the cables have been adjusted and fitted.
116019
a Refit the reverse gear trigger in the right direction.
a Fit a shim (9) between the trigger and the stop:
- 4 mm if the vehicle is fitted with a PK4 gearbox,
- 5 mm if the vehicle is fitted with an ND0 gearbox.
37A-83
MECHANICAL COMPONENT CONTROLS
Gearbox lever unit Removal - Refitting
37A
B84 or C84 or G84 or S84, and DP0
Tightening torquesm
battery cover bolts
0.4 daNm
WARNING
Mark the position of the gear lever clearly before
starting the operation: if not, position the gear
selector and the multifunction switch in neutral
«N».
REMOVAL
a Position the vehicle on a two-post lift.
a Remove the engine covers.
a Disconnect the battery, starting with the negative
terminal.
103424
a Remove the diagnostic socket access cover (3) .
a Turn the part (4) a quarter of a turn.
a Remove the part.
103408
a Remove:
- the multifunction switch cable ball joint (1) ,
- the control cable from the sheath stop (2) on the
modular connector support.
103425
a Remove the gear lever knob (5) by lifting it.
37A-84
MECHANICAL COMPONENT CONTROLS
Gearbox lever unit Removal - Refitting
37A
B84 or C84 or G84 or S84, and DP0
101322
a Unclip the handbrake lining trim (8) and (9) .
103426
a Unclip the console trim (6) .
101319
a Unclip the lower cover (10) .
103427
a Disconnect the connector (7) .
a Open the glove compartment.
101321
a Unclip the cigarette lighter support.
a Disconnect the cigarette lighter connector.
37A-85
MECHANICAL COMPONENT CONTROLS
Gearbox lever unit Removal - Refitting
37A
B84 or C84 or G84 or S84, and DP0
101320
a Disconnect the heated seat connectors (if fitted).
a Remove the two front seats ( (see 75A, Front seat
frames and mechanisms) ).
a Remove the bolts (11) .
101793
a Remove:
a Remove the three mounting nuts (15) from the exhaust bracket.
- the console carefully (12) ,
- the gear lever console.
101818
a Remove the two mounting bolts (16) .
101504
a Disconnect the connector (13) .
a Remove the sensor (14) .
37A-86
MECHANICAL COMPONENT CONTROLS
Gearbox lever unit Removal - Refitting
37A
B84 or C84 or G84 or S84, and DP0
102117
a Remove:
103429
a Remove the protector (19) .
- the mounting bolts (17) ,
- the front section of the heat shield.
103431
a Remove the four mounting bolts (20) from the control unit.
103428
a Pull back the carpet.
a Remove cover (18) .
a Hold the gear lever rod and release the control unit
retaining clips.
a Remove the unit-control cable assembly.
37A-87
MECHANICAL COMPONENT CONTROLS
Gearbox lever unit Removal - Refitting
37A
B84 or C84 or G84 or S84, and DP0
REFITTING
a To refit, proceed in the reverse order of removal.
a Adjust the control cable.
a Check that the system is operating correctly.
ADJUSTING THE CONTROL CABLE
a
WARNING
Mark the position of the gear lever clearly before
starting the operation: if not, position the gear
selector and the multifunction switch in neutral
«N».
23335
a Apply clip (22) to lock the cable end piece.
a Check that the system and gear selection are working correctly.
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
a Torque tighten the battery cover bolts (0.4 daNm).
23334
a Press on the slide (21) to release the cable.
a Clip the control cable into the sleeve stop.
a Clip the cable end piece to the multifunction switch
ball joint.
37A-88
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: List and location of components
38C
19113
102311
The Anti-lock Braking System pump assembly is
equipped with a 26-track computer.
102384
The ABS and Electronic Stability Program pump assembly is equipped with a 46-track computer.
38C-1
(1)
Brake hydraulic unit computer
(2)
Brake hydraulic unit pressure
modulation unit
(3)
Brake hydraulic unit hydraulic
pump
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
B84 or C84 or G84 or S84, and M9R, and LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
bolts securing the
hydraulic unit onto its
support
8 Nm
bolts securing the pipes
on the hydraulic unit
17 Nm
bolts supporting the
hydraulic unit on the
body
6.5 Nm
WARNING
Prepare for brake fluid outflow to prevent damage to
the mechanical parts and bodywork around the braking system.
REMOVAL
a Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift).
a Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting).
a Fit a pedal press to the brake pedal to limit the
amount of brake fluid running out.
a Remove:
- the engine cover,
- the scuttle panel grille (see MR 365, 55A, Exterior
protection, Scuttle panel grille: Removal - Refitting),
- the soundproofing under the scuttle panel grille,
- the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting),
- the bulkhead heat shield clips,
- the bulkhead heat shield central bolt,
- the lifting eye mounting bolts,
- the lifting eye.
a Remove the heat shield.
38C-2
38C
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
B84 or C84 or G84 or S84, and M9R, and LEFT-HAND DRIVE
a Loosen the brake pipe union (7) by moving the hydraulic unit forward.
a Remove:
- the hydraulic unit and support assembly,
- the bolts securing the support onto the hydraulic
unit,
- the hydraulic unit.
Note:
To remove the hydraulic unit computer, see 38C,
Anti-lock braking system, Computer: Removal - Refitting).
REFITTING
a Proceed in the reverse order to removal.
101935
106032
106032
a
a Remove:
WARNING
- the condensation drain channel (1) ,
Set up the earth terminal with the wires facing
downwards to optimise the hydraulic unit computer connector sealing.
- the ABS computer earth terminal mounting bolt (2)
.
a Disconnect the computer connector by lifting bracket
(3) .
a Torque tighten:
a Loosen the brake pipe unions (4) .
- the bolts securing the hydraulic unit onto its
support (8 Nm),
a Remove the hydraulic unit support mounting bolts
(5) .
- the bolts securing the pipes on the hydraulic
unit (17 Nm),
a Unpick the harness at (6) from the hydraulic unit on
its support.
- the bolts supporting the hydraulic unit on the
body (6.5 Nm).
38C-3
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
B84 or C84 or G84 or S84, and M9R, and LEFT-HAND DRIVE
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Connect the battery (see 80A, Battery, Battery: Removal - Refitting).
38C-4
38C
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
K4J, and 730 or 732
Essential equipment
AIR CONDITIONING or CLIMATE CONTROL
a Remove:
refrigerant charging station
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
pedal press
- the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 365,
55A, Exterior protection),
Tightening torquesm
brake hydraulic unit
bolts on the support
8 Nm
brake hydraulic unit support bolts
6.5 Nm
hose unions on the
brake hydraulic unit
17 Nm
air conditioning hose
bracket bolt on the bulkhead side
8 Nm
air conditioning hose
bracket bolt on the
dehydrator reservoir
side
8 Nm
- the front bumper (see Front bumper: Removal Refitting) (MR 365, 55A, Exterior protection).
a Drain the refrigerant circuit using the refrigerant
charging station.
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
a Remove:
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture),
- the throttle valve (see Throttle valve: Removal Refitting) (MR 364, 12A, Fuel mixture),
- the intake distributor (see Inlet manifold: Removal - Refitting) (MR 364, 12A, Fuel mixture).
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
102124
a Remove the lifting eye (1) .
AIR CONDITIONING or CLIMATE CONTROL
a Remove:
- the air conditioning hose bracket bolt on the bulkhead side,
- the air conditioning hose bracket bolt on the dehydrator reservoir side,
38C-5
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
K4J, and 730 or 732
- the air conditioning hose (2) between the bulkhead
bracket and the dehydrator reservoir.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
II - OPERATION FOR REMOVAL OF PART
CONCERNED
106032
a
WARNING
101935
Position the earth terminal wire downwards to
optimise the sealing on the brake hydraulic unit
computer connector.
a Remove:
- the condensate drain funnel (3) ,
- the bolt (4) from the brake hydraulic unit computer
earth terminal.
a Refit:
- the brake hydraulic unit on its support,
a Disconnect the brake hydraulic unit computer connector.
- the brake hydraulic unit bolts on the support,
a Undo the brake hydraulic unit pipe unions.
- the “support - brake hydraulic unit” assembly,
a Move aside the brake hydraulic unit pipes.
- the brake hydraulic unit support bolts.
a Remove:
a Torque tighten:
- the bolts (5) from the brake hydraulic unit support,
- the “support - brake hydraulic unit” assembly,
- the brake hydraulic unit bolts on the support (8
Nm),
- the brake hydraulic unit bolts on the support,
- the brake hydraulic unit support bolts (6.5 Nm).
- the brake hydraulic unit.
a Position the brake hydraulic unit hoses.
a Torque tighten the hose unions on the brake hydraulic unit (17 Nm).
a Connect the brake hydraulic unit computer connector.
a Refit:
- the bolt on the brake hydraulic unit computer earth
terminal,
38C-6
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
K4J, and 730 or 732
- the condensate drain neck.
- the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 365,
55A, Exterior protection),
a Tighten the bolt on the brake hydraulic unit computer
earth terminal.
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
II - FINAL OPERATION.
AIR CONDITIONING or CLIMATE CONTROL
a The seals at the ends of the air conditioning hose
must be replaced.
a Refit:
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
- the air conditioning hose between the bulkhead
bracket and the dehydrator reservoir,
- the air conditioning hose bracket bolt on the bulkhead side,
- the air conditioning hose bracket bolt on the dehydrator reservoir side.
a Torque tighten:
- the air conditioning hose bracket bolt on the
bulkhead side (8 Nm),
- the air conditioning hose bracket bolt on the dehydrator reservoir side (8 Nm).
a Refit the lifting eye.
a Refit:
- the intake distributor (see Inlet manifold: Removal - Refitting) (MR 364, 12A, Fuel mixture),
- the throttle valve (see Throttle valve: Removal Refitting) (MR 364, 12A, Fuel mixture),
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture).
a Remove the pedal press.
AIR CONDITIONING or CLIMATE CONTROL
a Fill the refrigerant circuit using the refrigerant charging station.
a Make sure the air conditioning is working properly
with the blower unit at top speed.
a If there is no cold air, check for leaks (see Air conditioning: Check) (MR 364, 62A, Air conditioning).
a Refit:
- the front bumper (see Front bumper: Removal Refitting) (MR 365, 55A, Exterior protection),
38C-7
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
M9R
Essential equipment
pedal press
Tightening torquesm
the brake hydraulic unit
support bolts on the
brake hydraulic unit
8 Nm
brake hydraulic unit support bolts
6.5 Nm
brake pipe unions on
the brake hydraulic unit
17 Nm
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
a Remove:
- the engine covers,
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 365, 56A, Exterior equipment),
- the soundproofing under the scuttle panel grille,
- the catalytic converter (see Catalytic converter:
Removal - Refitting) (MR 364, 19B, Exhaust),
- the bulkhead heat shield clips,
- the bulkhead heat shield central bolt,
- the lifting eye bolts,
- the lifting eye.
a Remove the heat shield.
38C-8
38C
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
M9R
a Detach the brake hydraulic unit wiring harness (6)
from its support.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Undo the brake pipe union (7) by moving the brake
hydraulic unit forward slightly.
a Remove:
- the “support - brake hydraulic unit” assembly,
- the brake hydraulic unit support bolts on the brake
hydraulic unit,
- the brake hydraulic unit.
101935
106032
a Remove:
- the condensate drain funnel (1) ,
- the bolt (3) from the brake hydraulic unit computer
earth terminal.
a Disconnect the connector (4) from the brake hydraulic unit computer connector.
a Undo the brake pipe unions (5) .
a Remove the bolts (2) from the brake hydraulic unit
support.
38C-9
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
M9R
a Refit:
REFITTING
- the bolt on the brake hydraulic unit computer earth
terminal,
I - REFITTING OPERATION FOR PART
CONCERNED
- the condensate drain neck.
a Tighten the bolt on the brake hydraulic unit computer
earth terminal.
II - FINAL OPERATION.
a Fit the heat shield.
a Refit:
- the lifting eye,
- the lifting eye bolts.
a Tighten the lifting eye bolts.
a Refit the bulkhead heat shield centre bolt.
a Tighten the bulkhead heat shield centre bolt.
a Refit:
- the bulkhead heat shield clips,
- the catalytic converter (see Catalytic converter:
Removal - Refitting) (MR 364, 19B, Exhaust),
106032
- the soundproofing under the scuttle panel grille,
a
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 365, 56A, Exterior equipment),
WARNING
Position the earth terminal wire downwards to
optimise the sealing on the brake hydraulic unit
computer connector.
- the engine covers.
a Remove the pedal press.
a Refit:
- the brake hydraulic unit on its support,
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
- the brake hydraulic unit support bolts on the brake
hydraulic unit,
a Connect the battery (see 80A, Battery, Battery: Removal - Refitting).
- the “support - brake hydraulic unit” assembly.
a Torque tighten the brake hydraulic unit support
bolts on the brake hydraulic unit (8 Nm).
a Tighten the brake pipe union (7) , moving the brake
hydraulic unit back slightly.
a Refit the brake hydraulic unit support bolts.
a Torque tighten:
- the brake hydraulic unit support bolts (6.5 Nm),
- the brake pipe unions on the brake hydraulic
unit (17 Nm).
a Connect the brake hydraulic unit computer connector.
a Clip the brake hydraulic unit wiring harness on its
support.
38C-10
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
K4M, and 760 or 761
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
Essential equipment
a Remove:
refrigerant charging station
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting),
pedal press
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting),
Tightening torquesm
brake hydraulic unit
bolts on the support
8 Nm
brake hydraulic unit support bolts
6.5 Nm
hose unions on the
brake hydraulic unit
17 Nm
air conditioning hose
bolts
8 Nm
- the inlet manifold (see 12A, Fuel mixture, Inlet
manifold: Removal - Refitting).
AIR CONDITIONING or CLIMATE CONTROL
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
102124
a Remove the air conditioning hose (1) between the
bulkhead bracket and the dehydrator reservoir.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift).
a Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting).
AIR CONDITIONING or CLIMATE CONTROL
a Remove:
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
- the front right-hand wheel arch liner (see MR 365
Bodywork, 55A, Exterior protection, Front
wheel arch liner: Removal - Refitting),
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper: Removal Refitting).
a Drain the refrigerant circuit using the refrigerant
charging station.
38C-11
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
K4M, and 760 or 761
REFITTING
II - REMOVAL OPERATION FOR PART
CONCERNED
I - REFITTING OPERATION FOR PART
CONCERNED
101935
a Remove:
- the condensate drain funnel (2) ,
106032
- the bolt (3) from the brake hydraulic unit computer
earth terminal.
a
WARNING
a Disconnect the brake hydraulic unit computer connector.
Position the earth terminal wire downwards to
optimise the sealing on the brake hydraulic unit
computer connector.
a Undo the brake hydraulic unit pipe unions.
a Move aside the brake hydraulic unit pipes.
a Refit:
a Remove:
- the brake hydraulic unit on its support,
- the bolts (4) from the brake hydraulic unit support,
- the brake hydraulic unit bolts on the support,
- the “support - brake hydraulic unit” assembly,
- the “support - brake hydraulic unit” assembly,
- the brake hydraulic unit bolts on the support,
- the brake hydraulic unit.
- the brake hydraulic unit support bolts.
a Torque tighten:
- the brake hydraulic unit bolts on the support (8
Nm),
- the brake hydraulic unit support bolts (6.5 Nm).
a Position the brake hydraulic unit hoses.
a Torque tighten the hose unions on the brake hydraulic unit (17 Nm).
a Connect the brake hydraulic unit computer connector.
a Refit:
- the bolt on the brake hydraulic unit computer earth
terminal,
38C-12
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
K4M, and 760 or 761
- the condensate drain neck.
a Tighten the bolt on the brake hydraulic unit computer
earth terminal.
a Connect the battery (see 80A, Battery, Battery: Removal - Refitting).
II - FINAL OPERATION.
AIR CONDITIONING or CLIMATE CONTROL
a The seals at the ends of the air conditioning hose
must be replaced.
a Refit the air conditioning hose between the bulkhead
bracket and the dehydrator reservoir.
a Torque tighten the air conditioning hose bolts (8
Nm).
a Refit:
- the inlet manifold (see 12A, Fuel mixture, Inlet
manifold: Removal - Refitting),
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting),
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting).
a Remove the pedal press.
AIR CONDITIONING or CLIMATE CONTROL
a Fill the refrigerant circuit using the refrigerant charging station.
a Make sure the air conditioning is working properly
with the blower unit at top speed.
a If there is no cold air, check for leaks (see 62A, Air
conditioning, Coolant circuit: Test).
a Refit:
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper: Removal Refitting),
- the front right-hand wheel arch liner (see MR 365
Bodywork, 55A, Exterior protection, Front
wheel arch liner: Removal - Refitting),
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
38C-13
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
F9Q or K9K
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper: Removal Refitting).
Essential equipment
refrigerant charging station
pedal press
AIR CONDITIONING or CLIMATE CONTROL
Tightening torquesm
brake hydraulic unit
bolts on the support
8 Nm
brake hydraulic unit support bolts
6.5 Nm
hose unions on the
brake hydraulic unit
17 Nm
air conditioning hose
bracket bolt on the bulkhead side
8 Nm
air conditioning hose
bracket bolt on the
dehydrator reservoir
side
8 Nm
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
101886
a Remove:
REMOVAL
- the air conditioning hose bracket bolt on the bulkhead side,
I - REMOVAL PREPARATION OPERATION
- the air conditioning hose bracket bolt on the dehydrator reservoir side,
a Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift).
- the air conditioning hose (1) between the bulkhead
bracket and the dehydrator reservoir.
a Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting).
AIR CONDITIONING or CLIMATE CONTROL
a Drain the refrigerant circuit using the refrigerant
charging station.
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
a Remove:
a Remove:
- the engine covers,
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
- the front right-hand wheel arch liner (see MR 365
Bodywork, 55A, Exterior protection, Front
wheel arch liner: Removal - Refitting),
- the lifting eye,
- the soundproofing screen mountings.
a Remove the soundproofing.
38C-14
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
F9Q or K9K
REFITTING
II - REMOVAL OPERATION FOR PART
CONCERNED
I - REFITTING OPERATION FOR PART
CONCERNED
101935
a Remove:
- the condensate drain funnel (2) ,
106032
- the bolt (3) from the brake hydraulic unit computer
earth terminal.
a
WARNING
a Disconnect the brake hydraulic unit computer connector.
Position the earth terminal wire downwards to
optimise the sealing on the brake hydraulic unit
computer connector.
a Undo the brake hydraulic unit pipe unions.
a Move aside the brake hydraulic unit pipes.
a Refit:
a Remove:
- the brake hydraulic unit on its support,
- the bolts (4) from the brake hydraulic unit support,
- the brake hydraulic unit bolts on the support,
- the “support - brake hydraulic unit” assembly,
- the “support - brake hydraulic unit” assembly,
- the brake hydraulic unit bolts on the support,
- the brake hydraulic unit.
- the brake hydraulic unit support bolts.
a Tighten to torque:
- the brake hydraulic unit bolts on the support (8
Nm),
- the brake hydraulic unit support bolts (6.5 Nm).
a Position the brake hydraulic unit hoses.
a Torque tighten the hose unions on the brake hydraulic unit (17 Nm).
a Connect the brake hydraulic unit computer connector.
a Refit:
- the bolt on the brake hydraulic unit computer earth
terminal,
38C-15
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
F9Q or K9K
- the condensate drain neck.
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
a Tighten the bolt on the brake hydraulic unit computer
earth terminal.
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
II - FINAL OPERATION.
AIR CONDITIONING or CLIMATE CONTROL
a The seals at the ends of the air conditioning hose
must be replaced.
a Connect the battery (see 80A, Battery, Battery: Removal - Refitting).
a Refit:
- the air conditioning hose between the bulkhead
bracket and the dehydrator reservoir,
- the air conditioning hose bracket bolt on the bulkhead side,
- the air conditioning hose bracket bolt on the dehydrator reservoir side.
a Torque tighten:
- the air conditioning hose bracket bolt on the
bulkhead side (8 Nm),
- the air conditioning hose bracket bolt on the dehydrator reservoir side (8 Nm).
a Refit:
- the lifting eye,
- the soundproofing screen,
- the engine covers.
a Remove the pedal press.
AIR CONDITIONING or CLIMATE CONTROL
a Fill the refrigerant circuit using the refrigerant charging station.
a Make sure the air conditioning is working properly
with the blower unit at top speed.
a If there is no cold air, check for leaks (see 62A, Air
conditioning, Coolant circuit: Test).
a Refit:
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper: Removal Refitting),
- the front right-hand wheel arch liner (see MR 365
Bodywork, 55A, Exterior protection, Front
wheel arch liner: Removal - Refitting),
38C-16
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
F4R, and 770 or 771 or 776
a Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.
Essential equipment
a Remove:
refrigerant charging station
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture),
pedal press
- the throttle valve (see Throttle valve: Removal Refitting) (MR 364, 12A, Fuel mixture),
Tightening torquesm
brake hydraulic unit
bolts on the support
8 Nm
brake hydraulic unit support bolts
6.5 Nm
hose unions on the
brake hydraulic unit
17 Nm
air conditioning hose
bolts
8 Nm
- the intake distributor (see Inlet manifold: Removal - Refitting) (MR 364, 12A, Fuel mixture),
- the soundproofing screen mountings,
- the soundproofing screen,
- the lifting eye.
AIR CONDITIONING or CLIMATE CONTROL
WARNING
Prepare for the flow of fluid, and protect the surrounding components.
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
102124
a Remove:
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
AIR CONDITIONING or CLIMATE CONTROL
a Remove:
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
- the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 365,
55A, Exterior protection),
- the front bumper (see Front bumper: Removal Refitting) (MR 365, 55A, Exterior protection).
a Drain the refrigerant circuit using the refrigerant
charging station.
38C-17
- the air conditioning hose (1) between the bulkhead
bracket and the dehydrator reservoir,
- the windscreen washer reservoir funnel (2) .
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
F4R, and 770 or 771 or 776
REFITTING
II - OPERATION FOR REMOVAL OF PART
CONCERNED
I - REFITTING OPERATION FOR PART
CONCERNED
101935
a Remove:
- the condensate drain funnel (3) ,
106032
- the bolt (4) from the brake hydraulic unit computer
earth terminal.
a
WARNING
a Disconnect the brake hydraulic unit computer connector.
Position the earth terminal wire downwards to
optimise the sealing on the brake hydraulic unit
computer connector.
a Undo the brake hydraulic unit pipe unions.
a Move aside the brake hydraulic unit pipes.
a Refit:
a Remove:
- the brake hydraulic unit on its support,
- the bolts (5) from the brake hydraulic unit support,
- the brake hydraulic unit bolts on the support,
- the “support - brake hydraulic unit” assembly,
- the “support - brake hydraulic unit” assembly,
- the brake hydraulic unit bolts on the support,
- the brake hydraulic unit.
- the brake hydraulic unit support bolts.
a Tighten to torque:
- the brake hydraulic unit bolts on the support (8
Nm),
- the brake hydraulic unit support bolts (6.5 Nm).
a Position the brake hydraulic unit hoses.
a Torque tighten the hose unions on the brake hydraulic unit (17 Nm).
a Connect the brake hydraulic unit computer connector.
a Refit:
- the bolt on the brake hydraulic unit computer earth
terminal,
38C-18
ANTI-LOCK BRAKING SYSTEM
Brake hydraulic assembly: Removal - Refitting
38C
F4R, and 770 or 771 or 776
- the condensate drain neck.
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
a Tighten the bolt on the brake hydraulic unit computer
earth terminal.
a Bleed the brake circuit (see 30A, General information, Brake circuit Bleeding, page 30A-4) .
II - FINAL OPERATION.
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
AIR CONDITIONING or CLIMATE CONTROL
a The seals at the ends of the air conditioning hose
must be replaced.
a Refit:
- the air conditioning hose between the bulkhead
bracket and the dehydrator reservoir,
- the windscreen washer reservoir funnel.
a Torque tighten the air conditioning hose bolts (8
Nm).
a Refit:
- the lifting eye,
- the soundproofing screen,
- the soundproofing screen mountings,
- the intake distributor (see Inlet manifold: Removal - Refitting) (MR 364, 12A, Fuel mixture),
- the throttle valve (see Throttle valve: Removal Refitting) (MR 364, 12A, Fuel mixture),
- the air filter box (see Air filter unit: Removal - Refitting) (MR 364, 12A, Fuel mixture).
a Remove the pedal press.
AIR CONDITIONING or CLIMATE CONTROL
a Fill the refrigerant circuit using the refrigerant charging station.
a Make sure the air conditioning is working properly
with the blower unit at top speed.
a If there is no cold air, check for leaks (see Air conditioning: Check) (MR 364, 62A, Air conditioning).
a Refit:
- the front bumper (see Front bumper: Removal Refitting) (MR 365, 55A, Exterior protection),
- the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 365,
55A, Exterior protection),
38C-19
ANTI-LOCK BRAKING SYSTEM
Wheel speed sensor: Removal - Refitting
38C
1 - Front of the vehicle
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
1 - Front of the vehicle
a Remove:
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the front section of the front wheel arch liner (see
Front wheel arch liner: Removal - Refitting) (MR
365, 55A, Exterior protection).
2 - Rear of the vehicle
a Remove the rear wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
119904
a Unlock the wheel speed sensor (1) by carefully pressing the sensor holder tab using a flat-blade
screwdriver to avoid any incorrect operation of the
ABS system.
a
WARNING
To avoid damaging the wheel speed sensor
cable:
- Do not tension the cable,
- Do not twist the cable,
- Check that there is no contact with the surrounding components,
- Do not use tools that may damage the cable.
119905
a Unclip the ABS sensor wiring harness (2) .
a Cut the clip (3) on the front side member.
a Disconnect the ABS sensor wiring harness connector (4) .
38C-20
ANTI-LOCK BRAKING SYSTEM
Wheel speed sensor: Removal - Refitting
38C
a Clip on the ABS sensor wiring harness.
2 - Rear of the vehicle
a Refit a new clip to the front side member.
a Position the wheel speed sensor, carefully pressing
the ABS sensor holder tab.
2 - Rear of the vehicle
a Connect the ABS sensor wiring harness connector.
a Clip on the ABS sensor wiring harness.
a Position the wheel speed sensor, carefully pressing
the ABS sensor holder tab.
II - FINAL OPERATION.
119907
a Unlock the wheel speed sensor (5) by carefully pressing the sensor holder tab using a flat-blade
screwdriver to avoid any incorrect operation of the
ABS system.
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
1 - Front of the vehicle
a Refit:
- the wheel arch liner (see Front wheel arch liner:
Removal - Refitting) (MR 365, 55A, Exterior protection),
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
2 - Rear of the vehicle
a Refit the rear wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
119906
a Unclip the ABS sensor wiring harness (6) .
a Disconnect the ABS sensor wiring harness connector (7) .
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
1 - Front of the vehicle
a Connect the ABS sensor wiring harness connector.
38C-21
ANTI-LOCK BRAKING SYSTEM
Yaw speed and transversal acceleration sensor: Removal - Refitting
38C
REFITTING
Essential equipment
diagnostic tool
Tightening torquesm
lateral acceleration and
yaw sensor nuts
8 Nm
REMOVAL
a
Note:
Handle the lateral acceleration and yaw sensor
with care.
a Disconnect the battery (see Battery : Removal Refitting) (MR 364, 80A, Battery).
a Remove:
20912
- the driver's seat,
a Refit the lateral acceleration and yaw sensor, paying
strict attention to its direction of fitting.
- the floor carpet on the driver's side (see Floor carpet: Removal - Refitting) (MR 365, 71A, Body internal trim).
a It is essential to fit the lateral acceleration and yaw
sensor in the vehicle's direction of travel (direction of
arrow).
a Disconnect the lateral acceleration and yaw sensor
connector.
a Remove:
a It is essential to replace any lateral acceleration and
yaw sensor that has sustained an impact.
- the lateral acceleration and yaw sensor nuts.
a Torque tighten the lateral acceleration and yaw
sensor nuts (8 Nm).
- the lateral acceleration and yaw sensor.
a Proceed in the reverse order to removal.
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
a Connect the battery (see Battery : Removal - Refitting) (MR 364, 80A, Battery).
a If replacing the lateral acceleration and yaw sensor,
carry out the necessary operations using the diagnostic tool (see Fault finding - Replacement of
components) (MR 366, 38C, ABS).
38C-22
ANTI-LOCK BRAKING SYSTEM
Braking computer: Removal - Refitting
a Refit the braking computer, holding it by its edge.
Essential special tooling
Mot. 1608
38C
Torque screwdriver 1 to 6.6
N.m.
Note:
Do not try to force the braking computer into
place when refitting; it should fit in without any
resistance.
Essential equipment
diagnostic tool
Tightening torquesm
braking computer bolts
3 Nm
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 364, 02A, Lifting equipment).
a Remove the entire hydraulic unit (see 38C, Antilock braking system, Brake hydraulic assembly:
Removal - Refitting, page 38C-2) .
19113
a The hydraulic pump (3) must be pressed against the
pressure modulation unit (4) .
Note:
When fitting a new braking computer, remember
to attach the interconnection fork (5) between the
pressure modulation unit and the braking computer.
a Refit the braking computer bolts on the pressure modulation unit.
a Torque tighten the braking computer bolts (3 Nm)
using the (Mot. 1608).
a Refit the entire hydraulic unit (see 38C, Anti-lock
braking system, Brake hydraulic assembly: Removal - Refitting, page 38C-2) .
115161
a Remove:
a Configure the speedometer index using the diagnostic tool (see Fault finding - Replacement of
components) (MR 366, 38C, Anti-lock braking system).
a Clear any faults stored by the braking computer.
- the braking computer bolts (1) on the pressure modulation unit,
a Carry out a road test to confirm the repair.
- the braking computer (2) .
REFITTING
a Do not clean the pressure modulation unit (4) .
a Always replace the braking computer bolts.
38C-23