Renault Clio Sasija PDF

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
X85
FEBRUARY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

CLIO III - Section 3ContentsPage
CLIO III - Section 3
Contents
Page
30A GENERAL INFORMATION 31A FRONT AXLE COMPONENTS
Brake circuit Operating Front brake calliper: Removal

diagram 30A-1 - Refitting 31A-6
Brake circuit Precautions for Front brake calliper: Repair 31A-10

repair 30A-2
Front brake calliper support:
Brake circuit Bleeding 30A-4 Removal - Refitting 31A-12
Brake circuit Tightening Front brake disc shield:

torque 30A-6 Removal - Refitting 31A-14
Brake fluid: Specifications 30A-8 Front brake disc: Removal -

Refitting 31A-15
Brake: Specifications 30A-9
Front brake disc: Description 31A-18
Steering: Tightening torque 30A-10
Hydraulic unit - master
Underbody height: cylinder brake pipe: Removal
Adjustment values 30A-11 - Refitting 31A-19
Front axle: Tightening torque 30A-14 Hydraulic unit - underbody
Front axle: Adjustment union brake pipe: Removal -
values 30A-18 Refitting 31A-21
Front axle: Adjusting 30A-23 Hydraulic unit - front left-

hand calliper brake pipe:
Rear axle: Tightening torque 30A-24 Removal - Refitting 31A-24
Rear axle: Adjustment values 30A-26 Hydraulic unit - front right-

hand calliper brake pipe:
Rigid brake pipe: Repair 30A-30 Removal - Refitting 31A-27
Front driveshaft hub carrier:

Removal - Refitting 31A-29
31A FRONT AXLE COMPONENTS Front hub carrier bearing:
Front brake pads: Removal -
Refitting 31A-1 Spring and front shock
absorber: Removal - Refitting 31A-39
Front brake hose: Removal -
Refitting 31A-4 Front driveshaft lower arm:
Contents
31A FRONT AXLE COMPONENTS 33A REAR AXLE COMPONENTS
Front driveshaft lower arm Rear drum bearing: Removal

ball joint: Check 31A-51 - Refitting 33A-29
Front axle sub-frame: Rear disc brake bearing:

Removal - Refitting 31A-53 Removal - Refitting 33A-30
Front anti-roll bar: Removal - Rear stub-axle carrier:

Refitting 31A-67 Removal - Refitting 33A-32
Complete rear axle: Removal

- Refitting 33A-37
33A REAR AXLE COMPONENTS
Rubber bushing: Adjustment 33A-1

35A WHEELS AND TYRES
Rear brake pads: Removal -
Refitting 33A-3 Wheel: Removal - Refitting 35A-1
Rear brake hose: Removal - Wheel: Balancing 35A-7

Refitting 33A-5
Tyres: Removal - Refitting 35A-10
Brake calipers: Repair 33A-6
Tyres: Repair 35A-15
Rear brake caliper: Removal
- Refitting 33A-8 Tyre inflation pressure:
Identification 35A-18
Rear brake calliper
mounting: Removal - Tyres: Identification 35A-20
Refitting 33A-10 Wheel rim: Identification 35A-21
Rear brake disc shield: Spare wheel winch: Removal
Removal - Refitting 33A-11 - Refitting 35A-22
Rear brake disc: Removal -
Refitting 33A-12
Rear brake disc: Description 33A-14 35B TYRE PRESSURE MONITOR

Rear brake lining: Removal -
Refitting 33A-15 SSPP: List and location of
components 35B-1
Rear brake cylinder:
Removal - Refitting 33A-17 Tyre pressure monitor
computer: Removal -
Rear brake drum: Removal - Refitting 35B-3
Refitting 33A-19
Pressure sensor: Removal -
Rear brake drum: Refitting 35B-5
Description 33A-21
Brake pipe: Removal -

Refitting 33A-22
Shock absorber: Removal -

Refitting 33A-24
Rear suspension spring:

Contents
36A STEERING ASSEMBLY 37A MECHANICAL COMPONENT CONTROLS
Steering rack: Removal - Manual gear shift control:

Refitting 36A-1 Adjusting 37A-1
Track rod: Removal - Master cylinder: Removal -

Refitting 36A-3 Refitting 37A-2
Axial ball joint linkage: Right-hand front calliper-

Removal - Refitting 36A-5 master cylinder brake
pipe:Removal - Refitting 37A-20
Steering column: List and
location of components 36A-7 Left-hand front calliper-
master cylinder brake pipe:
Steering column: Removal - Removal - Refitting 37A-22
Refitting 36A-9
Underbody union-master
Steering rack gaiter: cylinder brake pipe: Removal
Removal - Refitting 36A-13 - Refitting 37A-24
Bulkhead seal: Removal - Brake servo non-return
Refitting 36A-14 valve: Removal - Refitting 37A-26
Intermediate shaft: Removal Brake servo: Removal -
- Refitting 36A-15 Refitting 37A-32
Steering column adjustment Vacuum pump: Removal -
handle Removal - Refitting 36A-18 Refitting 37A-68
Steering wheel: Removal - Accelerator pedal: Removal -
Refitting 36A-22 Refitting 37A-69
Emergency brake
assistance: Function 37A-73
36B POWER ASSISTED STEERING Brake pedal: Removal -
Refitting 37A-74
Power assisted steering:
Function 36B-1 Brake pedal switch: Removal
- Refitting 37A-79
Power assisted steering rack:
List and location of Brake compensator:
components 36B-2 Removal - Refitting 37A-81
Power assisted steering rack: Brake compensator: Check 37A-83

Removal - Refitting 36B-3
Brake compensator:
Electric power assisted Adjustment 37A-87
steering computer:
Parking brake lever: Removal
Configuration 36B-10
- Refitting 37A-88
Parking brake lever:

Adjusting 37A-90
Clutch control: List and

location of components 37A-91
Clutch pedal: Removal -

Refitting 37A-92
Contents
37A MECHANICAL COMPONENT CONTROLS
Clutch pedal spring:

Clutch pedal switch:

Clutch circuit: Bleeding 37A-100
Clutch master cylinder:

Clutch circuit: Removal -

Refitting 37A-110
Gear control: List and

location of components 37A-118
Gear control unit: Removal -

Refitting 37A-122
Parking brake cables:

Brake servo: Check 37A-134
38C ANTI-LOCK BRAKING SYSTEM
Hydraulic assembly without

ESP: Removal - Refitting 38C-1
Hydraulic assembly with

ESP: Removal - Refitting 38C-8
Wheel speed sensor:

Removal - Refitting 38C-13
Yaw speed and transversal

acceleration sensor:
Removal - Refitting 38C-14
Braking computer: Removal -

Refitting 38C-16
GENERAL INFORMATION
Brake circuit Operating diagram 30A
« X » braking system with load-sensitive « X » braking system with ABS
compensator
108548
IMPORTANT
This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before 105586
removing them.
IMPORTANT
This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before
removing them.
30A-1
GENERAL INFORMATION
Brake circuit Precautions for repair 30A
I - SAFETY III - GENERAL RECOMMENDATIONS
When replacing brake pads, always replace the pads

1 - Advice to be followed before any operation on the other side as well.
For an operation requiring the use of a lift, follow the When replacing a disc, always replace the disc on the
safety advice (see Vehicle: Towing and lifting) (02A, opposite side.
Lifting equipment).
When replacing brake discs, you must replace the bra-
The brake regulation circuit must be free of all hydrau- ke pads.
lic and electrical faults.
In case of incorrect handling, the brake fluid can cause
serious injury and damage. Follow the manufacturer's WARNING
instructions for brake fluid.
In order not to damage the brake hose:
To prevent dust from entering the master cylinder re-
servoir and the brake circuit, the plug must be removed - do not tension the hose,
just before filling and closed immediately afterwards, - do not twist the hose,
- check that there is no contact with the surrounding
2 - Instructions to be followed during the operation components.
Do not press on the brake pedal during work on the
brake system.
If, during work on the brake system, any damage on IMPORTANT
any part is observed, it must be repaired before driving To avoid any accident, bring the pistons, brake pads
the vehicle again. and brake discs into contact by depressing the
Brake fluid is highly corrosive. Ensure any brake fluid brake pad several times.
spilt on parts of the vehicle is cleaned off.
Always replace the rigid brake pipe clips.
Use brake fluids that comply with the Renault standard
(see Precautions for repair) . Reminder:
Check the brake fluid levels in the braking circuit and - The pipes between the master cylinder, callipers and
the bleeding device. the hydraulic assembly are connected using threaded
unions with a metric thread.
Check that the pressure of the bleeding device is
between 1.5 bar and 2 bar. - 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 da-
maged by brake fluid with a cover.
2 - Instructions to be followed during the operation

Clean around the braking system with BRAKE CLEA-
NER (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products).
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
Do not allow friction materials to come into contact with

grease, oil or other lubricants and cleaning products
which are mineral oil based. 78491
30A-2
GENERAL INFORMATION
Brake circuit Precautions for repair 30A
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 stan-
dard (see Vehicle: Parts and ingredients for the re-
pairwork) (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 hy-
draulic and electrical faults,
- check that the pressure of the bleeding device is
between 1.5 bars and 2 bars.
30A-3
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 opera-
tion recommendations before carrying out any
repair (see 30A, General information, Brake cir-
cuit Precautions for repair, page 30A-2) .
This procedure must be applied after one of the fol-

lowing components has been removed or replaced:
- the master cylinder,
- the brake fluid,
- the hydraulic unit, 115993
- a rigid pipe, a Use locally produced containers to collect the used

brake fluid.
- a hose,
- the reservoir, Front and rear callipers:
- a calliper. - 2 washer fluid containers (1) (1 litre),
- 4 mm diameter transparent pipes (2) ,

WARNING
Switch off the vehicle ignition so as not to activate - 4 pipettes (3) (part no: 00 00 081 501),
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 compo-
nents, position a pedal press to limit the outflow
of brake fluid and prevent any air from entering
the master cylinder and the circuits downstream
of the master cylinder:
- hydraulic unit,
- pipes between the hydraulic unit and brake cal-
lipers,
- brake hoses,
- brake calliper.
Remove the pedal press before carrying out 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 30A
a Connect the brake circuit bleeding device (after a Remove the brake circuit bleeding device from
having received Renault approval) to the master cy- the master cylinder reservoir.
linder reservoir (see the instructions for the equip-
a Check pedal travel and resistance. If it is not correct,
ment).
finish bleeding the brake circuit with the help of a se-
a Pressurise the brake circuit. cond operator. Start the bleed operation by bleeding
the calliper that is the furthest away from the master
a Adjust the pressure to between 1.5 bar < P < 2 bar cylinder:
for 3 minutes to stabilise it in the braking circuit.
- 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 depen- a Top up the brake fluid level in the reservoir, if neces-
ding on the type of equipment used: sary. Check the sealing of the front and rear bleed
screws and ensure that the sealing covers are in pla-
- valve, ce (see 30A, General information, Brake circuit
- switch. Tightening torque, page 30A-6) .
a During a road test, trigger braking regulation to con-
a Fit the bleed containers to the four bleed screws of
firm that the brake pedal travel is correct.
the callipers.
a Clean off any traces of brake fluid on the vehicle
a Undo the calliper bleed screws: using BRAKE CLEANING PRODUCT (see Vehi-
- front left-hand, cle: 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
EQUIPMENT LEVEL E3 LEISURE or EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4 or EQT LEVEL EA5 or EQT LEVEL EAG
I - FRONT AND REAR BRAKES
Description Tightening
torque
(Nm)
Front calliper bleed screw 6.5
Rear calliper bleed screw 10
Front calliper inlet brake hose 17
Rear calliper inlet brake pipe 14
Brake hose on brake pipe 14
Front brake guide pin bolt 32
Calliper support bolt 105
Rear brake guide pin bolt 32
Disc mounting bolt 15
Brake cylinder mounting bolt 9
II - BRAKE CONTROL
torque
(Nm)
Brake servo mounting bolts 21
Master cylinder mounting nuts 50
Master cylinder outlet pipe 14
Mounting bolt securing the hydrau- 8

lic unit to its support
Hydraulic unit pipe unions 14
Parking brake control mounting 8

nuts
Bolts mounting hydraulic unit sup- 65

port on vehicle body
30A-6
GENERAL INFORMATION
Brake circuit Tightening torque 30A
EQUIPMENT LEVEL EAC or EQT LEVEL SPORT
I - FRONT AND REAR BRAKES
torque
(Nm)
Front calliper bleed screw 14
Rear calliper bleed screw 10
Front calliper inlet brake hose 27
Rear calliper inlet brake pipe 14
Brake hose on brake pipe 14
Front brake calliper bolt 160
Rear brake guide pin bolt 32
Front brake disc mounting bolt 21
Rear brake disc mounting bolt 15
II - BRAKE CONTROL
torque
(Nm)
Brake servo mounting bolts 21
Master cylinder mounting nuts 50
Master cylinder outlet pipe 14
Mounting bolt securing the hydrau- 8

lic unit to its support
Hydraulic unit pipe unions 14
Parking brake control mounting 8

nuts
Bolts mounting hydraulic unit sup- 65

port on vehicle body
30A-7
GENERAL INFORMATION
Brake fluid: Specifications 30A
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc bra-
kes (hollow pistons which conduct little heat, have a
low volume of fluid in the cylinder, sliding callipers avoi-
ding 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-8
GENERAL INFORMATION
Brake: Specifications 30A
Engine
D4F, K4J, K4M, M4R F4R

K9K
Front brakes (mm)
Outer diameter of calliper pistons 54 54 40
Disc diameter 260 280 312
Disc thickness (new) 22 24 28
Minimum disc thickness (1) 19.8 21.8 26
Maximum disc run-out 0.07
Brake pad thickness (including backplate) 17.4 18 17.4
Minimum pad thickness (including backplate) 8 6 8
Rear brakes (mm)
Outer diameter of calliper pistons 34 38
Internal drum diameter 203.2 //
Maximum internal drum diameter 204.4 //
Drum lining thickness (including mounting) (new) 5.5 //
Minimum drum lining thickness (including mounting) 2.4 //
Disc diameter 240 274
Disc thickness 8 11
Minimum disc thickness (1) 7 9.5
Maximum disc run-out 0.07
Disc lining thickness (including mounting) 15.8
Minimum disc lining thickness (including mounting) 7.5
(1) Brake discs cannot be reworked. If they are too

heavily worn or scratched they must be replaced.
30A-9
GENERAL INFORMATION
Steering: Tightening torque 30A
torque
(Nm)
Steering wheel mounting bolt 44
Mounting nuts for 21

the steering column
Intermediate shaft mounting bolt on 32

steering column
Universal joint bolt on the steering 24

rack
30A-10
GENERAL INFORMATION
Underbody height: Adjustment values 30A
I - MEASURING POINTS
138443
Radius under load:
- (R1) : Distance between the ground and the front
wheel shaft
139131
- (R2) : Distance between the ground and the rear
wheel shaft (W1) : Height between the ground and the rear cross
member bolt head
1 - Front height (W1)
2 - Rear height (W2)
109715
109716
30A-11
GENERAL INFORMATION
1 - Plate higher than the lift:
126087
Measure the heights (1) , (2) , (3) .

Example: (1) = 13 cm, (2) = 8 cm, (3) = 10 cm.
139130 Calculate the height Wx:
(W2) : Height between the ground and the shaft of the Wx = height (1) + height (3) - height (2)
rubber bush on the bearing Wx = 15 cm
II - MEASURING PROCEDURE 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

Measure the heights (1) , (2) , (3) .
Example: (1) = 8 cm, (2) = 10 cm, (3) = 4 cm.
Note:
Calculate the height Wx:
The value of Wx to be entered into the geometry
bench is the average of the W1 heights, right-hand Wx = height (1) + height (2) + height (3)
and left-hand and of the W2 heights, right-hand and
left-hand. Wx = 22 cm
III - VEHICLE IN RUNNING ORDER POSITION
Note: VODM (Vehicle in working order) position:
If the measuring points are located in empty space - Tank full,

(between the rails of the lift), use a bar. - Empty vehicle (without luggage, etc.).
30A-12
GENERAL INFORMATION
EQUIPMENT LEVEL E3 LEISURE or EQT LEVEL
EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or
EQT LEVEL EA4 or EQT LEVEL EA5 or EQT
LEVEL EAG
(W1) = 171 ± 13 mm
(W2) = 259 ± 16 mm
EQUIPMENT LEVEL EAC or EQT LEVEL SPORT,

and WITHOUT COMPLEMENT OF P
(W1) = 156 ± 5 mm
(W2) = 257 ± 16 mm

and EXTREME PACK COMP
(W1) = 148 +7-14mm
(W2) = 249 + 9-16mm
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-13
GENERAL INFORMATION
Front axle: Tightening torque 30A
109387
No. Description Tightening torque

(N.m)
(1) « Spring and shock absorber » assembly mounting bolt on body 21
(2) Lower arm rear bolt 105
(3) Sub-frame stud bolt 110
(4) Rear cross member bolt 105
(5) Anti-roll bar bearing mounting bolt on the sub-frame 21
(6) Radiator cross member front mounting bolt 105
(7) Calliper support bolt 105
(8) Bolt mounting the side reinforcement on the radiator cross member 21
(9) Bolt mounting the steering rack on the sub-frame 110
(10) Lower arm front bolt 70
30A-14
GENERAL INFORMATION
109388

(N.m)
(11) Shock absorber nut 62
(12) Anti-roll bar tie-rod ball joint nut 44
(13) Shock absorber base bolt 105
(14) Subframe tie-rod bolt 105
(15) Lower arm ball joint bolt 60
(16) Driveshaft nut 280
(17) Wheel bolts 105
(18) Track rod end nut 35
30A-15
GENERAL INFORMATION
30A-16
GENERAL INFORMATION
120785

(Nm)
(1) Anti-rolling linkage nut 80
(2) lower ball joint nut 60
(3) Hub carrier lower ball joint locking bolt 27
(4) Hub carrier upper nut 80
(5) Track rod end nut 37
(6) Shock absorber lower nut 105
(7) « spring - shock absorber » assembly bolt on the body 21
(8) Shock absorber nut 62
(9) Side stiffener bolt on the radiator cross member 21
(10) Lower arm bolt 70
(11) Acoustic tie-rod bolt 105
(12) Anti-roll bar bearing bolt on the subframe 21
(13) Brake calliper bolt 102 (170)
(14) Bearing assembly bolt on the hub-carrier 120
(15) Pivot lower ball joint holder assembly bolt 10
(16) Anti-roll bar upper nut on the shock absorber 44
(17) driveshaft nut 280
(18) Disc bolt 21
(19) Subframe tie-rod bolt 110
(20) Wheel bolt 140
30A-17
GENERAL INFORMATION
Front axle: Adjustment values 30A
I - PRELIMINARY OPERATIONS
Value Position of vehi-

Before checking the axles on the test bench, check the cle
tyre pressures (see 35A, Wheels and tyres, Tyre in-
4˚ 30’ ± 60’ Vehicle in running
flation pressure: Identification, page 35A-18) .
order
maximum right - left diffe-
rence = 30’
WARNING
The vehicle should be empty (no luggage or pas-
III - CAMBER
sengers on board) when the axle assembly values
are checked. Not adjustable
Make sure that the steering wheel is positioned
straight ahead during wheel alignment, such that
the angular position of the steering wheel is cor-
rectly aligned with the straight-ahead position of the
front wheels. The steering wheel being offset in
relation to the position of the wheels may result in
the vehicle being returned by the customer.
Position of vehicle: Vehicle in running order
Front in mm Rear in mm
Underbody W1: 171 ± 13 W2: 259 ± 16

height
93013

WARNING cle
Adjust the vehicle ground clearance in accordance
with the specifications before checking the geo- 0˚ 00’ ± 60’ Vehicle in running
metry of the wheels. If the ground clearance is not order
correct, adjust it by lowering or raising the body.
rence = 30’
II - CASTOR IV - PIVOT
Not adjustable Not adjustable
93012 93014
30A-18
GENERAL INFORMATION
VI - WHEEL ALIGNMENT

cle
9˚ 40’ ± 35’ Vehicle in running

order
rence = 30’
V - WHEEL ALIGNMENT: MEANING OF SYMBOLS
Toe-out: minus sign
93011
Value (for two wheels) Position of vehi-

cle
Toe-in: 0˚ 00’ ± 10’ Vehicle in running

order
93011
WARNING
Meaning of signs featured in this document, - = toe-
out.
Toe-in: plus symbol
93011-1
WARNING
Meaning of signs used in this document, + = toe-in.
30A-19
GENERAL INFORMATION
I - PRELIMINARY OPERATIONS II - CASTOR ANGLE
Not adjustable
Before checking the axles on the test bench, check the

Note:
are checked.
Make sure that the steering wheel is in the straight-
ahead position straight during wheel alignment
adjustment to avoid offsetting the angular position
of the steering wheel with the straight-ahead posi-
tion front wheels. The steering wheel being offset in 93012
Value Position of vehicle
5˚38’ ± 39’ Vehicle in running

WITHOUT COMPLEMENT OF P order
Maximum left - right diffe-
Position of vehicle: Vehicle in running order rence = 30’
III - CAMBER
Not adjustable
Underbody W1: 156 ± 5 W2: 257 ± 5
height
EXTREME PACK COMP
Underbody W1: 148+7-14 W2: 249+9-16

height 93013
-0˚59’ ± 30’ Vehicle in running

order
Maximum left - right diffe-
Note: rence = 30’
with the specifications before checking the geo-
metry of the wheels. If the ground clearance is not IV - PIVOT
correct, adjust it by lowering or raising the body. Not adjustable
30A-20
GENERAL INFORMATION
Toe-in: plus sign
93014 93011-1
Value Position of vehicle WARNING
-8˚57’ ± 40’ Vehicle in running Symbols used by RENAULT:

order
Maximum left - right diffe- - -: toe-out,
rence = 30’
- +: toe-in.
V - WHEEL ALIGNMENT: MEANING OF SYMBOLS

VI - WHEEL ALIGNMENT
Toe-out: minus sign

WITHOUT COMPLEMENT OF P
93011
93011
WARNING
Symbols used by RENAULT: Value (for two wheels) Position of vehicle
- -: toe-out, -0˚10’ ± 8’ Vehicle in running

- +: toe-in. order
30A-21
GENERAL INFORMATION
EXTREME PACK COMP
93011
Value (for two wheels) Position of vehicle
-0˚12’ ± 12’ Vehicle in running

order
30A-22
GENERAL INFORMATION
Front axle: Adjusting 30A
Essential equipment
steering wheel lock
Tightening torquesm
wheel alignment adjust- 53 N.m

ment lock nuts
I - ADJUSTMENT PREPARATION STAGE
VEHICLE WITH CARD

a
Note:
Throughout the axle assembly checking and
adjustment process:
121364
- the Renault Card must remain in the reader, a Loosen the wheel alignment adjustment lock nut (1)
- do not press the « START » button. .
a Turn the track rod sleeve (2) to the required value.
a After adjustment, torque tighten the wheel align-
ment adjustment lock nuts (53 N.m).
a Check the geometry (see Axle assemblies: Check)
.
2 - Castor angle
II - ADJUSTMENT OPERATION a Not adjustable.
1 - Wheel alignment 3 - Camber
a Set the wheels straight ahead. a Not adjustable.
a Lock the steering wheel using a steering wheel

lock. 4 - Pivot
a Adjust the wheel alignment by rotating the track rod a Not adjustable.
sleeves.
30A-23
GENERAL INFORMATION
Rear axle: Tightening torque 30A
109389
30A-24
GENERAL INFORMATION
Rear axle: Tightening torque 30A
109390
Mark Description Tightening torque

(Nm)
(1) Stub-axle (or drum) nut 175
(2) Calliper mounting bolt 105
(3) Guide pin bolt 32
(4) Bearing mounting bolt 62
(5) Shock absorber lower mounting bolt 105
Shock absorber upper mounting nut 21
(6) Brake pipe nut 14
(7) Bearing - rear axle mounting bolt nut 105
30A-25
GENERAL INFORMATION
Rear axle: Adjustment values 30A
I - PRELIMINARY OPERATIONS

-1˚ 10’ ± 25’ Vehicle in running order
III - WHEEL ALIGNMENT: MEANING OF SYMBOLS
WARNING
Toe-out: minus sign
are checked.
Make sure that the steering wheel is positioned
straight ahead during wheel alignment, such that
the angular position of the steering wheel is cor-
rectly aligned with the straight-ahead position of the
front wheels. The steering wheel being offset in
Front in mm Rear in mm 93011
Underbody W1: 171 ± 13 W2: 259 ± 16

height WARNING
Meaning of signs featured in this document, - = toe-
out.
WARNING
Adjust the vehicle ground clearance in accordance Toe-in: plus sign
metry of the wheels. If the ground clearance is not
II - CAMBER
Not adjustable
93011-1
WARNING
Meaning of signs used in this document, + = toe-in.
IV - WHEEL ALIGNMENT
93013 Not adjustable.
30A-26
GENERAL INFORMATION
93011-1
1 - Normal suspension

cle

order
2 - Reinforced suspension

cle

order
30A-27
GENERAL INFORMATION
I - PRELIMINARY OPERATIONS II - CAMBER
Not adjustable

Note:
are checked.
Make sure that the steering wheel is in the straight-
ahead position straight during wheel alignment
adjustment to avoid offsetting the angular position
of the steering wheel with the straight-ahead posi-
93013
tion front wheels. The steering wheel being offset in
the vehicle being returned by the customer. Value Position of vehicle
-1˚33’ ± 20’ Vehicle in running order
WITHOUT COMPLEMENT OF P
III - WHEEL ALIGNMENT: MEANING OF SYMBOLS
Front in mm Rear in mm Toe-out: minus sign

Underbody W1: 156 ± 13 W2: 257 ± 16
height
EXTREME PACK COMP
Underbody W1: 148+7-14 W2: 249+9-16 93011

height
WARNING
Symbols used by RENAULT:

- -: toe-out,
- +: toe-in.
Note:
metry of the wheels. If the ground clearance is not
30A-28
GENERAL INFORMATION
Toe-in: plus sign
93011-1
WARNING
Symbols used by RENAULT:

- -: toe-out,
- +: toe-in.
IV - WHEEL ALIGNMENT
Not adjustable
93011-1
Value (for two wheels) Position of vehicle
Toe-in: 0˚31’ ± 30’ Vehicle in running order
30A-29
GENERAL INFORMATION
Rigid brake pipe: Repair 30A
Tightening torquesm
brake pipe bolts 8 Nm
underbody unions 6 Nm
(female/male)
This procedure applies to copper pipes diameter 4.7

mm.
Note:
This procedure does not apply to:
- hybrid pipes (pipe + hose), 128666
- pipes with diameters 6 mm and 8 mm.
REPAIR
I - PIPE PREPARATION OPERATION

a
WARNING
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

128643
tube cutter (see Garage equipment catalogue).
128665
a Put the nuts or bolts on the pipe before forming the

rivets.
II - MAKING THE RIVETS
Note:
To make the rivets, fit the rivet press in a vice.
30A-30
GENERAL INFORMATION
a Fit the pipe in the rivet press (see Garage Equip-
ment Catalogue).
a Adjust the length of the pipe to be shaped.
a Torque tighten the press end piece(40 Nm).
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,
IV - PREPARATION OF THE PIPE BEFORE
- the rivet centring in relation to the pipe shaft.
BENDING
Note:
Impurities may spread inside the pipe while the
rivets are being made.
a Blow inside the pipe in both directions using a com-

pressed air gun.
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-31
GENERAL INFORMATION
128659
a Measure the dimensions (X3) (in mm) curve after
curve, between each curve radius « centre » (1) of
the old pipe.
30A-32
GENERAL INFORMATION
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 alternati-
vely 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-33
GENERAL INFORMATION
V - CHECKING BENDING VI - REFITTING THE PIPE
a
Note:
When refitting the rigid brake pipe:
- respect the original routing as much as possi-
ble,
- 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
128664 damage to the pipe. In order to avoid these con-
tacts, adjust the pipe routing by hand.
128670
a Check the out-of-roundness of the outer diameter at 128644
the centre of the curve radius (2) using a sliding cal-
a Torque tighten the brake pipe bolts (8 Nm).
liper (the out-of-roundness of the outer diameter is
correct if it is less than 10% flattening):
- nominal diameter of the pipe: 4.75 mm,
- minimum diameter after bending: 4.30 mm.
128646
a Torque tighten the underbody unions (female/ma-
le) (6 Nm).
30A-34
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting 31A
REFITTING
Tightening torquesm
I - REFITTING PREPARATION OPERATION
guide pin bolt 32 Nm
a Check the thickness of the pads (see 30A, General
information, Brake: Specifications, page 30A-9) .
When replacing brake pads, be sure to replace the
pads on the opposite side. a Replace any faulty parts.
a Clean the calliper mountings.
a Clean the callipers.
REMOVAL
a Push the piston.
a Always replace the guide pin bolts after each remo-
I - REMOVAL PREPARATION OPERATION
val.
Towing and lifting) . II - REFITTING OPERATION FOR PART
CONCERNED
a Unlock the steering column.
a Fit the pads, starting from the inside.
a Remove the front wheels (see 35A, Wheels and ty- a Tilt the calliper downwards to return it to its original
res, Wheel: Removal - Refitting, page 35A-1) . position.
a Refit the new guide pin bolt.
II - OPERATION FOR REMOVAL OF PART a Tighten to torque the guide pin bolt (32 Nm).
CONCERNED
a Secure the brake hose to the shock absorber.
WARNING
Do not twist the brake hose.
III - FINAL OPERATION

a Refit the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
IMPORTANT
Depress the brake pedal several times to bring
the pistons, brake pads and discs into contact.
108835
a Remove the lower guide pin bolt (1) while holding

the nut (2) .
a Unclip the brake hose (3) from the shock absorber.
a Tilt the calliper upwards.
a Remove the pads.
31A-1
REFITTING
Tightening torquesm
I - REFITTING PREPARATIONS OPERATION
wheel bolts 130 Nm
a Check the thickness of the brake pads (see 30A,
General information, Brake: Specifications, page
When replacing brake pads, be sure to replace the 30A-9) .
pads on the opposite side.
a Replace any faulty parts.
a Clean the brake callipers.
REMOVAL

Towing and lifting) (MR 392, 02A, Lifting equip-
ment).
a Remove the front wheels (see 35A, Wheels and ty-

res, Wheel: Removal - Refitting, page 35A-1) .
II - OPERATION FOR REMOVAL OF PART

CONCERNED
106080
a Push the pistons back until they are at the end of
their bores.
II - REFITTING OPERATION FOR PART

CONCERNED
a Install the new brake pads starting from the inside.
105892
a Remove:
- the brake pad retaining pins (1) ,
- the spring (2) ,
- the brake pads.
31A-2
105892
a Refit:
- the spring (3) ,
- the brake pad retaining pins (4) .
III - FINAL OPERATION.

a Torque tighten the wheel bolts (130 Nm).
IMPORTANT
31A-3
Front brake hose: Removal - Refitting 31A
CONCERNED
Essential equipment
pedal press
Tightening torquesm
brake hose on the calli- 17 Nm

per
brake hose on the union 14 Nm
108834
a Loosen the hose at the union (1) .
a Unclip the brake hose (2) from the shock absorber.

101707
a Loosen the hose at the calliper (3) .
a Remove the brake hose.
REMOVAL
I - REMOVAL PREPARATION OPERATION REFITTING

Towing and lifting) (MR 392, 02A, Lifting equip- I - REFITTING PREPARATIONS OPERATION
ment).
a
WARNING WARNING
Prepare for brake fluid outflow, to prevent Do not twist the brake hose, and set the wheels
damage to the mechanical parts and bodywork straight ahead as turning the steering wheel
around the braking system. increases the likelihood of the hose becoming
twisted.
a Fit the pedal press to the brake pedal to limit the
Make sure that there is no contact between the
outflow of brake fluid. brake hose and the surrounding components.
Note:
The hoses supplied as spare parts are encased
in a spring to prevent them from being twisted
during fitting.

CONCERNED
a Screw on the brake hose at the calliper end.
31A-4
Front brake hose: Removal - Refitting 31A
a Torque tighten the brake hose on the calliper (17
Nm).
a Place the female end of the brake hose on the retai-
ning lug of the shock absorber, without torsion
stress.
a Make sure that the end piece engages freely into the
bracket splines.
a Fit:
- the staple,
- the rigid pipe on the brake hose, making sure that
the hose does not twist when screwing on the rigid
pipe.
a Torque tighten the brake hose on the union (14
Nm).

a Remove the pedal press from the brake pedal.
a Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .
31A-5
Front brake calliper: Removal - Refitting 31A
CONCERNED
Essential equipment
pedal press
Tightening torquesm
guide pin bolts 32 Nm
brake hose 17 Nm
Note:
The callipers supplied as replacement parts are
pre-filled.
REMOVAL

a Position the vehicle on a two-post lift (see Vehicle: 108835
Towing and lifting) (MR 392, 02A, Lifting equip- a Unlock the brake hose (1) on the brake calliper.
ment).
a Remove:
WARNING - the two guide pin bolts (2) while holding the nuts (3)
,
Prepare for brake fluid outflow, to prevent
damage to the mechanical parts and bodywork - the brake calliper from the hose,
around the braking system.
- the brake pads.
outflow of brake fluid. REFITTING
a Unlock the steering wheel.
a Remove the front wheel on the side concerned (see I - REFITTING PREPARATIONS OPERATION
35A, Wheels and tyres, Wheel: Removal - Refit- a Check the condition of the gaiter and calliper piston
ting, page 35A-1) . (replace defective parts).
a Clean the backplate and the calliper.
a Push the piston back until it is at the end of its bore.
a Fit the pads, starting from the inside.
val.
WARNING
Do not twist the brake hose, and set the wheels
straight ahead as turning the steering wheel
increases the likelihood of the hose becoming
twisted.
brake hose and the surrounding components.
31A-6
CONCERNED
a Set the wheels straight ahead.
a Without using a tool, screw the calliper to the brake
hose as tightly as possible.
a Refit:
- the pads starting from the inside,
- the calliper,
- the new guide pin bolts.
a Torque tighten:
- the guide pin bolts (32 Nm),
- the brake hose (17 Nm).
WARNING
- Refasten the brake hose and wheel speed sen-
sor wiring if they have been unclipped.
- Do not twist the brake hose.

a Bleed the brake circuit partially if the compensation
reservoir is not completely emptied during the proce-
dure. If necessary, bleed the circuit completely (see
30A, General information, Brake circuit Blee-
ding, page 30A-4) .
a Check the brake fluid level.
IMPORTANT
a Refit the wheels (see 35A, Wheels and tyres,

31A-7
CONCERNED
Essential equipment
pedal press
Tightening torquesm
brake calliper mounting 170 Nm

bolts
brake hose mounting 25 Nm

bolts on the brake calli-
per
Note:
pre-filled.
REMOVAL
105892
I - REMOVAL PREPARATION OPERATION a Open the bleed screws (1) .

a Position the vehicle on a two-post lift (see Vehicle: a Remove:
ment). - the brake hose (2) on the brake calliper,
- the brake calliper mountings (3) ,
WARNING - the brake calliper,
- the brake pads.
damage to the mechanical parts and bodywork
REFITTING
outflow of brake fluid.
a Clean the calliper.
a Remove the front wheel on the side concerned (see
35A, Wheels and tyres, Wheel: Removal - Refit- a Check the condition of the gaiters and calliper pis-
ting, page 35A-1) . tons (replace any faulty parts).
a Push the pistons back until they are at the end of
their bores.
a Install the brake pads starting from the inside.

CONCERNED
a Refit:
- the brake calliper,
- the brake calliper mounting bolts.
a Torque tighten the brake calliper mounting bolts
(170 Nm).
31A-8
a Refit the brake hose.
WARNING
Refasten the brake hose and wheel speed sen-
sor wiring if they have been unclipped.
a Torque tighten the brake hose mounting bolts on

the brake calliper (25 Nm).
a Remove the pedal press.

a Partially bleed the brake circuit if the compensation
reservoir has not been completely emptied during
the operation. If necessary, bleed the circuit comple-
tely (see 30A, General information, Brake circuit
Bleeding, page 30A-4) .
IMPORTANT
Correctly attach the brake hose and ABS sensor
wiring.
a Refit the front wheel on the side concerned (see

35A, Wheels and tyres, Wheel: Removal - Refit-
ting, page 35A-1) .
31A-9
Front brake calliper: Repair 31A
II - REPAIR OPERATION FOR PART CONCERNED
Essential special tooling
Fre. 1190-01 Brake calliper piston return

tool.
Essential equipment
pedal press
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see Front axle assemblies: Precautions
for repair) .
81546
a Remove the piston using compressed air, making

WARNING sure to insert a wooden block between the calliper
Prepare for the flow of fluid, and protect the sur- and the piston to avoid damaging it. Any trace of im-
rounding components. pact on the end panel will render the piston unfit for
use.
REPAIR a Remove the dust seal.
I - REPAIR PREPARATION OPERATION

a Position the pedal press on the brake pedal to limit
the outflow of brake fluid.
a Remove:
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
- the front brake calliper (see 31A, Front axle com-
ponents, Front brake calliper: Removal - Refit-
ting, page 31A-6) .
81545
a Remove the rectangular section seal from the calli-

per groove with a round edged spring blade (feeler
gauge).
WARNING
The whole calliper must systematically be repla-
ced if there are any scratches in the calliper bore.
a Clean the parts using methylated spirit.
31A-10
Front brake calliper: Repair 31A
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
a Refit:
- the new rectangular section seal in the calliper
groove,
- the piston (after having smeared it with the grease
supplied in the repair kit) using the (Fre. 1190-01),
- the dust seal.
II - FINAL OPERATION.
a Refit:
- the brake calliper (see 31A, Front axle compo-
nents, Front brake calliper: Removal - Refitting,
page 31A-6) ,
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A-11
Front brake calliper support: Removal - Refitting 31A
CONCERNED
Tightening torquesm
calliper mounting bolts 105 Nm
REMOVAL

a Put the vehicle on a two-post lift (see Vehicle:
Towing and lifting) ;.
a Remove:
- the front wheels (see 35A, Wheels and tyres,
- the front brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) .
108836
a Remove:
- the two calliper mounting bolts (3) ,
- the calliper mounting.
REFITTING
a Clean the calliper mounting and the hub carrier.
a Coat the calliper mounting bolts with a FRENBLOC

type product before fitting them.
112340 a Always replace the guide pin bolts after each remo-
val.
a Remove the guide pin upper bolt (1) while holding
the nut (2) .
WARNING CONCERNED
Do not twist the brake hose. a Refit:
a Hang the brake calliper from the suspension spring. - the calliper mounting,
- the calliper mounting bolts.
a Torque tighten the calliper mounting bolts (105

Nm).
a Refit the calliper and the new upper guide pin bolt.
31A-12
Front brake calliper support: Removal - Refitting 31A
a Refit the brake pads (see 31A, Front axle compo-
page 31A-1) .
31A-13
Front brake disc shield: Removal - Refitting 31A
REMOVAL REFITTING

a Always replace the bearing whenever a hub is remo-
a Remove: ved.

Wheel: Removal - Refitting, page 35A-1) , II - REFITTING OPERATION FOR PART
CONCERNED
- the front brake pads (see 31A, Front axle compo- a Refit:
page 31A-1) , - the brake disc protector,
- the rivets.
- the calliper supports (see 31A, Front axle compo-
nents, Front brake calliper support: Removal -
Refitting, page 31A-12) , III - FINAL OPERATION.
a Refit:
- the brake disc (see 31A, Front axle components,
Front brake disc: Removal - Refitting, page 31A- - the hub carrier bearing (see 31A, Front axle com-
15) , ponents, Front hub carrier bearing: Removal -
Refitting, page 31A-33) ,
- the hub carrier (see 31A, Front axle components, - the hub carrier (see 31A, Front axle components,
Front driveshaft hub carrier: Removal - Refit- Front driveshaft hub carrier: Removal - Refit-
ting, page 31A-29) , ting, page 31A-29) ,
- the hub carrier bearing (see 31A, Front axle com- - the brake disc (see 31A, Front axle components,
ponents, Front hub carrier bearing: Removal - Front brake disc: Removal - Refitting, page 31A-
Refitting, page 31A-33) . 15) ,
page 31A-1) ,
CONCERNED
109886
a Drill out the brake disc protector mounting rivets (1) .
a Remove the brake disc protector.
31A-14
Front brake disc: Removal - Refitting 31A
CONCERNED
Tightening torquesm
disc mounting bolts 15 Nm
Brake discs cannot be reground. If there is excessive

scoring or wear, they will need to be replaced (see
30A, General information, Brake: Specifications,
page 30A-9) .
When replacing a brake disc, be sure to replace the
disc on the opposite side.
ke pads.
REMOVAL

ment).
108837
a Remove:
a Remove
Wheel: Removal - Refitting, page 35A-1) , - the two disc mounting bolts (1) ,
- the front brake pads (see 31A, Front axle compo- - the disc.
page 31A-1) ,
REFITTING
- the calliper mountings (see 31A, Front axle com-
ponents, Front brake calliper support: Removal
- Refitting, page 31A-12) . I - REFITTING PREPARATIONS OPERATION
a Clean the brake discs using a spray.

CONCERNED
a Refit:
- the disc,
- the two brake disc mounting bolts.
a Torque tighten the disc mounting bolts (15 Nm).

a Refit:
page 31A-1) ,
31A-15
31A-16
CONCERNED
Tightening torquesm
disc mounting bolts 21 Nm

page 30A-9) .
ke pads.
REMOVAL

ment).
106081
a Remove:
a Remove:
Wheel: Removal - Refitting, page 35A-1) , - the two disc mounting bolts (1) ,
- the front brake callipers (see 31A, Front axle com-
- the disc.
ting, page 31A-6) .
REFITTING

CONCERNED
a Refit:
- the disc,
- the two brake disc mounting bolts.
a Torque tighten the disc mounting bolts (21 Nm).
a Refit:
- the front brake callipers (see 31A, Front axle com-

ting, page 31A-6) ,

31A-17
Front brake disc: Description 31A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Remove the wheel (see 35A, Wheels and tyres,
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-9) .

Replace the discs if necessary (see 31A, Front axle
components, Front brake disc: Removal - Refitting,
page 31A-15) .
Refit the wheel (see 35A, Wheels and tyres, Wheel:
Removal - Refitting, page 35A-1) .
117057
Position the Palmer tool (1) to measure the disc thic-
kness.
31A-18
Hydraulic unit - master cylinder brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
brake pipe unions on 14 Nm

the hydraulic unit

the master cylinder
REMOVAL

Towing and lifting) .
112618
a Disconnect the battery (see Battery : Removal -
a Remove the soundproofing clips (1) .
Refitting) .
a Fit a pedal press on the brake pedal. a Move the soundproofing to one side in order to see
the pipes.
K4J or K4M or K9K

a Remove the battery (see Battery : Removal - Refit- CONCERNED
ting) .
a Remove:
- the front engine cover (if fitted to the vehicle),
- the air filter unit (see Air filter unit: Removal - Re-
fitting) .
114679
a Loosen the hydraulic unit brake pipe unions (2) .
31A-19
Hydraulic unit - master cylinder brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
K4J or K4M or K9K

a Refit the battery (see Battery : Removal - Refit-
ting) .
a Remove the brake pedal pedal press.

a Connect the battery (see Battery : Removal - Refit-
ting) .
114684
a Loosen the master cylinder brake pipe unions (3) .
a Remove the brake pipes between the hydraulic unit

and master cylinder.
REFITTING

CONCERNED
a Refit the brake pipes between the hydraulic unit and

master cylinder.
a Tighten to torque:
- the brake pipe unions on the hydraulic unit (14

Nm),
- the brake pipe unions on the master cylinder

(17 Nm).
II - FINAL OPERATION
a Refit:
- the bulkhead soundproofing material,
- the soundproofing clips,
fitting) ,
- the engine cover (if fitted to the vehicle).
31A-20
Hydraulic unit - underbody union brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
Essential equipment
refrigerant charging station
pedal press
Tightening torquesm

the hydraulic unit
underbody pipe unions 14 Nm
pipe union mounting 8 Nm

bolts
REMOVAL
I - REMOVAL PREPARATION OPERATION 112618

a Remove the two soundproofing clips (1) .
Towing and lifting) . a Move the soundproofing to one side in order to see
the pipes.
a Drain the coolant circuit using refrigerant charging
station.
a Fit a pedal press on the brake pedal.
Refitting) .
K4J or K4M or K9K

a Remove the battery (see Battery : Removal - Refit-
ting) .
a Remove:
fitting) .
112745
a Remove bolts (2) mounting the pipe unions on the
expansion valve.
a Separate the pipe unions from the expansion valve.
a Fit protective plugs in each opening.
31A-21
LEFT-HAND DRIVE
112744
a Fit hose clamps (3) .
a Disconnect the heater matrix hoses.

114680
CONCERNED
a Loosen the hydraulic unit brake pipe unions (7) .
a Remove the brake pipes between the hydraulic unit
and underbody unions.
REFITTING

a Replace the seals on the expansion valve pipes.
a Oil the seals using recommended air conditioning oil
to make fitting easier.

CONCERNED
a Refit the brake pipes between the hydraulic unit and
underbody unions.
a Refit the heat shield mountings.
101504 a Clip the brake pipes into position.
a Loosen the underbody brake pipe unions (4) . a Tighten to torque:
a Detach the brake pipes from the clips (5) . - the brake pipe unions on the hydraulic unit (14
a Remove the heat shield mountings (6) . Nm),
- the underbody pipe unions (14 Nm).

a Connect the heater matrix hoses.
a Remove the hose clamps.
a Fit the pipe unions on the expansion valve with the
new seal.
31A-22
LEFT-HAND DRIVE
a Refit the bolts mounting the pipe unions on the ex-
pansion valve.
a Tighten to torque the pipe union mounting bolts (8
Nm).
a Refit:
- the soundproofing on the bulkhead,
- the soundproofing mounting clips,
fitting) ,
K4J or K4M or K9K

ting) .
a Remove the brake pedal pedal press.

a Top up the coolant level.
a Fill the coolant circuit using refrigerant charging
station.
ting) .
31A-23
Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
brake pipe union on the 14 Nm

hydraulic unit
pipe union on the hose 14 Nm

bolts
REMOVAL

Towing and lifting) . a Move the soundproofing to one side in order to see
the pipes.
station.
a Fit a pedal press on the brake pedal.
Refitting) .
a Remove the front left-hand wheel (see 35A, Wheels
and tyres, Wheel: Removal - Refitting, page 35A-
1) .
K4J or K4M or K9K

a Remove the battery (see Battery : Removal - Refit-
ting) .
a Remove:
112745
fitting) .
a Remove the bolts (2) mounting the pipe unions on
the expansion valve.
a Fit protective plugs in each orifice.
31A-24
LEFT-HAND DRIVE
112744
a Fit hose clamps (3) .
a Disconnect the heater matrix hoses.

114681
CONCERNED
a Loosen the hydraulic unit brake pipe union (5) .
a Remove the brake pipe between the hydraulic unit

and front left-hand brake hose.
REFITTING


CONCERNED
a Refit the brake pipe between the hydraulic unit and

front left-hand brake hose.
a Clip the brake pipe into position.
114683
a Loosen the brake hose brake pipe union (4) . a Tighten to torque:
a Detach the brake pipe from the clips. - the brake pipe union on the hydraulic unit (14
Nm),
- the pipe union on the hose (14 Nm).

a Connect the heater matrix hoses.
a Remove the hose clamps.

a Fit the pipe unions on the expansion valve with new
seals.
31A-25
LEFT-HAND DRIVE
a Refit the bolts mounting the pipe unions on the ex-
pansion valve.
Nm).
a Refit:
- the soundproofing on the bulkhead,
fitting) ,
- the front engine cover (if fitted to the vehicle).
K4J or K4M or K9K

ting) .

a Top up the coolant level.
a Fill the coolant circuit using refrigerant charging
station.
a Refit the front left-hand wheel (see 35A, Wheels
1) .
ting) .
31A-26
Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
brake pipe union on the 14 Nm

hydraulic unit
pipe union on the hose 14 Nm

bolts
REMOVAL
a Put the vehicle on a two-post lift (see Vehicle: a Remove the soundproofing clips (1) .
a Move the soundproofing clips to one side in order to
see the pipes.
station.
a Fit a pedal press on the brake pedal. a Remove the coolant circuit pipe mounting nut (2) .
Refitting) .
a Remove:
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
- the front engine cover (if fitted to the vehicle).
112745
a Remove bolts (3) mounting the pipe unions on the

expansion valve.
a Fit protective plugs in each opening.
31A-27
Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED


CONCERNED
a Refit the brake pipe between the hydraulic unit and

front left-hand brake hose.
a Clip the brake pipe.
- the brake pipe union on the hydraulic unit (14

Nm),
114683
- the pipe union on the hose (14 Nm).
a Loosen the brake pipe union (3) .
a Detach the brake pipe from the clips.
a Fit the pipe unions on the expansion valve with new

seals.
a Refit the expansion valve pipe union mounting bolts.

Nm).
a Refit the bulkhead soundproofing.
a Refit:

114682
a Loosen the hydraulic unit brake pipe union (4) . a Fill the coolant circuit using tool refrigerant char-
a Remove the brake pipes between the hydraulic unit ging station.
and front left-hand brake hose.
a Refit the front right-hand wheel (see 35A, Wheels
1) .

ting) .
31A-28
Front driveshaft hub carrier: Removal - Refitting 31A
Rou. 604-01 Hub locking tool.
Tav. 1420-01 Screw jack for tools Tav.

1420, Tav.1050-04 , Tar.
1454, Tar. 1850.
Tav. 1050-04 Universal driveshaft pusher

tool (back-plate and claws,
without jack).
Tav. 476 Ball joint extractor.
Tightening torquesm
shock absorber lower 105 Nm

bolts
lower ball joint bolt 60 Nm
track rod end nut 35 Nm
hub nut 280 Nm
REMOVAL

a Remove:
page 31A-1) ,
Front brake disc: Removal - Refitting, page 31A-
15) .
31A-29
II - OPERATION FOR REMOVAL OF PART 604-01 ,
CONCERNED
- the track rod end nut (3) ,
- the lower ball joint bolt (4) ,
- the bolt (5) from the ABS wiring bracket,
- the lower bolts (6) from the shock absorber.
a Separate the driveshaft from the hub carrier using

the (Tav. 1420-01) and (Tav. 1050-04), if necessary.
112866
112619
a Extract the track rod end using the (2) Tav. 476 .
a Remove the lower arm ball joints.
a Remove the front driveshaft hub carrier.
112342
REFITTING
a Unclip the ABS sensor (1) on the hub carrier.

WARNING CONCERNED
In order to prevent irreversible damage to the a Refit the front driveshaft hub carrier.
front hub bearing:
a Refit:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground. - the shock absorber lower bolts,
- Do not place the vehicle with its wheels on the - the bolt to the ABS wiring bracket,
ground when the driveshaft has been loosened
or removed. - the lower ball joint bolt,
a Remove: - the track rod end nut,
- the hub nut (2) using the (Hub locking tool) Rou. - the hub nut.
31A-30
113735
a Check that the bush is correctly positioned on the

lower arm ball joint.
a Clip the ABS sensor onto the hub carrier.
a Torque tighten:
- the shock absorber lower bolts (105 Nm),
- the lower ball joint bolt (60 Nm),
- the track rod end nut (35 Nm),
- the hub nut (280 Nm), using the (Rou. 604-01).
a Refit:

15) ,


page 31A-1) ,

31A-31
REFITTING
Tightening torquesm
bolt mounting the shock 105 Nm CONCERNED
absorber on the hub
a Refit:
carrier
- the hub carrier onto the shock absorber,
- the bolt mounting the shock absorber on the hub
REMOVAL
carrier.
a Torque tighten the bolt mounting the shock ab-
sorber on the hub carrier (105 Nm).
ment).
a Refit the hub carrier/shock absorber assembly (see
a Remove the hub carrier/shock absorber assembly
Hub carrier-shock absorber assembly: Removal
(see Hub carrier-shock absorber assembly: Re-
- Refitting) .
moval - Refitting) .

CONCERNED
116774
a Remove:
- the bolt (1) mounting the shock absorber on the
hub carrier,
- the hub carrier.
31A-32
Front hub carrier bearing: Removal - Refitting 31A
CONCERNED
WARNING
In order to prevent irreversible damage to the front

hub bearing:
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 Remove:
nents, Front brake pads: Removal - Refitting, 20786
page 31A-1) ,
a Remove:
nents, Front brake calliper support: Removal - - the hub, with the press, applying pressure with a 35
Refitting, page 31A-12) , mm diameter tube,
- the brake disc (see 31A, Front axle components, - the circlip.
15) ,
- the hub carrier (see 31A, Front axle components,
Front driveshaft hub carrier: Removal - Refit-
ting, page 31A-29) .
101230
a Remove the internal bush from the hub using a

jawed extractor.
a Place the extractor jaws in the groove of the internal
bush.
31A-33
CONCERNED
20787
a Remove the bearing, applying pressure to the inner
bush with a 46 mm diameter tube 113759
a Refit the sensor holder.
REFITTING a Position the sensor holder at (X) = 35˚ ± 5˚ from ver-
tical. This position corresponds to the centre of the
housing.
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.
WARNING
To ensure that the wheel speed sensor works
properly, do not mark the sensor target on the
bearing.
WARNING
Do not press the bearing's inner bush so as to
avoid damaging the bearing (very high shrink-fit-
ting force).
20788
a Apply pressure to the outer bush with a tube with an
external diameter of 70 mm.
31A-34
15) ,
page 31A-1) ,
101933
a Refit the circlip.
20789
a Refit the hub using a tube with an outer diameter of

60 mm.
a Refit:
- the hub carrier (see 31A, Front axle components,

Front driveshaft hub carrier: Removal - Refit-
ting, page 31A-29) ,
31A-35
II - REMOVAL OPERATION FOR PART
CONCERNED
Tightening torquesm
hub-bearing assembly 120 Nm

bolts
REMOVAL

a Remove:
- the front wheel concerned (see 35A, Wheels and
- the hub carrier/shock absorber assembly concer-
ned (see Hub carrier-shock absorber assembly:
Removal - Refitting) .
- the brake disc concerned (see 31A, Front axle
components, Front brake disc: Removal - Refit-
120771
WARNING
a Remove:
In order to prevent irreversible damage to the
front hub bearing: - the bolts (1) from the hub carrier « hub - bearing »
assembly,
the wheels are on the ground. - the « hub - bearing » assembly.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened
or removed.
120698
a Fit an extractor with jaws (2) , to the « hub -

bearing » assembly.
a Refit the ears (3) of the bearing section of the « hub

- bearing » assembly to the jaws of the extractor.
31A-36
REFITTING

a It is essential to check the condition of the hub surfa-
ce before refitting the bearing.
a Replace the hub if it is damaged.
a Clean the hub surfaces in contact with the new bea-
ring.
WARNING
To ensure that the wheel speed sensor works
properly, do not mark the sensor target on the
bearing.

CONCERNED
120696
a Refit the hub (4) , using the press, by applying pres-
sure to the hub (4) using a tube with an outer diame-
ter of between 40 and 44 mm.
a Activate the hydraulic jack to separate the hub from
the bearing.
120697
a Position the hub (4) on the press body and offer up
the new bearing (6) to the hub.
a Apply pressure to the inner bearing bush using a
tube (5) with an outer diameter of between 57 and
63 mm, ensuring that the assembly is correctly cen-
tred.
101230
a Extract the internal bush from the hub using an ex-
tractor with jaws and a press. Note:
a Place the extractor jaws in the neck of the inner It is essential that the assembly is centred cor-
bush. rectly to prevent the hub or bearing from being
damaged.
a Activate the hydraulic jack to fit the bearing onto the

hub.
31A-37
a Refit:
- the « hub - bearing » assembly to the hub-carrier
assembly,
- the « hub - bearing » assembly bolts.
a Torque tighten the hub-bearing assembly bolts
(120 Nm).
III - FINAL REFITTING OPERATION

a Refit:
15) ,
- the hub carrier/shock absorber assembly concer-
ned (see Hub carrier-shock absorber assembly:
- the front wheel concerned (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
31A-38
Spring and front shock absorber: Removal - Refitting 31A
CONCERNED
Essential equipment
spring compressor
spanner for shock absorber rod nut
Tightening torquesm
shock absorber rod nut 62 Nm
shock absorber turret 21 Nm

bolts

mounting bolts
anti-roll bar tie rod ball 44 Nm

joint nut
shock absorber cup 8 Nm

cover nut
112052
REMOVAL a Remove the shock absorber cup cover nut (1) .

a Unclip the shock absorber cup cover at (2) .
I - REMOVAL PREPARATION OPERATION a Remove the shock absorber cup cover (3) .
ment).
Refitting) (MR 392, 80A, Battery).
a Remove:
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 393, 56A, Exterior equi-
pment).
31A-39
112049 112051
a Unclip: a Remove:
- the brake hose,
- the bolts (7) from the shock absorber turret,
- the wheel speed sensor.
- the spring-shock absorber unit.
a Remove:
a Place the appropriate cups on the spring compres-
- the hose retaining bracket bolt (4) , sor and position the assembly on the spring.
- the upper nut (5) from the anti-roll bar tie rod ball
a Detach the spring from the cups by compressing the
joint,
spring.
- the shock absorber lower mounting studs (6) .
a Suspend the hub carrier.
96049
a Remove the shock absorber rod nut using the span-

ner for shock absorber rod nut.
31A-40
a Separate the components which make up the
spring-shock absorber unit.
REFITTING

a
Note:
When removing/refitting springs, you must not
strike the springs as this could damage their sur-
face treatments.
a Always replace the shock absorber rod nut and the

upper lock nut of the anti-roll bar tie-rod ball joint.

CONCERNED
95435
a Fit the spring compressor in the vice.
Note:
When replacing the spring for easier fitting,
ensure that the positioning and orientation of the
spring and the tool cups are correct.
31A-41
102201
a Insert the spring in the neck of the cup.
31A-42
a Remove the spring compressor.
a Refit the spring-shock absorber unit.
a Refit:
- the spring-shock absorber unit,
- the shock absorber turret bolts.
a Torque tighten the shock absorber turret bolts (21

Nm).
a Refit:
- the lower mounting bolts of the shock absorber,
- the new upper nut of the anti-roll bar tie-rod ball

joint,
- the hose retaining bracket bolt,
a Torque tighten:
101939
a Respect the order and direction of fitting for the - the shock absorber lower mounting bolts (105
constituent parts. Nm),
- the anti-roll bar tie rod ball joint nut (44 Nm).
Note:
Ensure the revolving stop is correctly orientated WARNING
to make refitting easier. Do not twist the brake hose.
a Fasten the brake hose.
a Fit the wheel speed sensor.
a Refit the shock absorber cup cover.
a Clip on the shock absorber cup cover.
a Refit the nut of the shock absorber cup cover.
a Torque tighten the shock absorber cup cover nut

(8 Nm).
a Refit:

pment).
96049-1
a Torque tighten the shock absorber rod nut (62 Wheel: Removal - Refitting, page 35A-1) .
Nm).
a Decompress the spring. ting) (MR 392, 80A, Battery).
31A-43
REFITTING
Tightening torquesm
bolt mounting the shock 105 Nm CONCERNED
absorber on the hub
a Refit:
carrier
- the shock absorber onto the hub carrier,
- the bolt mounting the shock absorber on the hub
REMOVAL
carrier.
a Torque tighten the bolt mounting the shock ab-
sorber on the hub carrier (105 Nm).
ment).
a Refit the hub carrier/shock absorber assembly (see
a Remove the hub carrier/shock absorber assembly
Hub carrier-shock absorber assembly: Removal
(see Hub carrier-shock absorber assembly: Re-
- Refitting) .
moval - Refitting) .

CONCERNED
116774
a Remove:
- the bolt (1) mounting the shock absorber on the
hub carrier,
- the shock absorber.
31A-44
Front driveshaft lower arm: Removal - Refitting 31A
CONCERNED
Essential equipment
component jack
safety strap(s)
Tightening torquesm
front mounting stud on 70 Nm

the lower arm of the
sub-frame
rear mounting bolt on 105 Nm

the lower arm of the
sub-frame
lower ball joint stud 62 Nm
radiator cross member 105 Nm

bolts
side reinforcement lower 21 Nm 112864

bolts
a Remove:
- the side stiffener lower bolts (1) ,
WARNING - the bumper lower mounting bolts (2) ,
Do not use the lower arm for support with a lifting - the radiator cross member mounting bolt (3) ,
system.
- the radiator cross member,
- the lower ball joint stud (4) .
a Remove the lower ball joint.
REMOVAL

ment).

a Strap the cooling radiator by the cooling radiator top

hose and the bonnet opening striker plate.
a Remove:
- the wheel arch protector (see Front wheel arch

liner: Removal - Refitting) (MR 393, 55A, Exterior
protection),
- the engine undertray.
31A-45
- the lower ball joint into its housing.
108829
a Position the component jack under the sub-frame. 113735
a
a Remove:
- the lower arm front and rear mounting bolts (5) , WARNING
Check that the bush is correctly positioned on the
- the lower arm.
REFITTING a Remove the component jack.

a Always replace the sub-frame and arm mounting
bolts after each removal.
a Leave the component jack under the sub-frame.
WARNING
It is essential to place a 10 mm thick shim
between the radiator cross member and the sub-
frame. Centre the radiator cross member pin in
the sub-frame hole at the level of the lower arm
front mounting, to torque tighten the radiator
cross member mountings.
a Position the lower ball joint bolt head so that it faces

the front of the vehicle.

CONCERNED
a Refit:
- the lower arm,
- the lower arm front and rear mounting bolts,
31A-46
- the wheel arch protector (see Front wheel arch
liner: Removal - Refitting) (MR 393, 55A, Exterior
protection).
a Check the values of the axle assemblies (see 30A,
General information, Front axle: Adjustment va-
lues, page 30A-18) .
107304
WARNING
When refitting, position the lower arm below the
sub-frame rear mounting bolt head (H) = 6 mm
to tighten the rubber bushes freely.
a Position the component jack in contact with the

sub-frame rear mounting bolt head.
a Lower the component jack by (H) = 6 mm.
a Rest the lower arm ball joint (6) on the component
jack without adjusting the settings.
a In this position, tighten to torque:
- the front mounting stud on the lower arm of the
sub-frame (70 Nm),
- the rear mounting bolt on the lower arm of the
sub-frame (105 Nm)
a Remove the component jack.
a Torque tighten the lower ball joint stud (62 Nm).
a Refit the radiator cross member with 10 mm shims.
a Torque tighten the radiator cross member bolts
(105 Nm).
a Refit the side reinforcement lower bolts.
a Torque tighten the side reinforcement lower bolts
(21 Nm).

a Remove the safety strap(s) from the cooling radia-
tor between the cooling radiator top hose and the
bonnet opening striker panel.
a Refit:
- the engine undertray,
31A-47
CONCERNED
Essential equipment
component jack
Tightening torquesm
front bolt mounting the 70 Nm

lower arm on the sub-
frame
rear bolt mounting the 105 Nm

frame
bolts between the lower 110 Nm

arm and the hub carrier
hub carrier ball joint bolt 27 Nm
anti-roll tie-rod nuts 80 Nm
116771
REMOVAL
a Remove the nuts (1) from the anti-roll tie rod.

ment).
a Attach the cooling radiator by the radiator top hose
and the bonnet opening striker plate.
a Remove the radiator mounting cross member (see
Radiator support cross member: Removal - Re-
fitting) (MR 393, 41A, Front lower structure).
116772
a
Note:
Do not fit the component jack against the brake
disc.
Engage the driveshaft using a component jack.

a Remove the anti-roll tie-rod.
31A-48
REFITTING

a Always replace the driveshaft lower arm bolts after
each removal.

CONCERNED
a Refit:
- the front driveshaft lower arm,
- the lower arm rear bolt on the sub-frame,
- the front bolt between the front driveshaft interior
arm and the hub carrier.
116777
a Remove the bolts (4) from the hub carrier.
107304
a
WARNING
To tighten the rubber bushes freely, position the
lower arm below the head of the rear bolt on the
sub-frame (H) = 6 mm.
a Lower the component jack by (H) = 6 mm.

a In this position, tighten to torque:
- the front bolt mounting the lower arm on the
116778
sub-frame (70 Nm),
a Fit a component jack (5) under the sub-frame to - the rear bolt mounting the lower arm on the
secure the sub-frame. sub-frame (105 Nm).
a Remove: a Remove the component jack.
- the bolts (6) from the lower arm,

- the lower arm.
31A-49
116777
a Torque tighten:
- the bolts between the lower arm and the hub
carrier (110 Nm) (7) ,
- the hub carrier ball joint bolt (27 Nm) (8) .
a Engage the driveshaft using a component jack.
a Refit the linkage between the lower arm and the hub
carrier.
a Torque tighten the anti-roll tie-rod nuts (80 Nm).

a Refit the radiator mounting cross member (see Ra-
diator support cross member: Removal - Refit-
ting) (MR 393, 41A, Front lower structure).
a Detach the radiator by the radiator top hose and the
bonnet opening striker plate.
a Check the values of the axle assemblies (see 30A,
General information, Front axle: Adjusting, page
30A-23) .
31A-50
Front driveshaft lower arm ball joint: Check 31A
CHECKING 2 - Checking the fitting of the front driveshaft lower
arm ball joint
CHECKING THE FRONT DRIVESHAFT LOWER

ARM BALL JOINT
ment).
1 - Checking the condition of the front driveshaft

lower arm ball joint gaiter
a Check:
- the gaiter crimping on the front driveshaft lower
arm ball joint,
- that the front driveshaft lower arm ball joint gaiter is
not torn.
If the front driveshaft lower arm ball joint gaiter is in
poor condition and not crimped, replace the front dri-
veshaft lower arm ball joint (see Front driveshaft
lower arm ball joint: Removal - Refitting) .
113735
a Check:
- that the "lower arm ball joint-lower arm bolt-hub
carrier" assembly is correctly positioned,
- the correct positioning of the ring (1) on the front
driveshaft lower arm ball joint,
- the tightening torque (see 30A, General informa-
tion, Front axle: Tightening torque, page 30A-
14) .
If the front driveshaft lower arm ball joint is not fitted
correctly, replace the front driveshaft lower arm ball
joint (see Front driveshaft lower arm ball joint:
31A-51
Front driveshaft lower arm ball joint: Check 31A
3 - Checking the front driveshaft lower arm ball
joint clearance
117494
a Check that there is no play in the front driveshaft
lower arm ball joint:
- from a position underneath the vehicle,
- using both hands, hold the front driveshaft lower
arm as close as possible to the wheel,
- push downwards several times.
If there is play in the front driveshaft lower arm ball
joint, replace the front driveshaft lower arm ball joint
(see Front driveshaft lower arm ball joint: Remo-
val - Refitting) .
31A-52
Front axle sub-frame: Removal - Refitting 31A
REMOVAL
Tav. 476 Ball joint extractor. I - REMOVAL PREPARATION OPERATION

Essential equipment Towing and lifting) (02A, Lifting equipment).
steering wheel lock a Remove the front wheels (see 35A, Wheels and ty-
component jack
a Strap the cooling radiator by the cooling radiator top
safety strap(s) hose and the bonnet opening striker plate.

Tightening torquesm CONCERNED
sub-frame linkage bolt 105 Nm a Lift the floor carpet to access the universal joint bolt.
rear cross member bolt 105 Nm
bolts to the subframe 105 Nm

tie-rod
engine tie-bar bolt on 105 Nm

the gearbox
lower ball joint studs 60 Nm
front bolts mounting the 70 Nm

frame
rear bolt mounting the 105 Nm

lower arm on the sub- 113091
frame a Remove the universal joint cover (1) (do not keep).
radiator cross member 105 Nm a Set the wheels straight ahead.
bolts
a Position the steering wheel lock.
anti-roll bar linkage ball 44 Nm
joint nuts
track rod end nuts 35 Nm
side stiffener bolts 21 Nm
universal bolt joints 24 Nm
WARNING
Do not use the lower arm for support with a lifting
system.
31A-53
113092
a Remove the universal joint bolt (2) (do not keep),
WARNING
Tilt the universal joint to detach it from the pinion;
112049
do not pull out the intermediate shaft.
a Remove:
a Remove the universal joint from the steering rack.
- the wheel arch (see Front wheel arch liner: Re-
moval - Refitting) protectors (3) (55A, Exterior
protection),
a Unclip the wheel speed sensors (4) in the hub car-
rier.
a Remove:
- the track rod end nuts (5) ,
- the anti-roll bar tie-rod upper ball joint nuts (6) .
31A-54
JH3 or JR5
108831
a Remove the bolt (11) from the engine tie-bar on the
gearbox.
112864
a Loosen the bolt (12) on the engine tie-bar retaining
a Remove: bracket in order to be able to turn the retaining brac-
- the lower bumper bolts (7) , ket.
- the side stiffener lower bolts (8) ,

- the radiator cross member bolts (9) ,
- the radiator cross member,
- the lower ball joint stud (10) .
112619
a Remove:
- the track rod end using the (Tav. 476) (1) ,
- the anti-roll bar tie-rod upper ball joints.
31A-55
DP0 TL4
112879 113724
a Remove the mounting bolt (11) from the engine tie- a Remove the engine tie-bar bolt (11) .
bar on the gearbox.
a Loosen the bolt (12) on the engine tie-bar retaining
bracket in order to be able to turn the tie-bar.
a Fit the component jack underneath the subframe.
a Strap the subframe to the component jack.
a Remove the lower arm ball joints.
31A-56
a Unclip the xenon bulb position sensor wiring (if fitted
to the vehicle).
a Remove the sub-frame.
112871
a Remove:
- the rear cross member bolts (13) ,
- the rear cross member,
- the subframe bolts (14) on the body,
- the side reinforcements (15) .
a Lower the subframe by approximately 5 cm using

the component jack.
112872
a Disconnect the oxygen sensor connector (16) .

a Unclip the wiring (17) from the oxygen sensor.
a Disconnect (if fitted to the vehicle):
- the connector on the xenon bulb position sensor,
- the xenon bulb position sensor wiring harness con-
nector under the wheel arch.
31A-57
Subframe without xenon bulb
108820
31A-58
Subframe with xenon bulb
115062
a Remove the subframe fittings. a Clip on the xenon bulb position sensor wiring har-
ness (if fitted to the vehicle).
REFITTING a Connect (if fitted to the vehicle):
- the connector on the xenon bulb position sensor,
I - REFITTING PREPARATION OPERATION - the xenon bulb position sensor wiring connector
a Always replace the following after each removal under the wheel arch.
operation: a Clip the wiring to the oxygen sensor.
- the anti-roll bar link rod brake nuts, a Connect the oxygen sensor connector.
- the universal joint bolt and cam nut. a Fit the sub-frame to the body.
a Degrease the contact surface areas of the subframe a Refit:
and the body using SURFACE CLEANER (see Ve-
hicle: Parts and ingredients for the repairwork) - the rear cross member,
(04B, Consumables - Products). - the subframe and cross member bolts to the body,
- the subframe tie-rod bolts with the side reinforce-
II - REFITTING OPERATION FOR PART ments.
CONCERNED
a Refit the subframe equipment.
WARNING
a Degrease the surfaces of the body which are in con- Be sure to follow the subframe tightening order.
tact with the sub-frame and the cross member using
surface cleaner. a Tighten to torque and in order:
a Position the subframe using component jack. - the sub-frame linkage bolt (105 Nm),
31A-59
- the rear cross member bolt (105 Nm),
- the bolts to the subframe tie-rod (105 Nm).
a Remove the safety strap(s) and the component
jack.
107304
WARNING
When refitting, position the lower arm below the
sub-frame rear mounting bolt head (H) = 6 mm
to tighten the rubber bushes freely.
a Place the component jack against the subframe

rear bolt head.
113735 a Lower the component jack by (H) = 6 mm.
a a Rest the lower arm ball joint (18) on the component
jack without adjusting the settings.
WARNING
Check that the bush is correctly positioned on the a In this position, tighten to torque:
- the front bolts mounting the lower arm on the
subframe (70 Nm)
a Refit:
- the rear bolt mounting the lower arm on the
- the engine tie-bar bolt on the gearbox,
subframe (105 Nm).
- the lower ball joints in the hub carrier,
- the lower ball joint bolts.
WARNING
- the engine tie-bar bolt on the gearbox (105 Nm), A shim 10 mm thick must be placed between the
- the lower ball joint studs (60 Nm). radiator cross member and the sub-frame. Cen-
tre the pin of the radiator cross member in the
sub-frame opening at the level of the front lower
ar m mounting, to torque tighten the radiator
cross member mountings.
a Refit the radiator cross member with 10 mm shims.

a Torque tighten the radiator cross member bolts
(105 Nm).
a Refit:
- the ball joints and the nuts of the anti-roll bar link
rod upper ball joints,
- the ball joints and the track rod end nuts.
31A-60
a Clip: a Tighten to torque:
- the wheel speed sensors, - the side stiffener bolts (21 Nm),
- the xenon bulb position sensor tie-rod (if fitted to - the universal bolt joints (24 Nm).
the vehicle). a Refit the floor carpet.
- the anti-roll bar linkage ball joint nuts (44 Nm), Note:
- the track rod end nuts (35 Nm). Check that the floor carpet fits under the accele-
rator pedal end-stop.
a Refit:
- the lower bolts on the bumper,
- the side reinforcement lower bolts,
a Remove the safety strap(s) from the cooling radia-
- the engine undertray, tor between the cooling radiator top hose and the
bonnet opening striker panel.
- the wheel arch protectors (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec- a Refit the front wheels (see 35A, Wheels and tyres,
tion), Wheel: Removal - Refitting, page 35A-1) .
- the new bolt and new nut of the universal joint. a Check the values of the axle assemblies (see 30A,
General information, Front axle: Adjustment va-
a Set the wheels straight ahead. lues, page 30A-18) .
a It is essential to initialise the discharge bulb system
(if fitted to the vehicle) (see Fault finding - Configu-
ration and programming (80B, Headlights).
104020
a Ensure that the universal joint nut and bolt are fitted
the right way round.
WARNING
Do not separate the two sliding parts of the inter-
mediate shaft.
a Refit:
- the universal joint,
- the new universal joint bolt,
- the new universal joint nut.
a Pretighten the universal joint nut and bolt.
a Pull the intermediate shaft to make sure that the bolt
is present in the neck.
31A-61
Essential special tooling CONCERNED
Tav. 476 Ball joint extractor. a Lift the floor carpet to access the universal joint bolt.
Essential equipment
steering wheel lock
component jack
safety strap(s)
Tightening torquesm
sub-frame linkage bolt 105 Nm
rear cross member bolt 105 Nm
bolts to the subframe 105 Nm 113091

tie-rod a Remove the universal joint cover (1) (do not keep).
bolts securing the 105 Nm a Set the wheels straight ahead.

engine tie-bar on the a Position the steering wheel lock.
gearbox
sub-frame stiffener nuts 62 Nm
bolts between the lower 110 Nm

arm and the hub carrier
hub carrier ball joint bolt 27 Nm
tie-bar nuts between the 80 Nm

lower arms and the hub
carriers
anti-roll bar return tie- 44 Nm

bar upper ball joint nuts
track rod end nuts 35 Nm 113092
universal joint bolt 24 Nm a Remove the universal joint bolt (2) (do not keep),
WARNING
REMOVAL
Swivel the universal joint to detach it from the
sprocket; do not pull out the intermediate shaft.
a Remove the universal joint from the steering rack.
a Attach the cooling radiator by the radiator top hose
and the bonnet opening striker plate.
a Remove the radiator mounting cross member (see
Radiator support cross member: Removal - Re-
fitting) (41A, Front lower structure).
31A-62
116760 116768
a Unclip the wheel speed sensor wiring (3) . a Remove the anti-roll bar return tie-rod upper ball
joint nuts (5) .
116761
a Remove the track rod end nuts (4) . 116771
a Remove the nuts (6) .
a Extract the track rod ends using the (Tav. 476).
31A-63
116779
a Remove:
- the sub-frame stiffener nuts (10) ,
- the sub-frame stiffener.
116772
a Engage the driveshafts using the component jack
(7) .
a Remove the linkages (8) .
113724
a Remove the engine tie-bar bolt (11) .
a Place a component jack under the sub-frame.
a Strap the sub-frame onto the component jack.
116777
a Remove the bolts (9) between the lower arms and
the hub carriers.
31A-64
a Remove the subframe fittings.
REFITTING

a Always replace:
- the anti-roll bar tie-bar brake nuts,
- the universal joint bolt and cam nut.
a Degrease the contact surface areas of the sub-fra-
me and the body using SURFACE CLEANER (see
Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products).

CONCERNED
a Refit the subframe equipment.
112871
a Offer up the sub-frame using an component jack.
a Remove:
a Clip the wiring onto the discharge bulb position sen-
- the rear cross member bolts (12) , sor.
- the rear cross member, a Connect the connector to the discharge bulb posi-
tion sensor.
- the subframe bolts (13) on the body,
a Clip the wiring onto the oxygen sensor.
- the side reinforcements (14) .
a Connect the oxygen sensor connector.
a Lower the sub-frame by approximately 5 cm using
the component jack. a Fit the sub-frame to the body.
a Refit:
- the side stiffeners,
- the sub-frame bolts on the body,
- the rear cross member,
- the rear cross member bolts.
a Tighten to torque and in order:

- the sub-frame linkage bolt (105 Nm),
- the rear cross member bolt (105 Nm),
- the bolts to the subframe tie-rod (105 Nm).
112872 a Remove the safety strap(s) and the component

jack.
a Disconnect the oxygen sensor connector (15) .
a Refit the engine tie-bar bolt.
a Unclip the wiring (16) from the oxygen sensor.
a Torque tighten the bolts securing the engine tie-
a Disconnect the connector from the discharge bulb bar on the gearbox (105 Nm).
position sensor.
a Refit:
a Unclip the wiring from the discharge bulb position
sensor. - the sub-frame stiffener,
a Remove the sub-frame. - the sub-frame stiffener nuts.
31A-65
a Torque tighten the sub-frame stiffener nuts (62 a Refit the front wheels (see 35A, Wheels and tyres,
Nm). Wheel: Removal - Refitting, page 35A-1) .
a Refit the bolts between the lower arms and the hub a Check the front axle geometry values (see 30A, Ge-
carriers. neral information, Front axle: Adjusting, page
30A-23) .
a It is essential to initialise the discharge bulb system
- the bolts between the lower arm and the hub
(see Fault finding - Configuration and program-
carrier (110 Nm),
ming) (80B, Headlights).
- the hub carrier ball joint bolt (27 Nm).
a Engage the driveshafts using the component jack.
a Refit the linkages between the lower arms and the
hub carriers.
a Refit the tie-bar nuts between the lower arms and
the hub carriers.
a Torque tighten the tie-bar nuts between the lower
arms and the hub carriers (80 Nm).
a Refit the anti-roll bar return tie-bar upper ball joint
nut.
a Torque tighten the anti-roll bar return tie-bar up-
per ball joint nuts (44 Nm).
a Refit the track rod ends.
a Torque tighten the track rod end nuts (35 Nm).
a Clip the wiring onto the wheel speed sensors.
a Refit:
a Pretighten the universal joint nut and bolt.
a Torque tighten the universal joint bolt (24 Nm).
a Refit the floor carpet.
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.

a Refit the radiator mounting cross member (see Ra-
diator support cross member: Removal - Refit-
ting) (41A, Front lower structure).
a Detach the radiator by the radiator top hose and the
bonnet opening striker plate.
31A-66
Front anti-roll bar: Removal - Refitting 31A
Sus. 1829 Headlight height control posi-
tioning gauge
Tightening torquesm
anti-roll bar bearing 21 N.m

bolts on the subframe
steering box bolt on the 105 N.m

subframe
bolt mounting the dis- 21 N.m

charge bulb sensor on
the anti-roll bar
bracket bolts 8 N.m
steering box bolt on the 105 N.m

subframe
108824
EQUIPMENT LEVEL E3 LEISURE or EQT LEVEL a Unclip the bulkhead seal at (1) using a flat-blade
EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or screwdriver.
EQT LEVEL EA4 or EQT LEVEL EA5 or EQT
LEVEL EAG
a Diameter of the anti-roll bar: 20.5 mm.
a Diameter of the anti-roll bar: 19.5 mm.
REMOVAL

ment).

a Remove the front axle subframe (see 31A, Front

axle components, Front axle sub-frame: Remo-
val - Refitting, page 31A-53) .
31A-67
XENON BULBS
115062
a Remove the discharge bulb sensor (see Headlight
adjustment front sensor: Removal - Refitting)
(MR 392, 80C, Discharge bulbs).
31A-68
and XENON BULBS
108821
a Remove:
122108
- the anti-roll bar bolts (5) on the subframe,
a Remove: - the anti-roll bar bearings,
- the tie rod nut (2) on the bracket,
- the anti-roll bar.
- the tie rod from the bracket,
- the bolts (3) from the bracket, REFITTING
- the anti-roll bar bracket (4) .

CONCERNED
a Refit:
- the anti-roll bar,
- the anti-roll bar bearings by correctly positioning

the spigots on the anti-roll bar bearing retaining
brackets in the holes of the sub-frame,
- the anti-roll bar bearing bolts to the subframe.
a Torque tighten the anti-roll bar bearing bolts on

the subframe (21 N.m).
XENON BULBS
a Refit the discharge bulb sensor (see Headlight ad-

justment front sensor: Removal - Refitting) (MR
392, 80C, Discharge bulbs).
- the steering box bolt on the subframe (105

N.m),
31A-69
- the bolt mounting the discharge bulb sensor on
the anti-roll bar (21 N.m).
31A-70
- the tie rod onto the bracket,
EQUIPMENT LEVEL EAC or EQT LEVEL SPORT, - the tie rod nut.
and XENON BULBS a Torque tighten the bracket bolts (8 N.m).
a Remove:
- the steering box bolt,
- the (Sus. 1829).
a Refit the steering box bolt.
a Torque tighten the steering box bolt on the sub-
frame (105 N.m)
a Fit the bulkhead seal in its original position.
a Refit:
- the axle subframe (see 31A, Front axle compo-
nents, Front axle sub-frame: Removal - Refit-
ting, page 31A-53) ,
122109 - the front wheels (see 35A, Wheels and tyres,
a Be sure to initialise the xenon bulb system (if fitted to
the vehicle); (see Configurations and program-
ming) (MR 394, 80B, Headlights).
122110
a Remove the steering box bolt (6) .
a Position the (Sus. 1829) (7) .
a Refit the steering box bolt.
a Fit the anti-roll bar against the (Sus. 1829) at (8) .
a Refit:
- the bracket onto the anti-roll bar against the (Sus.
1829) at (9) ,
- the bracket bolts,
31A-71
REAR AXLE COMPONENTS
Rubber bushing: Adjustment 33A
Essential equipment
component jack
Tightening torquesm
rubber bush bolt 105 N.m
WARNING
Never use the rear axle as support for a lifting sys-
tem.
ADJUSTMENT
a Release the parking brake. 112047
a Remove the rear wheels (see 35A, Wheels and ty- a Loosen the rubber bush nuts (2) .
a Remove the springs (see 33A, Rear axle compo-
nents, Rear suspension spring: Removal - Refit-
3310
a Place the tool component jack in contact with a
shim under the rear axle near the shock absorber at
113757 (3).
a Unclip the speed sensor harness at (1) . a Adjust the component jack in order to obtain a dis-
tance (X1) of 150 mm between the lower mounting
of the shock absorber and the side member.
33A-1
Rubber bushing: Adjustment 33A
112047
a Torque tighten the rubber bush bolt (105 N.m).
a Do the same for the other side.
a Refit the springs (see 33A, Rear axle components,
Rear suspension spring: Removal - Refitting,
page 33A-27) .
a Clip on the speed sensor harness.
a Refit the rear wheels (see 35A, Wheels and tyres,
33A-2
Rear brake pads: Removal - Refitting 33A
16" ALUMINIUM WHEELS or 17" ALUMINIUM WHEELS or 16" STEEL WHEELS, and ESP

tool.
Tightening torquesm
guide pin bolt 32 Nm
When replacing brake pads, be sure to replace the

pads on the opposite side.
WARNING
To avoid damaging the parking brake cable protec-
tors and causing premature wear of the system, do
not handle the cables with a tool.
REMOVAL 108840
a Tilt the calliper upwards.
a Remove the brake pads.
REFITTING
a Release the parking brake.
a Remove the rear wheels (see 35A, Wheels and ty- I - REFITTING PREPARATION OPERATION
a Check the thickness of the pads (see 30A, General
information, Brake: Specifications, page 30A-9) .
CONCERNED
a Clean the calliper mountings.
a Remove the guide pin lower bolt.
a Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):
- the calliper brackets,
- the callipers.
a Always replace the brake calliper guide pin bolts.
33A-3
Rear brake pads: Removal - Refitting 33A
16" ALUMINIUM WHEELS or 17" ALUMINIUM WHEELS or 16" STEEL WHEELS, and ESP
IMPORTANT
the brake pad several times.
18931
a Push the calliper piston back using the (Fre. 1190-
01) until it reaches the end of its bore.
127485
a Remove the protective film from the brake pad.

CONCERNED
a Fit the brake pads.
a Pivot the calliper downwards to return it to its original
position.
a Refit a new guide pin bolt.
a Torque tighten the guide pin bolt (32 Nm).
33A-4
Rear brake hose: Removal - Refitting 33A
REFITTING
Essential equipment
pedal press
a
WARNING
Tightening torquesm
brake hose unions 14 Nm Make sure that there is no contact between the
REMOVAL
CONCERNED
a Refit the hose.
a Torque tighten the brake hose unions (14 Nm).
ment).
WARNING
Prepare for brake fluid outflow, to prevent a Bleed the brake circuit (see 30A, General informa-
damage to the mechanical parts and bodywork tion, Brake circuit Bleeding, page 30A-4) .
around the braking system. a Check the brake fluid level.


CONCERNED
112046
a Remove:
- the unions (1) from the pipe concerned,
- the pipe concerned.
33A-5
Brake calipers: Repair 33A
tool.
Essential equipment
pedal press
WARNING
REMOVAL

ment).
106308
a Remove the piston using compressed air, making
a Remove the rear wheels (see 35A, Wheels and ty- sure to insert a wooden block between the calliper
res, Wheel: Removal - Refitting, page 35A-1) . and the piston.
a Remove the dust seal.
a Remove the rear brake calliper (see 33A, Rear axle
components, Rear brake caliper: Removal - Re-
fitting, page 33A-8) .
106307
a Remove the rectangular section seal from the calli-

per groove with a round edged spring blade (feeler
gauge).
a Replace the complete calliper if the bore is scrat-
ched.
a Clean the parts using methylated spirit.
33A-6
Brake calipers: Repair 33A
REFITTING

CONCERNED
106309
a Refit:
- the rectangular section seal in the calliper groove,
- the piston (after having smeared it with the grease

supplied in the repair kit) using the (Fre. 1190-01),
- the dust seal.
a Refit:
- the brake calliper (see 33A, Rear axle compo-

nents, Rear brake caliper: Removal - Refitting,
page 33A-8) ,
- the rear wheels (see 35A, Wheels and tyres,


IMPORTANT
the brake pedal several times.
33A-7
Rear brake caliper: Removal - Refitting 33A
tool.
Essential equipment
pedal press
Tightening torquesm
guide pin bolts 32 Nm
rigid brake pipe 14 Nm
Note:
pre-filled.
REMOVAL 108841
a Unclip the parking brake cable (1) .
I - REMOVAL PREPARATION OPERATION a Remove the rigid brake pipe union (2) .
- the guide pin mounting bolts (3) , holding the nuts
(4) ,
WARNING - the calliper,
- the brake pads.
around the braking system. a Fit a cap on the rigid brake pipe union.

REFITTING
a Remove the rear wheel on the side concerned (see
35A, Wheels and tyres, Wheel: Removal - Refit- a Check the condition of the calliper piston boot.
ting, page 35A-1) .
a Clean the backplate and the calliper.
33A-8
Rear brake caliper: Removal - Refitting 33A
a Refit the wheel (see 35A, Wheels and tyres,
WARNING
18931
a Push the piston back using the (Fre. 1190-01) until it

is at the end of its bore.

val.

CONCERNED
a Refit:
- the brake pads,
- the calliper,
- the new guide pin bolts,
- the rigid brake pipe union.
a Torque tighten:
- the guide pin bolts (32 Nm),
- the rigid brake pipe (14 Nm).
a Refit the parking brake cable.
a Check that the parking brake cable stop is properly

engaged in its housing.

33A-9
Rear brake calliper mounting: Removal - Refitting 33A
BRAKE DISC
- the calliper mounting.
Tightening torquesm
REFITTING
calliper mounting bolt 105 Nm
REMOVAL a Clean the calliper mounting and the stub axle car-
rier.
I - REMOVAL PREPARATION OPERATION a Coat the calliper mounting bolts with a FRENBLOC
type product before fitting them.
Towing and lifting) . a Always replace the guide pin bolts whenever they
are removed.
a Remove:
- the rear wheels (see 35A, Wheels and tyres, II - OPERATION FOR REFITTING PART
Wheel: Removal - Refitting, page 35A-1) , CONCERNED
- the rear brake pads (see 33A, Rear axle compo- a Refit:
nents, Rear brake pads: Removal - Refitting, - the calliper mounting,
page 33A-3) ,
- the calliper mounting bolts.
- the upper guide pin bolt.
a Torque tighten calliper mounting bolt (105 Nm).
a Refit the calliper and the new upper guide pin bolt.
WARNING
a Suspend the brake calliper from the shock absorber a Refit:
without undoing the brake union.
- the brake pads (see 33A, Rear axle components,
Rear brake pads: Removal - Refitting, page 33A-
II - OPERATION FOR REMOVAL OF PART 3) ,
CONCERNED
112341
a Remove:
- the two calliper support mounting bolts (1) ,
33A-10
Rear brake disc shield: Removal - Refitting 33A
BRAKE DISC
REMOVAL II - REFITTING OPERATION FOR PART

CONCERNED
I - REMOVAL PREPARATION OPERATION a Refit the brake disc protector.

a Refit the rivets.
a Remove:
a Refit:
Wheel: Removal - Refitting, page 35A-1) , - the rear brake disc (see 33A, Rear axle compo-
nents, Rear brake disc: Removal - Refitting,
- the rear brake pads (see 33A, Rear axle compo- page 33A-12) ,
nents, Rear brake pads: Removal - Refitting,
- the calliper mounting (see 33A, Rear axle compo-
page 33A-3) ,
nents, Rear brake calliper mounting: Removal -
- the calliper mounting (see 33A, Rear axle compo- Refitting, page 33A-10) ,
nents, Rear brake calliper mounting: Removal - - the rear brake pads (see 33A, Rear axle compo-
Refitting, page 33A-10) , nents, Rear brake pads: Removal - Refitting,
- the rear brake disc (see 33A, Rear axle compo- page 33A-3) ,
nents, Rear brake disc: Removal - Refitting, - the rear wheels (see 35A, Wheels and tyres,
page 33A-12) . Wheel: Removal - Refitting, page 35A-1) .
II - REMOVAL STAGE FOR THE PART

CONCERNED
109887
a Drill out the rivets (1) .
a Remove the brake disc protector.
REFITTING
a Clean any swarf from the stub-axle carrier
33A-11
Rear brake disc: Removal - Refitting 33A
BRAKE DISC
CONCERNED
Tightening torquesm
stub axle nuts 175 Nm

page 30A-9) .
Be sure to replace the brake pads if the brake discs are
being replaced.
REMOVAL

ment).
108846
a Remove:
- the rear brake pads (see 33A, Rear axle compo-
page 33A-3) ,
- the calliper mountings (see 33A, Rear axle com-
ponents, Rear brake calliper mounting: Remo-
108845
a Remove:
- the hub covers (1)
- the stub axle nuts (2) ,
- the brake discs.
33A-12
Rear brake disc: Removal - Refitting 33A
BRAKE DISC
REFITTING

a Clean the stub axle.

CONCERNED
a Refit:
- the brake discs,
- the stub axle nuts.
a Torque tighten the stub axle nuts (175 Nm).
a Refit the hub cover plug.

a Refit:
page 33A-3) ,
33A-13
Rear brake disc: Description 33A
Remove the rear wheel concerned (see 35A, Wheels
and tyres, Wheel: Removal - Refitting, page 35A-1) .

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).

Replace the discs if necessary (see 33A, Rear axle
components, Rear brake disc: Removal - Refitting,
page 33A-12) .
Refit the rear wheel concerned (see 35A, Wheels and
117058
Position the Palmer tool (1) to measure the disc thic-
kness.
33A-14
Rear brake lining: Removal - Refitting 33A
DRUM BRAKE
Replace all the brake pads on one axle at the same ti-
me. Never mix brake pads of different brands or quali-
ties.
REMOVAL

ment).
a Remove:
- the brake drum (see 33A, Rear axle components,
Rear brake drum: Removal - Refitting, page
33A-19) .
109707
II - OPERATION FOR REMOVAL OF PART a Place the pliers on the slave cylinder pistons.
CONCERNED
a Remove:
- the shoe side retaining springs (3) by tilting them
outwards,
- the leading shoe (4) ,
- the tie-rod (5) ,
- the trailing shoe (6) .
a Uncouple the parking brake cable from the parking
brake lever.
REFITTING

a Remove any dust from the drums and flanges using
a brake cleaner.
a Lightly grease the support linkage thread.
109711 WARNING
a Remove the lower spring (1) then the upper spring The brake mechanism components are different
(2) using brake shoe pliers. on the left and right-hand sides, so it is important
not to confuse them.
Note:
On the left-hand brake: the bolt thread has a
right-hand thread.
On the right-hand brake: the bolt thread has a
left-hand thread.
33A-15
Rear brake lining: Removal - Refitting 33A
DRUM BRAKE
CONCERNED
a Refit the parking brake cable to the parking brake le-
ver.
a Refit:
- the trailing shoe,
- the linkage,
- the leading shoe,
- shoe side retaining springs tilting them outwards,
- the upper spring,
- the lower spring.
109706
a Use a screwdriver to adjust the piston ring diameter
with the linkage to obtain a diameter of 202.8 mm ±
0.1
a Carry out the same adjustment on the other side.
a Adjust the parking brake if the lever stops between
the first and second positions of the parking brake
lever's travel (see 37A, Mechanical component
controls, Parking brake lever: Adjusting, page
37A-90) .

a Refit:
116013
a Check that the parking brake cable is correctly posi-
tioned on the parking brake lever.
33A-19) ,
a Remove the pliers from the slave cylinder pistons.
a Adjust the brake pads by depressing the brake pedal
repeatedly.
a Check that the automatic wear take up system is
operating correctly (clicking noise from the drums
when the brake pedal is repeatedly depressed).
33A-16
Rear brake cylinder: Removal - Refitting 33A
DRUM BRAKE
Tightening torquesm
cylinder mounting bolts 9 Nm

on the backplate
rigid pipe union on the 14 Nm

brake cylinder
REMOVAL

a Remove:
109714
a Unscrew the rigid pipe union (2) from the brake cy-
linder (be prepared for brake fluid running out).
- the brake drum (see 33A, Rear axle components, a Fit a cap on the brake pipe union.
33A-19) . a Remove:
- the cylinder mounting bolts (3) on the backplate,
II - OPERATION FOR REMOVAL OF PART - the brake cylinder.
CONCERNED
REFITTING

a Remove any dust from the drums and flanges using
a brake cleaner.
a Check the condition of the brake cylinder boots and
pistons (replace any faulty parts).
II - OPERATION FOR REFITTING PART

CONCERNED
a Refit:
- the brake cylinder,
- the cylinder mounting bolts on the backplate,
- the rigid pipe union on the brake cylinder,
- the upper return spring using brake shoe pliers.
109708
- the cylinder mounting bolts on the backplate (9
a Remove the upper return spring (1) using brake Nm),
shoe pliers.
- the rigid pipe union on the brake cylinder (14
a Separate the shoes. Nm).
33A-17
Rear brake cylinder: Removal - Refitting 33A
DRUM BRAKE
a Refit:
33A-19) ,
a Adjust the brake shoes by pressing the brake pedal
repeatedly.
33A-18
Rear brake drum: Removal - Refitting 33A
CONCERNED
Tightening torquesm
drum nut 175 N.m
a When replacing a brake drum, it is essential to repla-

ce the drum on the opposite side as well.
a Always replace the brake pads if the brake drums
are being replaced.
IMPORTANT
The two brake drums must be of the same dia-
meter. If one drum is reground, the other also
must be reground. The maximum diameter is
etched on the drum.
REMOVAL

a Remove the rear wheels (see 35A, Wheels and ty-
109710
a Remove:
- the drum caps (1) ,
- the drum nuts (2) ,
- the brake drums.
REFITTING

a Check the internal diameter of the drum.
33A-19
Rear brake drum: Removal - Refitting 33A
a Clean:
- the brake linings,
- the brake drums.
- the stub axle.

CONCERNED
a Adjust the parking brake if the lever stops between
the first and second position of the parking brake le-
ver's travel (see 37A, Mechanical component con-
trols, Parking brake lever: Adjusting, page 37A-
90) .
a Refit:
- the brake drums.
- the drum nuts,
- the drum caps,
a Torque tighten the drum nut (175 N.m).

a Adjust the brake pads by depressing the brake pedal
repeatedly.
33A-20
Rear brake drum: Description 33A
Essential equipment Replace the rear drum concerned if necessary (see
Rear axle components: Removal - Refitting) .
sliding calliper
Refit the rear wheel concerned (see 35A, Wheels and

Towing and lifting) (MR 392, 02A, Lifting equipment).
Remove the rear wheel concerned (see 35A, Wheels

and tyres, Wheel: Removal - Refitting, page 35A-1) .
Remove the rear brake drum concerned (see 33A,

Rear axle components, Rear brake drum: Removal
- Refitting, page 33A-19) .

CONCERNED
Note:
To check the internal diameter of the drum, use a
sliding calliper type tool for drums.
116995
Position the sliding calliper to measure the internal

diameters of the brake drum.
Measure the interior diameters of the brake drum on

the perpendicular axes (1) and (2) .

33A-21
Brake pipe: Removal - Refitting 33A
CONCERNED
Essential equipment
pedal press 1 - rear left-hand rigid brake pipe
Tightening torquesm
rigid brake pipe at the 14 Nm

rear axle
rigid brake pipe on the 14 Nm

calliper
The pipes have a rigid section and a flexible section.
REMOVAL

ment).
outflow of brake fluid. 108847
a Raise the lift. a Unscrew:
- the rigid brake pipe from the rear axle (1) ,
- the rigid brake pipe from the calliper (2) .
a Unclip the rear axle rigid brake pipe.
a Remove the rigid brake pipe.
33A-22
Brake pipe: Removal - Refitting 33A
2 - Rear right-hand rigid brake pipe
108848
a Unscrew:
- the rigid brake pipe from the rear axle (3) ,
- the rigid brake pipe from the calliper (4) .
a Unclip the rear axle rigid brake pipe.
a Remove the rigid brake pipe.
REFITTING
a Always replace the rigid brake pipe mounting clips.
WARNING

CONCERNED
a Refit the rigid pipe in its original position.
a Torque tighten:
- the rigid brake pipe at the rear axle (14 Nm),
- the rigid brake pipe on the calliper (14 Nm).

33A-23
Shock absorber: Removal - Refitting 33A
Essential equipment S85
component jack
Tightening torquesm
upper shock absorber 21 N.m

nut
lower shock absorber 105 N.m

bolt
WARNING
To prevent any damage, do not use the rear axle as
support for the lifting system.
WARNING
To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle. 120568
a Remove the flap (1) from the rear loading trim which
gives access to the upper shock absorber nut.
WARNING
To prevent the components of the rear axle from
deteriorating (rubber bushes, brake hoses, etc.) do
not remove the two shock absorbers at the same
time. Proceed one side at a time.
REMOVAL

B85 or C85
a Remove the rear wheel arch trim (see Rear wheel
arch lining: Removal - Refitting) (71A, Body inter-
nal trim).

a Remove the rear aerodynamic diffuser (see Aero-
dynamic diffuser: Removal - Refitting) (55A, Ex-
terior protection).
33A-24
CONCERNED
K85
112055
126132
a Pull down the rear bench seatbacks to gain access a Loosen the upper shock absorber nut (2) , whilst hol-
to the upper shock absorber nut. ding the bolt head (3) , with the wheels on the
a Remove the rear wheel arch trim flap (1) . ground.
a Raise the lift.
108849
a Using a block, bring the component jack into con-

tact under the rear axle, near the shock absorber.
a Remove the lower bolt (4) from the shock absorber.
33A-25
a Remove:
- the upper shock absorber nut (2) , S85

a Refit the rear loading trim flap which gives access to
- the shock absorber.
the upper shock absorber nut.
REFITTING
I - REFITTING PREPARATION OPERATION K85

a The upper shock absorber nut must always be repla- a Refit:
ced.
- the rear wheel arch trim flap that gives access to
the upper shock absorber nut,
II - REFITTING OPERATION FOR PART - the rear bench seatbacks.
CONCERNED
a Refit:
- the shock absorber,
- the new shock absorber upper nut.
a Torque tighten the upper shock absorber nut (21

N.m) whilst holding the bolt head, with the wheels on
the ground.
a Raise the lift.

a Refit the shock absorber lower bolt.
a Torque tighten the lower shock absorber bolt (105

N.m) with the component jack in position.
a Repeat the operation on the opposite side.
B85 or C85
a Refit the rear wheel arch trim (see Rear wheel arch
lining: Removal - Refitting) (71A, Body internal
trim).
a Refit the rear aerodynamic diffuser (see Aerodyna-

mic diffuser: Removal - Refitting) (55A, Exterior
protection).
33A-26
Rear suspension spring: Removal - Refitting 33A
Essential equipment
component jack
Tightening torquesm

mounting bolts
WARNING
tem.
REMOVAL

108849
Towing and lifting) . a Using a block, bring the component jack into con-
res, Wheel: Removal - Refitting, page 35A-1) . a Mark the position where the springs are fitted.
a Remove the shock absorber lower mounting (2) .

CONCERNED a Remove the component jack.
a Repeat these operations on the opposite side.
113757
a Unpick the wheel speed sensor wiring harnesses (1)
108850
a Remove the springs by withdrawing the component

jack.
a Leave the rear axle suspended.
33A-27
Rear suspension spring: Removal - Refitting 33A
REFITTING a Refit the rear wheels (see 35A, Wheels and tyres,

CONCERNED
108849

113758
a Refit the springs in their housing.
a Compress the rear axle.

a Refit the lower shock absorber mounting bolts.
a Torque tighten the shock absorber lower moun-

ting bolts (105 Nm).
a Mount the wheel speed sensor wiring.
33A-28
Rear drum bearing: Removal - Refitting 33A
Using a dial gauge connected to the drum, check that - the surfaces of the drum in contact with the new
the end float is greater than 0.03 mm. bearing,
- the stub-axle surfaces in contact with the new bea-
REMOVAL ring,
a
I - REMOVAL PREPARATION OPERATION WARNING
a Position the vehicle on a two-post lift (see Vehicle: It is essential to check the condition of the sur-
Towing and lifting) . face of the stub axle and the bore of the drum
before refitting the bearing. Replace the stub
a Remove: axle carrier if it is faulty.
WARNING
- the brake drum (see 33A, Rear axle components, Do not apply pressure to the inner bearing bush,
Rear brake drum: Removal - Refitting, page to avoid damaging the bearing (significant force
33A-19) . is required for fitting).

CONCERNED II - REFITTING OPERATION FOR PART
CONCERNED
a Lift the bearing until it presses onto the shoulder
using a tube with an external diameter of 51 mm and
a press.
a Refit the circlip

a Refit:
33A-19) ,
109373
a From the drum, remove:
- the bearing retaining circlip (1) ,
- the bearing (2) using a tube with an external diame-

ter of 47 mm and a press.
Note:
Check that the tube is pressing against the outer
bush of the bearing.
REFITTING

a Clean:
- the internal and external surfaces of the new bea-
ring in contact with the drum and the stub axle,
33A-29
Rear disc brake bearing: Removal - Refitting 33A
REMOVAL

a Remove:
page 33A-3) ,
- the rear brake disc (see 33A, Rear axle compo-
page 33A-12) .
104396
II - OPERATION FOR REMOVAL OF PART a Remove the bearing by applying pressure with a
CONCERNED tube 50 mm in diameter.
REFITTING

a Clean:
- the internal and external surfaces of the new bea-
ring in contact with the disc and the stub axle,
- the surfaces of the disc in contact with the new
bearing,
- the stub-axle surfaces, in contact with the new bea-
ring,
a
WARNING
It is essential to check the condition of the sur-
face of the stub axle and the bore of the disc
before refitting the bearing. Replace the stub
104528 axle carrier if it is faulty.
a Remove circlip (1) .
WARNING
Do not apply pressure to the inner bearing ring,
to avoid damaging the bearing (significant force
is required for fitting).
33A-30
Rear disc brake bearing: Removal - Refitting 33A
CONCERNED
104395
a Raise the bearing until it presses on the retaining
wall, using a press and a tube with an outer diameter
of a maximum of 55 mm and a minimum of 43 mm
(to prevent pressing on the inner ring). When the
bearing is being fitted, the disc must be positioned
on the pressure face (3) of the wheel.
The markings on the bearing must be located at (2) .
a Refit the circlip.

a Refit:
page 33A-12) ,
page 33A-3) ,
33A-31
Rear stub-axle carrier: Removal - Refitting 33A
BRAKE DISC
CONCERNED
Essential equipment
component jack
Tightening torquesm
stub axle carrier moun- 80 Nm

ting bolts

mounting bolt
REMOVAL

ment).
a Remove: 116017
- the rear wheel in question (see 35A, Wheels and a Remove:
- the rivets (1) from the disc protector,
nents, Rear brake pads: Removal - Refitting, - the brake disc protector,
page 33A-3) , - the sensor holder (2) from the ABS sensor,
Note:
Mark the of the position of the inscription on the
stub axle carrier for the purpose of refitting
page 33A-12) .
33A-32
BRAKE DISC
REFITTING

a Clean the stub axle carrier.

CONCERNED
a Refit:
- the stub axle carrier,
- the stub axle carrier mounting bolts.
a Torque tighten the stub axle carrier mounting
bolts (80 Nm).
a Refit:
- the ABS sensor holder,
- the brake disc protector,
108849
- the disc protector rivets.
116014
a Fit a component jack with a shim under the rear
axle level with the shock absorber.
108849
a Remove:
a Refit and torque tighten the shock absorber lower
- the shock absorber lower mounting bolt (3) , mounting bolt (105 Nm) with the component jack
- the mounting bolts (4) from the stub axle carrier, fitted, with a shim, under the rear axle and level with
the shock absorber.
- the stub axle carrier.
a Refit:
page 33A-12) ,
33A-33
BRAKE DISC
page 33A-3) ,
- the rear wheel (see 35A, Wheels and tyres,
33A-34
DRUM BRAKE
CONCERNED
Tightening torquesm
stub axle carrier moun- 80 Nm

ting bolts
rigid pipe union on the 14 Nm

brake cylinder
REMOVAL

a Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Vehicle: Towing and lifting).
a Remove:
- the rear wheel in question (see 35A, Wheels and
33A-19) . 116207
a
Note:
Mark the of the position of the inscription on the
stub axle carrier for the purpose of refitting
Remove:
- the rigid pipe union (1) on the brake cylinder,
- the mounting bolts (2) from the stub axle carrier,
- the brake cylinder-flange-pad assembly.
REFITTING

a Clean the stub axle carrier.

CONCERNED
a Refit:
- the brake cylinder-flange-pad assembly,
- the stub axle carrier mounting bolts,
- the rigid pipe union on the brake cylinder,
- the stub axle carrier mounting bolts (80 Nm),
33A-35
DRUM BRAKE
- the rigid pipe union on the brake cylinder (14
Nm).
116013

a Refit:
33A-19) ,
- the rear wheel (see 35A, Wheels and tyres,
33A-36
Complete rear axle: Removal - Refitting 33A
Mot. 1390 Support for removing/refitting
the engine - gearbox assem- DRUM BRAKE
bly.
Essential equipment
pedal press
safety strap(s)
Tightening torquesm
bearing mounting bolts 62 Nm
brake hose nuts 14 Nm
109705
WARNING
a Remove the drums (see 33A, Rear axle compo-
Never use the rear axle as support for a lifting sys- nents, Rear brake drum: Removal - Refitting,
tem. page 33A-19) .
a Remove the parking brake cable (1) from the lever
REMOVAL (2) using pliers and a screwdriver.
a Unclip the parking brake cable sheath (3) from the
I - REMOVAL PREPARATION OPERATION drum back-plate.
a Position the vehicle on a two-post lift (see Vehicle: a Unclip the wheel speed sensors from the back-plate.
Towing and lifting) (MR 392, 02A, Lifting equip- a Unclip the wheel speed sensors from the rear axle.
ment).
33A-37
a Note the parking brake cable routing for refitting.
BRAKE DISC
112046
109210 a Unscrew the unions (6) connecting the rigid pipes

and the brake hoses.
a Remove the parking brake cables (4) at the brake
callipers. a Loosen the rear axle bearing bolts (7) .
a Unclip the wheel speed sensors. a Remove the springs (see 33A, Rear axle compo-
a Unclip the wheel speed sensors from the rear axle. nents, Rear suspension spring: Removal - Refit-
108857
112632 a Fit the (Mot. 1390) under the rear axle.

a Unclip the parking brake cables from their guides (5) a Position the pads of the (Mot. 1390) in contact with
. the rear axle.
33A-38
a Put a safety strap(s) around the rear axle. a Raise the vehicle.
a Remove the rear axle bearing bolts.
108856
a Remove the rear axle components (do not undo the
rubber bush bolts (8) ).
REFITTING

a Refit the rear axle equipment.
a Strap the rear axle onto the (Mot. 1390).
a Degrease the surfaces of the body which are in con-
tact with the rear axle bearing using surface cleaner.
a Position the rear axle under the vehicle.
33A-39
CONCERNED
108856
a Lower the lift. a Refit the parking brake cables in their guides and on
the calliper (or backplate).
a Position the bearing centring devices (9) opposite
the centring holes. a Check that the parking brake cable stops are proper-
ly inserted in their housing.
a Refit the mountings, starting with the left-hand bea-
ring.
a Raise the lift.
a Remove the safety strap(s).
a Remove the (Mot. 1390).
a Insert the brake pipes into their housing.
a Screw on the brake hose nuts.
- the bearing mounting bolts (62 Nm),
- the brake hose nuts (14 Nm).
a Refit the springs (see 33A, Rear axle components,
Rear suspension spring: Removal - Refitting,
page 33A-27) .
a Clip on and connect the wheel speed sensor con-
nectors.
33A-40
DRUM BRAKE
116013
a Adjust the parking brake cables (see 37A, Mechani-

cal component controls, Parking brake lever:
Adjusting, page 37A-90) .

33A-41
Mot. 1390 Support for removing/refitting
the engine - gearbox assem-
bly.
Essential equipment
pedal press
safety strap(s)
Tightening torquesm
bearing mounting bolts 62 Nm
brake hose nuts 14 Nm
WARNING
tem.
109210
a Remove the parking brake cables (1) at the brake

REMOVAL callipers.
a Unclip the wheel speed sensors.

a Position the vehicle on a two-post lift (see Vehicle: a Unfasten the wheel speed sensors from the rear
Towing and lifting) (MR 392, 02A, Lifting equip- axle.
ment).
112632
a Unfasten the parking brake cables from their guides

(2) .
a Note the parking brake cable routing for refitting.
33A-42
a Raise the vehicle.
112046
a Unscrew the unions (3) connecting the rigid pipes
and the brake hoses.
a Loosen the rear axle bearing bolts (4) .
a Remove the suspension springs (see 33A, Rear
axle components, Rear suspension spring: Re-
moval - Refitting, page 33A-27) .
108857
a Fit the (Mot. 1390) under the rear axle.
a Position the pads of the (Mot. 1390) in contact with
the rear axle.
a Put a safety strap(s) around the rear axle.
a Remove the rear axle bearing bolts.
33A-43
108856
a Remove the rear axle components (do not undo the
rubber bush bolts (5) ).
REFITTING

a Refit the rear axle equipment.
a Strap the rear axle onto the (Mot. 1390).
a Position the rear axle under the vehicle.
33A-44
CONCERNED
108856
a Lower the lift. a Refit the parking brake cables into the guides and
onto the calliper.
a Position the bearing centring devices (6) opposite
the centring holes. a Check that the parking brake cable stops are proper-
ly inserted in their housing.
a Refit the mountings, starting with the left-hand bea-
ring. a Adjust the parking brake cables (see 37A, Mechani-
a Raise the lift. Adjusting, page 37A-90)
a Remove the safety strap(s).
a Remove the (Mot. 1390). III - FINAL OPERATION.
a Insert the brake pipes into their housing. a Refit the rear wheels (see 35A, Wheels and tyres,
a Screw on the brake hose nuts.
a Torque tighten: tion, Brake circuit Bleeding, page 30A-4) .
- the bearing mounting bolts (62 Nm),
- the brake hose nuts (14 Nm).
a Refit the suspension springs (see 33A, Rear axle
components, Rear suspension spring: Removal
- Refitting, page 33A-27) .
a Clip on and connect the wheel speed sensor con-
nectors.
33A-45
WHEELS AND TYRES
Wheel: Removal - Refitting 35A
Tightening torquesm
wheel bolts 105 N.m
The removal - refitting procedure is the same for alloy

and steel wheels.
REMOVAL

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.
119649
a Strike around the edge of the tyre walls (1) several
Note: times using a mallet on the inner and outer surfaces
of the wheel to detach the wheel rim.
This mark is necessary for:
a Remove:
- marking the initial position of the wheel rim on
the hub, - the wheel bolts,
- perform the balancing operation. - the wheel.

CONCERNED
a Loosen the wheel bolts with the wheels 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
If this procedure does not work:
124750
106089 a Coat the wheel rim mating face (3) with COPPER
a Strike the inner surface of the wheel (2) using a mal- ANTI-SEIZE AGENT (see Vehicle: Parts and in-
let and a wooden block to detach it. gredients for the repairwork) (04B, Consumables
- Products).
Note: a Align the mark of the wheel rim with the mark on the
hub, which was made at the time of the removal ope-
Do not strike the surface of the wheel using ration.
excessive force as this may damage it.
a Fit the wheel to the vehicle, positioning the valve at
a Remove: the top.
- the wheel bolts, a Insert the wheel bolts.
- the wheel.
REFITTING

a Clean the hub carrier using a wire brush.
Note:
There are two types of wheel bolts for aluminium
and steel wheel rims; do not swap them.
a Check the condition of the tyre.

a Do not move or remove the balance weights.

CONCERNED
a Clean the mating surfaces between the wheel and
the hub carrier using a wire brush.
35A-2
WHEELS AND TYRES
113180
a Pretighten the wheel bolts (30 N.m), with the wheel
hanging, starting with the bottom bolts.
a Rotate the wheel through 180˚ to bring the valve into
the bottom position.
a Position the vehicle on its wheels.
a Torque tighten in order the wheel bolts (105 N.m).

a Refit the trim piece.
35A-3
WHEELS AND TYRES
Tightening torquesm
wheel bolts 140 Nm
The removal - refitting procedure is the same for alloy

and steel wheels.
REMOVAL

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. 118101
a Strike around the edge of the tyre walls (1) several
times using a mallet on the inner and outer surfaces
Note:
of the wheel to detach the wheel rim.
This mark is necessary for:
a Remove:
- marking the initial position of the wheel rim on
- the wheel bolts,
the hub,
- the wheel.
- perform the balancing operation.

CONCERNED
a Loosen the wheel bolts with the wheels 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 Undo the wheel bolts by one turn.
35A-4
WHEELS AND TYRES
If this procedure does not work:
124750
106089 a Coat the wheel rim mating face (3) with COPPER
a Strike the inner surface of the wheel (2) using a mal- ANTI-SEIZE AGENT (see Vehicle: Parts and in-
let and a wooden block to detach it. gredients for the repairwork) (04B, Consumables
- Products).
a Align the mark of the wheel rim with the mark on the
Note:
hub, which was made at the time of the removal ope-
Do not strike the surface of the wheel using ration.
excessive force as this may damage it.
a Fit the wheel to the vehicle, positioning the valve at
the top.
a Remove:
a Insert the wheel bolts.
- the wheel bolts,
- the wheel.
REFITTING

a Clean the hub carrier using a wire brush.
Note:
There are two types of wheel bolts for aluminium
and steel wheel rims; do not swap them.
a Check the condition of the tyre.

a Do not move or remove the balance weights.

CONCERNED
a Clean the mating surfaces between the wheel and
the hub carrier using a wire brush.
35A-5
WHEELS AND TYRES
118101
a Pretighten the wheel bolts (30 N.m), with the wheel
hanging, starting with the bottom bolts.
a Rotate the wheel through 180˚ to bring the valve into
the bottom position.
a Position the vehicle on its wheels.
a Tighten to torque and in order the wheel bolts (140
Nm).

a Refit the trim piece.
35A-6
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 com-
ponents and mountings.
Replace any faulty parts (see manufacturer's ins-
tructions).
The wheel and the wheel balancer must be clean.
Driver's perception
a If the wheels are not correctly balanced this causes 105870
the steering wheel and/or the vehicle floor to vibrate. a
These vibrations appear between 54 mph (90 km/h)
Note:
and 90 mph (150 km/h).
The ring is available from the supplier of the
equipment used.
II - BALANCING PREPARATION OPERATION
a Adjust the tyre pressure (see 35A, Wheels and ty- To reproduce the exact vehicle wheel assembly, use
res, Tyre inflation pressure: Identification, page a ring (1) of diameter:
35A-18) . a 60 mm
a Always carry out a road test for a minimum distance a There are three types of weight:
of 1 mile (2 km) before balancing the wheels, in or-
der to remove any flat spots on the tread caused by
the vehicle being immobilised.
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-7
WHEELS AND TYRES
113742 105871
a The wheel is fitted on the wheel balancer as follows:
(2) Steel wheel with flange
- (5) ring,
(3) Alloy wheel with flange
(4) Alloy wheel without flange - (6) wheel balancer back-plate,
- (7) wheel tightening device (certain alloy wheels
a In some countries, the use of lead weights is forbid-
require a device 200 mm in diameter to ensure that
den; in this case it is recommended to use ZAMAK
the wheel has been correctly tightened),
weights instead.
- (8) outer wheel plane,
Only use weights provided by the Parts Department.
a Remove the wheels (see 35A, Wheels and tyres, - (9) wheel.
a Always clean the wheel, disc, and hub bearing surfa-
ces.
III - PROCEDURE FOR BALANCING THE WHEEL IN

QUESTION
a Make sure that the wheel balancer bearing 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 val-
ve at the top, then lock the wheel in place.
a Remove any stones trapped in the tyre tread.
35A-8
WHEELS AND TYRES
a Enter the specific wheel parameters when starting
the wheel balancer.
a Start the wheel balancer and check the wheel balan-
ce, which should be 0 g on each plane of the wheel.
a If this is not the case, remove the old wheel balan-
cing weights and repeat the wheel balancing proce-
dure, checking that the wheel balance equals 0 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,
35A-9
WHEELS AND TYRES
Tyres: Removal - Refitting 35A
REMOVAL

a Remove:
- the wheel in question (see 35A, Wheels and tyres,

- the balance weights,
- the valve mechanism.

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 re-
WARNING
move the exterior bead from the tyre.
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

move the bead from inside the tyre.
a Remove the interior bead of the tyre, finishing at the
valve.
REFITTING
WITHOUT TYRE PRESSURE SENS.
a parts always to be replaced: Tyre valve (13,05,

02,02)
a Lubricate the two tyre beads correctly using the

TYRE PASTE (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
18884 Products).
a Detach:
- the bead from the outside of the tyre, starting with CONCERNED
the side opposite the valve,
a Engage the lower tyre bead approximately 15 cm af-
- the bead from the inside of the tyre. ter the valve.
35A-10
WHEELS AND TYRES
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.

a Refit the valve mechanism.
a Inflate the tyre to the recommended pressure (see
35A, Wheels and tyres, Tyre inflation pressure:
Identification, page 35A-18) .
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-7) .
a Refit the wheel in question (see 35A, Wheels and
35A-11
WHEELS AND TYRES
TYRE PRESSURE SENS.
REMOVAL

ment).
a Remove the wheels in question (see 35A, Wheels
1) .
a Remove:
- the balancing weights.

CONCERNED
18885
valve on the outside of the wheel rim.
a Remove the tyre bead, finishing at the valve.
move the bead from inside the tyre.
a Remove the tyre bead, finishing at the valve.
REFITTING

a Apply soap to the two tyre beads.
18884
CONCERNED
a Lift off the bead from the outside of the tyre, starting
with the side opposite the valve. a Engage the lower tyre bead approximately 15 cm af-
ter the valve.
WARNING a Finish fitting the tyre at the valve.

Make sure that the tyre bead does not pull on the a Fit the exterior bead approximately 15 cm after the
sensor at any point. valve using the tyre lever.
a Detach the bead from the inside of the tyre a Inflate the tyre to 3.5 bar to press the tyre beads

35A-12
WHEELS AND TYRES
TYRE PRESSURE SENS.
Note:
It is not necessary to drive the vehicle before and
a Refit the wheels (see 35A, Wheels and tyres,

35A-13
WHEELS AND TYRES
WITHOUT TYRE PRESSURE SENS.
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATIONS OPERATION
a Position the vehicle on a two-post lift (see Vehicle: a Always replace the valve.
Towing and lifting) (MR 392, 02A, Lifting equip- a Apply soap to the valve.
ment).
a Apply soap to the two tyre beads.
a Remove the wheels in question (see 35A, Wheels
1) . II - REFITTING OPERATION FOR PART
CONCERNED
a Remove:
a Fit a new valve.
- the balancing weights.
a Fit the lower bead.
a Fit the tyre.
a Fit the exterior bead using the tyre lever.
CONCERNED a Remove the valve mechanism.
a Detach: a Inflate the tyre to 3.5 bar to press the tyre beads
- the bead from the outside of the tyre,
- the bead from the inside of the tyre. III - FINAL OPERATION.
Note:
It is not necessary to dr ive the vehicle before and

18885
a Position the tyre lever on the outside of the wheel

rim in order to remove the bead on the outside of the
tyre.
a Remove the exterior bead.
a Position the tyre lever on the outside of the wheel
rim in order to remove the bead on the inside of the
tyre.
a Remove the interior bead.
a Remove the valve.
35A-14
WHEELS AND TYRES
Tyres: Repair 35A
Perforation
LCV load index less 6 3
There are two types of perforation: than or equal to
- single perforation: perforation caused by nail etc. not 121
requiring a reinforced tyre boot and which can be re-
HGV load index 10 3
paired when the tyres are cold,
122 to 177 (inc.)
- damage: rubber detachment etc. requiring repair and
reinforcement of damaged plies. LV: Light Vehicle
LCV: Light Commercial Vehicle
This repair method only covers single perforations.
HGV: Heavy Goods Vehicle
Tyre areas
* If the diameter of the puncture is greater than these fi-
gures, replace the tyre.
The tyre cannot be repaired if:
- a compulsory marking has been worn away (see 35A,
Wheels and tyres, Tyres: Identification, page 35A-
20) ,
- the interior of the tyre shows signs of under-inflation
or overloading,
- the rubber shows signs of chemical damage (hydro-
carbons and other corrosive substances),
- incorrect and irreversible repairs have previously
been made to the tyre,
- the carcass has been damaged,
- cuts or circumferential wear (cracks) are visible on the
interior or exterior of the tyre,
- the tyre bead has been damaged (ply visible),
123449
- the tyre's bead wires are visible, damaged or defor-
med,
Areas which cannot be repaired:
- the tyre shows an irregular wear pattern which may
- tyre bead (1) , impair vehicle handling,
- shoulder (3) . - the repair requires two tyre boots to be overlapped,
Areas which can be repaired: - the manufacturer has expressly prohibited any re-
- sidewall (2) , pairs, in writing,
- crown (4) . - there is damage to the shoulder area (junction

between the sidewall and the crown),
Perforation table *
- the angle of the perforation channel (hole) is greater
than 15˚.
Area
Crown: max Sidewall:

Ø in mm max Ø in
mm
LV speed rating 6 3
less than or equal
to T
LV speed rating 6 0
greater than or
equal to H
35A-15
WHEELS AND TYRES
Tyres: Repair 35A
119741
Tyre inflation kit
using the tyre inflation kit, supplied with vehicles or

available from retailers, will leave a film on the inner
surface of the tyre.
119740
Before carrying out the repair, clean the inner surface a Choose the size of plug (mushroom type plug) de-
of the tyre and the valve with water. pending on the size of the hole.
If the tyre cannot be cleaned in this way, contact the

tyre supplier for details of cleaning products which can II - REPAIR OPERATION
be used.
REPAIR
I - REPAIR PREPARATION OPERATION

a Remove the wheel (see 35A, Wheels and tyres,

a Inflate the tyre.
a Locate the perforation on the exterior of the tyre and 119742

mark it with chalk. a Use a drill fitted with a suitable bit, perpendicular to
the surface of the tyre, to bore the interior then the
a Remove the tyre. exterior of the perforation channel.
a Locate the perforation on the interior of the tyre and
mark it with chalk.
a Remove the foreign body which caused the punctu-

re.
a Determine the direction of the perforation channel.
a Determine the size of the hole:
- measure the size of the foreign body,
- measure the extent of the damage to the tyre.
35A-16
WHEELS AND TYRES
Tyres: Repair 35A
119743 119746
a Carefully scrape the rubber seal around the perfora- a Fit the (mushroom type) plug via the interior of the
tion, to the size of the base of the plug (mushroom tyre by pulling on it using pliers.
type plug).
a Press gently on the base of the mushroom plug, in-
side the tyre.
Note: a Refit the tyre.
If the rubber seal is damaged during this opera- a Inflate the tyre (see 35A, Wheels and tyres, Tyre
tion, replace the tyre. inflation pressure: Identification, page 35A-18) .
a Remove any dust and remaining particles of rubber
using a clean, dry cloth.
119747
a Cut the protruding end of the stalk without pulling on
119744 it.
a Apply the solution to the scraped surface. a Check the tyre seal.
Note: III - FINAL OPERATION.
Respect the required drying time for the solution. a Balance the wheel (see 35A, Wheels and tyres,
a Refit the wheel (see 35A, Wheels and tyres,
35A-17
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
I - INFLATION
Essential equipment
diagnostic tool WARNING

If checking the tyre pressure when hot, increase the
recommended pressure by 0.2 to 0.3 bar.
Without the tyre pressure monitor (without SSPP)
Tyre inflation pressure when cold (bar)
Wheel
Tyre
rim Front Rear
Emergency
spare wheel
Normal Motorway Normal Motorway
165/65 R15 81T 5.5 J 15 2.2 2.3 2 2 2.3
185/60 R15 84H 6 J 15 2.2 2.3 2 2 2.3
185/60 R15 88H 6 J 15 2.3 2.4 2 2 2.4
195/50 R16 88V 6 J 16 2.4 2.5 2.2 2.2 2.5
185/65 R15 88V 6 J 15 2.2 2.2 2 2 2.2
175/65 R15 88H 6 J 15 2.3 2.4 2.1 2.2 2.4
215/45 R17 87W 7.5 J 17 2.3 2.4 2.1 2.4 2.4
With the tyre pressure monitor (with SSPP)
Tyre inflation pressure when cold (bar)
Wheel
Tyre
rim Front Rear
Emergency
spare wheel
Normal Motorway Normal Motorway
165/65 R15 81T 5.5 J 15 2.4 2.5 2.2 2.2 2.5
185/60 R15 84H 6 J 15 2.4 2.5 2.2 2.2 2.5
185/60 R15 88H 6 J 15 2.5 2.6 2.2 2.2 2.6
195/50 R16 88V 6 J 16 2.6 2.7 2.4 2.4 2.7
185/65 R15 88V 6 J 15 2.4 2.4 2.2 2.2 2.4
175/65 R15 88H 6 J 15 2.5 2.6 2.3 2.4 2.6
215/45 R17 87W 7.5 J 17 2.5 2.6 2.3 2.6 2.6
The pressure values given are recommendations when II - CONFORMITY CHECK AND ADJUSTMENT
cold.
If the tyre size is changed, calibrate the electric power-
assisted steering computer using the diagnostic tool
(see MR 394 Fault finding, 36B, Electric power-as-
sisted steering, Replacement of components).
35A-18
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
Wheel rim offset:
- steel wheel rim: 43 mm,
- alloy wheel rims: 50 mm.
For information on fitting chains, see « Driver's
handbook » .
35A-19
WHEELS AND TYRES
Tyres: Identification 35A
Example of a tyre identification mark: 205/65 R 15 91 Speed code table:
V.
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
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-20
WHEELS AND TYRES
Wheel rim: Identification 35A
IDENTIFICATION 2 - Installation diameter for the wheel bolts
1 - Marking
The wheel bolts are positioned with a pitch circle dia-
There are two types of identification marking on the meter of:
wheel rims:
- 5 holes: 108 mm,
- engraved marking for steel wheel rims, - 4 holes: 100 mm.
- cast marking for alloy wheel rims.
The marking gives the main dimensional specifications 3 - Rim run-out
of the wheel rim. The maximum run-out is measured at the wheel rim
This marking may be: 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
The maximum out-of-round value is measured on the
1 Width (in inches) 6 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-21
WHEELS AND TYRES
Spare wheel winch: Removal - Refitting 35A
Tightening torquesm
emergency spare wheel 21 Nm

winch mounting nuts
IMPORTANT
Only manipulate the emergency spare wheel
lashing system when the vehicle is on the ground.
REMOVAL

a Open the vehicle's boot.
a Lift the luggage compartment carpet.
112625
a Fully undo the white wheel (2) .
112624
a Remove the emergency spare wheel cover (1) .
112626
a Press the arrow several times until the emergency
spare wheel falls on to the ground.
35A-22
WHEELS AND TYRES
Spare wheel winch: Removal - Refitting 35A
REFITTING

a
Note:
The handle and winch are sold unassembled
when purchased as a spare part. Assemble the
two components for fitting operations.
To assemble, clip the plastic cup located at the
end of the cable onto the winch.

CONCERNED
a Refit:
- the emergency spare wheel winch,
- the winch mounting nuts.
112616
a Torque tighten the emergency spare wheel winch
a Remove the winch cable (3) from its housing.
mounting nuts (21 Nm).
a Remove the emergency spare wheel.
a Check that there is a spacer under the floor; this
CONCERNED
should only be used for an emergency spare wheel
fitted with a 165 tyre.
a Place the winch cable back into the housing.
a Pull the winch lever to reposition the emergency
spare wheel.
a Tighten the white wheel whilst holding the lever.
a Continue tightening until you hear a click.
a Check that the emergency spare wheel has been
correctly attached.
a Refit the emergency spare wheel cover.
a Refit the boot carpet.
a Close the boot.
109672
a Remove:
- the winch mounting nuts (4) ,
- the emergency spare wheel winch.
35A-23
TYRE PRESSURE MONITOR
SSPP: List and location of components 35B
TYRE PRESSURE SENS.
113761
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 proces-
ses sensor signals, and then determines which mes-
sage to display,
- a display (3) integrated to the instrument panel,
107738
35B-1
SSPP: List and location of components 35B
TYRE PRESSURE SENS.
112441
- a UCH (4) located behind the passenger compart-

ment relay/fuse box (5) .
Note:
The position of the sensor on each wheel is auto-
matically identified by the UCH computer.
112623
The pressure sensor comprises:
- a conventional valve,
- a pressure sensor,
- a temperature sensor,
- an acceleration sensor,
- a specific radiofrequency transmitter,
- a non-removable battery.
35B-2
Tyre pressure monitor computer: Removal - Refitting 35B
TYRE PRESSURE SENS.
Essential equipment
diagnostic tool
Tightening torquesm
computer mounting nuts 20 Nm
REMOVAL
a Lock the airbag computer using the diagnostic tool

(see Fault finding - Replacement of components)
(MR 394, 88C, Airbag and pretensioners).
IMPORTANT 113760
It is essential to lock the airbag computer using a Disconnect the connector (1) .
the diagnostic tool before starting the removal.
When this function is activated, all the trigger a Remove:
lines are disabled and the airbag instrument - the computer mounting nuts (2) ,
panel warning light is continuously lit (with the
ignition on). Locking the airbag computer also - the computer.
unlocks the electric steering column lock.
IMPORTANT REFITTING
Handling the pyrotechnic systems (airbag and
pretensioners) near a heat source or flame is I - REFITTING OPERATION FOR PART
prohibited: there is a risk of triggering the airbags CONCERNED
or pretensioners.
a Refit the carpet and the sound insulation.
a Refit:
IMPORTANT
The steering column must be replaced if the air- - the computer's mounting nuts,
bag has been triggered. - the computer.

Refitting) (MR 392, 80A, Battery). a Reconnect the connector.
a Remove the front left-hand seat (see Complete a Torque tighten the computer mounting nuts (20
front seat: Removal - Refitting) (MR 393, 75A, Nm).
Front seat frames and runners).
a Remove the front door sill lining (see Front door sill II - FINAL OPERATION.
lining: Removal - Refitting) (MR 393, 71A, Body
internal trim). a Refit the front door sill lining (see Front door sill
lining: Removal - Refitting) (MR 393, 71A, Body
internal trim).
CONCERNED a Refit the front left-hand seat (see Complete front
seat: Removal - Refitting) (MR 393, 75A, Front
a Lift the carpet and the sound-insulation. seat frames and runners).
35B-3
Tyre pressure monitor computer: Removal - Refitting 35B
TYRE PRESSURE SENS.
ting) (MR 392, 80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of compo-
nents) (MR 394, 88C, Airbag and pretensioners).
35B-4
Pressure sensor: Removal - Refitting 35B
TYRE PRESSURE SENS.
REFITTING
Tightening torquesm
tyre pressure monitor 7.5 Nm
sensor retaining nut
REMOVAL

ment).
a Remove:
- the wheels (see 35A, Wheels and tyres, Wheel:
Removal - Refitting, page 35A-1) ,
- the tyres (see 35A, Wheels and tyres, Tyres: Re- 112623
a If necessary, replace the retaining nut (3) .
II - OPERATION FOR REMOVAL OF PART a Always replace the following parts:

CONCERNED
- the mechanism (4) ,
- the cap (5) ,
- the seal (6) .

CONCERNED
a Position the sensor in the valve opening, checking

that the seal is attached all around the edge of the
opening.
a Refit the retaining nut of the tyre pressure monitor

sensor.
112627
a Remove:
- the retaining nut (1) ,
- the pressure sensor (2) .
112628
a Make sure that the sensor is correctly positioned on

the wheel rim.
35B-5
Pressure sensor: Removal - Refitting 35B
TYRE PRESSURE SENS.
a Torque tighten the tyre pressure monitor sensor
retaining nut (7.5 Nm).
Note:
After using a tyre repair aerosol, remove the pro-
duct residue from the valve with a dry cloth or air
gun before refitting it on the wheel rim.

a Refit:
- the tyres (see 35A, Wheels and tyres, Tyres: Re-
moval - Refitting, page 35A-10) ,
35B-6
STEERING ASSEMBLY
Steering rack: Removal - Refitting 36A
a Remove:
Tightening torquesm - the front wheels (see 35A, Wheels and tyres,
steering box bolts on the 105 N.m
front axle subframe - the engine undertray bolts,

REMOVAL
- the front axle subframe (see 31A, Front axle com-
I - REMOVAL PREPARATION OPERATION ponents, Front axle sub-frame: Removal - Refit-
CONCERNED
RIGHT-HAND DRIVE
108820
a Remove:
- the heat shield bolts from the steering box,
- the steering box heat shield (1) ,
36A-1
STEERING ASSEMBLY
Steering rack: Removal - Refitting 36A
a Refit:
- the front axle sub-frame (see 31A, Front axle
components, Front axle sub-frame: Removal -
a Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-23) .
XENON BULBS
a It is essential to initialise the xenon bulb system (see
Fault finding - Replacement of components)
(80B, Headlights).
140642
a Tilt the anti-roll bar (2) backwards.
a Remove:
- the steering box bolts (3) ,
- the steering box of the front axle subframe.
REFITTING
a parts always to be replaced: Steering rack bolt

(13,04,03,05).

CONCERNED
a Refit the steering box on the front axle subframe.
a Tighten to torque the steering box bolts on the

front axle subframe (105 N.m).
a Tilt the anti-roll bar forward.
RIGHT-HAND DRIVE
a Refit the heat shield on the steering rack.
36A-2
STEERING ASSEMBLY
Track rod: Removal - Refitting 36A
Tightening torquesm
track rod ball joint nut 37 N.m
wheel alignment adjus- 53 N.m

ting lock nut
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see Steering: Precautions for repair) .
REMOVAL

a Loosen the wheel alignment adjustment lock nut (1)
.
a Remove the front wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) . a Remove the track rod ball joint nut (2) .
122713
a Extract the ball joint using (3) (Tav. 476).

116760
a Release the wheel speed sensor wiring a Unscrew the track rod anti-clockwise and note the
number of turns for refitting.
a Remove the track rod.
36A-3
STEERING ASSEMBLY
Track rod: Removal - Refitting 36A
REFITTING

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.
- the track rod ball joint nut (37 N.m),
- the wheel alignment adjusting lock nut (53
N.m).

a Refit the wheel speed sensor wiring.

a Check the axle geometry (see Axle assemblies:
Check) .
a If necessary, adjust the geometry of the axle assem-
blies (see 30A, General information, Front axle:
36A-4
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
Dir. 1305-01 Tool for removing/refitting 35
mm to 41 mm diameter axial
ball joints.
Dir. 1741 Tool for locking steering rack.
Tightening torquesm
axial ball joint 80 N.m
REMOVAL

a Remove the front wheel (see 35A, Wheels and ty-
a Remove the track rod (see 36A, Steering assem-
bly, Track rod: Removal - Refitting, page 36A-3) .
a Remove the steering rack gaiter (see 36A, Steering
assembly, Steering rack gaiter: Removal - Refit-
Note:
During this operation, the steering rack must be
in place on the vehicle.
109878
a Set up the (1) Dir. 1741 on the steering rack, at the
pinion end.
a Unlock the axial ball joint using tool (2) Dir. 1305-
01 .
a Remove the axial ball joint.
REFITTING

a parts always to be replaced: Steering axial ball
joint washer (13,04,02,04)
36A-5
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
CONCERNED
109875
a Refit:
- a new washer (1) ,
- the axial ball joint (2) .
a Torque tighten the axial ball joint (80 N.m) using
the tool (Dir. 1305-01).
a Remove the (Dir. 1741).
a Coat with SILICONE GREASE (see Vehicle: Parts
and ingredients for the repairwork) :
- the steering rack,
- the axial ball joint.

a Refit the steering box gaiter (see 36A, Steering as-
sembly, Steering rack gaiter: Removal - Refit-
a Refit the track rod (see 36A, Steering assembly,
Track rod: Removal - Refitting, page 36A-3) .
Check) .
a If necessary, adjust the axle assemblies' geometry
(see 30A, General information, Front axle: Adjus-
36A-6
STEERING ASSEMBLY
Steering column: List and location of components 36A
VEHICLE WITH KEY
108970
(1) Intermediate shaft

VEHICLE WITH CARD
(2) Steering column adjustment
handle
(3) Key-operated switch
112874
36A-7
STEERING ASSEMBLY
Steering column: List and location of components 36A
(4) Intermediate shaft
(5) Electric steering column lock
(6) Steering column adjustment
handle
36A-8
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
a Remove the steering column switch assembly (see
Steering wheel controls assembly: Removal -
Essential equipment
Refitting) (MR 392, 84A, Control - Signals).
diagnostic tool
VEHICLE WITH KEY
a Remove:
Tightening torquesm
- the immobiliser antenna/transponder ring (see
steering column bolts 21 Nm Transponder ring: Removal - Refitting) (MR
392, 82A, Immobiliser),
bolt connecting the 32 Nm
steering column to the - the ignition switch, if replacing the steering column
intermediate shaft (see Ignition switch: Removal - Refitting) (MR
392, 82A, Immobiliser).
universal joint bolt on 24 Nm
the steering box
VEHICLE WITH CARD
IMPORTANT a Remove the electric steering column lock (see Stee-

ring column electric lock: Removal - Refitting)
To avoid any risk of triggering when working on or
(MR 392, 82A, Immobiliser).
near a pyrotechnic component (airbags or preten-
sioners), lock the airbag computer using the dia-
gnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the ins- II - OPERATION FOR REMOVAL OF PART
trument panel lights up continuously (ignition on). CONCERNED
a Lift the floor carpet to access the universal joint bolt.
IMPORTANT
Never handle the pyrotechnic systems (pretensio-
ners or airbags) near to a source of heat or naked
flame - they may be triggered.
REMOVAL

113091
(MR 394, 88C, Airbags and pretensioners).
a Remove the universal joint cover (1) (do not keep).

a Remove the driver's front airbag (see Driver's front
airbag: Removal - Refitting) (MR 392, 88C, Air-
bags and seat belt pretensioners).
a Remove the steering wheel (see 36A, Steering as-
sembly, Steering wheel: Removal - Refitting,
page 36A-22) .
36A-9
STEERING ASSEMBLY
113092
a Remove:
- the universal joint bolt (2) (do not keep),
- the universal joint nut (do not keep).
112876
a Remove the steering column from the pre-supports

(4) to set it down on the shim.
112299
a Remove the steering column bolts (3) on the cross
member.
a Fit a shim, approximately 20 cm, on the floor under
the intermediate shaft bolt (6) to position the column
before disconnecting the connections (5) .
Note:
The column cannot be set down directly on the
floor since the cable is not long enough. 112874
a Disconnect the three connectors (5) while holding

the column on the shim.
a Remove:
- the steering column with the intermediate shaft,
- the bolt (6) connecting the steering column to the

intermediate shaft,
- the steering column intermediate shaft.
36A-10
STEERING ASSEMBLY
REFITTING a Remove the shim.
a Torque tighten the steering column bolts (21 Nm).

a Always replace:
- the steering wheel bolt after each removal,
- the universal joint bolt and cam nut after each re-
moval.
WARNING
mediate shaft.

CONCERNED
104020
a Observe the direction of fitting for the universal joint

cam nut and bolt.
a Refit:

a Pretighten the universal joint cam nut and bolt.

a Torque tighten:
- the bolt connecting the steering column to the

intermediate shaft (32 Nm),
- the universal joint bolt on the steering box (24

Nm).
109877
a Refit:
- the intermediate shaft of the steering column,
Note:
- the bolt connecting the steering column to the inter-
mediate shaft, Check that the floor carpet fits under the accele-
rator pedal end-stop.
- the steering column connectors,
- the steering column with the intermediate shaft,
- the steering column bolts on the cross member.
VEHICLE WITH CARD

a Refit the electric steering column lock (see Steering
Note: column electric lock: Removal - Refitting) (MR
Check that the steering column is held on the
cross member using the front and rear pre-sup-
ports (4) before tightening it.
36A-11
STEERING ASSEMBLY
VEHICLE WITH KEY
a Refit:
- the ignition switch, if replacing the steering column
(see Ignition switch: Removal - Refitting) (MR
392, 82A, Immobiliser),
- the immobiliser antenna/transponder ring (see
Transponder ring: Removal - Refitting) (MR
a Refit:
- the steering column switch assembly (see Stee-
ring wheel controls assembly: Removal - Refit-
ting) (MR 392, 84A, Control - Signals),
- the steering wheel (see 36A, Steering assembly,
Steering wheel: Removal - Refitting, page 36A-
22) ,
- the driver's front airbag (see Driver's front airbag:
Removal - Refitting) (MR 392, 88C, Airbags and
seat belt pretensioners).
tool (see Fault finding - Replacement of compo-
nents) (MR 394, 88C, Airbag and pretensioners).
a Configure the power-assisted steering computer
(MR 394, 36B, Electric steering).
36A-12
STEERING ASSEMBLY
Steering rack gaiter: Removal - Refitting 36A
REMOVAL REFITTING

Towing and lifting) (02A, Lifting equipment). a Always replace:
a Remove: - the steering box gaiter,

- the retaining clips.
- the track rod, (see 3 6 A, Steering assembly, a Clean the contact surfaces between the steering box
Track rod: Removal - Refitting, page 36A-3) and the gaiter using SURFACE CLEANER (see Ve-
hicle: Parts and ingredients for the repairwork) .
- the wheel alignment adjusting lock nut.
a Coat the gaiter bearing face on the axial ball joint
II - OPERATION FOR REMOVAL OF PART with SILICONE LUBRICANT (see Vehicle: Parts
CONCERNED and ingredients for the repairwork) to prevent the
gaiter from twisting.
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 irre-
versible damage.

CONCERNED
a Refit:
- a new steering box gaiter,
105678 - new retaining clips.

a
Note: III - FINAL OPERATION.

When removing the steering gaiter, blast the gai- a Refit:
ter surfaces with compressed air to eliminate any
impurities that could enter the steering box. - the wheel alignment adjustment lock nut,
a Remove the gaiter retaining clip (1) - the track rod, (see 3 6 A, Steering assembly,
a Cut the gaiter retaining clip (2) . Track rod: Removal - Refitting, page 36A-3)
a Remove the gaiter (3) . - the front wheel (see 35A, Wheels and tyres,

Check) .
a If necessary, adjust the axle assemblies' geometry

(see 30A, General information, Front axle: Adjus-
36A-13
STEERING ASSEMBLY
Bulkhead seal: Removal - Refitting 36A
REMOVAL II - FINAL OPERATION.
a Refit:
I - REMOVAL PREPARATION OPERATION - the steering box (see 36B, Power assisted stee-
ring, Power assisted steering rack: Removal -
a Position the vehicle on a two-post lift (see Vehicle: Refitting, page 36B-3) ,
Towing and lifting) (MR 392, 02A, Lifting equip- - the engine undertray,
ment).
a Remove:

- the steering box (see 36B, Power assisted stee-

ring, Power assisted steering rack: Removal -
Refitting, page 36B-3) .

CONCERNED
108823
a Unclip the bulkhead seal (2) at (1) using a flat-blade

screwdriver.
REFITTING

CONCERNED
a Fit the bulkhead seal in its original position.
36A-14
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
Tightening torquesm
universal joint bolt on 24 Nm

the steering rack
bolt on the steering 32 Nm

column
REMOVAL

112300
Refitting) .
a Remove:
- the lower cover mounting bolts (3) ,
- the lower cover mounting clip (5) .
a Unclip the lower cover (4) .
a Disconnect the various connectors (depending on
equipment level).
a Remove the lower cover.

CONCERNED
112629
a Remove:
- the mounting clips (1) from the lower trim of the dri-
ver's side dashboard,
- the lower trim (2) of the driver's side dashboard.
a Remove:
- the bolt-cover protective strip, 113091
- the instrument panel's side cover. a Remove the steering column universal joint cover
(6) (do not keep).
36A-15
STEERING ASSEMBLY
104020
a Ensure that the steering column universal joint cam

nut and bolt are fitted the right way round.
Note:
113089
a Remove: - always replace the steering column universal
joint bolt and cam nut (6) each time they are
- the universal joint bolt (7) (do not keep), removed.
- the universal joint nut (do not keep). - on a new intermediate shaft, the universal joint
- the intermediate shaft bolt (8) on the column, cam nut is prefitted; do not remove the cover (6)
.
- the intermediate shaft (9) .
a Refit the intermediate shaft to the column.
REFITTING a Pretighten the mounting bolt of the shaft on the colu-
mn.
I - REFITTING PREPARATION OPERATION a Pull the intermediate shaft to make sure that the bolt
a Always replace the universal joint bolt and cam nut is present in the neck
after each removal.
a Refit:
II - REFITTING OPERATION FOR PART - the universal joint,

CONCERNED
- the universal joint cam nut and bolt.
a Refit the intermediate shaft in its original position.
a Pretighten the universal joint cam nut and bolt.

WARNING
is present in the neck
mediate shaft. a Tighten to torque:
- the universal joint bolt on the steering rack (24

Nm),
- the bolt on the steering column (32 Nm).
Note:
Check that the floor carpet reaches under the
accelerator pedal end-stop.
36A-16
STEERING ASSEMBLY
a Refit the lower cover.
a Connect the various connectors (depending on equi-
pment level).
a Engage the lower cover clips.
a Refit:
- the lower cover mounting clip,
- the lower cover mounting bolts,
- the instrument panel's side cover,
- the bolt-cover protective strip,
- the lower trim of the driver's side dashboard,
- the mounting clips on the lower trim of the driver's
side dashboard.
ting) .
36A-17
STEERING ASSEMBLY
Steering column adjustment handle Removal - Refitting 36A
REMOVAL

Refitting) .
112300
a Remove:
- the lower cover mounting bolts (3) ,
- the lower cover mounting clip (or bolt) (5) .
a Unclip lower cover (4) .
a Disconnect the various connectors (depending on
equipment level).
a Remove the lower cover.
a Remove the mounting bolts of the half shells (see
112629 Steering wheel controls assembly: Removal -
a Remove: Refitting) .
- the mounting clips (1) on the lower trim of the dri-
ver's side dashboard, Note:
- the lower trim (2) of the driver's side dashboard. Do not remove the steering wheel switch assem-
a Remove: bly.
- the bolt-cover protective strip, a Unclip the two half shells .

- the instrument panel's side cover. a Remove the lower half shell.
36A-18
STEERING ASSEMBLY
CONCERNED

VEHICLE WITH KEY
VEHICLE WITH KEY
112301
109880
a Remove:
- the nut (6) on the adjustment handle shaft, (7) Handle

(8) Indexed adjustment plates
- the locking mechanism,
(9) Connection shaft
- the adjustment handle. (10) Locking mechanism
(11) Adjustment handle shaft nut
Note:
VEHICLE WITH CARD
When the handle is refitted, ensure the two
a Remove: indexed adjustment plates and retaining spring
are correctly positioned.
- the nut (12) on the adjustment handle shaft using
an 18 mm spanner,
- the washer,
- the adjustment handle,
- the locking mechanism.
Note:
the connecting shaft is trapped on the steering
column.
36A-19
STEERING ASSEMBLY
II - OPERATION FOR REFITTING PART
CONCERNED
VEHICLE WITH CARD
VEHICLE WITH KEY

a Refit:
- the adjustment handle.
- the adjustment handle mounting nut.
Note:
The amount of effort required to operate the han-
dle is determined by how much it is tightened.
Test to determine the correct tightening.
VEHICLE WITH CARD
113756 a Refit:
(12) Adjustment handle shaft nut
- the adjustment handle,
(13) Washer
(14) Handle - the washer,
(15) Indexed adjustment plates - the nut on the adjustment handle shaft.
(16) Locking mechanism
a Note:
The amount of effort required to operate the han-
Note:
dle is determined by how much it is tightened.
When refitting the handle, make sure that the Test to determine the correct tightening.
studs (17) of the indexed adjustment plates are
correctly positioned and that the direction of the
locking mechanism is correct.

a Reattach the two half shells.
a Refit the mounting bolts of the half shells.
a Refit the lower cover.
a Connect the various connectors (depending on equi-
pment level).
a Engage the lower cover clips.
a Refit:
- the lower cover mounting clip (or bolt),
- the lower cover mounting bolts,
- the instrument panel's side cover,
- the bolt-cover protective strip,
36A-20
STEERING ASSEMBLY
- the lower trim of the driver's side dashboard,
- the mounting clips on the lower trim of the driver's
side dashboard.
ting) .
36A-21
STEERING ASSEMBLY
Steering wheel: Removal - Refitting 36A
Essential equipment LEFT-HAND DRIVE
diagnostic tool
Tightening torquesm
steering wheel bolt 44 Nm
REMOVAL

(see MR 394 Fault Finding, 88C, Airbags and pre-
tensioners, Airbag computer locking procedu-
re).
112964
IMPORTANT a Disconnect the connectors (1) (if fitted to the vehi-
It is important to lock the airbag computer using cle).
the diagnostic tool before starting the removal.
When this function is activated, all the trigger a Remove:
lines are disabled and the airbag instrument - the steering wheel bolt (2) ,
panel warning light is lit when the ignition is swit-
ched on. Locking the airbag computer also - the steering wheel.
allows the electric steering column lock to be
released.
IMPORTANT
Handling the pyrotechnic systems (airbag and
pretensioners) near a heat source or flame is
prohibited: there is a risk of triggering the airbags
or pretensioners.
IMPORTANT
The steering column must be replaced if the air-
bag has been triggered.

Refitting) .
a Remove the frontal airbag (see Driver's front air-

bag: Removal - Refitting) .

CONCERNED
36A-22
STEERING ASSEMBLY
Steering wheel: Removal - Refitting 36A
RIGHT-HAND DRIVE a Refit the frontal airbag (see Driver's front airbag:
ting) .
tool (see MR 394 Fault Finding, 88C, Airbags and
pretensioners, Airbag computer locking proce-
dure).
112963
a Disconnect the connector (1) (if fitted to the vehicle).
a Remove:
- the steering wheel bolt (2) ,
- the steering wheel.
REFITTING

a The steering wheel slots onto the column using a
double tooth.
a Always replace the steering wheel bolt with a new
one after each removal.

CONCERNED
a Pass the various connectors into the opening in the
steering wheel
a Refit:
- the steering wheel in its original position,
- the new steering wheel bolt.
a Tighten to torque the steering wheel bolt (44 Nm).

a Connect the connectors (if fitted to the vehicle).
36A-23
POWER ASSISTED STEERING
Power assisted steering: Function 36B
Assistance varies according to vehicle speed.
IMPORTANT
Do not remove any steering column component.
Note:
During fault finding, the Service warning light
flashes at a frequency of 2 Hz.
36B-1
Power assisted steering rack: List and location of components 36B
108822
(1) Steering rack

(2) Track rod
(3) Axial ball joint linkage
(4) Bulkhead seal
36B-2
Power assisted steering rack: Removal - Refitting 36B
JH3 or JR5, and LEFT-HAND DRIVE
Tightening torquesm
steering box mounting 110 N.m

bolts
engine tie-bar mounting 105 N.m

bolt
exhaust d ownpipe 21 N.m

mounting bolts
113091
universal joint mounting 24 N.m a Remove the universal joint cover (1) (do not keep).
bolt
anti-roll bar tie-rod nuts 44 N.m
track rod nuts 35 N.m
REMOVAL

ment).
a Remove:
Wheel: Removal - Refitting, page 35A-1) , 113092
- the engine undertray. a Remove the universal joint bolt (2) (do not keep),
a Remove the universal joint from the steering box.
CONCERNED
36B-3
a Unclip the oxygen sensor wiring harness from the
steering rack.
108838
a Remove the steering box mountings (5) .
112050
a Remove:
- the mounting nuts (3) from the track rod,
- the anti-roll bar tie-bar upper nuts (4) .
Note:
It is necessary to rotate the anti-roll bar onto
itself in order to make it easier to position the
steering rack on the sub-frame cross member.
108838
a Remove the engine tie-bar mounting (6) on the engi-
ne.
a Loosen the engine tie-bar retaining bracket moun-
ting bolt (7) in order to be able to turn the retaining
bracket.
a Tip the engine forwards using a lever to remove the
steering rack.
112619
a Extract the ball joint using (1) Tav. 476 .

a Tilt the anti-roll bar towards the rear of the vehicle.
36B-4
a Refit the engine tie-bar mountings.
a Torque tighten the engine tie-bar mounting bolt
(105 N.m).
a Refit the exhaust downpipe mounting bolts, if they
were removed.
101793
104020
a Remove the exhaust downpipe mounting bolts (8) , if a Respect the direction when fitting the universal joint
necessary. nut and bolt.
a Remove the steering rack, going towards the left- a Refit:
hand side of the vehicle; two people are required to
carry out this operation. - the universal joint,
If the vehicle is fitted with xenon bulbs, be careful not - the new universal joint bolt,
to damage the xenon bulb sensor.
a Pre-tighten the universal joint nut and bolt.
REFITTING
a Always replace the following after each removal
operation: - the exhaust downpipe mounting bolts (21 N.m),
- the universal joint nut and bolt, - the universal joint mounting bolt (24 N.m).
- the anti-roll bar link rod brake nuts. a Refit the floor carpet.

Note:
CONCERNED
Check that the floor carpet fits under the accele-
a Refit: rator pedal end-stop.
- the steering rack inserting it from the left-hand side
of the vehicle, being careful not to damage the xe- a Clip the oxygen sensor wiring harness back onto the
non bulb beam sensor, steering rack.
- the xenon bulb beam sensor (if fitted to the vehi- a Tilt the anti-roll bar back into its original position.
cle), a Place the ball joints back into their housing.
- the steering rack mounting bolts. a Refit:
a Torque tighten the steering box mounting bolts - the track rod mounting nuts,
(110 N.m), starting with the bolt on the right-hand
side of the vehicle. - the anti-roll bar link rod lower nuts.
36B-5
- the anti-roll bar tie-rod nuts (44 N.m),
- the track rod nuts (35 N.m).

a Refit:
a Adjust the front axle assemblies (see Front axle:
Adjusting) .
a Be sure to initialise the xenon bulb system (if fitted to
the vehicle); (see MR 394 Fault finding, 80C, Dis-
charge bulbs, Replacement of components).
36B-6
DP0 or TL4, and LEFT-HAND DRIVE
Tightening torquesm
steering rack mounting 110 Nm

bolts
REMOVAL

a Remove:
- the sub-frame (see 31A, Front axle components,
Front axle sub-frame: Removal - Refitting, page
31A-53) .
36B-7
CONCERNED
vehicle sub-frame without xenon bulbs
108820
36B-8
vehicle sub-frame fitted with xenon bulbs
115062
a Remove: II - REFITTING OPERATION FOR PART

CONCERNED
- the steering rack mounting bolts (1) ,
a Refit:
- the steering rack (2) being careful not to damage
the xenon bulb beam sensor. - the steering rack,
- the xenon bulb beam sensor (if fitted to the vehi-
cle),
REFITTING
- the steering rack mounting bolts.
I - REFITTING PREPARATION OPERATION a Tighten to torque the steering rack mounting bolts
(110 Nm).
a Always replace the following after each removal
operation:
- the anti-roll bar link rod brake nuts,
a Refit:
- the universal joint bolt and cam nut.
- the sub-frame (see 31A, Front axle components,
Front axle sub-frame: Removal - Refitting, page
WARNING 31A-53) ,
Be sure to insert a 10 mm shim between the - the front wheels (see 35A, Wheels and tyres,
radiator cross member and the sub-frame, and Wheel: Removal - Refitting, page 35A-1) .
centre the radiator cross member pin in the sub-
a Adjust the front axle assemblies (see Front axle:
frame opening on the lower arm front mounting,
Adjusting) .
to torque tighten the radiator cross member
mountings. a Be sure to initialise the xenon bulb system (if fitted to
the vehicle); (see MR 394 Fault finding, 80C, Xe-
a Set the wheels straight ahead. non bulbs, Replacement of components).
36B-9
Electric power assisted steering computer: Configuration 36B
a Configure the power-assisted steering computer
(see MR 394 Diagnostic, 36B, Electric power as-
sisted steering, Component replacements).
36B-10
MECHANICAL COMPONENT CONTROLS
Manual gear shift control: Adjusting 37A
TL4
ADJUSTMENT
ADJUSTMENT OF SELECTION CABLE DURING A

REMOVAL OPERATION
1 - Passenger compartment
a Shift the selector lever to third gear.
117113
a Unlock the selector cable adjustment clip by com-
pressing the lock ring (3) and push the orange clip
(4) upwards b (1) .
a Adjust the length of the cable accordingly and fit it
onto the gear selection lever ball joint.
116198
a Fit a shim (1) (6 mm between the locking ring and
reverse gear interlock on the selector lever.
a Use a strap (2) to immobilise the lever against the
shim in third gear position.
2 - Engine compartment
a Position the gear lever on the gearbox in "third gear
engaged" position.
117113
a Lock the cable by pressing on the orange clip (5) .
a Check that gear selection is correct.
37A-1
Master cylinder: Removal - Refitting 37A
F4R or K4J or K4M or K9K or M4R, and LEFT-HAND DRIVE
Tightening torquesm
master cylinder reser- 8.5 Nm

voir mounting bolt
nuts mounting the mas- 25 Nm

ter cylinder
brake pipes on the mas- 17 Nm

ter cylinder
WARNING
Prepare for brake fluid outflow, to prevent damage
to the mechanical parts and bodywork around the
braking system.
REMOVAL
112297
I - REMOVAL PREPARATION OPERATION a Loosen the air duct clip (1) .

a Position the vehicle on a two-post lift (see Vehicle: a Withdraw the pipe (2) on the air duct.
a Remove the air duct (3) .
ment).
a Remove:
- the battery (see Battery : Removal - Refitting)
(MR 392, 80A, Battery),
fitting) (MR 392, 12A, Fuel mixture).
37A-2
CONCERNED
112622
a The master cylinder seals (9) must be replaced.

116781
CONCERNED
a Disconnect the electrical connector (4) from the
master cylinder reservoir. a Clip the master cylinder reservoir onto the master
cylinder correctly.
a Drain the master cylinder reservoir with a syringe.
a Refit the master cylinder reservoir mounting bolt on
a Remove: the master cylinder.
- the clutch master cylinder pipe (5) , if fitted to the a Torque tighten the master cylinder reservoir
vehicle, mounting bolt (8.5 Nm).
- the brake pipes (6) on the master cylinder,
- the master cylinder mounting nuts (7) on the servo,
- the « master cylinder/master cylinder reservoir »
assembly,
- the master cylinder reservoir mounting bolt (8) on
the master cylinder,
- the master cylinder reservoir.
37A-3
a Refit:
fitting) (MR 392, 12A, Fuel mixture),
(MR 392, 80A, Battery).
101711
a Line up the master cylinder with the brake servo so
that the pushrod goes into the master cylinder hou-
sing.
WARNING
When refitting the master cylinder, be sure that
the cup is centred in the brake servo.
a Refit the nuts securing the master cylinder to the

brake servo.
a Torque tighten the nuts mounting the master cy-
linder (25 Nm) on the servo.
a Refit the brake pipes to the master cylinder.
a Torque tighten the brake pipes on the master cy-
linder (17 Nm).
JH3 or JR5 or TL4

a Refit the clutch master cylinder pipe.
a Connect the electrical connector on the master cylin-

der reservoir.

a Refit:
- the air duct,
- the air duct pipe.
a Tighten the air duct clip.
37A-4
RIGHT-HAND DRIVE
CONCERNED
Tightening torquesm
master cylinder reser- 9 Nm

voir bolt
master cylinder nuts 25 Nm

ter cylinder
WARNING
113185
REMOVAL
a Disconnect the connector (1) from the master cylin-
der reservoir.
Towing and lifting) (MR 392, 02A, Lifting equip- a Remove:
ment). - the clutch master cylinder pipe (2) , if fitted to the
a Remove: vehicle,
- the engine cover (if fitted to the vehicle), - the brake pipes (3) on the master cylinder,
- the scuttle panel grille (see Scuttle panel grille: - the master cylinder nuts (4) on the servo,
pment), - the « master cylinder-reservoir » assembly,
- the scoop under the scuttle panel grille (see Scoop - the master cylinder reservoir bolt (5) on the master
under scuttle panel grille: Removal - Refitting) cylinder,
(MR 393, 56A, Exterior equipment). - the master cylinder reservoir.
REFITTING
112622
37A-5
RIGHT-HAND DRIVE
II - REFITTING OPERATION FOR PART III - FINAL OPERATION.
CONCERNED
a Refit:
a Clip the master cylinder reservoir onto the master - the scoop under the scuttle panel grille (see Scoop
cylinder correctly. under scuttle panel grille: Removal - Refitting)
(MR 393, 56A, Exterior equipment),
a Refit the bolt securing the master cylinder reservoir
to the master cylinder. - the scuttle panel grille (see Scuttle panel grille:
a Torque tighten the master cylinder reservoir bolt pment).
(9 Nm).
101711

sing.
a When refitting the master cylinder, be sure that the

cup is centred in the brake servo.
a Refit the master cylinder nuts to the brake servo.
a Torque tighten the master cylinder nuts (25 Nm)

on the servo.

linder (17 Nm).
JH3 or JR5 or TL4
a Connect the master cylinder reservoir connector.
37A-6
D4F, and LEFT-HAND DRIVE
CONCERNED
Tightening torquesm

voir mounting bolt
master cylinder moun- 25 Nm

ting nuts
master cylinder brake 17 Nm

pipes
WARNING
Prepare for brake fluid running out, to prevent
REMOVAL

112053
a Position the vehicle on a two-post lift (see Vehicle: a Disconnect the electrical connector (1) from the
master cylinder reservoir.
a Remove:
- the clutch master cylinder pipe (2) ,
- the master cylinder mounting nuts (4) on the servo,
- the « master cylinder - master cylinder reservoir »
assembly,
- the master cylinder reservoir mounting bolt (5) on
the master cylinder,
37A-7
REFITTING
112622
101711
II - REFITTING OPERATION FOR PART a Line up the master cylinder with the brake servo so
CONCERNED that the pushrod goes into the master cylinder hou-
sing.
a Clip the master cylinder reservoir onto the master
cylinder correctly.
WARNING
a Refit the master cylinder reservoir mounting bolt on
the master cylinder. When refitting the master cylinder, be sure that
a Tighten to torque the master cylinder reservoir
mounting bolt (8.5 Nm). a Refit the nuts securing the master cylinder to the
brake servo.
a Tighten to torque the master cylinder mounting
nuts (25 Nm) on the brake servo.
a Refit the brake pipes to the master cylinder,
a Tighten to torque the master cylinder brake pipes
(17 Nm) on the master cylinder.
der reservoir.

37A-8
M4R, and RIGHT-HAND DRIVE
Tightening torquesm

voir bolt

ter cylinder
WARNING
REMOVAL

117876
a Position the vehicle on a two-post lift (see Vehicle: a Disconnect the atmospheric pressure sensor con-
Towing and lifting) (MR 392, 02A, Lifting equip- nector (1) .
ment).
a Remove the atmospheric pressure sensor mounting
a Remove: bolt (2) .
- the engine cover (if fitted to the vehicle), a Move aside the atmospheric pressure sensor moun-
- the scuttle panel grille (see Scuttle panel grille: ting.
pment), II - OPERATION FOR REMOVAL OF PART
- the scoop under the scuttle panel grille (see Scoop CONCERNED
under scuttle panel grille: Removal - Refitting)
(MR 393, 56A, Exterior equipment).
113185
a Disconnect the connector (3) from the master cylin-
der reservoir.
37A-9
JH3 or JR5 or TL4
a Remove the clutch master cylinder pipe (4) .
a Remove:
- the master cylinder nuts (6) on the brake servo,
- the « master cylinder-reservoir » assembly,
- the master cylinder reservoir bolt (7) on the master

cylinder,

101711
REFITTING a Line up the master cylinder with the brake servo so

sing.
WARNING
When refitting the master cylinder, be sure that


on the servo.

linder (17 Nm).
112622
a The master cylinder seals (8) must be replaced. JH3 or JR5 or TL4
CONCERNED
a Clip the master cylinder reservoir onto the master a Connect the master cylinder reservoir connector.
cylinder correctly.
a Refit the bolt securing the master cylinder reservoir III - FINAL OPERATION.
to the master cylinder. a Refit the atmospheric pressure sensor mounting.
a Torque tighten the master cylinder reservoir bolt a Tighten the atmospheric pressure sensor mounting
(9 Nm). bolt.
37A-10
a Connect the atmospheric pressure sensor connec-
tor.
a Refit:
- the scoop under the scuttle panel grille (see Scoop
pment).
37A-11
F4R, and RIGHT-HAND DRIVE
CONCERNED
Tightening torquesm

voir bolt

ter cylinder
WARNING
113185
REMOVAL a Disconnect the connector (3) from the master cylin-
der reservoir.
I - REMOVAL PREPARATION OPERATION a Drain the master cylinder reservoir with a syringe.
ment). - the clutch master cylinder pipe (4) ,
- the master cylinder nuts (6) on the brake servo,
- the « master cylinder-reservoir » assembly,
- the master cylinder reservoir bolt (7) on the master

cylinder,
REFITTING
118007
a Disconnect:
- the fuel vapour absorber bleed solenoid valve con-

nector (1) ,
- the fuel vapour absorber pipe (2) on the solenoid

valve.
a Move aside the fuel vapour absorber bleed solenoid 112622
valve. a The master cylinder seals (8) must be replaced.
37A-12
II - REFITTING OPERATION FOR PART - the fuel vapour absorber bleed solenoid valve con-
CONCERNED nector.
a Clip the master cylinder reservoir onto the master a Bleed the brake circuit (see 30A, General informa-
cylinder correctly. tion, Brake circuit Bleeding, page 30A-4) .
to the master cylinder.
a Torque tighten the master cylinder reservoir bolt
(9 Nm).
101711

sing.
on the servo.
linder (17 Nm).

der reservoir.
a Refit the fuel vapour absorber bleed solenoid valve.
a Connect:
- the fuel vapour absorber pipe on the solenoid val-
ve,
37A-13
NO ANTI-LOCK BRAKES
CONCERNED
Tightening torquesm

voir bolt

ter cylinder
REMOVAL

ment).
a Remove:
- the engine cover,
- the engine undertray, 118182
- the air filter box air inlet pipe, a Disconnect the electrical connector (1) from the
master cylinder reservoir.
(MR 392, 80A, Battery), a Remove:
- the battery protective shield (see Battery tray: Re- - the clutch master cylinder pipe (2) ,
moval - Refitting) (MR 392, 80A, Battery),
- the brake pipes (3) from the master cylinder,
- the master cylinder nuts on the brake servo,
- the « master-cylinder and reservoir » assembly,
- the air filter box outlet air pipe.
- the master cylinder reservoir bolt,
WARNING
37A-14
NO ANTI-LOCK BRAKES
REFITTING
112622
a The master cylinder seals must be replaced.
101711
II - REFITTING OPERATION FOR PART a Line up the master cylinder with the brake servo so
CONCERNED that the pushrod goes into the master cylinder hou-
sing.
a Clip the master cylinder reservoir onto the master
cylinder correctly.
WARNING
to the master cylinder. When refitting the master cylinder, be sure the
a Torque tighten the master cylinder reservoir bolt
(8.5 Nm). a Screw the master cylinder nuts onto the brake servo.
on the brake servo.
linder (17 Nm).

der reservoir.
a Refit:
- the air filter box outlet air pipe,
- the battery protective shield (see Battery tray: Re-
37A-15
NO ANTI-LOCK BRAKES
- the air filter box air inlet pipe,
- the engine cover.
37A-16
D4F, and 784, and RIGHT-HAND DRIVE
Tightening torquesm
brake fluid reservoir bolt 9 Nm

ter cylinder
upstream oxygen sen- 44 Nm

sor
WARNING
REMOVAL
122105
I - REMOVAL PREPARATION OPERATION a Disconnect the upstream oxygen sensor connector

at (3) .
ment). - the upstream oxygen sensor (4) ,
a Disconnect the battery (see Battery: Removal - Re- - the bulkhead heat shield clips (5) ,
fitting) (MR 392, 80A, Battery).
- the bulkhead heat shield (6) .

CONCERNED
113185
a Drain the brake fluid reservoir with a syringe.
122106
a Remove: a Disconnect the brake fluid level sensor connector (7)

.
- the engine cover,
a Remove:
- the bolts (1) from the turbocharger heat shield,
- the clutch master cylinder pipe (8) from the brake
- the turbocharger heat shield (2) . fluid reservoir,
37A-17
- the master cylinder brake pipes (9) ,
- the master cylinder nuts (10) ,
- the “master cylinder-reservoir” assembly,
- the brake fluid reservoir bolt (11) ,
- the brake fluid reservoir from the master cylinder.
REFITTING
101711

sing.
112622
a The master cylinder seals (12) must be replaced. a Refit:

- the master cylinder nuts,
- the master cylinder brake pipes,
CONCERNED
a Refit: - the cylinder pipe to the brake fluid reservoir.
- the brake fluid reservoir to the master cylinder, a Torque tighten:
- the brake fluid reservoir bolt. - the master cylinder nuts (25 Nm),
a Torque tighten the brake fluid reservoir bolt (9 - the brake pipes on the master cylinder (17 Nm).
Nm).
a Refit:
- the bulkhead heat shield,
- the bulkhead heat shield clips,
- the upstream oxygen sensor.
a Torque tighten the upstream oxygen sensor (44
Nm).
a Connect the upstream oxygen sensor connector.
a Refit:
- the turbocharger heat shield,
- the heat shield bolts,
- the engine cover.
37A-18
a Connect the battery (see Battery: Removal - Refit-
37A-19
Right-hand front calliper-master cylinder brake pipe:Removal - Refitting 37A
LEFT-HAND DRIVE, and NO ANTI-LOCK BRAKES
CONCERNED
Tightening torquesm
brake pipe nut on the 17 Nm

master cylinder

brake hose
REMOVAL

ment).
a Remove:
- the engine cover,

118182
- the air filter unit air inlet pipe, a Loosen the brake pipe nut (2) on the master cylin-
der.

- the air filter box (see Air filter unit: Removal - Re-
118176
a Loosen the brake pipe nut (3) on the brake hose.
118185
a Remove the clips (1) from the soundproofing. WARNING

a lift away the upper section of the soundproofing. rounding components.
a Remove the front right-hand wheel (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) .
37A-20
Right-hand front calliper-master cylinder brake pipe:Removal - Refitting 37A
- the air filter unit air inlet pipe,
- the engine cover.
118184
a Unclip the brake pipe at (4) .
a Remove the brake pipe.
REFITTING

CONCERNED
a Refit the brake pipe.
a Screw on:
- the brake pipe nut on the master cylinder,
- the brake pipe nut on the brake hose.
- the brake pipe nut on the master cylinder (17
Nm),
- the brake pipe nut on the brake hose (14 Nm).
a Attach the brake pipe.
a Refit:
- the front right-hand wheel (see 35A, Wheels and
- the upper section of the soundproofing,
- the soundproofing pad clips,
- the air filter box air outlet pipe,
37A-21
Left-hand front calliper-master cylinder brake pipe: Removal - Refitting 37A
CONCERNED
Tightening torquesm

master cylinder

brake hose
REMOVAL

ment).
a Remove:
- the engine cover,
118183
- the battery (see Battery : Removal - Refitting) a Loosen the brake pipe nut (1) on the master cylin-
(MR 392, 80A, Battery), der.
- the front left-hand wheel (see 35A, Wheels and ty-
118175
a Loosen the brake pipe nut (2) on the brake hose.
WARNING
37A-22
Left-hand front calliper-master cylinder brake pipe: Removal - Refitting 37A
- the engine cover.
118179
a Unclip the brake pipe at (3) .

REFITTING

CONCERNED
a Refit the brake pipe.
a Screw on:
- the brake pipe nut on the master cylinder,
- the brake pipe nut on the brake hose.
a Torque tighten:
- the brake pipe nut on the master cylinder (17
Nm),
- the brake pipe nut on the brake hose (14 Nm).
a Refit:
- the front left-hand wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) ,
37A-23
Underbody union-master cylinder brake pipe: Removal - Refitting 37A
CONCERNED
Tightening torquesm
brake pipe nuts on the 17 Nm

master cylinder
brake pipe nuts on the 17 Nm

under body unions
REMOVAL

ment).
a Remove:
- the engine cover,
- the engine undertray, 118180
- the air filter box air inlet pipe, a Loosen the brake pipe nuts (2) on the master cylin-
der.

118178
a Loosen the brake pipe nuts (3) on the under body

unions.
118177
a Remove:
WARNING
- the brake pipe protective housing nuts (1) ,
- the brake pipe protective housing. rounding components.
37A-24
Underbody union-master cylinder brake pipe: Removal - Refitting 37A
- the engine cover.
118181
a Unclip the brake pipes at (4) .
REFITTING

CONCERNED
a Refit the brake pipes.

a Screw on:
- the brake pipe nuts on the master cylinder,

- the brake pipe nuts on the under body unions.
a Torque tighten:
- the brake pipe nuts on the master cylinder (17
Nm),
- the brake pipe nuts on the under body unions

(17 Nm).

a Refit:
- the brake pipe protective housing,

- the brake pipe protective housing nuts,
37A-25
Brake servo non-return valve: Removal - Refitting 37A
LEFT-HAND DRIVE
REMOVAL
K9K
K4J or K4M or K9K

a Remove the engine cover.

CONCERNED
112621
a Disconnect the non-return valve (2) at the vacuum
pump.
113722
a Disconnect the non-return valve (1) at the servo.
a Pull and turn the non-return valve to release it from
the rubber sealing washer.
37A-26
LEFT-HAND DRIVE
K4J or K4M D4F
113730
a
Note:
Do not damage the vacuum tube on the plenum
113088
chamber. If it is damaged, the plenum chamber
will have to be replaced.
a
Disconnect the non-return valve (4) at the inlet mani-
Note:
fold.
Disconnect the non-return valve (3) at the plenum

chamber.
37A-27
LEFT-HAND DRIVE
F4R D4F or F4R or K4J or K4M

a Connect the non-return valve at the inlet manifold.
a Connect the non-return valve on the servo,
K4J or K4M or K9K

a Refit the engine cover.
116783
Note:

chamber.
a Remove the non-return valve.
REFITTING
a Check the condition of the sealing washer and the

non-return valve.

CONCERNED
a Refit the non-return valve.
K9K
a Connect the non-return valve at the vacuum pump,
37A-28
RIGHT-HAND DRIVE
REMOVAL a Pull and turn the non-return valve to release it from

the rubber sealing washer.

K9K
K4J or K4M or K9K
a Remove the engine cover.
112621
a Disconnect the non-return valve (3) at the vacuum
pump,
113731
a Remove the soundproofing retaining clips (1) .
a lift away the upper section of the soundproofing.

CONCERNED
113087
a Disconnect the non-return valve (2) at the servo,
37A-29
RIGHT-HAND DRIVE
K4J or K4M D4F
113184
Note:
113088 chamber. If it is damaged, the plenum chamber
a will have to be replaced.
Note:
Disconnect the non-return valve (5) at the inlet mani-
Do not damage the vacuum tube on the plenum fold.

chamber. a Remove the non-return valve.
REFITTING
a Check the condition of the rubber sealing washer

and the non-return valve.

CONCERNED
a Refit the non-return valve.
K9K
a Connect the non-return valve at the vacuum pump,
37A-30
RIGHT-HAND DRIVE
D4F or K4J or K4M

a Connect the non-return valve at the inlet manifold.
a Connect the non-return valve at the servo,

a Refit the upper section of the soundproofing.
a Refit the soundproofing retaining clips
K4J or K4M or K9K

a Refit the engine cover.
37A-31
Brake servo: Removal - Refitting 37A
K4J or K4M or K9K or M4R, and LEFT-HAND DRIVE
Tightening torquesm
spacer mounting bolts 21 Nm
brake servo mounting 21 Nm

nuts
REMOVAL

ment).
- the bolts (2) ,
- the clip (3) ,
- the lower cover (4) , disconnecting the various con-
nectors.
113096
a Remove:

- the non-return valve (1) from the servo,
- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,
- the lower cover strip,
- the side section of the lower cover.
37A-32
II - OPERATION FOR REMOVAL OF PART - the blanking cover (8) from the brake servo moun-
CONCERNED ting nut,
- the brake servo mounting nuts (9) ,
- the brake servo.
109879
109207
a Remove:
- the mounting bolts (10) from the brake servo spa-
cer,
- the brake servo spacer.
109203
a Remove:
- the double safety connecting shaft (5) from

between the brake servo pushrod and the brake
pedal, and, after tilting the connecting shaft
upwards, move ring (6) using a flat-blade screwdri-
ver.
- the connector (7) from the accelerator pedal,
- the accelerator pedal connector wiring harness

clip,
37A-33
REFITTING II - REFITTING OPERATION FOR PART

CONCERNED
a Refit:
- the brake servo spacer,
- the brake servo spacer mounting bolts.
a Torque tighten the spacer mounting bolts (21
Nm).
a Refit:
- the brake servo,
- the brake servo mounting nuts.
a The shaft connecting the brake servo pushrod and
the brake pedal must be refitted from right to left,
and from top to bottom.
a Torque tighten the brake servo mounting nuts (21
Nm).
a Refit:
- the brake servo mounting nut blanking cover,
clip,
109206
- the accelerator pedal connector.
a Check that the brake servo seal (11) is present; re-
place the seal if it is faulty.
a The shaft connecting the brake servo pushrod and a Refit:
the brake pedal must be replaced every time it is re-
moved. - the lower cover, connecting the various connec-
tors.
- the clip,
- the bolts,
ting, page 37A-2) ,
a Reconnect the non-return valve at the servo.
91101 IMPORTANT
a Check the following dimension before refitting: (X1) Check that the brake servo pushrod-brake pedal
= 171 mm. connecting shaft is locked in place.
37A-34
a Adjust the brake light switch (see 37A, Mechanical
component controls, Brake pedal switch: Remo-
37A-35
K9K, and RIGHT-HAND DRIVE
Mot. 1672 Lower engine support.
Tightening torquesm
brake servo nuts 21 Nm
sub-frame bolts 105 Nm
REMOVAL

Towing and lifting) (MR 392, 02A, Lifting equip- - the bolts (1) ,
ment).
a Disconnect the battery (see Battery : Removal - nectors.
a Remove: nent controls, Clutch master cylinder: Removal
- the engine cover, - Refitting, page 37A-104) ,
- the engine undertray, - the engine tie-bar (see Lower engine tie-bar: Re-
moval - Refitting) (MR 392, 19D, Engine moun-
- the scuttle panel grille (see Scuttle panel grille: ting).
pment), a Remove the sub-frame bolts to fit the tool as shown
below.
- the non-return valve on the servo,
ting, page 37A-2) ,
- the dashboard side panel.
114647
a Position the (Mot. 1672).
37A-36
114648
a Remove:
- the lifting eye bolt,
- the lifting eye (5) ,
- the EGR tube bolt,
- the EGR tube (6) ,
- the right-hand suspended mounting support (7)
using only the (Mot. 1672) (see Right-hand sus-
pended engine mounting: Removal - Refitting)
(MR 392, 19D, Engine mounting).
a Lower the engine as much as possible using the
(Mot. 1672).
37A-37
CONCERNED
Note:
To pass the servo between the bulkhead and the
engine, the pushrod must be oriented towards
the bottom, with the engine slightly pulled
forward.
REFITTING
109879
109206
moved.
109449
a Remove:

ver.
- the brake servo nuts (10) ,
- the brake servo.
37A-38
- the engine tie-bar (see Lower engine tie-bar: Re-
ting),

nent controls, Clutch master cylinder: Removal
- Refitting, page 37A-104) ,

ting, page 37A-2) ,


pment),
91101
a Before refitting, check that the dimension: (X1) = - the engine cover.
128 mm.
a Torque tighten the sub-frame bolts (105 Nm).
II - REFITTING OPERATION FOR PART a Bleed:

CONCERNED
- the clutch circuit (see 37A, Mechanical compo-
a Refit: nent controls, Clutch circuit: Bleeding, page
37A-100) ,
- the brake servo,
- the brake servo nuts. - the brake circuit (see 30A, General information,
Brake circuit Bleeding, page 30A-4) .
the brake pedal must be refitted from right to left, a Adjust:
- the brake switch (see 37A, Mechanical compo-
a Torque tighten the brake servo nuts (21 Nm). nent controls, Brake pedal switch: Removal -
III - FINAL OPERATION. - the clutch switch (see Clutch pedal position sen-
sor: Removal - Refitting) .
a Refit:
a Check that the connecting shaft between the brake
- the right-hand suspended mounting support (see
Right-hand suspended engine mounting: Re- servo pushrod and the brake pedal is locked in pla-
moval - Refitting) (MR 392, 19D, Engine moun- ce.
ting),
a Refit:
- the EGR tube,
- the lower cover and connect the various connec-
- the EGR tube bolt, tors,
- the lifting eye, - the lower cover bolts,
- the lifting eye bolt. - the dashboard side panel,
a Refit:
- the sub-frame bolts, ting) (MR 392, 80A, Battery).
37A-39
Tightening torquesm

nuts
REMOVAL

112300
a Disconnect the battery (see Battery : Removal - a Remove:
Refitting) .
- the bolts (2) ,
- the clip (3) .
nectors.
112053
a Remove:
ting, page 37A-2) ,
37A-40
II - OPERATION FOR REMOVAL OF PART - the brake servo mounting nuts (9) ,
CONCERNED
- the brake servo.
109879
109207
a Remove:
- the brake servo spacer mounting bolts (10) ,
109203
a Remove:
pedal and, after tilting the connecting shaft
ver.
- the accelerator pedal connector (7) ,
clip,
- the brake servo mounting nut blanking cover (8) ,
37A-41

CONCERNED
a Refit:
- the brake servo spacer mounting bolts,
a Tighten to torque the spacer mounting bolts (21
Nm).
a Refit:
- the brake servo,
- the brake servo mounting nuts,
the brake pedal must be put back from right to left,
a Tighten to torque the brake servo mounting nuts
(21 Nm).
a Refit:
clip,
109206 - the accelerator pedal connector.
place the seal if it is faulty. III - FINAL OPERATION
a Refit:
the brake pedal must be replaced every time it is re- - the lower cover, connecting the various connec-
moved. tors.
- the clip,
- the bolts,
a Refit:
ting, page 37A-2) ,
IMPORTANT
Check that the connecting shaft between the
brake servo pushrod and the brake pedal is loc-
ked in place.
91101
a Adjust the brake circuit (see 37A, Mechanical com-
a Check the following dimension before refitting: (X1) ponent controls, Brake pedal switch: Removal -
= 174 mm. Refitting, page 37A-79) .
37A-42
K4J or K4M, and RIGHT-HAND DRIVE
Tightening torquesm
REMOVAL

ment).
Refitting) (MR 392, 80A, Battery). 112300
a Remove: a Remove:
- the engine cover, - the bolts (1) ,
- the scuttle panel grille (see Scuttle panel grille: - the lower cover (2) , disconnecting the various con-
Removal - Refitting) (MR 393, 56A, Exterior equi- nectors.
pment),
- the air intake distributor (see Inlet manifold: Re-
moval - Refitting) (MR 392, 12A, Fuel mixture),
ting, page 37A-2) ,
- the lifting eye,
37A-43
CONCERNED
109879
109206
a Check that the brake servo seal (6) is present; repla-

ce the seal if it is faulty.

moved.
109449
a Remove:

ver.
91101
a Before refitting, check that the dimension: (X1) =
- the brake servo. 128 mm.
37A-44
CONCERNED
a Refit:
- the brake servo,

- the brake servo nuts.

a Torque tighten the brake servo nuts (21 Nm).
a Refit:
- the lifting eye,

ting, page 37A-2) ,


pment),
- the engine cover.

servo pushrod and the brake pedal is locked in pla-
ce.

a Refit:
tors,
- the lower cover bolts,

- the dashboard side panel,

37A-45
D4F, and RIGHT-HAND DRIVE
Tightening torquesm
REMOVAL

ment).
Refitting) (MR 392, 80A, Battery). 112300
a Remove: a Remove:
- the air filter unit (see Air filter unit: Removal - Re- - the bolts (1) ,
fitting) (MR 392, 12A, Fuel mixture), - the lower cover (2) , disconnecting the various con-
- the scuttle panel grille (see Scuttle panel grille: nectors.
Removal - Refitting) (MR 393, 56A, Exterior equi- - the clutch master cylinder (see 37A, Mechanical
pment), component controls, Clutch master cylinder:
- the scoop under the scuttle panel grille (see Scoop Removal - Refitting, page 37A-104) .
- the ignition coil (see Coils Removal - Refitting)
(MR 392, 17A, Ignition),
ting, page 37A-2) ,
37A-46
CONCERNED
Note:
To remove the servo between the engine and the
bulkhead, the pushrod must be facing down.
REFITTING
109879
109206
a Check that the brake servo seal (6) is present; repla-
ce the seal if it is faulty.
moved.
109449
a Remove:

ver.
- the brake servo.
37A-47
pment),
a Bleed:
- the clutch circuit (see 37A, Mechanical compo-
nent controls, Clutch circuit: Bleeding, page
37A-100) ,
- the brake circuit (see 30A, General information,
a Adjust:
- the brake switch (see 37A, Mechanical compo-
nent controls, Brake pedal switch: Removal -
91101
- the clutch switch (see Clutch pedal position sen-
sor: Removal - Refitting) .
128 mm.
servo pushrod and the brake pedal is locked in pla-
II - REFITTING OPERATION FOR PART ce.
CONCERNED
a Refit:
a Refit:
- the brake servo, tors,
the brake pedal must be refitted from right to left, - the lower cover strip,
and from top to bottom. a Connect the battery (see Battery : Removal - Refit-
a Refit:
- the clutch master cylinder (see 37A, Mechanical

component controls, Clutch master cylinder:

ting, page 37A-2) ,
- the ignition coil (see Coils Removal - Refitting)

(MR 392, 17A, Ignition),

37A-48
F4R, and LEFT-HAND DRIVE
Tightening torquesm

nuts
REMOVAL

ment).
112379
a Remove the side panel (12) .
116783
a Remove:
ting, page 37A-2) ,
112380
a Unclip the trim (13) .
37A-49
CONCERNED
112300
a Remove:
- the bolts (2) ,
- the clip (3) .
nectors.
109879
109203
a Remove:

ver.
- the connector (7) from the accelerator pedal,

clip,
37A-50
- the blanking cover (8) from the brake servo moun- REFITTING
ting nut,
- the brake servo mounting nuts (9) ,
- the brake servo.
109206
109207
a Remove: a Check that the brake servo seal (11) is present; re-
- the mounting bolts (10) from the brake servo spa-
cer, a The shaft connecting the brake servo pushrod and
- the brake servo spacer. the brake pedal must be replaced every time it is re-
moved.
91101
a Check the following dimension before refitting: (X1)

= 171 mm.
37A-51
II - REFITTING OPERATION FOR PART a Bleed the brake circuit (see 30A, General informa-
CONCERNED tion, Brake circuit Bleeding, page 30A-4) .
a Refit:
IMPORTANT
- the brake servo spacer,
Check that the brake servo pushrod-brake pedal
- the brake servo spacer mounting bolts. connecting shaft is locked in place.
a Torque tighten the spacer mounting bolts (21 a Adjust the brake light switch (see 37A, Mechanical
Nm). component controls, Brake pedal switch: Remo-
a Refit:
- the brake servo,
- the brake servo mounting nuts.

a Torque tighten the brake servo mounting nuts (21

Nm).
a Refit:

clip,
- the accelerator pedal connector,
- the double safety connecting piece between the

brake servo pushrod and the brake pedal.
a Refit:
- the lower cover, connecting the various connec-

tors.
- the clip,
- the bolts,
- the dashboard trim piece,

ting, page 37A-2) ,

a Connect the non-return valve on the servo,
37A-52
Mot. 1453 Multiple-adjusting engine

mounting support with retai-
ning straps.
Tightening torquesm
REMOVAL

a Remove the clips (1) from the acoustic shield.
Towing and lifting) (MR 392, 02A, Lifting equip- a Move aside the acoustic shield.
ment).
a Remove:
- the engine cover,
pment),
ting, page 37A-2) ,
- the intake distributor (see Inlet manifold: Remo-
117870
val - Refitting) (MR 392, 12A, Fuel mixture).
a Remove the dashboard side face (2) .
37A-53
118174
a Fit the (Mot. 1453).
a Remove the right-hand suspended mounting sup-
port (see Right-hand suspended engine moun-
ting: Removal - Refitting) (MR 392, 19D, Engine
117871 mounting).
a Unclip protective strip (3) . a Lower the engine as much as possible using the
(Mot. 1453).
117872
a Remove:
- the bolts (4) from the lower cover,
- the lower cover, disconnecting the various connec-
tors.
- the engine tie-bar (see Lower engine tie-bar: Re-
ting).
37A-54
CONCERNED
117874
a Move aside the brake pipes (8) .
109879
a Remove the brake servo (9) .
Note:
forward.
117877
a Tilt the connecting shaft (5) upwards.
a Remove:
- the double safety connecting shaft using a flat-bla-
de screwdriver to move the ring (6) ,
- the brake servo nuts (7) .
37A-55

CONCERNED
I - REFITTING PREPARATIONS OPERATION a Refit:

- the brake servo,
a Refit:
- the bulkhead acoustic shield,
- the bulkhead acoustic shield clips,
Right-hand suspended engine mounting: Re-
ting).
109206
a Refit:
a Check that the brake servo sealing ring is in place
(10) . - the engine tie-bar (see Lower engine tie-bar: Re-
a Replace the seal if it is damaged. ting),
a The shaft connecting the brake servo pushrod and - the intake distributor (see Inlet manifold: Remo-
the brake pedal must be replaced every time it is re- val - Refitting) (MR 392, 12A, Fuel mixture),
moved.
ting, page 37A-2) ,
pment),
- the engine cover.
91101
a Before refitting, check that the dimension: (X1) = servo pushrod and the brake pedal is locked in pla-
128 mm. ce.
37A-56
a Refit:
tors,
37A-57
Tightening torquesm
cooling radiator moun- 105 Nm

ting cross member bolt
sub-frame rear bolt 110 Nm
REMOVAL

117870
ment).
a Remove the dashboard side face (1) .
a Remove:
pment),
- the non-return valve at the brake servo,
ting, page 37A-2) .
117871
a Unclip the lower cover protective strip (2) .
37A-58
a Lower the engine as much as possible using the
(Mot. 1672).
117872
a Remove:
- the bolts (3) from the lower cover,
- the lower cover, disconnecting the various connec-

tors.
- the lower engine tie-bar (see Lower engine tie-

bar: Removal - Refitting) (MR 392, 19D, Engine
mounting),
- the front bumper (see Front bumper: Removal -

Refitting) (MR 393, 55A, Exterior protection),
- the cooling radiator mounting cross member bolt,
- the sub-frame rear bolt.
114647
a Position the (Mot. 1672).
a Remove:

Right-hand suspended engine mounting: Re-
ting),
- the throttle valve (see Throttle valve: Removal -
Refitting) (MR 392, 12A, Fuel mixture).
37A-59
CONCERNED
Note:
forward.
REFITTING
109879
109206
a Check that the brake servo sealing ring is in place
(7) .
a Replace the seal if it is damaged.
moved.
109449
a Tilt the connecting shaft (4) upwards.
a Remove:
- the double safety connecting shaft using a
screwdriver to move the ring (5) ,
- the brake servo.
37A-60
a Torque tighten:
- the cooling radiator mounting cross member
bolt (105 Nm),
- the sub-frame rear bolt (110 Nm).
a Refit:
ting, page 37A-2) ,
pment),
91101
128 mm.
II - REFITTING OPERATION FOR PART component controls, Brake pedal switch: Remo-
CONCERNED val - Refitting, page 37A-79) .
a Refit: a Check that the connecting shaft between the brake
- the brake servo, servo pushrod and the brake pedal is locked in pla-
ce.
a Refit:
a The shaft connecting the brake servo pushrod and - the lower cover and connect the various connec-
the brake pedal must be refitted from right to left, tors,
III - FINAL OPERATION. - the lower cover strip,

a Refit the right-hand suspended mounting support
(see Right-hand suspended engine mounting:
Removal - Refitting) (MR 392, 19D, Engine moun-
ting).
a Refit:
- the throttle valve (see Throttle valve: Removal -
Refitting) (MR 392, 12A, Fuel mixture),
- the rear engine tie-bar (see Lower engine tie-bar:

Removal - Refitting) (MR 392, 19D, Engine moun-
ting),
- the cooling radiator mounting cross member bolt,
- the sub-frame rear bolt.
37A-61
Tightening torquesm
sub-frame rear bolt 110 Nm
right-hand side radiator 105 Nm

mounting cross mem-
ber bolt
oxygen sensor 44 Nm
REMOVAL
117872
a Remove:
- the protective strips from the lower cover (2) ,
- the bolts (3) ,
117870 - the lower cover (4) , disconnecting the various con-
a Remove the dashboard side face (1) . nectors.
ment).
a Remove:
- the engine cover,
pment),
37A-62
- the scoop under the scuttle panel grille (see Scoop - the master cylinder (see 37A, Mechanical compo-
under scuttle panel grille: Removal - Refitting) nent controls, Master cylinder: Removal - Refit-
(MR 393, 56A, Exterior equipment). ting, page 37A-2) ,
- the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 392,
19D, Engine mounting).
122106
a Remove:
- the bolts (5) ,
- the turbocharger heat shield (6) ,
- the upstream oxygen sensor (7) .
122107
a Remove:
- the radiator mounting cross member bolt (10) ,
- the sub-frame rear bolt (11) .
122105
a Remove:
- the clips (8) ,
- the bulkhead heat shield (9) ,
37A-63
CONCERNED
114647
a Fit the (Mot. 1672) as shown above.
a Remove the front left-hand suspended engine
mounting (see Left-hand suspended engine
mounting: Removal - Refitting) (MR 392, 19D, En-
gine mounting).
a Fully lower the engine using the (Mot. 1672).
122104
a Remove the brake servo non-return valve (13) (see
37A, Mechanical component controls, Brake ser-
vo non-return valve: Removal - Refitting, page
37A-26) .
122106
a Remove the petrol vapour rebreathing solenoid val-
ve (12) .
37A-64
Note:
To remove the brake servo, the engine must be
tilted towards the front of the vehicle.
REFITTING
a It is essential to replace the sub-frame rear bolts.
109879
109206
a Check that the brake servo seal (17) is in place and
replace the seal if it is faulty.
moved.
109449
a Remove:
- the double safety connecting shaft (14) between
the brake servo pushrod and the brake pedal by
pressing on the ring (15) with a flat-blade screwdri-
ver,
- the brake servo.
37A-65
- the right-hand side radiator mounting cross
member bolt (105 Nm).
a Refit:
- the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 392,
19D, Engine mounting),

ting, page 37A-2) ,

91101 - the upstream oxygen sensor.

a Check the following dimension before refitting: (X1) a Torque tighten the oxygen sensor (44 Nm).
= 128 mm.
a Refit:
II - REFITTING OPERATION FOR PART - the turbocharger heat shield,

CONCERNED - the turbocharger heat shield bolts,
a Refit: - the scoop under the scuttle panel grille (see Scoop
- the brake servo, under scuttle panel grille: Removal - Refitting)
a The connecting shaft between the brake servo pus- Removal - Refitting) (MR 393, 56A, Exterior equi-
hrod and the brake pedal must be refitted from right pment),
to left and from top to bottom.
- the engine cover.
a Bleed:
III - FINAL OPERATION. - the clutch circuit (see 37A, Mechanical compo-
nent controls, Clutch circuit: Bleeding, page
a Fit the petrol vapour rebreathing solenoid valve onto 37A-100) ,
its mounting.
- the brake circuit (see 30A, General information,
a Refit the front left-hand suspended engine mounting Brake circuit Bleeding, page 30A-4) .
(see Left-hand suspended engine mounting: Re-
moval - Refitting) (MR 392, 19D, Engine moun- a Connect the battery (see Battery : Removal - Refit-
ting). ting) (MR 392, 80A, Battery).
a Remove the (Mot. 1672). a Remove the vehicle from the lift.
a Refit: a Adjust:
- the sub-frame rear bolt, - the brake switch (see 37A, Mechanical compo-
nent controls, Brake pedal switch: Removal -
- the right-hand side radiator mounting cross mem-
ber bolt.
- the clutch switch (see 37A, Mechanical compo-
a Torque tighten:
nent controls, Clutch pedal switch: Removal -
- the sub-frame rear bolt (110 Nm), Refitting, page 37A-97) .
37A-66
a Refit:
tors,
- the lower cover protective strips.
37A-67
Vacuum pump: Removal - Refitting 37A
K9K
REFITTING
Tightening torquesm
vacuum pump bolts 21 Nm
a Be sure to replace the vacuum pump seal.
vacuum pump retaining 21 Nm
bracket bolt II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
REMOVAL
- the vacuum pump with the new seal,
- the vacuum pump bolts.
a Torque tighten:
a Remove: - the vacuum pump bolts (21 Nm),
- the engine covers, - the vacuum pump retaining bracket bolt (21
Nm).
- the air filter duct. a Refit:
- the pipe,
II - OPERATION FOR REMOVAL OF PART - hose connected to the brake servo,
CONCERNED

a Refit:
- the air filter duct,
- the engine covers.
112621
a Undo the vacuum pump retaining bracket bolt (3) .
a Remove:
- the hose (1) connected to the brake servo,
- the pipe (2) ,
- the vacuum pump bolts (4) ,
- the vacuum pump.
37A-68
Accelerator pedal: Removal - Refitting 37A
VERSION WITHOUT ADAPTATION SUPPLEMENT
CONCERNED
Tightening torquesm
accelerator pedal moun- 8 N.m

ting nuts
REMOVAL
113179
112629
a Remove:
- the retaining clips on the driver side dashboard
lower trim,
- the driver side dashboard lower trim.
113089
a Disconnect the accelerator pedal potentiometer con-
nector (1) .
a Remove:
- the accelerator pedal mounting nuts (2) ,
- the accelerator pedal.
37A-69
REFITTING

CONCERNED
a Refit:
- the accelerator pedal,
- the accelerator pedal mounting nuts,
a Connect the accelerator pedal potentiometer con-
nector.
a Torque tighten the accelerator pedal mounting
nuts (8 N.m).
a Refit:
- the driver's side dashboard lower trim,
- the retaining clips on the driver side dashboard
lower trim,
37A-70
DRIVING SCHOOL VEHICLE
2 - Instructor side
Tightening torquesm
accelerator pedal bolts, 8 Nm

driver's side
accelerator pedal shaft, 16 Nm

instructor's side
REMOVAL


CONCERNED
113667
1 - student side a Remove:

- the circlip (4) from the accelerator pedal to the link
bar connection control lever,
- the accelerator pedal nut (5) ,
- the accelerator pedal shaft,
- the accelerator pedal.
REFITTING

a Always replace the connecting circlips whenever
they have been removed.

CONCERNED
1 - student side
113199
a Refit:
a Disconnect the accelerator pedal potentiometer con- - the accelerator pedal,
nector (1) .
- the accelerator pedal bolts (3) ,
a Remove:
- the circlip (2) from the accelerator pedal to the link bar connection control lever.
bar connection control lever, a Torque tighten the accelerator pedal bolts, dri-
ver's side (8 Nm).
- the accelerator pedal bolts (3) ,
a Connect the accelerator pedal potentiometer con-
- the accelerator pedal. nector (1) .
37A-71
2 - instructor side
a Refit:
- the accelerator pedal,
- the accelerator pedal shaft,
- the accelerator pedal nut (5) ,
bar connection control lever.
a Torque tighten the accelerator pedal shaft, ins-
tructor's side (16 Nm).

37A-72
Emergency brake assistance: Function 37A
102886
(1) Without emergency brake assist

(2) With emergency brake assist
Emergency brake assist is a system which supple-

ments ABS.
Emergency brake assist enables the system to reco-

gnise the situation and act immediately to provide the
best possible stopping distance.
Emergency braking is calculated according to how

quickly the brake pedal is depressed; in this situation,
braking assistance immediately reaches its maximum
level of output.
The system works conditionally for current braking sys-

tems.
The emergency brake assist is a mechanical system

built into the brake servo and completely independent
of any electronic component.
The brake servo is fitted with a magnet which reacts by

locking the control unit when the pedal is depressed
sharply.
37A-73
Brake pedal: Removal - Refitting 37A
CONCERNED
Tightening torquesm
brake pedal stud, on the 16 Nm 1 - student side

driver's side
shaft for the brake and 35 Nm

clutch pedals, on the
driver's side
REMOVAL

113664
109879
a Remove:
- the brake light switch (1) (see 37A, Mechanical
component controls, Brake pedal switch: Re-
moval - Refitting, page 37A-79) ,
37A-74
- the double safety connecting shaft (2) from II - REFITTING OPERATION FOR PART
between the brake servo pushrod and the brake CONCERNED
upwards, move the ring (3) using a flat-blade
1 - student side
screwdriver.
a Refit:
- the circlip (4) from the brake pedal to the link bar
connection control lever, - the brake pedal,
- the brake pedal stud (5) ,
- the brake pedal stud (5) ,
- the circlip (4) from the brake pedal to the link bar
- the brake pedal.
connection control lever,
- the double safety connecting shaft (2) between the
2 - Instructor side brake servo pushrod and the brake pedal, from ri-
ght to left, and from top to bottom,
- the brake light switch (1) (see 37A, Mechanical
component controls, Brake pedal switch: Re-
a Torque tighten the brake pedal stud, on the dri-
ver's side (16 Nm).
2 - instructor side
a Refit:
- the connection control lever,
- the circlip from the brake pedal to the connection
control lever,
- the brake and clutch pedals,
- the shaft (8) for the brake and clutch pedals,
- the circlip (7) from the clutch pedal to the link bar
113666 - the circlip (6) from the brake pedal connection con-
trol lever to the link bar.
a Remove:
a Torque tighten the shaft for the brake and clutch
- the circlip (6) from the brake pedal connection con- pedals, on the driver's side (35 Nm).
trol lever to the link bar,
- the circlip (7) from the clutch pedal to the link bar, III - FINAL OPERATION.
- the brake and clutch pedal shaft (8) , a Connect the battery (see Battery : Removal - Refit-
- the circlip from the brake pedal to the connection

control lever,
- the connection control lever.
REFITTING

37A-75
CONCERNED
Tightening torquesm
pedal assembly nuts 21 N.m
nuts of the brake pedal 21 N.m

impacter
REMOVAL

a Remove:
- the lower cover moulding,
- the side section to the lower cover.
113089
a Disconnect the accelerator pedal connector (4) .
a Remove the brake pedal switch (see 37A, Mechani-
cal component controls, Brake pedal switch: Re-
112300
a Remove:
- the bolts (1) ,
- the clip (2) ,
nectors.
37A-76
128482 113090
a Remove the dual safety connecting shaft (5)
between the brake pedal to the brake servo pus-
hrod.
- unlock the shaft in accordance with (6) ,
- extract the shaft in accordance with (7) .
113178
a Remove:
- the impacter nuts (8) ,
- the nuts (9) of the pedal yoke,
- the impacter (10) ,
- « the brake - accelerator pedal assembly » .
37A-77
REFITTING

a Always replace the parts always to be replaced:
Connecting shaft between the brake pedal and
the brake servo pushrod (30,03,02,07).
128483
a Refit a new connecting shaft between the brake pe-
dal and the brake servo pushrod:
- insert the shaft in accordance with (13) ,
- lock the shaft in accordance with (14) .
108957
a a Refit the brake light switch (see 37A, Mechanical
Note: val - Refitting, page 37A-79) .
Check that the brake pedal collapse rivet (12) is a Connect the accelerator pedal connector.
not faulty; if it is, replace the pedal.
II - REFITTING OPERATION FOR PART a Refit:
CONCERNED
a Refit: tors.
- « the brake - accelerator pedal assembly » , - the clip,
- the brake pedal impacter. - the bolts,
a Tighten to torque: - the side section to the lower cover.
- the pedal assembly nuts (21 N.m), - the lower cover moulding,
- the nuts of the brake pedal impacter (21 N.m).
37A-78
Brake pedal switch: Removal - Refitting 37A
REMOVAL II - OPERATION FOR REMOVAL OF PART
CONCERNED
113089
a
112629
a Remove: WARNING
- the retaining clips on the driver side dashboard Handle the brake light switch (2) with care.
lower trim, Actuate piston (4), only, to adjust the dimension
- the driver side dashboard lower trim. (X).
a Disconnect the brake light switch connector (1) .

a Turn the brake light switch (2) a quarter of a turn
anti-clockwise.
a Remove the brake light switch.
37A-79
Brake pedal switch: Removal - Refitting 37A
REFITTING a Carefully follow the return of the brake pedal.
I - REFITTING PREPARATIONS OPERATION Note:

The brake pedal switch has an automatic adjust-
When removing and refitting or when replacing the ment which adapts to the pedal position.
brake light switch
The automatic adjustment makes a clicking noise
when in operation.
a Connect the brake light switch connector.

a Check that the brake light switch is operating cor-
rectly:
- depress the brake pedal to switch on the lights,
- release the brake pedal to extinguish the lights.
a Refit:
- the driver side dashboard lower trim.
108436 - the retaining clips on the driver side dashboard

lower trim,
a
WARNING
Handle the brake light switch (3) with care.
Act on piston (4) , only, to adjust dimension (X) .
The brake light switch must always be replaced:
- if the piston (4) is separated from the switch (3)
,
- if the dimension (X) has to be adjusted more
than 3 times during the operation.
a Measure the dimension (X) of the piston (4) . If the

dimension (X) is less than 19 mm, carefully pull the
end of the piston to adjust the dimension (X) to
between 19 mm minimum and 20 mm maximum.

CONCERNED
a Depress the brake pedal by hand.
a Position the brake light switch on the pedal assem-
bly.
a Lock the brake light switch by turning it a quarter of
a turn clockwise.
37A-80
Brake compensator: Removal - Refitting 37A
NO ANTI-LOCK BRAKES
Fre. 1085-01 Braking circuit pressure
gauge 0 to 250 bar.
Essential equipment
pedal press
Tightening torquesm
bolts of the brake limiter 10 N.m

retaining bracket
brake limiter bolts 18 N.m
hydraulic unions 17 N.m
bolt of the brake limiter 10 N.m

rod on the rear axle
REMOVAL 120865
a Remove the bolt (1) of the brake limiter rod on the
I - REMOVAL PREPARATION OPERATION rear axle.
a Position the vehicle on a two-post lift (see Vehicle: a Mark the position of the brake pipes (2) at the brake
Towing and lifting) (MR 392, 02A, Lifting equip- limiter (3) .
ment). a Disconnect the brake pipes (2) from the brake limiter
a Fit the tool pedal press in order to limit the outflow (3) .
of the brake fluid.
WARNING
37A-81
Brake compensator: Removal - Refitting 37A
NO ANTI-LOCK BRAKES
a Bleed the brake circuit using the tool (Fre. 1085-01)
(see 3 0 A , General information, Brake circuit
Bleeding, page 30A-4) .
120866
a Remove:
- the bolts (4) of the brake limiter (5) ,
- the brake limiter (5) .
a Undo, but do not remove, the bolts (6) of the brake
limiter retaining bracket.
REFITTING

CONCERNED
a Refit:
- the brake limiter,
- the brake limiter bolts.
- the bolts of the brake limiter retaining bracket
(10 N.m),
- the brake limiter bolts (18 N.m).
a Connect the brake pipes on the brake limiter as mar-
ked at the time of the removal.
a Torque tighten the hydraulic unions (17 N.m).
a Refit the bolt of the brake limiter rod on the rear axle.
a Torque tighten the bolt of the brake limiter rod on
the rear axle (10 N.m).
37A-82
Brake compensator: Check 37A
NO ANTI-LOCK BRAKES
- damaged: replace the component (see 37A, Me-
Essential special tooling chanical component controls, Brake compen-
sator: Removal - Refitting, page 37A-81) .
Fre. 1085-01 Braking circuit pressure
gauge 0 to 250 bar.
II - ADJUSTING THE ROD DIMENSION IN THE
Essential equipment REBOUND POSITION (WHEELS SUSPENDED)
a Loosen the adjusting screw (1) .
a Adjust to the dimension of 155 mm.
a Torque tighten the adjusting screw (12 Nm).
Tightening torquesm
adjusting screw 12 Nm III - CHECKING THE OUTPUT PRESSURE

a Lower the intermediate lift so that the dimension of
the (X2) compensator rod is equal to 142 mm.
CHECKING
a Position the vehicle on a four-post lift equipped with WARNING
an intermediate lifting system (see Vehicle: Towing
and lifting) (MR 392, 02A, Lifting).
I - CHECKING THE DIMENSION OF THE BRAKING

COMPENSATOR ROD IN THE REBOUND POSITION
(WHEELS SUSPENDED)
a Raise the vehicle using the intermediate lift.
122273
a Check the compensator rod dimension (X1) .
The dimension should be 155 mm.
a The compensator is set in the factory, therefore the

rod dimension should be correct.
If this is not the case, the compensator is either:
- not adjusted: adjust it,
37A-83
NO ANTI-LOCK BRAKES
1 - Checking the output pressure for an input
pressure (PE) = 60 bar
37A-84
NO ANTI-LOCK BRAKES
85925
a Fit the pressure gauges of the (Fre. 1085-01) in acc-
cordance with the diagram I.
a Bleed the pressure gauges using the brake circuit

bleeding device by opening the pressure gauge
bleed screws.
a Depress the brake pedal until the value PE = 60 bar

is obtained on the front pressure gauge.
a Read the value on the rear pressure gauge PS1.
a Position the pressure gauges in accordance with

diagram II.

bleed screws.
a Depress the brake pedal until the value PE = 60 bar

is obtained on the front pressure gauge.
a Read the value on the rear pressure gauge PS2
a Check the differences in pressure at the rear brake

output, PS1 - PS2 ≤ 4 bar.
a Check the value of Pm :
Pm = (PS1 + PS2) / 2
Pm = 28 ± 4 bar
2 - Checking the output pressure for an input

pressure (PE) = 100 bar
a Depress the brake pedal until the value PE = 100

bar is obtained on the front pressure gauge.
a Read the value on the rear pressure gauge PS2.

diagram I.

bleed screws.

a Read the value on the rear pressure gauge PS1’.

output, PS1’ - PS2’ ≤ 4 bar.
a Check the value of Pm’ :
Pm = (PS1’ + PS2’) / 2
Pm = 28 ± 4 bar
37A-85
NO ANTI-LOCK BRAKES
3 - Checking the output pressure values
a PS1 for PE = 60 bar
PS1’ for PE = 100 bar
PS1 - PS1’ = 6 ± 1 bar
a PS2 for PE = 60 bar
PS2’ for PE = 100 bar
PS2 - PS2’ = 6 ± 1 bar
4 - Checking the output pressures by compressing

the spring by 5 mm
a Compress the brake limiter spring by 5 mm (X3) .
a Read the value on the rear pressure gauge PS1’’.
diagram II.
bleed screws.
a Read the value on the rear pressure gauge PS2’’.
output, PS1’’ - PS2’’ ≤ 4 bar.
a Check the value of Pm :
Pm = (PS1’’ + PS2’’) / 2
Pm = 28 ± 4 bar
5 - Checking value D’
a D’ = 20.6 ± 2 bar
D’1 = PS1’’ - PS1
D’2 = PS2’’ - PS2
37A-86
Brake compensator: Adjustment 37A
NO ANTI-LOCK BRAKES
Tightening torquesm
adjusting screw 12 Nm
ADJUSTMENT
122273
a
Note:
When adjusting the brake limiter, do not move
the rod nut (3) .
118187
a Loosen the bolt (1)
a Adjust the rod dimension to the rebound position va-
lue (wheels suspended) of 155 mm.
a Torque tighten the adjusting screw (12 Nm).
37A-87
Parking brake lever: Removal - Refitting 37A
CONCERNED
Tightening torquesm
parking brake lever 21 Nm

mounting nuts
REMOVAL

a Remove the centre console (see Centre console:
Removal - Refitting) (MR 393, 57A, Interior equip-
ment).
113726
112631
a Disconnect the parking brake lever switch (1) .
a Loosen the adjusting nut (2) for the parking brake
cables enough to be able to remove the parking bra-
ke cables.
a Remove the parking brake cables (3) .
a Remove:
- the parking brake lever mounting nuts (4) ,
- the parking brake lever.
37A-88
Parking brake lever: Removal - Refitting 37A
REFITTING

CONCERNED
a Refit:
- the parking brake lever,
- the nuts securing the parking brake lever.
a Torque tighten the parking brake lever mounting
nuts (21 Nm).
a Refit the parking brake cables into their housing.
a Connect the switch on the parking brake lever.
a Refit the centre console (see Centre console: Re-
moval - Refitting) (MR 393, 57A, Interior equip-
ment).
37A-89
Parking brake lever: Adjusting 37A
A poorly adjusted parking brake: a Put the parking brake lever into the released posi-
tion.
- prevents correct operation of the automatic compen-
sation system for the brake shoes, a The disc or the drum must be able to turn freely. If
not, move the nut gradually until the disc or drum
- causes premature wear of brake shoes.
can turn freely.
ADJUSTMENT Wheel: Removal - Refitting, page 35A-1) .
I - ADJUSTMENT PREPARATION OPERATION

a Apply the parking brake five times to condition the
cables for normal use.
a Put the parking brake lever into the released posi-
tion.
a Check that the rear wheels turn freely. If they do not,
check the following components and if necessary re-
pair:
- the parking brake cables,
- the calliper piston,
- the automatic compensation system,
- calliper
II - OPERATION FOR ADJUSTMENT OF PART

CONCERNED
112631
a Loosen the nut (1) to release the cables.
a Position the parking brake lever at the 2nd notch.
a Move the adjustment nut until the disc or drum can
no longer be turned by hand.
a Pull the brake lever several times.
37A-90
Clutch control: List and location of components 37A
No. Description
(1) Slave cylinder supply pipe (engine compartment)
(2) Left-hand drive slave cylinder supply pipe (engine compartment)
(3) Master cylinder (engine compartment / passenger compartment connection)
(4) Brake pipe connector
(5) Master cylinder supply pipe (engine compartment)
(6) Right-hand drive slave cylinder supply pipes (engine compartment)
113905
37A-91
Clutch pedal: Removal - Refitting 37A
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX, and VERSION WITHOUT ADAPTATION SUPPLEMENT
Tightening torquesm
clutch pedal plate 21 Nm

mounting nuts
REMOVAL

a Remove:
112300
a Remove:
- the bolts (1) ,
- the clip (2) .
nectors.
37A-92
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX, and VERSION WITHOUT ADAPTATION SUPPLEMENT
II - OPERATION FOR REMOVAL OF PART a Unclip the wiring harness (6) from the clutch pedal.
CONCERNED
a Remove the master cylinder ball joint (7) from the
clutch pedal.
a Remove:
- the clutch pedal mounting nuts (8) ,
- the clutch pedal.
REFITTING

CONCERNED
a Refit:
- the clutch pedal,
- the clutch pedal mounting nuts,
a Torque tighten the clutch pedal plate mounting
nuts (21 Nm).
a Refit the clutch cylinder ball joint on the pedal.
113095 a Clip the harness on the clutch pedal.
a Refit the clutch switch(es) (see Clutch pedal posi-
tion sensor: Removal - Refitting) .
a Refit:
tors.
- the clip,
- the bolts,
113094
a Disconnect the connector(s) (4) from the clutch

switch(es).
Note:
If the vehicle is keyless, the clutch pedal is fitted
with two switches.
a Remove the clutch switch(es) (5) by turning a quar-

ter of a turn anti-clockwise.
37A-93
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX, and DRIVING SCHOOL VEHICLE
2 - Instructor side
Tightening torquesm
clutch pedal stud, on the 16 Nm

driver's side
shaft for the brake and 35 Nm

clutch pedals, on the
driver's side
REMOVAL


CONCERNED
113666
1 - student side a Remove:
- the circlip (5) from the brake pedal connection con-
trol lever to the link bar,
- the brake and clutch pedal shaft (7) ,
- the brake and clutch pedals.
REFITTING


CONCERNED
113665 1 - student side

a Remove: a Remove:
- the clutch switch (1) (see Clutch pedal position - the clutch pedal,
sensor: Removal - Refitting) ,
- the clutch pedal stud (4) ,
- the clutch master cylinder ball joint (2) from the
clutch pedal, - the circlip (3) from the clutch pedal to the link bar
- the clutch master cylinder ball joint (2) from the
clutch pedal,
- the clutch pedal bolt (4) ,
- the clutch switch (1) (see Clutch pedal position
- the clutch pedal. sensor: Removal - Refitting) .
37A-94
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX, and DRIVING SCHOOL VEHICLE
a Torque tighten the clutch pedal stud, on the dri-
ver's side (16 Nm).
2 - instructor side
a Refit:
- the shaft (7) for the brake and clutch pedals,
- the circlip (5) from the brake pedal connection con-
trol lever to the link bar.
a Torque tighten the shaft for the brake and clutch
pedals, on the driver's side (35 Nm).

37A-95
Clutch pedal spring: Removal - Refitting 37A
Essential equipment
pedal press
REMOVAL
OPERATION FOR REMOVAL OF PART

CONCERNED
113095
a Remove the clutch pedal spring at (1) using a flat-
blade screwdriver.
a Fit the pedal press on the clutch pedal.
a Remove the spring from its mounting at (2) using a
flat-blade screwdriver.
REFITTING
REFITTING OPERATION FOR PART CONCERNED

a Refit the spring onto its mounting.
a Refit the spring onto the clutch pedal.
37A-96
Clutch pedal switch: Removal - Refitting 37A
JH3 or JR5 or TL4, and CRUISE CONTROL – JH3 or JR5 or TL4, and VEHICLE WITH CARD
REMOVAL II - OPERATION FOR REMOVAL OF PART

CONCERNED

CRUISE CONTROL
112629
a Remove: 113094
- the driver side dashboard lower trim clips (1) , a Disconnect the clutch switch connector (3) .
- the driver side dashboard lower trim (2) .
113095
a Turn the clutch switch (4) one quarter of a turn anti-

clockwise.
a Remove the clutch switch (4) .
37A-97
REFITTING
VEHICLE WITH CARD
108436
WARNING
113094
a Disconnect the clutch switch connector (5) . To avoid damaging the clutch switch (7) :
- handle the switch with care,
- only activate the piston during the adjustment
phase,
- do not perform more than 3 adjustments to
dimension (X),
- do not separate the piston from the switch.
Replace the switch:
- if the piston is separated from the switch
- if more than 3 consecutive adjustments to
dimension (X) have been performed.
a Measure dimension (X) of the piston (8) . If dimen-

sion (X) is less than 21 mm, carefully pull on the end
of the piston to adjust the dimension (X) between 21
mm minimum and 23 mm maximum.

113095
CONCERNED
a Turn the clutch switch (6) one quarter of a turn anti-
clockwise.
a Remove the clutch switch (6) . CRUISE CONTROL
a Depress the clutch pedal by hand.
a Position the clutch pedal on the pedal assembly.
a Lock the clutch switch by turning it a quarter of a turn

clockwise.
37A-98
a At the same time, carefully return the clutch pedal.
Note:
The clutch pedal switch has an automatic adjust-
ment feature, adapting to the pedal position.
when in operation.
a Connect clutch switch connector.
VEHICLE WITH CARD

a Position the clutch pedal on the pedal assembly.
a Lock the clutch switch by turning it a quarter of a turn
clockwise.
a Carefully depress the clutch pedal.
Note:
The clutch pedal switch has an automatic adjust-
ment feature, adapting to the pedal position.
when in operation.
a Connect clutch switch connector.

a Refit the driver side dashboard lower trim.
37A-99
Clutch circuit: Bleeding 37A
JH3 or JR5
Essential equipment
Note:
- Even the tiniest air bubble in the circuit can cause
faulty operation (pedal failing to return properly,
crunching sound when changing gear, etc.).
- Incorrect bleeding can lead to incorrect detection
of faults and unnecessary part replacements.
Each time an operation is carried out on the
hydraulic clutch system, bleed the circuit at the fol-
lowing locations:
- between the reservoir and the bleed hole,
- between the bleed hole and the clutch thrust bea-
ring.
113732
a Remove the bleed plug (1) .
BLEEDING
a Connect a transparent pipe between the bleed hole
a Position the vehicle on a two-post lift (see Vehicle: and an empty container placed under the bleed hole.
ment). a Fasten the clip (2) to lock the clutch control pipe.
a Keep the clutch pedal in the upper position. a Remove clip (3) .
a Fill the hydraulic circuit with approved fluid. a Pull out the clutch control pipe by one position to free
the bleed hole.
a Connect the brake circuit bleeding device to the
hydraulic circuit reservoir. a Activate the pump of the brake circuit bleeding de-
vice.
a Remove the engine undertray.
a Let the fluid flow out until there are no more air bub-
bles.
WARNING
The fluid level must always be above the hydrau-
lic control union.
a Lock the clip (3) .

a Push back the clutch control pipe to close off the
bleed hole as soon as the fluid flows out without any
air.
WARNING
As you lock the clutch control pipe, you should
hear a safety click.
a Remove the brake circuit bleeding device.

a Disengage and engage the clutch about ten times.
a Connect a syringe containing 60 cc of approved li-
quid to the end of the transparent pipe.
37A-100
JH3 or JR5
a Lift up the clip (3) .
a Pull out the master cylinder control pipe by one
notch.
a Slowly inject all the liquid contained in the syringe
into the clutch circuit.
a Lock the clip (3) .
a Push the clutch control pipe to seal the bleed hole.
WARNING
a Check that the clutch system is operating correctly.

a Repeat the operation if necessary.
a Refit:
- the bleed plug,
a Top up the brake fluid level until it reaches the maxi-
mum mark on the reservoir.
37A-101
TL4
Ms. 554-07 Cooling system tester kit

(complete). Contains plugs
554-01, 554-04, 554-06
Note:
- Even the tiniest air bubble in the circuit can cause
faulty operation (pedal failing to return properly,
crunching sound when changing gear, etc.).
- Incorrect bleeding can lead to incorrect detection
of faults and unnecessary part replacements.
hydraulic clutch system, bleed the circuit at the fol-
lowing locations:
- between the bleed hole and the clutch thrust bea- 112868
ring.

BLEEDING and an empty container placed under the bleed hole.
a Press clip (3) .
ment).
a Keep the clutch pedal in the upper position. WARNING
a Fill the hydraulic circuit with approved fluid. Do not pull the clip. If it is incorrectly handled in
any way, the pipe will need to be replaced.
a Connect (Ms. 554-07) to the hydraulic circuit reser-
voir. a Pull out the master cylinder control pipe by one
a Remove the engine undertray. notch.
a Activate the pump of the (Ms. 554-07).

a Let the fluid flow out until there are no more air bub-
bles.
WARNING
The fluid level must always be above the hydrau-
lic control union.
a Push back the clutch control pipe to close off the

bleed hole as soon as the fluid flows out without any
air.
WARNING
a Remove the (Ms. 554-07).

a Disengage and engage the clutch about ten times.
37A-102
TL4
a Connect a syringe containing 60 cc of approved li-
quid to the end of the transparent pipe.
a Press the clip (3).
WARNING
Do not pull the clip. If it is incorrectly handled in

notch.
a Slowly inject all the liquid contained in the syringe
into the clutch circuit.
a Push the clutch control pipe to seal the bleed hole.
WARNING

a Repeat the operation if necessary.
a Refit:
- the bleed plug,
a Top up the brake fluid level until it reaches the maxi-
mum mark on the reservoir.
37A-103
Clutch master cylinder: Removal - Refitting 37A
LEFT-HAND DRIVE
REMOVAL
TL4
K4J or K4M or K9K
a Remove:
- the battery (see Battery : Removal - Refitting) ,
fitting) .

CONCERNED
a Fit a hose clamp on the connection between the bra-

ke fluid reservoir and the master cylinder.
112868
JH3 or JR5
a Press on the clip (5) and pull the clutch control pipe.
Note:
Expect some brake fluid to run out.

and an empty container placed under the bleed hole.
a Depress the clutch pedal with your hand (to drain the
master cylinder and the clutch pipe).
113732
a Fasten the clip (2) to lock the clutch control pipe.
a Remove clip (3) .
a Pull out the clutch control pipe one notch to free the
bleed hole.
37A-104
LEFT-HAND DRIVE
19399
a Remove the master cylinder by turning it one quarter
of a turn clockwise (bayonet type mounting) using
the (9) (Emb. 1596).
113094 REFITTING
a Uncouple the clutch pedal master cylinder ball joint
(6) in the passenger compartment. I - REFITTING PREPARATIONS OPERATION
a Place a cloth under the master cylinder.
103116
a Check the condition of the seals.
112865
a Lift the master cylinder clip (7) .
a Uncouple the pipe from the master cylinder.
a Disconnect the pipe (8) between the master cylinder

and the brake fluid reservoir.
a Fit plugs to the openings.
37A-105
LEFT-HAND DRIVE
CONCERNED
a Refit the master cylinder by turning it one quarter of

a turn anti-clockwise (bayonet type mounting) using
tool (Emb. 1596).
Note:
The master cylinder has a foolproofing device, it
only fits in one position.
WARNING
Do not use the branching pipe as a support when
fitting the master cylinder.
a Remove the plugs from the openings.
a Refit the pipe to the master cylinder.
a Press the master cylinder clip.
a Refit the pipe between the master cylinder and the

brake fluid reservoir.
Note:
Lubricate both ends of the supply pipe with brake
fluid to facilitate fitting on the brake fluid reservoir
take-off pipe.
a Refit the clutch pedal master cylinder ball joint in the

passenger compartment.
a Bleed the clutch control (see 3 7 A, Mechanical

component controls, Clutch circuit: Bleeding,
page 37A-100) .
K4J or K4M or K9K
a Refit:
fitting) ,
- the battery (see Battery : Removal - Refitting) .
37A-106
RIGHT-HAND DRIVE
REMOVAL
JH3 or JR5
K4J or K4M or K9K

a Remove the air inlet duct.
113732
a Remove clip (4) .
bleed hole.
113731
a Move the soundproofing to one side to access the
master cylinder.

CONCERNED
a Fit a hose clamp on the connection between the bra-
ke fluid reservoir and the master cylinder.
37A-107
RIGHT-HAND DRIVE
TL4
113094
a Disconnect the master cylinder ball joint (6) from the

112868 clutch pedal in the passenger compartment.
a Press clip (5) and pull the clutch control pipe out one
notch. a Place a cloth under the master cylinder.
Note:
Expect some brake fluid to run out.

113723
a Lift up the master cylinder clip (7) .
a Disconnect the pipe (8) between the master cylinder

and the brake fluid reservoir.
a Fit plugs into the openings.
37A-108
RIGHT-HAND DRIVE
CONCERNED
a Refit the master cylinder by turning it one quarter of
a turn anti-clockwise (bayonet type mounting) using
the (Emb. 1596) (9) .
Note:
The master cylinder has a foolproofing device, it
only fits in one position.
WARNING
Do not use the branching pipe as a support when
19399 fitting the master cylinder.
a Remove the master cylinder by turning it one quarter
a Remove the plugs from the openings.
of a turn clockwise (bayonet type mounting) using
the (Emb. 1596 (9) ). a Refit the pipe to the master cylinder.
a Press the master cylinder clip.
REFITTING a Refit the pipe between the master cylinder and the
brake fluid reservoir.
note:
Lubricate both ends of the supply pipe with brake
fluid to facilitate fitting on the brake fluid reservoir
take-off pipe.
a Refit the clutch pedal master cylinder ball joint in the

passenger compartment.

a Bleed the clutch control (see 37A, Mechanical
page 37A-100) .
a Reposition the soundproofing.
103116
a Refit the soundproofing clips.
a Check the condition of the seals.
37A-109
Clutch circuit: Removal - Refitting 37A
JH3 or JR5
Note: RIGHT-HAND DRIVE

hydraulic clutch system, bleed the circuit:
- between the bleed hole and the clutch release
bearing.
REMOVAL
K4J or K4M
a Remove the resonator.

113731
K4J or K4M or K9K a Remove:
a Remove: - the soundproofing mounting clips (1) ,
- the battery (see Battery : Removal - Refitting) , - the soundproofing partially from the bulkhead in the
engine compartment.
fitting) .
D4F
a Remove the air filter unit (see Air filter unit: Remo-
val - Refitting) .
37A-110
JH3 or JR5
CONCERNED
112865
a Fit a hose clamp on the connection (2) between the
brake fluid reservoir and the master cylinder. 113732
a Disconnect the hose (3) on the master cylinder.
bleed hole.
a Depress the pedal using your hand (to drain the
37A-111
JH3 or JR5
RIGHT-HAND DRIVE
113732
a Disconnect the pipes from the slave cylinder. 109148
a Fit plugs into the openings. a Lift up the clip (9) on the sleeve at the gearbox end.
a Disconnect the pipe from the sleeve.
a Remove:
- the pipe (10) between the slave cylinder and the
sleeve,
- the pipe (11) between the master cylinder and the
sleeve.
LEFT-HAND DRIVE
a Remove the clutch control pipe between the master
cylinder and the slave cylinder.
112865
a Lift up the master cylinder clip (8) .
37A-112
JH3 or JR5
REFITTING
RIGHT-HAND DRIVE
I - REFITTING OPERATION FOR PART a Refit:
CONCERNED
- the bulkhead soundproofing in the engine compart-
ment,
RIGHT-HAND DRIVE
- the soundproofing mounting clips.
a Refit:
- the pipe between the slave cylinder and the sleeve,
- the pipe between the master cylinder and the slee-

ve. D4F
a Remove the plugs from the sleeve openings. a Refit the air filter unit (see Air filter unit: Removal -
Refitting) .
a Connect the pipe to the sleeve.
a Fasten the sleeve clip on the gearbox end.
K4J or K4M or K9K

a Refit:
LEFT-HAND DRIVE - the air filter unit (see Air filter unit: Removal - Re-
fitting) ,
a Refit the clutch control pipe between the master cy-
linder and the slave cylinder.
a Remove the plugs from the master cylinder ope- K4J or K4M or K9K
nings.
a Refit the air inlet duct.
a Connect the pipe to the master cylinder.
a Fasten the clip onto the master cylinder.
a Remove the cloth from under the master cylinder.

K4J or K4M
a Remove the plugs from the slave cylinder openings.
a Refit the resonator.
a Connect the slave cylinder pipe.
a Fasten the clip on the pipe side.
a Connect the hose to the master cylinder.
a Remove the hose clamp from the connection

between the brake fluid reservoir and the master cy-
linder.
a Bleed the clutch control (see 3 7 A, Mechanical

page 37A-100) .
a Refit the bleed plug.
37A-113
TL4
Note:
For every operation on the hydraulic clutch system,
it is essential to bleed:
- between the bleed hole and the clutch thrust bea-
ring.
REMOVAL
a Remove:
- the battery (see Battery : Removal - Refitting) ,

112865
a Fit a hose clamp on the connection (2) between the
fitting) .
brake fluid reservoir and the master cylinder.
a Disconnect the hose (3) on the master cylinder.
RIGHT-HAND DRIVE
113731
a Remove:
- the soundproofing mounting clips (1) ,
- the soundproofing partially from the bulkhead in the

engine compartment.
37A-114
TL4
CONCERNED
112868
a Press clip (5) .
112868
a Disconnect the pipes from the slave cylinder.
a Press clip (5) .
WARNING
Do not pull the clip. If it is incorrectly handled in

notch.
112865
a Lift the master cylinder clip (6) .
37A-115
TL4
CONCERNED
RIGHT-HAND DRIVE
RIGHT-HAND DRIVE
a Refit:
- the pipe between the slave cylinder and the sleeve,
- the pipe between the master cylinder and the slee-
ve.
a Remove the plugs from the sleeve openings.
a Connect the pipe to the sleeve.
a Fasten the sleeve clip on the gearbox end.
LEFT-HAND DRIVE
a Refit the clutch control pipe between the master cy-
linder and the slave cylinder.
109148
a Lift up the clip (7) on the sleeve at the gearbox end.

a Remove the plugs from the master cylinder ope-
a Disconnect the pipe from the sleeve. nings.
a Connect the pipe to the master cylinder.
a Fasten the clip onto the master cylinder.
a Remove:
a Remove the cloth from under the master cylinder.
- the pipe (8) between the slave cylinder and the a Remove the plugs from the slave cylinder openings.
sleeve,
a Connect the slave cylinder pipe to the first notch.
- the pipe (9) between the master cylinder and the
a Fasten the clip on the pipe side.
sleeve.
a Connect the hose to the master cylinder.

a Remove the hose clamp from the connection
LEFT-HAND DRIVE between the brake fluid reservoir and the master cy-
linder.
a Remove the clutch control pipe between the master
cylinder and the clutch slave cylinder. a Bleed the clutch control (see 37A, Mechanical
page 37A-100) .
a Check that the clutch system is working properly.
a Refit the bleed plug.
REFITTING
RIGHT-HAND DRIVE
I - REFITTING PREPARATION OPERATION a Refit:
a Check the condition of the pipe seals, replacing - the bulkhead soundproofing in the engine compart-
them if necessary. ment,
37A-116
TL4
- the soundproofing mounting clips.
a Refit the air inlet duct.

a Refit:
fitting) ,
a Refit the resonator.
37A-117
Gear control: List and location of components 37A
JH3 or JR5
Mark Description
(A) Gear selection cable
(B) Gear cable
109150
37A-118
JH3 or JR5
109149
(A) Press at « A » to separate the

gearbox control cables from the
anchoring ball joint on the gear-
box
(B) Press at « B » to separate the
gearbox control cables from the
sheath stops on the gearbox
37A-119
TL4
Mark Description
(1) Gear selection cable
(2) Gear cable
113903
Note:
The external control of the TL4 gearbox has an
adjusting system (3) on the selection cable.
104732
37A-120
DP0
No. Description
(1) Gear selection cable
113904
37A-121
Gear control unit: Removal - Refitting 37A
JH3 or JR5 or TL4
Tightening torquesm
control unit mounting 21 N.m

bolts
exhaust bracket moun- 25 Nm

tings
exhaust pipe rubber 8 Nm

bush mountings
REMOVAL

ment).
109402
K4J or K4M or K9K
a Remove:
- the battery (see Battery: Removal - Refitting)
D4F
a Disconnect the battery (see Battery: Removal - Re-
a Remove the engine undertray.
108257
a Remove:
- the exhaust bracket mountings,
- the exhaust pipe rubber bush mountings (1) .
a Let the exhaust pipe rest on the rear axle.
Note:
The oxygen sensor wiring harness must not be
under tension.
37A-122
JH3 or JR5 or TL4
CONCERNED
TL4
109404
112867
109405
a Remove:
- the heat shield mountings (2) ,
- heat shield (3) .
101743
a Unclip the two gear lever cables on the gearbox at:
- the anchoring ball joints (4) ,
- the cable sleeve stops (5) .
37A-123
JH3 or JR5 or TL4
JH3 or JR5 ment).
a Unclip the gear lever gaiter with its knob.
a Remove the soundproofing pad covering the gear

control unit.
108265
113183
a Remove the gear selection unit mountings (8) .
a Unclip the gear selection unit from the floor at (9) .
109149
a Unclip:
- the gear control cables from the gearbox by pres-

sing at (6) ,
- the gearbox control cable sleeve stops by pulling

the catch (7) .
109403
a Lower the gearbox control unit so it is resting on the

exhaust.
37A-124
JH3 or JR5 or TL4
a Remove the gear control unit by feeding it out a Refit:
between the exhaust and the tunnel.
- the exhaust pipe at the silencer,
- the mountings from the exhaust pipe rubber moun-
REFITTING ting bushes,
- the exhaust bracket mountings.
a The external control unit and the selector levers on
the gearbox must be in the neutral position to facili- - the exhaust bracket mountings (25 Nm),
tate attachment of the control cables to the gearbox. - the exhaust pipe rubber bush mountings (8
Nm).
When refitting the exhaust pipe rubber mounting
bushes, make sure that they are perfectly in line with
the axis of the vehicle. K4J or K4M or K9K
There is no system to adjust the control cables on a Refit:
JH3 and JR5 gearboxes.
CONCERNED
- the battery (see Battery: Removal - Refitting)
a Reposition the gear control unit by feeding it (MR 392, 80A, Battery).
a Reclip the gear control unit to the floor.
a Refit the gear control unit mountings.
a Torque tighten the control unit mounting bolts (21 D4F
N.m).
a Refit the engine undertray.
TL4 ting) (MR 392, 80A, Battery).
a Adjust the selection cable (see 37A, Mechanical
component controls, Manual gear shift control:
a Refit the soundproofing covering the gear control

unit.
ment).
a Reclip the gear lever gaiter with its knob.
a Reclip:
- the gearbox control cable sleeve stops,
- the gearbox control cables.

a Refit:
- the heat shield,
- the heat shield mountings.
37A-125
DP0
Tightening torquesm
control unit mounting 21 N.m

bolts
exhaust manifold moun- 25 N.m

tings
exhaust pipe rubber 8 Nm

bush mountings
REMOVAL

ment).
a Move the gear lever to the Neutral position. 109402
a Remove:
108257
a Remove:
- the exhaust pipe rubber bush mountings (1) ,
- the exhaust manifold mountings.
a Let the exhaust pipe rest on the rear axle.
Note:
The oxygen sensor wiring harness must not be
under tension.
37A-126
DP0
CONCERNED
109404
110246
a Disconnect the automatic gearbox wiring harness
connector by pulling out the slide (4) .
109405
a Remove:
- the heat shield mountings (2) ,
- heat shield (3) .
37A-127
DP0
110245 110217
a Turn the part (7) a quarter of a turn.
a Lower the part (7) .
110243
a Remove:
- the multifunction switch control cable ball joint by
pressing at (5) , 110216
- the control cable sheath stop from the modular a Remove:

connector support by pulling the catch at (6) .
- the control lever knob (8) , lifting it up and off,
- the part (7) ,
- the centre console (see Centre console: Removal

- Refitting) (MR 393, 57A, Interior equipment),
- the soundproofing pad covering the gear control

unit.
37A-128
DP0
REFITTING

a When refitting the exhaust pipe rubber mountings,
make sure that they are perfectly in line with the axis
of the vehicle.

CONCERNED
a Reposition the gear control unit by feeding it
a Reclip the gear control unit to the floor.
a Refit the gear control unit mountings.
a Torque tighten the control unit mounting bolts (21
N.m).
a Connect the control unit connector.
113183
a Refit:
a Remove the gear selection unit mountings (9) . - the soundproofing pad covering the gear control
unit,
a Disconnect the control unit connector (10) .
- the centre console (see Centre console: Removal
a Unclip the gear selection unit from the floor at (11) . - Refitting) (MR 393, 57A, Interior equipment),
- the part (7),
- the control lever knob.
a Turn the part (7) a quarter of a turn.
109403
a Lower the gearbox control unit so it is resting on the
exhaust.
a Remove the gear control unit by feeding it out
37A-129
DP0
a Clip the control cable into the sheath stop.
a Clip the cable end piece to the multifunction switch
ball joint.
a Fasten the clip (13) to lock the cable end piece.
a Check that the system and gear selection are wor-
king correctly.
a Connect the automatic gearbox wiring harness con-
nector.

a Refit:
- the heat shield,
- the heat shield mountings.
a Refit:
- the exhaust pipe at the silencer,
- the exhaust manifold mountings,
103113
- the exhaust pipe rubber bush mountings.
a
WARNING
- the exhaust manifold mountings (25 N.m),
- Always replace the clip (12) of the automatic
gearbox control cable each time it is removed. - the exhaust pipe rubber bush mountings (8
Nm).
- Mark the position of the gear lever clearly
before starting the operation: if this is not possi- a Refit:
ble, put the selector and the multifunction switch - the engine undertray,
in the Neutral position.
110244
a Push the clip (13) forward.
a Lift the clip (14) upward.
37A-130
Parking brake cables: Removal - Refitting 37A
REMOVAL
DRUM BRAKE

ment).

ment).
DRUM BRAKE
a Remove:
109705
Removal - Refitting, page 35A-1) , a Remove the parking brake cable (4) from the lever
(5) using pliers and a screwdriver.
- the drums (see 33A, Rear axle components,
Rear brake drum: Removal - Refitting, page a Unclip the parking brake cable sheath (6) from the
33A-19) . drum back-plate.
II - OPERATION FOR REMOVAL OF PART BRAKE DISC

CONCERNED
112630
a Loosen the adjusting nut (1) for the parking brake

cables enough to be able to remove the parking bra-
ke cables.
109210
a Remove the parking brake cables (2) at the control a Remove the parking brake cables (7) at the brake
lever. callipers.
a Unclip the sheath (3) from its stop on the bodywork

using a pair of pliers.
37A-131
DRUM BRAKE
112632
a Unclip the parking brake cables from their guides (8)
. 116013
a Remove the parking brake cables: a Reattach the parking brake cable sheath onto the
drum back-plate.
REFITTING a Refit the parking brake cable back into the lever hou-
sing using a pair of pliers and a screwdriver.
I - REFITTING OPERATION FOR PART a Check that the cables (9) are correctly positioned on
CONCERNED the levers.
a Refit the parking brake cables.
a Hook the parking brake cables onto their guides.
BRAKE DISC
a Refit the parking brake cables at the brake callipers.
a Reattach the sheath stop to the bodywork (3) .

a Refit the parking brake cables at the control lever.
DRUM BRAKE
a Refit:
- the drums (see 33A, Rear axle components,
33A-19) ,
37A-132

ment).
37A-133
Brake servo: Check 37A
RIGHT-HAND DRIVE
CHECKING
I - CHECKING THE SEALS
122228
There is no "RENAULT" tool to check the braking as-
sistance circuit.
Use a vacuum pump fitted with couplings, part num- 117948
bers 7701349942 and 7700105874 with hose part a When checking the brake servo seal, ensure that
number 8200027352 or 8200376245. there is a perfect seal between this and the master
cylinder (A) .
If there is a leak in this area, replace the seal
between the brake servo and the master cylinder
(see 37A, Mechanical component controls, Mas-
ter cylinder: Removal - Refitting, page 37A-2) .
The brake servo seals must be checked on the vehi-
cle with the hydraulic circuit operational.
II - CHECKING THE BRAKE SERVO

a Remove the front engine cover (if fitted to the vehi-
cle).
37A-134
RIGHT-HAND DRIVE
D4F, and 784
122106
122105
a Remove:
- the oxygen sensor (3) (see Oxygen sensors: Re-

moval - Refitting) (MR 392, 17B, Petrol injection),
- the bulkhead heat shield clips (4) ,
37A-135
RIGHT-HAND DRIVE
- in the non-return valve seal, in which case replace
the seal (see 37A, Mechanical component con-
trols, Brake servo non-return valve: Removal -
- in the pushrod diaphragm, in which case replace
the brake servo (see 37A, Mechanical compo-
nent controls, Brake servo: Removal - Refitting,
page 37A-32) .
a Refit the non-return valve on the brake servo (see
37A, Mechanical component controls, Brake ser-
vo non-return valve: Removal - Refitting, page
37A-26) .
D4F, and 784

a Refit:
122104
- the oxygen sensor (see Oxygen sensors: Remo-
val - Refitting) (MR 392, 17B, Petrol injection),
- the turbocharger heat shield bolts.
III - CHECKING THE NON-RETURN VALVE
D4F or F4R or K4J or K4M or M4R

a Disconnect the non-return valve on the inlet mani-
fold side.
K9K
a Disconnect the non-return valve on the vacuum
122236 pump side.
a Remove the non-return valve (6) of the brake servo
(see 37A, Mechanical component controls, Bra-
ke servo non-return valve: Removal - Refitting,
page 37A-26) .
a Connect a vacuum pump directly to the brake servo.
a Activate the vacuum pump to obtain a vacuum of

500 mbar.
a Check that the vacuum does not fall by more than 33

mbar in 15 seconds.
If the vacuum falls by more than 33 mbar in 15 se-

conds, there is a leak which may be located:
37A-136
RIGHT-HAND DRIVE
IV - CHECKING THE VACUUM PUMP
K9K
122234
a Connect a vacuum pump to the end of the non-re-
turn valve.
a Activate the vacuum pump to obtain a vacuum of 106889
500 mbar. a Connect the external vacuum pump to the engine
a Check that the vacuum pressure does not drop. If it vacuum pump.
does, the non-return valve is pierced. Replace the a Start the engine.
valve (see 37A, Mechanical component controls,
Brake servo non-return valve: Removal - Refit- a Check the following values:
ting, page 37A-26) . - 550 mbar in 5 seconds at an engine speed of 700
rpm,
D4F or F4R or K4J or K4M or M4R - 700 mbar in 3 seconds and 900 mbar in 5 se-
conds at an engine speed of 4050 rpm.
a Refit the non-return valve on the inlet manifold.
a Replace the vacuum pump if the values are different
(see 37A, Mechanical component controls, Va-
cuum pump: Removal - Refitting, page 37A-68) .
a Refit the front engine cover (if fitted to the vehicle). a Refit the non-return valve to the vacuum pump.
37A-137
ANTI-LOCK BRAKING SYSTEM
Hydraulic assembly without ESP: Removal - Refitting 38C
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
hydraulic unit nuts on its 8 Nm

mounting

the hydraulic assembly
WARNING
REMOVAL 112618
a Remove the two soundproofing clips (1) .
I - REMOVAL PREPARATION OPERATION a Remove the soundproofing to access the hydraulic
a Position the vehicle on a two-post lift (see Vehicle: unit.
ment). K4J or K4M
a Position a pedal press on the brake pedal to limit
K9K
a Remove:
- the wiper arms (see Wiper arms: Removal - Refit-
ting) (MR 392, 85A, Wiping - Washing),
pment),
(MR 392, 56A, Exterior equipment).
112054
a Remove the lifting eye (2) .
M4R
a Remove the intake distributor (see Inlet manifold:
Removal - Refitting) (MR 392, 12A, Fuel mixture).
38C-1
LEFT-HAND DRIVE
CONCERNED
K9K
D4F or K4J or K4M or M4R
112617
a Disconnect the computer connector from the hy-
112054 draulic unit.
a Disconnect the connector (3) from the hydraulic unit
a Remove the brake pipe unions on the hydraulic unit.
computer by lifting the lock on the connector (4) .
a Undo the hydraulic unit nuts (5) on its mounting.
a Remove the brake pipe unions from the hydraulic
unit.
a Undo the hydraulic unit nuts (5) on its support.
a Remove the hydraulic unit.
REFITTING

CONCERNED
a Refit the hydraulic unit.
a Torque tighten the hydraulic unit nuts on its
mounting (8 Nm).
a Refit the brake pipe unions to the hydraulic unit.
a Torque tighten the brake pipe unions on the hy-
draulic assembly (14 Nm).
a Connect the computer connector on the hydraulic
unit.
38C-2
LEFT-HAND DRIVE
K4J or K4M
a Refit the lifting eye.
M4R
a Refit the intake distributor (see Inlet manifold: Re-
moval - Refitting) (MR 392, 12A, Fuel mixture).
K9K
a Refit:
pment),
ting) (MR 392, 85A, Wiping - Washing).

38C-3
RIGHT-HAND DRIVE
CONCERNED
Essential equipment
pedal press
Tightening torquesm
nuts on the hydraulic 8 Nm

unit support

WARNING
braking system.
112875
REMOVAL
a Lift the bracket at the bottom of the computer con-
nector (1) on the hydraulic unit.
a Disconnect the computer connector from the hy-
a Position the vehicle on a two-post lift (see Vehicle: draulic unit.
ment). a Remove:
a Disconnect the battery (see Battery : Removal - - the brake pipe unions (2) on the hydraulic unit,
Refitting) (MR 392, 80A, Battery). - the nuts (3) on the hydraulic unit support,
a Fit the pedal press to the brake pedal to limit the - the hydraulic unit.
a Remove:
REFITTING
- the battery tray (see Battery : Removal - Refit- CONCERNED
ting) (MR 392, 80A, Battery),
a Refit:
- the hydraulic unit,
- the nuts on the hydraulic unit support.
a Torque tighten the nuts on the hydraulic unit sup-
port (8 Nm).
a Finger tighten the brake pipe unions on the hydraulic
unit.
unit.
a Lower the computer connector bracket on the hy-
draulic unit.
38C-4
RIGHT-HAND DRIVE
a Refit:
- the battery tray (see Battery : Removal - Refit-
ting) (MR 392, 80A, Battery),
a Remove the pedal press tool on the brake pedal.
a Bleed the braking circuit using the brake circuit
bleeding device (see 30A, General information,
38C-5
D4F, and 784, and LEFT-HAND DRIVE
Essential equipment - the oxygen sensor (3) (see Oxygen sensors: Re-
moval - Refitting) (MR 392, 17B, Petrol injection).
pedal press
Tightening torquesm
hydraulic unit nuts 8 Nm

the hydraulic unit
WARNING
REMOVAL

Towing and lifting) (MR 392, 02A, Lifting equip- 122105
ment). a Remove:
a Disconnect the battery (see Battery: Removal - Re- - the bulkhead heat shield clips (4) ,
a Remove the front engine cover.
122106
a Remove:
38C-6
D4F, and 784, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART II - FINAL OPERATION.
CONCERNED
a Refit:
- the oxygen sensor (see Oxygen sensors: Remo-
val - Refitting) (MR 392, 17B, Petrol injection).
a Refit:
- the heat shield bolts,
- the engine cover.
112054
a Lift the lock (6) at the bottom of the hydraulic unit

computer connector.
a Disconnect the hydraulic unit computer connector

(7) .
a Remove:
- the hydraulic unit brake pipe unions (8) ,

- the hydraulic unit nuts (9) ,
- the hydraulic unit.
REFITTING

CONCERNED
a Refit:
- the hydraulic unit nuts,
- the hydraulic unit brake pipe unions.
a Torque tighten:
- the hydraulic unit nuts (8 Nm),
- the brake pipe unions on the hydraulic unit (14

Nm).
a Connect the hydraulic unit computer connector.

a Lower the hydraulic unit computer connector lock.
38C-7
Hydraulic assembly with ESP: Removal - Refitting 38C
LEFT-HAND DRIVE
Essential equipment M4R
pedal press a Remove the intake distributor (see Inlet manifold:

Removal - Refitting) (MR 392, 12A, Fuel mixture).
Tightening torquesm
nuts mounting the 8 Nm

hydraulic unit on its
mounting

WARNING
braking system.
REMOVAL

112618
Towing and lifting) (MR 392, 02A, Lifting equip- a Remove the two soundproofing clips (1) .
ment). a Move the soundproofing aside to access the hydrau-
lic unit.

F4R or K9K
a Remove:

ting) (MR 392, 85A, Wiping - Washing),

pment),
- the scoop under the scuttle panel grille (see Scutt-

le panel grille: Removal - Refitting) (MR 392,
56A, Exterior equipment).
38C-8
LEFT-HAND DRIVE
CONCERNED
K4J or K4M
D4F or K4J or K4M or M4R
112054
a Remove the lifting eye (2) .
112054
a Disconnect the hydraulic unit computer connector
(3) by lifting the lug (4) .
a Remove the brake pipe unions on the hydraulic unit.
a Loosen the nuts (5) mounting the hydraulic unit on
its mounting.
38C-9
LEFT-HAND DRIVE
F4R or K9K
K4J or K4M
a Refit the lifting eye.
F4R or K9K
a Refit:
- the scoop under the scuttle panel grille (see Scutt-
le panel grille: Removal - Refitting) (MR 392,
56A, Exterior equipment),
pment),
ting) (MR 392, 85A, Wiping - Washing).
112617
a Disconnect the hydraulic unit computer connector a Remove the pedal press tool on the brake pedal.
(3) by lifting the lug (4) . a Bleed the brake circuit (see 30A, General informa-
a Remove the brake pipe unions on the hydraulic unit. tion, Brake circuit Bleeding, page 30A-4) .
a Loosen the nuts (5) mounting the hydraulic unit on a Connect the battery (see Battery : Removal - Refit-
its mounting. ting) (MR 392, 80A, Battery).
a Remove the hydraulic unit.
REFITTING

CONCERNED
a Refit the hydraulic unit.
a Torque tighten the nuts mounting the hydraulic
unit on its mounting (8 Nm).
a Refit the six brake pipe unions on the hydraulic unit.
a Connect the hydraulic unit computer connector.
38C-10
D4F or K4J or K4M or K9K or M4R, and 784, and RIGHT-HAND DRIVE
CONCERNED
Essential equipment
pedal press
Tightening torquesm
nuts on the hydraulic 8 Nm

unit support

WARNING
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle: a Lift the lock at the bottom of the hydraulic unit com-
Towing and lifting) (MR 392, 02A, Lifting equip- puter connector (1) .
ment). a Disconnect the computer connector from the hy-
a Disconnect the battery (see Battery : Removal - draulic unit.
Refitting) (MR 392, 80A, Battery). a Remove:
a Position a pedal press on the brake pedal to limit - the brake pipe unions (2) on the hydraulic unit,
- the nuts (3) on the hydraulic unit support,
a Remove:
- the hydraulic unit.
- the battery tray (see Battery tray: Removal - Re- REFITTING
fitting) (MR 392, 80A, Battery),
- the air filter unit (see Air filter unit: Removal - Re- I - REFITTING OPERATION FOR PART
fitting) (MR 392, 12A, Fuel mixture). CONCERNED
a Refit:
- the nuts on the hydraulic unit support.
a Torque tighten the nuts on the hydraulic unit sup-
port (8 Nm).
a Finger tighten the brake pipe unions on the hydraulic
unit.
unit.
a Lower the hydraulic unit computer connector lock.
38C-11
D4F or K4J or K4M or K9K or M4R, and 784, and RIGHT-HAND DRIVE
a Refit:
- the battery tray (see Battery tray: Removal - Re-
fitting) (MR 392, 80A, Battery),
38C-12
Wheel speed sensor: Removal - Refitting 38C
Tightening torquesm
wheel speed sensor 8 Nm

mounting bolt
REMOVAL
a Position the vehicle on a two-post lift (see 02A, Lif-

ting Equipment, Vehicle: Towing and lifting).
a Disconnect the battery (see 80A, Battery, Battery:

Removal - Refitting).
a Remove:
- the front wheels (see 35A, Wheels and tyres, 116770

a Remove:
- the wheel arch liners (see MR 393 Bodywork, - the mounting bolt (1) from the wheel speed sensor,
55A, Exterior protection, Front wheel arch liner:
Removal - Refitting). - the wheel speed sensor.

CONCERNED

CONCERNED
a Refit:
- the wheel speed sensor,
- the mounting bolt to the wheel speed sensor.
a Torque tighten the wheel speed sensor mounting

bolt (8 Nm).
a Connect the wheel speed sensor in the wheel arch.
a Refit:
- the wheel arch liners (see MR 393 Bodywork,

55A, Exterior protection, Front wheel arch liner:
Removal - Refitting),
116760
a Detach the wheel speed sensor wiring harness. Wheel: Removal - Refitting, page 35A-1) .
a Disconnect the wheel speed sensor in the wheel a Connect the battery (see 80A, Battery, Battery: Re-
arch. moval - Refitting).
38C-13
Yaw speed and transversal acceleration sensor: Removal - Refitting 38C
Essential equipment
diagnostic tool
Tightening torquesm
yaw speed and trans- 6 Nm

verse acceleration sen-
sor mounting nuts
REMOVAL

Removal - Refitting) (MR 393, 57A, Interior equip- 113181
ment). a Disconnect the connector (1) .
a Remove:
CONCERNED - the mounting bolts (2) from the lateral acceleration
and yaw sensor,
- the sensor.
113182
a Cut the carpet using a sharp tool.
38C-14
Yaw speed and transversal acceleration sensor: Removal - Refitting 38C
REFITTING
113182
a Fit the carpet at (3) with PIG'S SNOUT CLIPS (Part
no. 77 01 047 751).
20912
a III - FINAL OPERATION.
WARNING
The sensor must be fitted facing the vehicle's ment).
direction of travel (as shown by the arrow).
Be sure to replace any sensor which has sustai- ting) (MR 392, 80A, Battery).
ned an impact.
IMPORTANT
Be sure to confirm the repair with a road test and
CONCERNED
a check using the diagnostic tool.
a Refit:
- the sensor,
- yaw speed and transverse acceleration sensor
mounting bolts.
a Connect the connector.
a Torque tighten the yaw speed and transverse ac-
celeration sensor mounting nuts (6 Nm).
38C-15
Braking computer: Removal - Refitting 38C
Mot. 1608 Torque screwdriver 1 to 6.6
N.m.
Essential equipment
diagnostic tool
Tightening torquesm
braking computer bolts 3 Nm
Note:
Removal of the ESP or ABS computer is allowed.
REMOVAL

Towing and lifting) (MR 392, 02A, Lifting equip- - the (1) braking computer bolts on the pressure mo-
ment). dulation unit,
a Remove the entire hydraulic unit (see Brake hy- - the braking computer (2) .
draulic assembly: Removal - Refitting) .
REFITTING
19113
a Do not clean the pressure modulation unit (3) .
a Always replace the braking computer bolts.
38C-16
Braking computer: Removal - Refitting 38C
CONCERNED
a Refit the braking computer, holding it by its edge.
Note:
Do not try to force the braking computer into
place when refitting; it should fit in without any
resistance.
19113
a Fit the hydraulic pump (4) securely onto the pressu-

re modulation unit (5) .
Note:
When a new braking computer is being fitted,
remember to attach the interconnection fork (6)
between the pressure modulation unit and the
braking computer.
a Refit the braking computer bolts on the pressure mo-

dulation unit.
a Torque tighten the braking computer bolts (3 Nm)

using the (Mot. 1608).
a Refit the entire hydraulic unit (see Brake hydraulic

assembly: Removal - Refitting) .
a Configure the speedometer index using the dia-

gnostic tool (see Fault finding - Replacement of
components) (MR 394, 38C, Anti-lock braking sys-
tem.
a Clear any faults stored by the braking computer.
a Carry out a road test to confirm the repair.
38C-17

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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

FEBRUARY 2009 Edition Anglaise

© Renault s.a.s 2008

CLIO III - Section 3

30A GENERAL INFORMATION 31A FRONT AXLE COMPONENTS

Brake circuit Operating Front brake calliper: Removal

Brake circuit Precautions for Front brake calliper: Repair 31A-10

Brake circuit Tightening Front brake disc shield:

Brake fluid: Specifications 30A-8 Front brake disc: Removal -

Front axle: Adjusting 30A-23 Hydraulic unit - front left-

Rear axle: Adjustment values 30A-26 Hydraulic unit - front right-

Front driveshaft hub carrier:

31A FRONT AXLE COMPONENTS 33A REAR AXLE COMPONENTS

Front driveshaft lower arm Rear drum bearing: Removal

Front axle sub-frame: Rear disc brake bearing:

Front anti-roll bar: Removal - Rear stub-axle carrier:

Complete rear axle: Removal

33A REAR AXLE COMPONENTS

Rubber bushing: Adjustment 33A-1

Rear brake hose: Removal - Wheel: Balancing 35A-7

Rear brake disc: Description 33A-14 35B TYRE PRESSURE MONITOR

Brake pipe: Removal -

Shock absorber: Removal -

Rear suspension spring:

36A STEERING ASSEMBLY 37A MECHANICAL COMPONENT CONTROLS

Steering rack: Removal - Manual gear shift control:

Track rod: Removal - Master cylinder: Removal -

Axial ball joint linkage: Right-hand front calliper-

Power assisted steering rack: Brake compensator: Check 37A-83

Parking brake lever:

Clutch control: List and

Clutch pedal: Removal -

37A MECHANICAL COMPONENT CONTROLS

Clutch pedal spring:

Clutch pedal switch:

Clutch circuit: Bleeding 37A-100

Clutch master cylinder:

Clutch circuit: Removal -

Gear control: List and

Gear control unit: Removal -

Parking brake cables:

Brake servo: Check 37A-134

38C ANTI-LOCK BRAKING SYSTEM

Hydraulic assembly without

Hydraulic assembly with

Wheel speed sensor:

Yaw speed and transversal

Braking computer: Removal -

When replacing brake pads, always replace the pads

1 - Advice to be followed before any operation