Renault Duster 2007 Manual
  1. Manuals
  2. Brands
  3. Renault Manuals
  4. Automobile
  5. Duster 2007
  6. Manual

Renault Duster 2007 Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

Download this manual
General vehicle information
0
VEHICLE MECHANICAL SPECIFICATIONS
01A
VEHICLE BODYWORK SPECIFICATIONS
01C
LIFTING EQUIPMENT
02A
COLLISION
03B
CONSUMABLES - PRODUCTS
04B
"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are
constructed".
X79
NOVEMBER 2009
All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference
numbering system is forbidden without the prior written authority of Renault.
© Renault s.a.s 2007
EDITION ANGLAISE

Advertisement

Table of Contents
loading

Related Manuals for Renault Duster 2007

Summary of Contents for Renault Duster 2007

  • Page 1 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 2 DUSTER - Chapitre 0 DUSTER - Chapitre 0ContentsPages Contents Pages VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 01A-1 VEHICLE BODYWORK SPECIFICATIONS Vehicle: Identification 01C-1 Vehicle panel gaps: Adjustment value 01C-2 LIFTING EQUIPMENT Vehicle: Towing and lifting 02A-1 COLLISION Vehicle involved in an impact: Impact fault finding 03B-1 CONSUMABLES - PRODUCTS...
  • Page 3 VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 144900 4X2 TRANSMISSION Dimensions in metres: 0.822 2.673 0.820 4.315 1.560 (F) (unladen) 1.690 1.567 1.822 01A-1...
  • Page 4 VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 4X4 TRANSMISSION Dimensions in metres: 0.822 2.671 0.822 4.315 1.560 (F) (unladen) 1.682 1.570 1.822 Engine Gearbox Emissions Engine type Engine suf- Cubic capac- Gearbox type Gearbox suffix Transmission standard fix ity(cc) type EURO 4 1598 EURO 5 EURO 4...
  • Page 5 VEHICLE BODYWORK SPECIFICATIONS Vehicle: Identification I - LOCATION OF VEHICLE IDENTIFICATION III - DETAILED VIEW OF THE VEHICLE PLATE (A) IDENTIFICATION PLATE Plate (A) 145261 19031 II - LOCATION OF THE VEHICLE IDENTIFICATION NUMBER (B) Vehicle type and type number; this information also appears on marking (B) MGVW (Maximum Gross Vehi-...
  • Page 6 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value WARNING The clearance values are given for information pur- poses. When adjusting clearances, certain rules have to be followed: - maintain symmetry with respect to the opposite side, - ensure the flush fitting is correct, - check correct operation of the opening, and water/ air-tightness.
  • Page 7 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Location Clearances (mm) 4.5 ± 1 windscreen / roof 18 ± 1 side doors / roof 4.5 ± 1 front side door / rear side door 4.5 ± 1 (10) rear side door / rear wing panel 6 ±...
  • Page 8 LIFTING EQUIPMENT Vehicle: Towing and lifting 2 - Position of rear attachment point Equipment required safety strap(s) I - TOWING WARNING See the current towing regulations in each country. Never use the driveshafts, axle assembly compo- nents or suspension components as attachment points.
  • Page 9 LIFTING EQUIPMENT Vehicle: Towing and lifting III - LIFTING ON A LIFT 1 - Safety advice reminder 108416 14894 If it is necessary to remove heavy components from the vehicle, it is preferable to use a four-post lift. After removing certain components (e.g. engine and transmission assembly, rear axle, fuel tank, etc.), there is a danger that the vehicle will tip on a two post lift.
  • Page 10 LIFTING EQUIPMENT Vehicle: Towing and lifting 2 - Fitting the straps IMPORTANT Only the jacking points described in this section allow the vehicle to be raised in complete safety. Do not raise the vehicle using points other than those described in this section. At the front 108420 For safety purposes, the straps must always be in per-...
  • Page 11 COLLISION Vehicle involved in an impact: Impact fault finding 145391 I - CHECKING THE SUBFRAME Chronological order of checks a FRONT impact Compare the following distances between diagonal- ly opposite points: - 1: B1 - G2 = B2 - G1 - 2: G1 - C2 = G2 - C1 a REAR impact Compare the following distances between diagonal-...
  • Page 12 COLLISION Vehicle involved in an impact: Impact fault finding II - DETAILED VIEW OF INSPECTION POINTS Point C1 - C2 Point B1 - B2 145392 Point J1 - J2 145397 Point G1 - G2 145395 145393 03B-2...
  • Page 13 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair Consumables for mechanical repair: DEFINITION PACKAGING PART NUMBER MECHANICAL SEALANTS SILICOR 85 g tube 77 11 236 470 sealing paste MASTIXO 100 g tube 77 11 236 172 Joint face seal BEARING SEALING KIT 77 11 237 896 For crankshaft bearing cap side...
  • Page 14 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair INJECTOR CLEANER 355 ml container 77 11 224 188 or 77 11 225 539 CLOTH FOR INJECTION SYSTEM 77 11 211 707 SUPER RELEASING AGENT 500 ml aerosol 77 11 236 166 SUPER RELEASING AGENT 250 ml aerosol 77 11 420 439...
  • Page 15 77 11 230 111 Varnish for repairing heated rear screens BRAKE 0.5 L container 77 11 218 589 DOT 4, ISO CLASS 6, RENAULT STANDARD: 03-50-006, 5 L container 77 11 238 318 For vehicles with and without elec- tronic stability program (ESP)
  • Page 16 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair AXLE OIL (see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubri- cants) ELF RENAULT MATIC D2 2 L container 77 01 402 037 Oil for power-assisted steering: Pump connected, pump assembly...
  • Page 17 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair Consumables for bodywork repair: HOLLOW SECTION WAX SPR CC 1 L container 77 11 172 672 SPR CC SPRAY 500 ml aerosol 77 11 211 654 STRUCTURAL ADHESIVE STRUCTURAL ADHESIVE Kit =2 80 ml cartridges 77 11 219 885 HIGH PERFORMANCE STRUC-...
  • Page 18 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair PREFORMED SEALING MASTIC 2.6 m roll 77 01 423 330 BEAD BRUSH MASTIC 1 kg pack 77 11 228 113 FILLER MASTIC 60 beads Ø 6 mm by 0.3 m 77 11 170 230 GREASE WHITE GREASE...
  • Page 19 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair PIXTO SPRAYABLE POL YESTER 1.5 kg tin 77 11 172 237 MASTIC Finishing mastic IXTRA POLYESTER MASTIC 1.625 kg pack 77 11 172 233 Anti-grit mastic MAG PRO 1 310 ml cartridge 77 11 172 679 MAG PRO 3 (Dual component) 1.5 kg tin...
  • Page 20 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair ANTI-SPLASH SPRAY 400 ml aerosol 77 11 218 270 SPECIFIED UNDERCOAT PRE-TREATMENT PRIMER WITH- 77 11 420 027 (Primer) OUT ZINC CHROMATE (I-Alpha) + 1 L container 77 11 420 028 (Thinner) THINNER 77 11 239 243 (Primer) I-PREMIA REACTIVE PRIMER (do...
  • Page 21 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 22 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".

  • Page 23: Table Of Contents

    DUSTER - Chapitre 1 DUSTER - Chapitre 1ContentsPages Contents Pages ENGINE AND CYLINDER BLOCK TOP AND FRONT OF ENGINE ASSEMBLY Crankshaft seal on timing Pressure at end of end: Removal - Refitting 10A-1 compression: Check 11A-1 Crankshaft seal, gearbox Accessories belt: Removal - end: Removal - Refitting 10A-5 Refitting...
  • Page 24 Contents FUEL MIXTURE DIESEL INJECTION Throttle valve: Removal - Crankshaft position sensor: Refitting 12A-11 Removal - Refitting 13B-8 Inlet distributor: Removal - High pressure pump: Refitting 12A-12 Removal - Refitting 13B-9 Injector holder shim: Flow actuator: Removal - Removal - Refitting 12A-14 Refitting 13B-14...
  • Page 25 Contents ANTIPOLLUTION COOLING Exhaust gas recirculation Engine cooling system: solenoid valve: Removal - Operating diagram 19A-1 Refitting 14A-4 Engine cooling system: Exhaust gas cooler: Removal Specifications 19A-2 - Refitting 14A-7 Engine cooling system: Exhaust gas recirculation Check 19A-3 assembly: Removal - Engine cooling circuit: List Refitting 14A-9...
  • Page 26 Contents EXHAUST Intermediate pipe: Removal - Refitting 19B-18 Silencer: Removal - Refitting 19B-20 TANK Fuel tank: Draining 19C-1 Fuel tank: Removal - Refitting 19C-3 Fuel level sensor module: Removal - Refitting 19C-8 ENGINE MOUNTING Suspended engine mounting: Tightening torque 19D-1 Left-hand suspended engine mounting: Removal - Refitting...

  • Page 27: Engine And Cylinder Block Assembly

    ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 28 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft seal on timing end. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks).
  • Page 29 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 20772 20770 a Screw the threaded rod (10) of theinto the crank- a Fit the protector with the new seal in place on the shaft. spacer, taking care not to touch the seal. 20771 20769 a On the crankshaft, fit the spacer (11) of the.
  • Page 30 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 20768 20766 a Remove the nut, the cup, the protector and the threaded rod. III - FINAL OPERATION a Refit: - the timing belt sprocket (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-17) , - the timing belt (see 11A, Top and front of engine,...

  • Page 31: Crankshaft Seal, Gearbox End: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting K4M or K9K REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 32 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting K4M or K9K II - REFITTING OPERATION 22760 a Extract the crankshaft seal at the gearbox end by screwing the threaded rod (7) . 18687 Note: REFITTING This type of seal is extremely fragile. Only touch the protective part (8) when handling I - REFITTING PREPARATION OPERATION the gasket.
  • Page 33 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting K4M or K9K 20760 20762 a Mount theon the crankshaft, securing it using bolts a Fit the cover (11) and nut (12) (with the thread (13) (10) . of the nut towards the outside of the engine) of the.
  • Page 34 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting K4M or K9K 20764 134544 a Refit the crankshaft seal at the gearbox end, using the tool (14) . III - FINAL OPERATION a Refit: - the flywheel (see 10A, Engine and cylinder block assembly, Flywheel: Removal - Refitting, page 10A-75) (20A, Clutch), - the clutch (see Pressure plate - Disc: Removal -...

  • Page 35: Lower Cover: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Remove: Special tooling required - the front wheels (see Wheel: Removal - Refitting) Tav. 1747 Threaded rods for carrying (35A, Wheels and tyres), out subframe operations. - the front wheel arch side liners, - the lower engine tie-bar (see 19D, Engine mount- ing, Lower engine tie-bar: Removal - Refitting, Tightening torquesm...
  • Page 36 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 24762 a Remove the power-assisted steering low pressure pipe bolt (2) on the front axle subframe. 144756 a Remove the front axle subframe tie-rod upper bolts (5) . 145789 a Remove the cooling pipe support bolt (3) on the sump.
  • Page 37 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 144755 a Remove: - the bracket bolts (12) , - one by one, the front axle subframe bolts (11) and replace them in turn with the threaded rods of the 108645 (Tav.
  • Page 38 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - REMOVAL OPERATION STANDARD HEATING RECIRCULA TION 107936 a Remove: - the engine-gearbox coupling bolts (14) , 24761 - the sump bolts, a Remove the power-assisted steering pump support bolt (13) on the sump.
  • Page 39 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Clean the cylinder block joint face using SUPER CLEANING AGENT FOR JOINT FACES (see Ve- hicle: Parts and consumables for the repair) (04B, Consumables - Products). WARNING T o ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks).
  • Page 40 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - REFITTING OPERATION 20170 Note: When refitting the sump, ensure that: - the oil splash plate tabs (17) are positioned cor- rectly in the slots (18) , - the coupling faces of the sump and cylinder block are correctly aligned, to prevent the clutch housing being deformed when fitting the gear- box.
  • Page 41 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting Note: If the oil pump was loosened beforehand in order to extract the sump, position the sump in order to slide the oil pump strainer into the oil splash plate of the sump.
  • Page 42 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a One by one, remove the threaded rods of the (Tav. 1747) and replace them in turn with new front axle subframe bolts. a Refit: - the relay bearing bolts, - the right-hand driveshaft flange bolt(s) on the relay bearing.
  • Page 43 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Remove: Special tooling required - the front wheels (see Wheel: Removal - Refitting) Tav. 1747 Threaded rods for carrying (35A, Wheels and tyres), out subframe operations. - the front wheel arch side liners, - the lower engine tie-bar (see 19D, Engine mount- ing, Lower engine tie-bar: Removal - Refitting, Tightening torquesm...
  • Page 44 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 145789 135708 a Remove the cooling pipe support bolt (2) on the a Remove: sump. - the right-hand driveshaft flange bolt (5) on the relay bearing, - the bolts (6) from the relay bearing, - the relay bearing.
  • Page 45 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 144755 a Remove: - the bracket bolts (11) , - one by one, the front axle subframe bolts (10) and replace them in turn with the threaded rods of the 108645 (Tav.
  • Page 46 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Clean the cylinder block joint face using SUPER II - REMOVAL OPERATION CLEANING AGENT FOR JOINT FACES (see Ve- hicle: Parts and consumables for the repair) (04B, Consumables - Products). WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin-...
  • Page 47 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - REFITTING OPERATION 20166 20170 Note: When removing the sump, ensure that: - the oil splash plate tabs (15) are positioned cor- rectly in the slots (16) , - the coupling faces of the sump and cylinder block are correctly aligned, to prevent the clutch housing being deformed when fitting the gear- box.
  • Page 48 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting - the sump bolt on the multifunction support (25 N.m). III - FINAL OPERATION a Fit the front axle subframe. a Refit the brackets. a Torque tighten the bracket bolts (62 N.m). a One by one, remove the threaded rods of the (Tav.
  • Page 49 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Refit the front bumper (see Front bumper assem- bly: Exploded view) and (see Exterior body front trim assembly: Exploded view) (55A, Exterior pro- tection). a Refit: - the engine undertray, - the front wheel arch side liners, - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).

  • Page 50: Conrod Bearing Shell: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting a Strap the radiator to the vehicle using safety strap(s). Equipment required a Remove the front axle subframe (see Front axle safety strap(s) subframe: Removal - Refitting) (31A, Front axle components).
  • Page 51 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 112328 140917 a Remove the catalytic converter upstream stay (3) . a Tilt the engine oil sump forwards in order to access the oil pump bolts. a Partially loosen the oil pump bolts 3 mm to 5 mm. a Detach the oil pump from its position in order to re- move the engine oil sump.
  • Page 52 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting II - REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO.2 139300 a Remove: 139306 - the con rod bolts, a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consum- - the con rod cap, ables - Products) to clean the big ends.
  • Page 53 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 139310 139315 a Fit the tie rod of the toolon the con rod body. a Push the con rod upwards to release the con rod WARNING from the crankpin. Failure to observe the following procedure may a Turn the crankshaft 90˚...
  • Page 54 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting Note: Always replace con rod bearing shells with a width of 20 mm by con rod bearing shells with a width of 18 mm. If the set of con rod bearing shells only includes con rod bearing shells which are 18mm wide, only use the head of the toolwith the marking "...
  • Page 55 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting II - REMOVAL - REFITTING OPERATIONS FOR THE CON ROD BEARING SHELLS ON CYLINDERS NO.3, 1 AND 4 a Perform the same removal - refitting operations as for the con rod bearing shells on cylinder no. 2. Note: For removing and refitting the con rod bearing shells on cylinders no.
  • Page 56 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 20166 140918 a Tilt the engine oil sump forwards in order to access the oil pump bolts. a Torque tighten the oil pump bolts (25 N.m) using the torque wrench PROSTEEL, part number 77 11 226 888 starting with the 13 mm bolt.
  • Page 57 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 123824 a Disconnect the crankshaft position sensor (4) to pre- vent the engine from starting. a Refit the oil filter (see 10A, Engine and cylinder block assembly, Oil filter: Removal - Refitting, page 10A-34) a Fill up the engine oil (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling,...

  • Page 58: Engine Oil: Draining - Refilling

    ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling K4M or K9K III - PARTS AND CONSUMABLES FOR REPAIR a parts always to be replaced: Drain plug seal on Equipment required engine oil sump. oil recovery tray a Consumable: oil change wrench - Engine oil (see Engine oil: Specifications) .
  • Page 59 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling K4M or K9K V - FILLING a Fill the engine with oil, respecting the recommended quantity. a Wait at least 10 minutes. a Check the oil level using the dipstick. a Top up the engine oil level if necessary.

  • Page 60: Oil Filter: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting REFITTING Special tooling required Mot. 1329 Oil filter removing tool (76 I - REFITTING PREPARATION OPERATION mm diameter) a parts always to be replaced: Oil filter. a Lubricate the new oil filter seal with new engine oil. WARNING II - REFITTING OPERATION FOR PART Always check the oil level using the dipstick.
  • Page 61 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - REMOVAL OPERATION Special tooling required Mot. 1329 Oil filter removing tool (76 mm diameter) Equipment required oil recovery tray IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 62 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Top up the engine oil level to the dipstick if neces- sary (see 10A, Engine and cylinder block assem- bly, Engine oil: Draining - Refilling, page 10A-32) 10A-36...

  • Page 63: Oil-Coolant Heat Exchanger: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting K9K, and 796 Tightening torquesm oil heat exchanger bolt 39 N.m oil filter support bolt 28 N.m 106794 - the engine undertray, Oil filter holder mounting bolt - the closure panel component under the diesel filter. Oil filter a Drain the cooling system (see 19A, Cooling, Cool- Oil filter holder...
  • Page 64 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting K9K, and 796 24821 113894 a Disconnect the air outlet duct (7) on the intercooler. a Disconnect the oil pressure sensor connector (9) . a Place a container under the engine on the oil filter side.
  • Page 65 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting K9K, and 796 113895 107306 a Remove: a Remove the oil-water heat exchanger seals (13) . a Use SURFACE CLEANER (see Vehicle: Parts - the bolt (12) from the oil-coolant heat exchanger, and consumables for the repair) (04B, Consuma- - the oil-water heat exchanger.
  • Page 66 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting K9K, and 796 III - FINAL OPERATION 107306 a Refit new seals (14) and (15) on the oil-water heat 133518 exchanger. a Apply soapy water to the two seals (15) in contact with the coolant pump inlet pipe.
  • Page 67 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting K9K, and 796 a Connect the air outlet duct to the intercooler. a Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Refit: - the closure panel component under the diesel filter, - the engine undertray, - the engine cover.

  • Page 68: Oil Pressure Sensor: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting Tightening torquesm oil pressure sensor 33 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the engine undertray.
  • Page 69 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - FINAL OPERATION a Connect the oil pressure sensor connector. Tightening torquesm a Refit the engine undertray. oil pressure sensor 35 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

  • Page 70: Oil Pump: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED Tightening torquesm a Refit the oil pump. oil pump bolts 25 N.m a Torque tighten the oil pump bolts (25 N.m). III - FINAL OPERATION REMOVAL a Refit the sump (see 10A, Engine and cylinder block assembly, Lower cover: Removal - Refit-...
  • Page 71 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - REFITTING OPERATION a Refit the oil pump. Tightening torquesm a Torque tighten the oil pump bolts (25 N.m). oil pump bolts 25 N.m III - FINAL OPERATION REMOVAL a Refit the sump (see 10A, Engine and cylinder block assembly, Lower cover: Removal - Refit- ting, page 10A-9) .

  • Page 72: Oil Pressure: Check

    ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure: Check K4M or K9K Oil pressure tables: II - CHECK a Remove the oil pressure sensor (see 10A, Engine Minimum oil pressure Maxi- and cylinder block assembly, Oil pressure sen- (bar) mum oil sor: Removal - Refitting, page 10A-42) .
  • Page 73 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure: Check K4M or K9K a Top up the engine oil level if necessary (see Engine oil: Specifications) . a Start the vehicle and check that there are no oil leaks at the oil pressure sensor. 10A-47...

  • Page 74: Multifunction Support: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING a Remove the air conditioning compressor bolts (with- out opening the circuit) (see Compressor: Remov- Tightening torquesm al - Refitting) (62A, Air conditioning). a Attach the air conditioning compressor to the sub- multifunction support 44 N.m...
  • Page 75 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING a Refit (see Power-assisted steering pump: Remo- REFITTING val - Refitting) (36B, Power-assisted steering): - the power-assisted steering pump, I - REFITTING OPERATION - the bolt of the power-assisted steering high pres- sure pipe on the cylinder block.
  • Page 76 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION II - REMOVAL OPERATION Tightening torquesm multifunction support 44 N.m bolts on the cylinder block multifunction support 25 N.m bolt on the sump REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 77 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION REFITTING - the high pressure pipe bolt on the cylinder block. I - REFITTING OPERATION a Refit: - the alternator (see 16A, Starting - Charging, Al- ternator: Removal - Refitting, page 16A-1) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting,...
  • Page 78 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting AIR CONDITIONING Tightening torquesm a Disconnect the air conditioning compressor connec- multifunction support 44 N.m tor. bolts on the cylinder a Remove the air conditioning compressor bolts (with- block out opening the circuit) (see Compressor: Remov- multifunction support 25 N.m al - Refitting) (62A, Air conditioning).
  • Page 79 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting REFITTING REFITTING OPERATION 19704 a Refit the multifunction support. a Position bolts (1) to (7) without tightening them. a Pretighten the multifunction support bolts (1) and (2) on the cylinder block 5 N.m. a Loosen bolts (1) and (2) a half-turn.

  • Page 80: Engine - Gearbox Assembly: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting REMOVAL Special tooling required Mot. 1448 Remote operation pliers for I - REMOVAL PREPARATION OPERATION hose clips. Mot. 1390 Support for removal - refitting IMPORTANT of engine - gearbox assembly To prevent the vehicle from falling, lash it to the vehicle lift using a strap.
  • Page 81 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 116654 145507 a Disconnect the accelerator cable on the throttle a Remove the fuse and relay box cover. valve at (1) . a Remove the side protector (6) of the fuse and relay a Remove the accelerator cable from the inlet distribu- box.
  • Page 82 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . 145509 a Disconnect the connector (12) from the fuel vapour 145510 recirculation solenoid valve. a Disconnect: a Disconnect (see Power-assisted steering pump: - the fuel supply pipe (9) on the injector rail,...
  • Page 83 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting STANDARD HEATING RECIRCULA TION AIR CONDITIONING 145498 145497 a Remove: a Remove: - the power-assisted steering low pressure pipe (13) - the power-assisted steering low pressure pipe (17) on the oil reservoir using the (Mot.
  • Page 84 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting AIR CONDITIONING a Remove (see Compressor: Removal - Refitting) (62A, Air conditioning): - the pipe retaining bracket bolt on the compressor, - the pipe union bolts on the compressor. Note: Plugs must be fitted on the hoses to prevent moisture from entering the system.
  • Page 85 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Remove (see ) (36A, Steering assembly): - the heat shield bolts on the steering box, - the steering box heat shield, - the steering box bolts on the front axle subframe. a Attach the steering rack to the body.
  • Page 86 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 118882 24810 WARNING Do not pull the clip. If it is incorrectly handled in any way, the pipe will need to be replaced. a Disconnect the clutch control pipe on the clutch slave cylinder by pressing the clip (32) .
  • Page 87 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting II - REMOVAL OPERATION 135949 a Remove: 136472 a Mark the positions of the suspended engine mount- - the bolts (33) from the exhaust flange, ings on the body. - the exhaust bracket ring.
  • Page 88 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 107929 123542 a Remove the nut (35) on the rubber pad support of a Lift the vehicle to remove the engine - gearbox as- the left-hand suspended engine mounting. sembly.
  • Page 89 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Remove the (Mot. 1390) from the engine - gearbox a Check that there are no leaks. assembly. III - FINAL OPERATION a Proceed in the reverse order to removal. a Torque tighten: - the exhaust flange bolts (21 N.m), - the front axle subframe tie-rod upper bolts (21...
  • Page 90 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 REMOVAL Special tooling required Mot. 1448 Remote operation pliers for I - REMOVAL PREPARATION OPERATION hose clips. Mot. 1390 Support for removal - refitting IMPORTANT of engine - gearbox assembly To prevent the vehicle from falling, lash it to the vehicle lift using a strap.
  • Page 91 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 145506 a Remove the engine wiring bolt (1) on the battery mounting. a Unclip the battery wiring at (2) . a Remove the earth strap bolt (3) on the battery 145507 mounting.
  • Page 92 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 - the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . 145503 a Disconnect: 145502 - the fuel supply pipe (11) , a Disconnect the connector (9) from the water detec- tion sensor on the diesel filter.
  • Page 93 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 - the air duct nut (18) on the gearbox, - the intercooler air ducts. a Disconnect (see Power-assisted steering pump: Removal - Refitting) (36B, Power-assisted stee- ring): - the power-assisted steering low pressure hose on the power-assisted steering pump using the (Mot.
  • Page 94 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 AIR CONDITIONING 145505 a Remove the earth strap bolt (25) on the body. a Disconnect the pump assembly connectors (26) . 145499 a Remove the power-assisted steering high pressure a Unclip the pump assembly wiring at (27) .
  • Page 95 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 145559 145500 a Move aside the cooling hose clip (32) on the water a Remove: chamber using the (Mot. 1448). - the power-assisted steering high pressure pipe bolt a Disconnect the cooling hose on the water chamber.
  • Page 96 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 - the steering box heat shield, - the steering box bolts on the front axle subframe. a Attach the steering rack to the body. 24817 144756 a Remove: - the front axle subframe tie-rod upper bolts (34) ,...
  • Page 97 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 24810 135949 a Remove: - the bolts (38) from the exhaust flange, WARNING Do not pull the clip. If it is incorrectly handled in - the exhaust bracket ring. any way, the pipe will need to be replaced.
  • Page 98 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 II - REMOVAL OPERATION 112813 107929 a Remove the nut (40) on the rubber pad support of the left-hand suspended engine mounting. a Strike the gearbox stud with a copper hammer to separate the engine - gearbox assembly from the body.
  • Page 99 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 a Remove the (Mot. 1390) from the engine - gearbox assembly. III - FINAL OPERATION a Proceed in the reverse order to removal. a Torque tighten: - the exhaust flange bolts (21 N.m), - the front axle subframe tie-rod upper bolts (21 N.m),...
  • Page 100 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 a Check that there are no leaks. 10A-74...

  • Page 101: Flywheel: Removal - Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting REFITTING Tightening torquesm I - REFITTING PREPARATION OPERATION 25 N.m + 50˚ ± ± ± ± flywheel bolts a Check the condition of the flywheel. 6˚ a On the crankshaft, clean the flywheel bolt threading. a Use SURFACE CLEANER (see Vehicle: Parts REMOVAL and consumables for the repair) (04B, Consuma-...
  • Page 102 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting 107913 a Screw in the new flywheel bolts without tightening them. a Lock the engine using the. a Torque tighten in order the flywheel bolts (25 N.m + 50˚ ± ± ± ± 6˚). a Remove the tool.
  • Page 103 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- Tightening torquesm bles - Products) to clean and degrease: flywheel bolts 55 N.m - the crankshaft bearing face on the flywheel if re- used, REMOVAL - the flywheel pressure face on the crankshaft,...

  • Page 104: Top And Front Of Engine

    TOP AND FRONT OF ENGINE Pressure at end of compression: Check a Fully depress the accelerator pedal in order to open the throttle valve during the compression measure- Equipment required ments. petrol compression gauge Note: Diagnostic tool It is necessary to wait for at least 10 seconds before starting the engine each time (the starter CHECK will not run due to its thermal protection).

  • Page 105: Accessories Belt: Removal - Refitting

    TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K9K, and STANDARD HEATING RECIRCULA TION II - OPERATION FOR REMOVAL OF PART CONCERNED Equipment required offset spanner Auto tensioner Tightening torquesm new accessories belt 40 N.m tensioning roller bolt WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul-...
  • Page 106 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K9K, and STANDARD HEATING RECIRCULA TION REFITTING I - REFITTING PREPARATION OPERATION WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. a Use a brush to remove any deposits from the crank- shaft accessories pulley V-grooves.
  • Page 107 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K9K, and AIR CONDITIONING II - REMOVAL OPERATION Tightening torquesm tensioning roller bolt 40 N.m WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 108 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K9K, and AIR CONDITIONING II - REFITTING OPERATION FOR PART CONCERNED 101878 a Rotate the tensioning roller clockwise using a 16 mm offset wrench. a Refit a new accessories belt. a Turn the crankshaft two revolutions clockwise (tim- ing end) to position the accessories belt correctly.
  • Page 109 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING II - REMOVAL OPERATION Tightening torquesm the automatic tensioning 21 N.m roller mounting bolts the fixed roller mount- 21 N.m ing bolt IMPORTANT Wear cut-resistant gloves during the operation.
  • Page 110 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING a Torque tighten: - the automatic tensioning roller mounting bolts (21 N.m), - the fixed roller mounting bolt (21 N.m). a Turn the accessories belt auto tensioner clockwise using a 16 mm spanner.
  • Page 111 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION II - REMOVAL OPERATION Tightening torquesm auto tensioner bolts 40 N.m IMPORTANT Wear cut-resistant gloves during the operation. WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 112 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION a Refit the front right-hand wheel (see Wheel: Re- moval - Refitting) (35A, Wheels and tyres). 11A-9...

  • Page 113: Crankshaft Accessories Pulley: Removal - Refitting

    TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - REMOVAL OPERATION Special tooling required Mot. 1489 TDC locating pin. Tightening torquesm accessories pulley bolt 120 N.m + 95˚ ± ± ± ± 15˚ TDC pin plug 25 N.m IMPORTANT Wear cut-resistant gloves during the operation.
  • Page 114 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft acces- sories pulley bolts. WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. a If reusing the crankshaft accessories pulley, clean the crankshaft accessories pulley V-grooves with a brush to eliminate any deposits.
  • Page 115 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 14489 a Turn the crankshaft clockwise (timing end) smoothly using the bolt of the crankshaft accessories pulley, until the crankshaft presses against the tool (Mot. 1489) (9) . a Torque and angle tighten (with the crankshaft in con- tact with the TDC setting pin) the accessories pul- ley bolt (120 N.m + 95˚...
  • Page 116 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting Tightening torquesm new crankshaft acces- 40 N.m + 145˚ ± ± ± ± 15˚ sories pulley bolt TDC pin plug 25 N.m IMPORTANT Wear cut-resistant gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a lift (see Vehicle: Towing...
  • Page 117 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - REMOVAL OPERATION 14489 a Turn the crankshaft in its operating direction (clock- 14487 a Remove the crankshaft accessories pulley bolt (6) . wise at timing end), until the crankshaft presses against the TDC setting pin.
  • Page 118 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 145073 130493 a Position the setting tool. a If the crankshaft is not pressing against the TDC tool, bring the crankshaft back by turning the fly- a Secure theto the ends of the camshafts using an M6 wheel using a screwdriver (9) .
  • Page 119 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting - the air resonator (see 12A, Fuel mixture, Air res- onator: Removal - Refitting, page 12A-2) , - the air inlet duct. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery).

  • Page 120: Timing Belt: Removal - Refitting

    TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Tightening torquesm timing fixed roller bolt 50 N.m new crankshaft acces- 40 N.m + 145˚ ± ± ± ± 15˚ sories pulley bolt timing tension wheel nut 27 N.m lower timing cover bolts 12 N.m 30 N.m + 84˚...
  • Page 121 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting II - REMOVAL OPERATION II - REFITTING OPERATION FOR PART CONCERNED a The first procedure applies to replacing any timing face component which has a crankshaft timing sprocket without a collet and which does not require one or more of the camshaft sprockets to be loos- ened.
  • Page 122 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 14487-5 14487-3 a Position the RENAULT badge (7) engraved on the a Refit: stem of each camshaft sprocket vertically and point- - the crankshaft timing sprocket (9) , ing upwards.
  • Page 123 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a - Lower timing cover with a timing flap 103263 a Position the adjustable index (11) opposite the mark 130497 a Refit the lower timing cover (14) . (12) , by turning the eccentric (13) clockwise using a 6 mm Allen key.
  • Page 124 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting c - Lower timing cover with a timing flap 130493 109052 a Remove the timing flap from the lower timing cover. d - continuation of the refitting procedure regardless of the type of lower timing cover a Remove: - the bolt of the tool, - the setting tool,...
  • Page 125 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 103263 14490 a Check that the adjustable index (17) is opposite the a Position (without forcing) the camshaft setting notch (18) , if this is not the case: tool(the camshaft end grooves must be horizontal and offset towards the bottom).
  • Page 126 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a - Lower timing cover with a timing flap II - REFITTING OPERATION a The second procedure is used when replacing any timing face component which has a crankshaft tim- ing sprocket with or without a collet, that requires one or more of the camshaft sprockets to be loos- ened.
  • Page 127 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 1 - Adjusting the timing Note: If the stud loosens with the nut (see 11A, Top and front of engine, Camshaft: Removal - Refitting, page 11A-49) (11A, Top and front of engine).
  • Page 128 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 145073 130493 a Fit: - the (23) onto the ends of the camshafts, - an M6 bolt (24) to hold the. a Refit: - the crankshaft timing sprocket, - the camshaft sprockets, - every camshaft sprocket nut.
  • Page 129 Timing belt: Removal - Refitting 14487-3 135896 a Position the RENAULT badge (27) etched on the a Refit a new timing belt starting with the sprocket of stem of each camshaft sprocket vertically and point- each camshaft (without moving the sprocket of each ing upwards.
  • Page 130 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Torque tighten the timing tensioning roller nut (7 N.m). Note: There are two types of lower timing cover: - without a timing flap, - with a timing flap. a - Lower timing cover with a timing flap 14487-2 a Refit a new timing fixed roller.
  • Page 131 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting c - Lower timing cover with a timing flap 109051 109052 a Remove the timing flap from the lower timing cover. d - continuation of the refitting procedure regardless of the type of lower timing cover a Remove: - the bolt of the tool, - the,...
  • Page 132 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 5 - Checking the timing a - Lower timing cover with a timing flap a Ensure that the index and the notch on the timing tensioning roller are in the correct position before checking the timing.
  • Page 133 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-4) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-2) , - the front right-hand wheel (see Wheel: Removal -...
  • Page 134 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 REMOVAL Special tooling required Mot. 1453 Engine anchorage support I - REMOVAL PREPARATION OPERATION with multiple adjustments and a Position the vehicle on a two-post lift (see Vehicle: retaining straps.
  • Page 135 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 145429 136656 a Mark the position of the suspended engine mounting in relation to the body. a Remove: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-4) , - the camshaft position sensor (1) (see 13B, Diesel...
  • Page 136 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 136660 136658 a Remove: - the bolts (5) from the right-hand suspended engine mounting support on the cylinder head, - the right-hand pendulum suspension support. II - REMOVAL OPERATION 136662 a Unclip the three tabs (4) .
  • Page 137 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 19702 14489 a Turn the crankshaft to position the camshaft pulley a Turn the crankshaft clockwise (timing end) smoothly hole (7) almost opposite the cylinder head hole (8) . until the crankshaft is against the (Mot.
  • Page 138 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 - the timing belt tensioning roller. REFITTING I - REFITTING PREPARATION OPERATION WARNING The belt must be replaced with a new one if it has been removed. WARNING When replacing the belt, always replace the ten- sion wheels and idler pulleys.
  • Page 139 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 III - REFITTING OPERATION 19656-2 a Refit: - the crankshaft timing sprocket, - a new timing belt tensioning roller. a Put the tensioning roller lug (13) in the cylinder head groove (14) .
  • Page 140 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 19657 19658 a Fit the new timing belt, starting with the crankshaft a Position the timing belt tensioning roller adjustable sprocket, aligning the marks on the belt with those index opposite the lug (19) by turning the eccentric on the camshaft and high pressure pump pulleys.
  • Page 141 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 19702 19655 a Rotate the crankshaft clockwise through two revolu- a Set the camshaft pulley using the (Mot. 1430). tions (timing end). a Before the camshaft pulley hole (20) is opposite the Note: cylinder head hole (21) , screw the (Mot.
  • Page 142 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 1 - First position 111083 111081 a Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mmAllen key. a Gradually align the adjustable index marker (24) in the middle of the timing window (25) , turning the key anti-clockwise.
  • Page 143 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 2 - Second position der block. a Bring the crankshaft slowly and smoothly into con- tact with the tool (Mot. 1489). 111082 19655 a Set the camshaft pulley using the (Mot. 1430). a If the tool (Mot.
  • Page 144 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 19659 a Refit the lower timing cover, positioning the tab (28) in the opening (29) on the inner cover. a Clip on the lower timing cover. a Refit: - the upper timing cover, - the upper timing cover bolt.

  • Page 145: Rocker Cover: Removal - Refitting

    TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting Tightening torquesm rocker cover bolts 22, 8 N.m 23, 20 and 13 rocker cover bolts 1 to 15 N.m 12, 14 to 19, 21 to 24 rocker cover bolts 22, 15 N.m 23, 20 and 13 flywheel end lifting eye...
  • Page 146 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REMOVAL OPERATION 14497 a Remove the rocker cover bolts. a Remove the rocker cover vertically by tapping the lugs (1) with a copper hammer. a Remove the rocker cover. 11A-43...
  • Page 147 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting REFITTING WARNING Applying excess sealant could cause it to be I - REFITTING PREPARATION OPERATION squeezed out when parts are tightened. A mix- ture of sealant and fluid could damage certain components (engine, radiator, etc.) IMPORTANT Wear cut-resistant gloves during the operation.
  • Page 148 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 126216 a Use a cloth to remove any RESIN GLUE in the bear- ing channels (2) on the rocker cover. 11A-45...
  • Page 149 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REFITTING OPERATION 14497 a Refit the rocker cover. - the camshaft seals (see 11A, Top and front of en- gine, Camshaft seal, timing end: Removal - Re- a Tighten to torque and in order: fitting, page 11A-56) , - rocker cover bolts 22, 23, 20 and 13 (8 N.m), - the inlet distributor (see 12A, Fuel mixture, Inlet...
  • Page 150 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REFITTING OPERATION Tightening torquesm rocker cover bolts 12 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) . 19712-1 WARNING Applying excess sealant could cause it to be...
  • Page 151 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting III - FINAL OPERATION a Connect the oil vapour rebreathing pipe. a Refit the air filter unit (see 12A, Fuel mixture, Air fil- ter unit: Removal - Refitting, page 12A-6) . 11A-48...

  • Page 152: Camshaft: Removal - Refitting

    TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting Equipment required roller-type stud removal tool Tightening torquesm the camshaft dowel 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 153 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting II - REMOVAL OPERATION 14498 a Remove: - the inlet camshaft (1) , - the exhaust camshaft (2) . 11A-50...
  • Page 154 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting Replacing a camshaft dowel Note: It is essential to replace the camshaft dowel if it comes loose at the same time as the nut. a - Removal a Place the camshaft in a vice with aluminium jaws. 14499 a Remove: - the valve rockers (3) ;...
  • Page 155 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) , - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-17) , - the air resonator (see 12A, Fuel mixture, Air res- onator: Removal - Refitting, page 12A-2) , - the right-hand suspended engine mounting (see...
  • Page 156 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting Tightening torquesm bolts of the camshaft 10 N.m bearings REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 157 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION a parts always to be replaced: Camshaft seal on timing end. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks).
  • Page 158 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Apply four beads (6) of RESIN ADHESIVE (see Ve- - the crankshaft accessories pulley (see 11A, Top hicle: Parts and consumables for the repair) and front of engine, Crankshaft accessories (04B, Consumables - Products) 7 mm in diameter pulley: Removal - Refitting, page 11A-10) , on the cylinder head.

  • Page 159: Camshaft Seal, Timing End: Removal - Refitting

    TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting Tightening torquesm 30 N.m + 84˚ ± ± ± ± inlet camshaft hub nut 4˚ 30 N.m + 84˚ ± ± ± ± exhaust camshaft hub 4˚ REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 160 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting II - REMOVAL OPERATION 135237 a Push theuntil contact is made between the ends of 105257 the claws (7) and the camshaft seal. Note: The inlet and exhaust camshaft seals are removed using the.
  • Page 161 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the seal mating face of each camshaft, - the camshaft seal housings.
  • Page 162 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 105531 135229 a Fit the cover (14) and the collar nut (15) of the. 135231 a Fit the protector fitted with a new seal (13) on the in- let and exhaust camshaft, taking care not to touch the seal.
  • Page 163 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting III - FINAL OPERATION a Refit: - the inlet camshaft pulley with a new nut, - the exhaust camshaft pulley with a new nut. a Fit the locking toolon the camshaft pulleys. a Torque tighten: - the inlet camshaft hub nut (30 N.m + 84˚...
  • Page 164 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting II - REMOVAL OPERATION Special tooling required Mot. 1430 Set of 5 crankshaft and cam- shaft pulley timing pins. Tightening torquesm camshaft stud 12 N.m 30 N.m + 86˚ ± ± ± ± camshaft pulley nut 6˚.
  • Page 165 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting - the camshaft pulley. 105270 a Position the claws of theon the camshaft. 123970 105257 105271 a Push the tooluntil contact is made between the ends (9) of the claws and the camshaft seal. Note: The camshaft seal is removed using the.
  • Page 166 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the camshaft seal housing in the cylinder head, - the camshaft seal mating face on the camshaft.
  • Page 167 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED Note: For camshaft seals delivered fitted to a protective sleeve: - do not remove the camshaft seal from its pro- tective sleeve, - fit the sleeve fitted with the camshaft seal to the camshaft, - push the protective sleeve towards the cylinder...
  • Page 168 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 21687-3 123075 a Screw on the collar nut until the cover touches the cylinder head. Note: The spacer (17) is used to fit the seal (18) and is 2 - Second fitting of the camshaft seal used in addition to the tool (19) .
  • Page 169 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 3 - Continued for both methods a Remove: - the collar nut from the, - the cover from the, - the stud of the, - the protective sleeve and the spacer, if fitted then throw them away.
  • Page 170 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting III - FINAL OPERATION 107269 a Set the camshaft pulley hub using the tool (Mot. 1430). Note: If the pin (Mot. 1430) does not engage, turn the camshaft pulley hub using an 18 mm offset wrench to facilitate the setting of the camshaft pulley hub.

  • Page 171: Oil Decanter: Removal - Refitting

    TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) , Tightening torquesm - the throttle valve (see 12A, Fuel mixture, Throttle new oil separator bolts 15 N.m valve: Removal - Refitting, page 12A-11) , - the inlet distributor (see 12A, Fuel mixture, Inlet...
  • Page 172 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: oil decanter bolt WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
  • Page 173 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting 14497-4 a Torque tighten in order the new oil separator bolts (15 N.m). III - FINAL OPERATION a Refit: - the ignition coils (see 17A, Ignition, Coils: Re- moval - Refitting, page 17A-1) , - the inlet distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-12) , - the throttle valve (see 12A, Fuel mixture, Throttle...

  • Page 174: Fuel Mixture

    FUEL MIXTURE Air inlet: Description Diagram of the air inlet circuit 102071 Air inlet trunking Air resonator Air filter unit Air filter Throttle valve Inlet manifold Injector holder shim Air inlet 12A-1...

  • Page 175: Air Resonator: Removal - Refitting

    FUEL MIXTURE Air resonator: Removal - Refitting REMOVAL REMOVAL OPERATION FOR PART CONCERNED 116562 a Remove: - the elastic mounting (1) from the air resonator unit, - the air resonator unit (2) . REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit: - the air resonator unit, - the air resonator elastic mounting.

  • Page 176: Air Filter: Removal - Refitting

    FUEL MIXTURE Air filter: Removal - Refitting REMOVAL II - REFITTING OPERATION FOR PART CONCERNED a Refit: I - REMOVAL PREPARATION OPERATION - the air filter, a Remove the air resonator (see 12A, Fuel mixture, - the air filter cover, Air resonator: Removal - Refitting, page 12A-2) .
  • Page 177 FUEL MIXTURE Air filter: Removal - Refitting REMOVAL 2 - Second fitting of air filter unit I - REMOVAL PREPARATION OPERATION a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) . II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - First fitting of air filter unit...
  • Page 178 FUEL MIXTURE Air filter: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the air filter in the air filter unit cover. WARNING If the air filter is fitted incorrectly in the air filter unit, unfiltered air may enter the engine and cause the engine to malfunction.

  • Page 179: Air Filter Unit: Removal - Refitting

    FUEL MIXTURE Air filter unit: Removal - Refitting REMOVAL II - REFITTING OPERATION FOR PART CONCERNED a Fit the air filter unit sideways against the EGR valve I - REMOVAL PREPARATION OPERATION mounting. a Remove the engine cover. a Slide the air filter unit to the right. a Refit: - the turbocharger pressure sensor on the air filter unit.
  • Page 180 FUEL MIXTURE Air filter unit: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm air filter unit bolts 9 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .
  • Page 181 FUEL MIXTURE Air filter unit: Removal - Refitting 116571 101488 a Unclip: a Remove the two bolts (10) from the air filter unit. - the coolant pipes at (6) , - the breather (7) . 15757 a Remove the air filter unit. 116564 a Remove the coolant pipes mounting bracket (8) .
  • Page 182 FUEL MIXTURE Air filter unit: Removal - Refitting - the plastic rivets and clips every time they are re- moved. II - REFITTING OPERATION a Refit: - the air filter unit, - the two air filter unit bolts. a Torque tighten the air filter unit bolts (9 N.m). a Attach the electrical wiring to the oxygen sensor.
  • Page 183 FUEL MIXTURE Air flowmeter: Removal - Refitting K9K, and 796 REMOVAL - the air flowmeter seal. REFITTING I - REMOVAL PREPARATION OPERATION a Remove the engine cover. I - REFITTING PREPARATION OPERATION a Always replace the air flowmeter seal on the air filter unit.

  • Page 184: Throttle Valve: Removal - Refitting

    FUEL MIXTURE Throttle valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm throttle valve bolts 13 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) .

  • Page 185: Inlet Distributor: Removal - Refitting

    FUEL MIXTURE Inlet distributor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm intake distributor mount- 9 N.m ing bolts REMOVAL I - REMOVAL PREPARATION OPERATION 116653 a Remove: - the inlet distributor bolts (7) , - the inlet distributor.
  • Page 186 FUEL MIXTURE Inlet distributor: Removal - Refitting III - FINAL OPERATION a Refit the throttle valve equipped with a new seal (see WARNING 12A, Fuel mixture, Throttle valve: Removal - Re- Do not scrape the joint faces of the aluminium, fitting, page 12A-11) .

  • Page 187: Injector Holder Shim: Removal - Refitting

    FUEL MIXTURE Injector holder shim: Removal - Refitting Tightening torquesm injector holder shim 25 N.m bolts (7) and (8) injector holder shim 21 N.m bolts 9 to 16 upper timing cover bolt 41 N.m suspended mounting 62N.m bolt REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 188 FUEL MIXTURE Injector holder shim: Removal - Refitting REFITTING - the injector rail (see 17B, Petrol injection, Injec- tor rail - Injectors: Removal - Refitting, page 17B-10) , I - REFITTING PREPARATION OPERATION - the inlet distributor (see 12A, Fuel mixture, Inlet a The injector holder shim seal must always be re- distributor: Removal - Refitting, page 12A-12) .

  • Page 189: Exhaust Manifold: Removal - Refitting

    FUEL MIXTURE Exhaust manifold: Removal - Refitting REFITTING Tightening torquesm I - REFITTING PREPARATION OPERATION exhaust manifold stud 9 N.m a parts always to be replaced: exhaust manifold seal. exhaust manifold nuts 26 N.m a Use GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consuma- REMOVAL bles - Products) to clean the joint face:...
  • Page 190 FUEL MIXTURE Exhaust manifold: Removal - Refitting III - FINAL OPERATION a Refit: - the turbocharger (see 12B, Turbocharging, Tur- bocharger: Removal - Refitting, page 12B-1) , - the exhaust gas recirculation assembly (see 14A, Antipollution, Exhaust gas recirculation as- sembly: Removal - Refitting, page 14A-9) , - the catalytic converter (see 19B, Exhaust, Cata- lytic converter: Removal - Refitting, page 19B-...
  • Page 191 FUEL MIXTURE Exhaust manifold: Removal - Refitting Tightening torquesm exhaust manifold studs 8 N.m e x h a u s t m a n i fold 23 N.m mounting nuts bolts (6) mounting the 21 N.m stay on the cylinder block nut (7) mounting the 21 N.m...
  • Page 192 FUEL MIXTURE Exhaust manifold: Removal - Refitting 116640 116642 a Remove the stay (4) between the exhaust manifold a Using the workbench, remove: and the cylinder block. - the bolts (5) from the exhaust manifold lower heat shield, II - REMOVAL OPERATION - the lower heat shield from the exhaust manifold.
  • Page 193 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 15101 a Refit the exhaust manifold. a Tighten to torque and in order the exhaust manifold mounting nuts (23 N.m). 12A-20...
  • Page 194 FUEL MIXTURE Exhaust manifold: Removal - Refitting III - FINAL OPERATION 116640 a Refit the stay between the exhaust manifold and the cylinder block. a Tighten to torque and in order: - the bolts (6) mounting the stay on the cylinder block (21 N.m), - the nut (7) mounting the stay on the exhaust manifold (21 N.m).

  • Page 195: Turbocharging

    TURBOCHARGING Turbocharger: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm new turbocharger studs 9 N.m on the exhaust manifold new turbocharger stud 9 N.m on the turbocharger turbocharger nuts 28 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 196 TURBOCHARGING Turbocharger: Removal - Refitting a parts always to be replaced: exhaust manifold II - REMOVAL OPERATION stud on the turbocharger (if loosened). WARNING Ensure that no foreign bodies enter the turbine or compressor during the refitting operation. Check that the turbocharger oil return pipe is not partially or completely blocked by scale.
  • Page 197 TURBOCHARGING Turbocharger: Removal - Refitting a Use an open wrench to fit the new turbocharger nuts without tightening them (the turbocharger must be in contact with the manifold and the wrench should no longer turn without effort). a Torque tighten the turbocharger nuts (28 N.m). III - FINAL OPERATION a Refit (see 12B, Turbocharging, Turbocharger oil pipe: Removal - Refitting, page 12B-4) :...

  • Page 198: Turbocharger Oil Pipe: Removal - Refitting

    TURBOCHARGING Turbocharger oil pipe: Removal - Refitting Equipment required Note: self-contained starter This procedure deals with removing and refitting the turbocharger oil return pipe and the turbocharger oil Diagnostic tool supply pipe. Tightening torquesm REMOVING THE TURBOCHARGER OIL SUPPLY PIPE new turbocharger oil Torx bolt 18 supply pipe hollow bolt...
  • Page 199 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Remove: - the turbocharger oil supply pipe hollow boltfrom the turbocharger, - the turbocharger oil supply pipe. a Wipe away any oil run-off. REFITTING THE TURBOCHARGER OIL SUPPLY PIPE I - REFITTING PREPARATION OPERATION a parts always to be replaced: turbocharger oil supply pipe a parts always to be replaced: turbocharger oil...
  • Page 200 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Remove: - the turbocharger oil supply pipe nut on the cyl- inder head (shouldered nut 35 N.m or non- - the engine undertray bolts, shouldered nut 23 N.m) using toolor tool. - the engine undertray, III - FINAL OPERATION - the catalytic converter (see 19B, Exhaust, Cata- lytic converter: Removal - Refitting, page 19B-...
  • Page 201 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Extract the turbocharger oil return pipe from the cyl- inder block. a Remove the turbocharger oil return pipe seals. REFITTING THE TURBOCHARGER OIL RETURN PIPE I - REFITTING PREPARATION OPERATION a parts always to be replaced: turbocharger oil pipe seal.

  • Page 202: Intercooler: Removal - Refitting

    TURBOCHARGING Intercooler: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove the front bumper (see Front bumper as- sembly: Exploded view) (55A, Exterior protection).
  • Page 203 TURBOCHARGING Intercooler: Removal - Refitting 145428 119000 a Push the « radiator - fan » assembly in the direction a Remove the intercooler (7) in the direction of the ar- of the arrow (4) in order to remove the intercooler. rows (8) then (9) .

  • Page 204: Fuel Supply

    FUEL SUPPLY Fuel circuit: Operating diagram Operating diagram of the fuel supply circuit ( « pump - sender - fuel filter » assembly) 19310 The fuel supply circuit does not have a return. The fuel pressure does not vary with engine load. The circuit comprises: - a rail (1) without a return pipe and without a supply pressure regulator,...
  • Page 205 FUEL SUPPLY Fuel circuit: Operating diagram Operating diagram of the fuel supply circuit (external filter) 106938 The fuel supply circuit does not have a return. The fuel pressure does not vary with engine load. The circuit comprises: - a rail (7) without a return pipe union and without a supply pressure regulator, - a single pipe (8) coming from the tank, - a «...

  • Page 206: Manual Priming Pump: Removal - Refitting

    FUEL SUPPLY Manual priming pump: Removal - Refitting IMPORTANT Note: The priming pump is incorporated in the fuel supply To avoid all risk of damage to the systems, apply pipe. the safety and cleanliness instructions and opera- tion recommendations before carrying out any To remove the priming pump, remove the fuel sup- repair: ply pipe assembly.
  • Page 207 FUEL SUPPLY Manual priming pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - FINAL OPERATION CONCERNED a Prime the fuel circuit using the priming pump. WARNING Check that there are no leaks: - run the engine at idle speed for 2 minutes, - accelerate several times at no load, - switch off the ignition, - check that there is no fuel escaping.

  • Page 208: Diesel Filter: Removal - Refitting

    FUEL SUPPLY Diesel filter: Removal - Refitting 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 Diesel injection: Precautions for the repair) , - (see Vehicle: Precautions for the repair) (01D, Mechanical introduction).
  • Page 209 FUEL SUPPLY Diesel filter: Removal - Refitting II - REMOVAL OPERATION DELPHI type filter MAHLE type filter 146378 a Disconnect the water detection sensor connector (5) 24798 a Remove: a Remove: - the diesel filter protection plate nuts (6) , - the diesel filter protection plate nuts (2) , - the diesel filter protection plate, - the diesel filter protection plate,...
  • Page 210 FUEL SUPPLY Diesel filter: Removal - Refitting II - DRAINING THE WATER INSIDE THE DIESEL FILTER Note: - Certain vehicles have a sensor for detecting water in the diesel fuel, located in the diesel fil- ter. If water is detected, the injection fault warn- ing light comes on.
  • Page 211 FUEL SUPPLY Diesel filter: Removal - Refitting Priming the supply circuit 24732 a Prime the fuel system with the manual priming pump (11) (automatic degassing). 13A-8...

  • Page 212: Fuel Pressure: Check

    FUEL SUPPLY Fuel pressure: Check Special tooling required Mot. 1311-08 Union for taking fuel pres- sure measurements. Tightening torquesm fuel pipe protector nuts 7 N.m fuel pipe protector bolt 7 N.m IMPORTANT 145185 During this operation, be sure to: a Remove: - refrain from smoking or bringing red hot objects - the nuts (1) and the bolt (2) from the fuel pipe pro- near the working area,...
  • Page 213 FUEL SUPPLY Fuel pressure: Check 109173 a Connect: - the « T » union (Mot. 1311-08) (6) to the fuel tank outlet pipe, - the pipe (5) fitted with a pressure gauge contained in the test kitonto the « T » union (6) , - the fuel supply pipe (7) to the «...

  • Page 214: Fuel Flow: Check

    FUEL SUPPLY Fuel flow: Check Special tooling required Mot. 1311-08 Union for taking fuel pres- sure measurements. Tightening torquesm fuel pipe protector nuts 7 N.m fuel pipe protector bolt 7 N.m IMPORTANT 145185 During this operation, be sure to: a Remove: - refrain from smoking or bringing red hot objects - the nuts (1) and the bolt (2) from the fuel pipe pro- near the working area,...
  • Page 215 FUEL SUPPLY Fuel flow: Check 109173 116568 a Disconnect the connector (12) from the passenger a Connect: compartment engine harness. - the « T » union (Mot. 1311-08) (6) to the fuel tank outlet pipe, - the pipe (5) contained in the test kitonto the « T » union (6) , - the fuel supply pipe (7) to the «...
  • Page 216 FUEL SUPPLY Fuel flow: Check 109172 a Connect the connector terminal (13) to the + BAT- TERY to operate the fuel pump. a Note the time taken for the measuring cylinder to fill Note: The minimum flow rate from the fuel pump is 60 l/h.

  • Page 217: Diesel Injection

    DIESEL INJECTION Diesel injection: List and location of components K9K, and 796 123977 Description Description Turbocharger High pressure pump Cylinder reference sensor Injection computer Coolant temperature sensor Injector rail pressure sensor TDC sensor Spherical injector rail Pre-postheating unit Diesel temperature sensor Turbocharger control solenoid valve (only for K9K 796 engine) Diesel fuel flow actuator...
  • Page 218 DIESEL INJECTION Diesel injection: List and location of components K9K, and 796 102085 102084 High-pressure pump (1) . Injector rail pressure sensor (3) , Spherical injector rail (4) , Diesel temperature sensor (5) , Diesel fuel flow actuator (6) , Accelerometer (7) , Injectors (8) , Venturi (9) .
  • Page 219 DIESEL INJECTION Diesel injection: List and location of components K9K, and 796 24831 Air flowmeter with integrated temperature sensor (12) , Turbocharging air pressure sensor (13) . 20796 Coolant temperature sensor (15) . 24749 Cylinder marking sensor (14) . 24817 Top Dead Centre sensor (16) .
  • Page 220 DIESEL INJECTION Diesel injection: List and location of components K9K, and 796 24729 Pre-postheating unit (17) . 24750 Accelerator pedal potentiometer (19) . 13B-4...

  • Page 221: Diesel Injection Computer: Removal - Refitting

    DIESEL INJECTION Diesel injection computer: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm injection computer nuts 8 N.m injection computer pro- 8 N.m tector bolts Note: When programming, reprogramming or replacing the computer, it is necessary to program the new computer with the C2I parameters (injector flow cor- rection) and the engine adaptives using the Diag- nostic tool.
  • Page 222 DIESEL INJECTION Diesel injection computer: Removal - Refitting REFITTING I - REFITTING OPERATION a Fit the injection computer on its mounting studs. a Torque tighten the injection computer nuts (8 N.m). a Connect the injection computer connectors. II - FINAL OPERATION a Refit the injection computer protector.

  • Page 223: Camshaft Position Sensor: Removal - Refitting

    DIESEL INJECTION Camshaft position sensor: Removal - Refitting REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 24749 a Disconnect the connector (1) from the camshaft po- sition sensor. a Remove: - the bolt (2) from the camshaft position sensor, - the camshaft position sensor. REFITTING I - REFITTING OPERATION FOR PART CONCERNED...

  • Page 224: Crankshaft Position Sensor: Removal - Refitting

    DIESEL INJECTION Crankshaft position sensor: Removal - Refitting K9K, and 796 a Torque tighten the crankshaft position and speed sensor bolt (8 N.m). Tightening torquesm a Connect the crankshaft position sensor connector. crankshaft position and 8 N.m speed sensor bolt II - FINAL OPERATION a Refit the engine undertray.

  • Page 225: High Pressure Pump: Removal - Refitting

    DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 796 Equipment required Note: Diagnostic tool Never run the engine in the opposite direction to that of normal operation. Tightening torquesm REMOVAL the high pressure pump 23 N.m bolts I - REMOVAL PREPARATION OPERATION high pressure pump pul- 70 N.m a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 226 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 796 109466 102360 a Disconnect: - the fuel return pipe (7) connecting the injectors to the high-pressure pump, - the injector rail pressure sensor (8) , - the accelerometer (9) , - the camshaft position sensor (10) .
  • Page 227 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 796 102083 23168 a Remove the high pressure pipe (13) between the in- a Fit the high pressure pump pulley retaining tool (14) . jector rail and the high pressure pump (see 13B, a If necessary, turn the engine slowly to adjust the po- Diesel injection, High pressure pipe between sition of the locking tool on the pump pulley teeth.
  • Page 228 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 796 II - REMOVAL OPERATION 23169 a Position the (16) fitted with the. 102085 a Remove: - the high pressure pump bolts (17) , WARNING Ensure that the tool pushrod is correctly oriented - the bracket (18) from the engine cover.
  • Page 229 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 796 - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-4) , - the neck located on the injector rail. a Secure the engine wiring on the neck. a Connect: - the camshaft position sensor, - the accelerometer,...

  • Page 230: Flow Actuator: Removal - Refitting

    DIESEL INJECTION Flow actuator: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm flow actuator bolts 6 N.m dipstick guide and filler 21 N.m neck nuts on the high pressure rail 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 Diesel injection: Precautions for the...
  • Page 231 DIESEL INJECTION Flow actuator: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Only unpack the new component when you are ready to fit it. WARNING Do not remove the blanking plugs from each component until the last moment. WARNING Do not damage the seal when refitting.

  • Page 232: Venturi: Removal - Refitting

    DIESEL INJECTION Venturi: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm Venturi bolt 6 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see Diesel injection: Precautions for the repair) .
  • Page 233 DIESEL INJECTION Venturi: Removal - Refitting III - FINAL OPERATION a Connect the return pipe connecting the injector to the high-pressure pump. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). a Start the engine. a Check that there are no fuel leaks. a Refit the engine cover.

  • Page 234: High Pressure Pipe: Check

    DIESEL INJECTION High pressure pipe: Check Equipment required Diagnostic tool WARNING Check that there are no diesel leaks after each operation. Note: the Diagnostic tool can be used for testing the high pressure circuit with the engine running. This command can be used to run fault finding on a leak due to an incorrectly fitted or tightened union.

  • Page 235: High Pressure Pipe Between Pump And Rail: Removal - Refitting

    DIESEL INJECTION High pressure pipe between pump and rail: Removal - Refitting REMOVAL Equipment required I - REMOVAL PREPARATION OPERATION Diagnostic tool a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove the front engine cover. Tightening torquesm nut of the high pressure 28 N.m...
  • Page 236 DIESEL INJECTION High pressure pipe between pump and rail: Removal - Refitting - the injectors. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: High pressure pipe between the pump and rail. 24752 a Disconnect: - the high pressure pump connectors (3) . - the injector rail pressure sensor.
  • Page 237 DIESEL INJECTION High pressure pipe between pump and rail: Removal - Refitting a Slightly pretighten the high pressure pipe nuts. a Torque tighten: - the nut of the high pressure pipe between the pump and the injector rail on the high pressure pump (28 N.m), - the nut of the high pressure pipe between the pump and the rail on the injector rail (28 N.m).

  • Page 238: High Pressure Pipe Between Rail And Injector: Removal - Refitting

    DIESEL INJECTION High pressure pipe between rail and injector: Removal - Refitting REMOVAL Equipment required I - REMOVAL PREPARATION OPERATION Diagnostic tool a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove: Tightening torquesm - the engine cover, injector rail nuts 28 N.m - the air filter unit (see 12A, Fuel mixture, Air filter...
  • Page 239 DIESEL INJECTION High pressure pipe between rail and injector: Removal - Refitting 109466 24752 a Disconnect the following connectors (2) : a Disconnect the high pressure pump connectors (3) . - the heater plugs, a Remove the bolts mounting the neck onto the injec- - the injectors.
  • Page 240 DIESEL INJECTION High pressure pipe between rail and injector: Removal - Refitting a Slightly pretighten the high pressure pipe nuts. Note: The assembly order of the « rail-injector » high pressure pipes is not important. a Mount a new clip provided with the new high pres- sure pipe.

  • Page 241: Injector Rail: Removal - Refitting

    DIESEL INJECTION Injector rail: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm injector rail nuts 28 N.m nuts of the neck and 21 N.m dipstick guide on the injector rail 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 Diesel injection: Precautions for the...
  • Page 242 DIESEL INJECTION Injector rail: Removal - Refitting 109466 102360 a Disconnect: - the pressure sensor (7) from the injector rail, - the accelerometer (8) . 24752 a Disconnect: - the heater plugs (3) , - the injectors (4) , 24733 a Unclamp the engine wiring (9) and place it to one - the connectors on the high pressure pump (5) , side.
  • Page 243 DIESEL INJECTION Injector rail: Removal - Refitting - the high pressure pipes between the injector rail - the high pressure pipe between the high pressure and the injectors (see 13B, Diesel injection, High pump and the injector rail (see 13B, Diesel injec- pressure pipe between rail and injector: Re- tion, High pressure pipe between pump and moval - Refitting, page 13B-22) .

  • Page 244: Fuel Temperature Sensor: Removal - Refitting

    DIESEL INJECTION Fuel temperature sensor: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm fuel temperature sensor 15 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see Diesel injection: Precautions for the repair) .
  • Page 245 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Lubricate the O-ring with lubricant from the applica- tor supplied with the new part. II - REFITTING OPERATION Note: Do not damage the O-ring when refitting. a Remove the blanking plugs.

  • Page 246: Injector Leak Flow: Check

    DIESEL INJECTION Injector leak flow: Check Equipment required Diagnostic tool PARTS AND CONSUMABLES FOR THE REPAIR Consumables: - cleaning cloths (see Vehicle: Parts and consum- ables for the repair) (04B, Consumables - Products). - set of K9K blanking plugs (DELPHI injection) (see Ve- hicle: Parts and consumables for the repair) (04B, Consumables - Products).
  • Page 247 DIESEL INJECTION Injector leak flow: Check 107637 a Connect four of the transparent pipes (3) of theonto the diesel injector return. a Insert these pipes in the four graduated measuring cylinders (4) of the. Note: If necessary, attach the graduated measuring cylinder rail of theto the bonnet.

  • Page 248: Diesel Injector: Removal - Refitting

    DIESEL INJECTION Diesel injector: Removal - Refitting a Remove: Equipment required - the engine cover, - the air filter unit (see 12A, Fuel mixture, Air filter Diagnostic tool unit: Removal - Refitting, page 12A-6) . Tightening torquesm diesel injector clamp 28 N.m bolt injector rail nuts...
  • Page 249 DIESEL INJECTION Diesel injector: Removal - Refitting 109466 102360 a Disconnect: - the pressure sensor (7) from the injector rail, - the accelerometer (8) . 24752 a Disconnect: - the heater plugs (3) , - the injectors (4) , 24733 a Unclamp the engine wiring (9) and place it to one - the connectors (5) on the high pressure pump, side.
  • Page 250 DIESEL INJECTION Diesel injector: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REMOVING THE INJECTORS USING TOOLS (MOT. CONCERNED 921-01) AND (EMB. 880) 109462 120509 a Loosen the injector clamp bolt (11) . Tool for extracting injector hold- ers (Mot.
  • Page 251 DIESEL INJECTION Diesel injector: Removal - Refitting a Torque tighten the diesel injector clamp bolt (28 REFITTING N.m). I - REFITTING PREPARATION OPERATION III - FINAL OPERATION a Always replace the heat protection washer of the a Fit the high pressure pipes (see 13B, Diesel injec- diesel injector concerned.
  • Page 252 DIESEL INJECTION Diesel injector: Removal - Refitting 19724 a Program the alphanumeric code (C2I) (13) for the replaced injector(s) using the Diagnostic tool (see Fault finding - Replacement of components) (13B, Diesel injection). a Start the engine. a Check that there are no fuel leaks. 13B-36...

  • Page 253: Accelerometer: Removal - Refitting

    DIESEL INJECTION Accelerometer: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm accelerometer 20 N.m dipstick guide and filler 21 N.m neck nuts on the high pressure rail 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 Diesel injection: Precautions for the repair) .
  • Page 254 DIESEL INJECTION Accelerometer: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED a Remove the accelerometer using. REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the accelerometer. a Torque tighten the accelerometer (20 N.m) using the. II - FINAL OPERATION a Connect the accelerometer connector.

  • Page 255: Pre-Postheating Unit: Removal - Refitting

    PREHEATING Pre-postheating unit: Removal - Refitting II - FINAL OPERATION a Connect the battery (see Battery: Removal - Refit- Tightening torquesm ting) (80A, Battery). pre-postheating unit bolt 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).

  • Page 256: Heater Plugs: Removal - Refitting

    PREHEATING Heater plugs: Removal - Refitting II - REMOVAL OPERATION Equipment required compressed air nozzle hinged wrench for heater plug Tightening torquesm heater plugs 15 N.m REMOVAL I - REMOVAL PREPARATION STAGE a Remove the front engine cover. 109466 15762 a Disconnect the connector from each heater plug.
  • Page 257 PREHEATING Heater plugs: Removal - Refitting a Unscrew the heater plugs using a 10 mm long sock- et connected to a universal joint or a hinged wrench for heater plug. a Use a hose to unscrew the heater plugs completely. a Remove the heater plugs.

  • Page 258: Antipollution

    ANTIPOLLUTION Exhaust gas recirculation: List and location of components 112326 Exhaust gas recirculation sole- noid valve Intercooler Exhaust gas inlet pipe Metal air inlet tube Intercooler bracket on the fly- wheel end Intercooler suppor t on the timing 14A-1...

  • Page 259: Fuel Vapour Absorber: Removal - Refitting

    ANTIPOLLUTION Fuel vapour absorber: Removal - Refitting a Remove the front right-hand wheel (see Wheel: Re- moval - Refitting) (35A, Wheels and tyres). IMPORTANT a Move aside the front section of the front right-hand wheel arch liner. During this operation, be sure to: - refrain from smoking or bringing red hot objects II - REMOVAL OPERATION close to the working area,...
  • Page 260 ANTIPOLLUTION Fuel vapour absorber: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Remove the blanking plugs. II - REFITTING OPERATION a Refit: - the fuel vapour absorber, - the fuel vapour absorber nuts. a Clip on the breather pipe (2) a Connect: - the solenoid valve connector, - the fuel vapour absorber pipes (1) .

  • Page 261: Antipollution

    ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting K9K, and 796 Tightening torquesm exhaust gas recircula- 10 N.m tion solenoid valve bolts Note: The exhaust gas recirculation solenoid valve is fit- ted into the exhaust gas recirculation unit. REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) .
  • Page 262 ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting K9K, and 796 Note: Use the toolto detach the exhaust gas recircula- tion solenoid valves jammed in their exhaust gas cooler mountings on the gearbox end. Remove: - the bracket bolt (3) from the air filter unit, - the air filter unit bracket.
  • Page 263 ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting K9K, and 796 a Torque tighten the exhaust gas recirculation sole- noid valve bolts (10 N.m). a Connect the exhaust gas recirculation solenoid valve connector. III - FINAL OPERATION a Refit the air filter unit (see 12A, Fuel mixture, Air fil- ter unit: Removal - Refitting, page 12A-6) .

  • Page 264: Exhaust Gas Cooler: Removal - Refitting

    ANTIPOLLUTION Exhaust gas cooler: Removal - Refitting K9K, and 796 II - REMOVAL OPERATION Tightening torquesm exhaust gas cooler bolts 12 N.m exhaust gas recircula- 12 N.m tion rigid pipe bolts IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 265 ANTIPOLLUTION Exhaust gas cooler: Removal - Refitting K9K, and 796 a Fit the exhaust gas recirculation assembly equipped - the joint face of the exhaust gas cooler mounting on the gearbox end, with the exhaust gas recirculation rigid pipe on the cylinder head.

  • Page 266: Exhaust Gas Recirculation Assembly: Removal - Refitting

    ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting K9K, and 796 Special tooling required Ms. 583 Pipe clamps. Tightening torquesm bolts of the exhaust gas 21 N.m recirculation assembly bolts on the « timing 10 N.m end lifting eye - air inlet metal tube assembly »...
  • Page 267 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting K9K, and 796 II - REMOVAL OPERATION 145641 a Remove: - the bolts (9) from the lifting eye at the timing end, 118974 - the lifting eye on the timing end (10) , a Position the (Ms.
  • Page 268 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting K9K, and 796 a Use GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consum- ables - Products) to clean the joint faces of the ex- haust gas cooler mounting at the gearbox end. WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in...

  • Page 269: Exhaust Gas Recirculation Rigid Pipe: Removal - Refitting

    ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting K9K, and 796 - the timing end lifting eye (2) , Tightening torquesm II - REMOVAL OPERATION bolts of the exhaust gas 21 N.m recirculation rigid pipe bracket on the cylinder head bolts of the exhaust gas 36 N.m...
  • Page 270 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting K9K, and 796 a Clean using ABRASIVE PADS : - the joint face of the exhaust gas recirculation as- sembly, - the exhaust manifold seal face. WARNING T o ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks).

  • Page 271: Starting - Charging

    STARTING - CHARGING Alternator: Removal - Refitting Tightening torquesm alternator bolts 21 N.m alternator lead nut 14 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Re- fitting, page 11A-2) .
  • Page 272 STARTING - CHARGING Alternator: Removal - Refitting II - REFITTING OPERATION a Refit: - the alternator with its lower bolt, - the alternator upper bolt. a Torque tighten the alternator bolts (21 N.m). a Connect the connector to the alternator. a Refit the alternator lead.
  • Page 273 STARTING - CHARGING Alternator: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING Tightening torquesm alternator bolts 21 N.m alternator lead nut 14 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 274 STARTING - CHARGING Alternator: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING II - REMOVAL OPERATION REFITTING I - REFITTING PREPARATION OPERATION 116659 a Remove: - the alternator lead nut, 18987 a Push the rings (8) to make fitting easier. - the alternator lead (4) .
  • Page 275 STARTING - CHARGING Alternator: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). 16A-5...
  • Page 276 STARTING - CHARGING Alternator: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION Tightening torquesm alternator bolts 21 N.m positive terminal nut on 14 N.m the alternator REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 277 STARTING - CHARGING Alternator: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION REFITTING I - REFITTING PREPARATION OPERATION 18987 a Push the rings (10) to make fitting easier. II - REFITTING OPERATION a Refit the alternator. a Torque tighten the alternator bolts (21 N.m). III - FINAL OPERATION a Connect the alternator electrical connections.

  • Page 278: Starter: Removal - Refitting

    STARTING - CHARGING Starter: Removal - Refitting Tightening torquesm starter bolts 44 N.m nut on the starter sole- 5 N.m noid lead starter lead nut 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 279 STARTING - CHARGING Starter: Removal - Refitting III - FINAL OPERATION a Clip: - the engine wiring, - the intercooler duct on the fan assembly. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). 16A-9...
  • Page 280 STARTING - CHARGING Starter: Removal - Refitting Tightening torquesm starter bolts 44 N.m starter lead nut 8 N.m nut on the starter sole- 5 N.m noid lead REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 281 STARTING - CHARGING Starter: Removal - Refitting II - REMOVAL OPERATION III - FINAL OPERATION a Clip: - the gearbox control cable sleeve stops on the gear- box, - the control cables onto the gearbox. a Refit the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .

  • Page 282: Alternator Pulley: Removal - Refitting

    STARTING - CHARGING Alternator pulley: Removal - Refitting Equipment required pneumatic or electric wrench torque wrench open-ended spanner for torque wrench Tightening torquesm alternator pulley 80 N.m I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) .
  • Page 283 STARTING - CHARGING Alternator pulley: Removal - Refitting Mot. 1732 110276 117672 a Position the hexagonal socket (1) or the splined socket (2) from the kitorin the alternator pulley (de- pending on the version). 117671 16A-13...
  • Page 284 STARTING - CHARGING Alternator pulley: Removal - Refitting - the alternator pulley. III - REFITTING PREPARATION OPERATION a parts always to be replaced: Accessories belt parts always to be replaced: Accessories fixed roller parts always to be replaced: Accessories belt tensioning roller parts always to be replaced: Accessories ten- sioning roller bolt...
  • Page 285 STARTING - CHARGING Alternator pulley: Removal - Refitting IV - REFITTING OPERATION FOR THE ALTERNATOR PULLEY 110269 110266 110274 a Position: 110271 - the hexagonal socket (3) or the splined socket (6) a Tighten the new alternator pulley. in the alternator pulley (depending on the version), - the end piece (4) in the recess of the alternator ro- tor, - the end piece holder (5) on the end piece.
  • Page 286 STARTING - CHARGING Alternator pulley: Removal - Refitting 119770 a Immobilise the alternator rotor using the spanner (7) a Torque tighten the alternator pulley (80 N.m) using the torque wrench (8) equipped with a 15mm open-ended spanner for torque wrench. a Remove the tools.
  • Page 287 STARTING - CHARGING Alternator pulley: Removal - Refitting Tightening torquesm alternator pulley nut 80 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove: - the accessories belt (see 11A, Top and front of 114623 engine, Accessories belt: Removal - Refitting, a Fit:...
  • Page 288 STARTING - CHARGING Alternator pulley: Removal - Refitting 114623 a Fit: - the splined socket (4) of thein the free wheel pulley (5) , - the end piece and holder assembly (6) of theon the alternator shaft. a Immobilise the splined socket (4) . a Torque tighten the alternator pulley nut (80 N.m).

  • Page 289: Ignition

    IGNITION Coils: Removal - Refitting Tightening torquesm ignition coil bolts 14 N.m REMOVAL REMOVAL OPERATION 116655 a Disconnect the connectors (1) from the ignition coils. a Remove: - the ignition coil bolts (2) , - the ignition coils. REFITTING I - REFITTING PREPARATION OPERATION a Always replace the ignition coil bolts.
  • Page 290 IGNITION Coils: Removal - Refitting 106443 a When refitting the ignition harness, it is essential to apply a bead of FLUOSTAR 2L 2 mm in diameter around the inner edge of the high-tension caps on the side of the spark plugs and coil (see Vehicle: Parts and consumables for the repair) (04B, Con- sumables-Products).

  • Page 291: Petrol Injection

    PETROL INJECTION Petrol injection: List and location of components 116656 Air pressure sensor Idle speed stepper motor Air temperature sensor Throttle position potentiometer Ignition coil Throttle valve Upstream oxygen sensor Downstream oxygen sensor Injection computer (10) Relay unit (11) Crankshaft position sensor (12) Coolant temperature sensor (13)
  • Page 292 PETROL INJECTION Petrol injection: List and location of components Throttle position potentiometer Ignition coil 145183 Injection computer 116635 Throttle valve Upstream oxygen sensor 116570 (10) Relay unit 108424 Downstream oxygen sensor 17B-2...
  • Page 293 PETROL INJECTION Petrol injection: List and location of components 116648 101493 (11) Crankshaft position sensor (14) Injectors (15) Injector rail 101498 108415 (12) Coolant temperature sensor (13) Pinking sensor (16) Fuel vapour recirculation sole- noid valve (17) Petrol vapour absorber 17B-3...

  • Page 294: Oxygen Sensors: Removal - Refitting

    PETROL INJECTION Oxygen sensors: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm 1 - Upstream oxygen sensor upstream oxygen sen- 45 N.m dow n s t r e a m oxygen 45 N.m sensor WARNING Do not use any product designed to improve the electrical contact in the injection computer and oxy- gen sensor connectors or on the bodies of the oxy- gen sensors.
  • Page 295 PETROL INJECTION Oxygen sensors: Removal - Refitting a Clip on the downstream oxygen sensor wiring at (6) . 2 - Downstream oxygen sensor II - FINAL OPERATION Upstream oxygen sensor a Refit: - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) , - the air resonator (see 12A, Fuel mixture, Air res- onator: Removal - Refitting, page 12A-2) .

  • Page 296: Throttle Valve Potentiometer: Removal -Refitting

    PETROL INJECTION Throttle valve potentiometer: Removal -Refitting II - REMOVAL OPERATION Tightening torquesm throttle valve potentiom- 2.4 N.m eter bolts air filter unit bolts 9 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .

  • Page 297: Petrol Injection Computer: Removal - Refitting

    PETROL INJECTION Petrol injection computer: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm injection computer nuts 8 N.m WARNING Do not use any product designed to improve the electrical contact in the injection computer and oxy- gen sensor connectors or on the bodies of the oxy- gen sensors.
  • Page 298 PETROL INJECTION Petrol injection computer: Removal - Refitting REFITTING I - REFITTING OPERATION a Refit the injection computer. a Torque tighten the injection computer nuts (8 N.m). a Connect the two connectors of the injection comput- II - FINAL OPERATION a Refit the channel.

  • Page 299: Crankshaft Position Sensor: Removal - Refitting

    PETROL INJECTION Crankshaft position sensor: Removal - Refitting REFITTING Equipment required I - REFITTING OPERATION Diagnostic tool a Refit the crankshaft position sensor. a Refit the engine wiring harness mounting support. Tightening torquesm a Refit the two bolts of the crankshaft position sensor. crankshaft position sen- 8 N.m a Torque tighten the crankshaft position sensor...

  • Page 300: Injector Rail - Injectors: Removal - Refitting

    PETROL INJECTION Injector rail - Injectors: Removal - Refitting Tightening torquesm injector rail bolts 9 N.m injector rail protector 21 N.m nuts IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. 101801 IMPORTANT a Remove: During this operation, be sure to: - the two nuts (1) from the injector rail protector, - refrain from smoking or bringing red hot objects - the injector rail protector (2) .
  • Page 301 PETROL INJECTION Injector rail - Injectors: Removal - Refitting II - REMOVAL OPERATION REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: injector clip on in- jector rail. a parts always to be replaced: injector seal. a Refit: - new seals on each injector, - the injectors on the injector rail, - a new clip on each injector.

  • Page 302: Engine Cooling System: Operating Diagram

    COOLING Engine cooling system: Operating diagram K9K, and 796 133248 Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat Bleed screw Oil-water heat exchanger Temperature switch (10) 19A-1...

  • Page 303: Engine Cooling System: Specifications

    COOLING Engine cooling system: Specifications Vehicles in the current range have cooling systems with the following basic specifications: - hermetically-sealed pressurised circuit (expansion chamber valve), - circuit using a type "D" coolant, - passenger compartment heating system via a "heater matrix"...

  • Page 304: Engine Cooling System: Check

    COOLING Engine cooling system: Check 1 - Checking the expansion bottle cap valve IMPORTANT When working in the engine compartment, take care as the radiator fan(s) may start up unexpect- edly (risk of being cut). To avoid any risk of serious burns when the engine is hot: - do not open the expansion bottle cap, - do not drain the cooling system,...
  • Page 305 COOLING Engine cooling system: Check 1 - Checking the expansion bottle cap valve 97871 a Fit onto the tester, the adapter (Ms. 554-06). a Fit the expansion bottle cap to the adapter (Ms. 554- 06). Note: The pressure should not drop; if it does, look for the leak.

  • Page 306: Engine Cooling Circuit: List And Location Of Components

    COOLING Engine cooling circuit: List and location of components I - LIST OF COMPONENTS (14) Expansion bottle The engine cooling system is composed of: (15) Bleed screw (16) Engine - an engine cooling fan assembly (see 19A, Cooling, Engine cooling fan assembly: Removal - Refitting, page 19A-27) , - a cooling radiator (see 19A, Cooling, Cooling radia- tor: Removal - Refitting, page 19A-9) ,...

  • Page 307: Cooling System: Draining - Refilling

    There are two procedures for filling the cooling system: - the method using the tool, is recommended by Renault. It saves a considerable amount of time IMPORTANT because it does not require the cooling system bleed screws to be opened,...
  • Page 308 COOLING Cooling system: Draining - Refilling 123103 123975 a Open the bleed screw (2) . 123104 a Open the bleed screws (4) and (5) . a Fill the cooling system with engine coolant recom- mended by the manufacturer (see Vehicle: Parts and consumables for the repair) (04B, Consum- ables - Products) via the expansion bottle until it overflows.
  • Page 309 COOLING Cooling system: Draining - Refilling a Pressurise the system using the toolto check that there are no leaks (see 19A, Cooling, Engine cool- ing system: Check, page 19A-3) . a Refit the expansion bottle cap. a Clean any surfaces soiled by the coolant. IV - BLEEDING WARNING Do not open the bleed screw whilst the engine is...

  • Page 310: Cooling Radiator: Removal - Refitting

    COOLING Cooling radiator: Removal - Refitting - the injector rail protector (see 13B, Diesel injec- Special tooling required tion, Injector rail: Removal - Refitting, page 13B- 25) , Mot. 1448 Remote operation pliers for hose clips. - the air resonator (see 12A, Fuel mixture, Air res- onator: Removal - Refitting, page 12A-2) , Car.
  • Page 311 COOLING Cooling radiator: Removal - Refitting II - REFITTING OPERATION a Proceed in the reverse order to removal. a Refill and bleed the cooling system (see 19A, Cool- ing, Cooling system: Draining - Refilling, page 19A-6) . a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery).
  • Page 312 COOLING Cooling radiator: Removal - Refitting - the engine cover, Special tooling required - the air intake sleeve, Mot. 1448 Remote operation pliers for - the intercooler (see 12B, Turbocharging, Inter- hose clips. cooler: Removal - Refitting, page 12B-8) , Car.
  • Page 313 COOLING Cooling radiator: Removal - Refitting II - REFITTING OPERATION a Proceed in the reverse order to removal. a Refill and bleed the cooling system (see 19A, Cool- ing, Cooling system: Draining - Refilling, page 19A-6) . a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery).

  • Page 314: Coolant Pump: Removal - Refitting

    COOLING Coolant pump: Removal - Refitting K9K, and 796 - the engine undertray. a Remove the front bumper (see Front bumper: Re- Tightening torquesm moval - Refitting) (55A, Exterior protection). bolts of the coolant 10 N.m a Drain the cooling system (see 19A, Cooling, Cool- pump ing system: Draining - Refilling, page 19A-6) .
  • Page 315 COOLING Coolant pump: Removal - Refitting K9K, and 796 REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: coolant pump seal. a Use SURFACE CLEANER (see ) (04B, Consuma- bles - Products) to clean and degrease: - the coolant pump sealing face if it is to be reused, - the cylinder block gasket face.
  • Page 316 COOLING Coolant pump: Removal - Refitting K9K, and 796 a Refit: II - REFITTING OPERATION - the engine undertray, - the engine undertray bolts, - the engine cover. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). a Bleed the cooling system (see 19A, Cooling, Cool- ing system: Draining - Refilling, page 19A-6) .
  • Page 317 COOLING Coolant pump: Removal - Refitting - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, Tightening torquesm page 11A-2) , - the timing belt (see 11A, Top and front of engine, coolant pump M8 bolt 27 N.m Timing belt: Removal - Refitting, page 11A-17) .
  • Page 318 COOLING Coolant pump: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. IMPORTANT Wear goggles with side protectors for this opera- tion. WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
  • Page 319 COOLING Coolant pump: Removal - Refitting II - REFITTING OPERATION 14505 a Apply one to two drops of FRENETANCHE (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to the coolant pump bolts (1) and (4) . a Refit the coolant pump.

  • Page 320: Thermostat: Removal - Refitting

    COOLING Thermostat: Removal - Refitting a The thermostat is integral with the coolant outlet unit. The coolant outlet unit must be replaced to re- place it (see 19A, Cooling, Water chamber: Re- moval - Refitting, page 19A-22) . 19A-19...
  • Page 321 COOLING Thermostat: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1448 Remote operation pliers for hose clips. IMPORTANT When working in the engine compartment, take care as the radiator fan(s) may start up unexpect- edly (risk of being cut).
  • Page 322 COOLING Thermostat: Removal - Refitting - the thermostat cover. III - FINAL OPERATION a Fill and bleed the cooling system (see 19A, Cool- ing, Cooling system: Draining - Refilling, page 19A-6) . a Refit: - the engine undertray, - the air resonator (see 12A, Fuel mixture, Air res- onator: Removal - Refitting, page 12A-2) .

  • Page 323: Water Chamber: Removal - Refitting

    COOLING Water chamber: Removal - Refitting K9K, and 796 - the expansion bottle nuts. a Move aside the expansion bottle. Tightening torquesm water chamber bolts 11 N.m expansion bottle nuts 8 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 324 COOLING Water chamber: Removal - Refitting K9K, and 796 II - REMOVAL OPERATION 146342 a Disconnect the EGR assembly outlet pipe at (6) . 20070 a Move the EGR assembly outlet pipe aside. a Remove: a Disconnect the coolant temperature sensor connec- - the water chamber bolts (8) , tor.
  • Page 325 COOLING Water chamber: Removal - Refitting K9K, and 796 II - REFITTING OPERATION a Refit: - a new water chamber seal in the water chamber housing, - the water chamber. a Torque tighten the water chamber bolts (11 N.m). a Connect: - the cooling hoses to the water chamber, - the coolant temperature sensor connector, - the EGR assembly outlet pipe,...
  • Page 326 COOLING Water chamber: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm coolant outlet unit bolts 4 N.m (initial torque) water chamber bolts 12 N.m REMOVAL I - OPERATION FOR REMOVAL OF PART CONCERNED a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 327 COOLING Water chamber: Removal - Refitting 116636 a Screw on the water chamber bolts without tightening them. a Torque tighten in order: - the coolant outlet unit bolts (initial torque) (4 N.m), - the water chamber bolts (12 N.m). III - FINAL OPERATION a Connect: - the coolant temperature sensor, - the expansion bottle hose,...

  • Page 328: Engine Cooling Fan Assembly: Removal - Refitting

    COOLING Engine cooling fan assembly: Removal - Refitting REMOVAL II - REMOVAL OPERATION I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove: - the injector rail protector (see 13B, Diesel injec- tion, Injector rail: Removal - Refitting, page 13B- 25) , - the air resonator (see 12A, Fuel mixture, Air res-...
  • Page 329 COOLING Engine cooling fan assembly: Removal - Refitting STANDARD HEATING RECIRCULA TION AIR CONDITIONING 145561 145563 a Disconnect the cooling fan assembly connector (5) . a Disconnect: a Unclip the engine cooling fan assembly wiring. - the engine cooling fan assembly connector (7) , a Move aside the wiring of the engine cooling fan as- - the engine cooling fan assembly resistor connector sembly.
  • Page 330 COOLING Engine cooling fan assembly: Removal - Refitting II - REFITTING OPERATION a Proceed in the reverse order to removal. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). III - CHECKING THE OPERATION OF THE FAN UNIT a Start the engine.
  • Page 331 COOLING Engine cooling fan assembly: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove: - the engine cover, - the air intake sleeve,...
  • Page 332 COOLING Engine cooling fan assembly: Removal - Refitting II - REMOVAL OPERATION STANDARD HEATING RECIRCULA TION 144817 145561 a Disconnect the cooling fan assembly connector (7) . a Unclip the engine cooling fan assembly wiring. a Move aside the wiring of the engine cooling fan as- sembly.
  • Page 333 COOLING Engine cooling fan assembly: Removal - Refitting AIR CONDITIONING 144817 a Unclip the « condenser - expansion valve » connect- ing pipe at (11) . WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. 145563 a Pull the fan assembly according to the arrows (12) a Disconnect:...
  • Page 334 COOLING Engine cooling fan assembly: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION In the event of replacement a Refit on the fan assembly: - the power-assisted steering hose clips, - the wiring clip, - the support of the intercooler duct and coolant hose on the fan assembly.

  • Page 335: Coolant Pump Inlet Pipe: Removal - Refitting

    COOLING Coolant pump inlet pipe: Removal - Refitting K9K, and 796 a Remove the front bumper (see Front bumper: Re- moval - Refitting) (55A, Exterior protection). Tightening torquesm a Drain the engine cooling system (see 19A, Cooling, coolant pump inlet pipe 22 N.m Cooling system: Draining - Refilling, page 19A-6) bolt...
  • Page 336 COOLING Coolant pump inlet pipe: Removal - Refitting K9K, and 796 a Use SURFACE CLEANER (see ) (04B, Consuma- bles - Products) to clean and degrease: - the coolant pump inlet pipe seal housing if it is be- ing reused, - the seal housing in the cylinder block.
  • Page 337 COOLING Coolant pump inlet pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm coolant pump inlet pipe 22 N.m bolt REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 338 COOLING Coolant pump inlet pipe: Removal - Refitting a Refit the injector rail protector. a Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). a Bleed the cooling system (see 19A, Cooling, Cool- ing system: Draining - Refilling, page 19A-6) .

  • Page 339: Expansion Bottle: Removal - Refitting

    COOLING Expansion bottle: Removal - Refitting REMOVAL Special tooling required Ms. 583 Pipe clamps. REMOVAL OPERATION Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm expansion bottle nuts 8 N.m IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns).
  • Page 340 COOLING Expansion bottle: Removal - Refitting - the expansion bottle bottom hose. a Refit the following using the tool (Mot. 1448) or « CLIC » clip pliers: - the clamp of the top hose of the expansion bottle, - the clamp of the bottom hose of the expansion bot- tle.

  • Page 341: Coolant Temperature Sensor: Removal - Refitting

    COOLING Coolant temperature sensor: Removal - Refitting Tightening torquesm expansion bottle nuts 8 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot.
  • Page 342 COOLING Coolant temperature sensor: Removal - Refitting II - REMOVAL OPERATION REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: coolant tempera- ture sensor seal. a Use SURFACE CLEANER (see ) to clean and de- grease: - the mating face of the coolant temperature sensor if it is to be reused, - the coolant outlet unit.
  • Page 343 COOLING Coolant temperature sensor: Removal - Refitting a Perform the following operations: - top up the cooling system, - bleed the cooling system (see 19A, Cooling, Cool- ing system: Draining - Refilling, page 19A-6) . 19A-42...
  • Page 344 COOLING Coolant temperature sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm coolant temperature 30 N.m sensor IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot.
  • Page 345 COOLING Coolant temperature sensor: Removal - Refitting III - FINAL OPERATION a Refit the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) . a Perform the following operations: - top up the coolant level, - bleed the cooling system (see 19A, Cooling, Cool- ing system: Draining - Refilling, page 19A-6) .

  • Page 346: Exhaust

    EXHAUST Exhaust: List and location of components 19B-1...
  • Page 347 EXHAUST Exhaust: List and location of components 144569 19B-2...
  • Page 348 EXHAUST Exhaust: List and location of components Area to be cut A Area to be cut B Exhaust system sealing ring Catalytic converter Downstream oxygen sensor Expansion chamber Expansion chamber rubber pad Silencer Silencer rubber pad 19B-3...
  • Page 349 EXHAUST Exhaust: List and location of components 144609 19B-4...
  • Page 350 EXHAUST Exhaust: List and location of components Area to be cut A Area to be cut B Exhaust system sealing ring Intermediate pipe Intermediate pipe rubber pad Silencer Silencer rubber pad 19B-5...

  • Page 351: Exhaust: Precautions For The Repair

    EXHAUST Exhaust: Precautions for the repair To do this: Special tooling required - clean the bearing faces of the connection using Mot. 1199-01 Exhaust pipe cutter (diame- GREY ABRASIVE PADS, ter 35/50 mm and diameter 50/65mm). Complete kit in a - degrease the bearing faces of the connection using case.
  • Page 352 EXHAUST Exhaust: Precautions for the repair 102118 Fit the (Mot. 1199-01) (1) on the exhaust pipe. Tighten the two bolts on the tool until they touch the pipe in order to clamp the tool onto the pipe. Turn the cutting tool using the handle and pressing it 100649 against the pipe (as indicated in the diagram above).
  • Page 353 EXHAUST Exhaust: Precautions for the repair Exhaust sleeve with 1 bolt Note: If necessary , use a component jack to lift and hold the heavy and bulky components of the exhaust system. Position the second exhaust pipe onto the lugs inside the exhaust sleeve.
  • Page 354 EXHAUST Exhaust: Precautions for the repair Note: If there are leaks from the EXHAUST SLEEVES WITH 1 BOLT, apply EXHAUST MASTIC to the sleeve (see part no. in Technical Note 5068, 04B, Consumables - Products). If the application of exhaust mastic does not fix the leak: - remove and replace the used exhaust sleeve, - check the condition of the exhaust pipes (condition...

  • Page 355: Catalytic Converter: Removal - Refitting

    EXHAUST Catalytic converter: Removal - Refitting K9K, and 796 REMOVAL Tightening torquesm I - REMOVAL PREPARATION OPERATION turbocharger output 9 N.m a Position the vehicle on a two-post lift (see Vehicle: studs Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- catalytic converter nuts 28 N.m on the turbocharger...
  • Page 356 EXHAUST Catalytic converter: Removal - Refitting K9K, and 796 144536 145311 a Remove the bolt from the downstream strut on the a Remove the catalytic converter nuts on the turbo- catalytic converter (2) . charger (5) . a Loosen the downstream strut bolt and nut on the gearbox (3) .
  • Page 357 EXHAUST Catalytic converter: Removal - Refitting K9K, and 796 REFITTING II - REFITTING OPERATION I - REFITTING PREPARATION OPERATION Note: If a stud loosens during this operation, coat it with HIGH STRENGTH THREAD LOCK (see WARNING Vehicle: Parts and consumables for the T o ensure proper sealing, the gasket surfaces repair) (04B, Consumables - Products).
  • Page 358 EXHAUST Catalytic converter: Removal - Refitting K9K, and 796 a Check that there are no leaks and deal with them if necessary. 19B-13...
  • Page 359 EXHAUST Catalytic converter: Removal - Refitting K4M, and 4X2 TRANSMISSION a Disconnect the battery (see Battery: Removal - Re- Special tooling required fitting) (80A, Battery). Mot. 1199-01 Exhaust pipe cutter (diame- ter 35/50 mm and diameter II - REMOVAL OPERATION 50/65mm).
  • Page 360 EXHAUST Catalytic converter: Removal - Refitting K4M, and 4X2 TRANSMISSION 109399 a parts always to be replaced: ring between ex- haust manifold and catalytic converter II - REFITTING OPERATION 135949 a Refit: a Remove: - the downstream oxygen sensor (if replacing the catalytic converter), - the exhaust flange bolts (2) , - the catalytic converter.
  • Page 361 EXHAUST Catalytic converter: Removal - Refitting K4M, and 4X2 TRANSMISSION a Check that there are no leaks and deal with them if necessary. 19B-16...

  • Page 362: Expansion Chamber: Removal - Refitting

    EXHAUST Expansion chamber: Removal - Refitting K4M, and 4X2 TRANSMISSION a Remove the rubber pad from the expansion cham- Special tooling required ber using the tool (Mot. 1857). Mot. 1199-01 Exhaust pipe cutter (diame- ter 35/50 mm and diameter Note: 50/65mm).

  • Page 363: 19B

    EXHAUST Intermediate pipe: Removal - Refitting II - REMOVAL OPERATION Special tooling required Mot. 1199-01 Exhaust pipe cutter (diame- ter 35/50 mm and diameter 50/65mm). Complete kit in a case. Mot. 1857 Pliers for removing exhaust pipe rubber mounting bushes Equipment required component jack Tightening torquesm...
  • Page 364 EXHAUST Intermediate pipe: Removal - Refitting REFITTING I - REFITTING OPERATION a Refit the intermediate pipe. a Refit the exhaust sleeves (see 19B, Exhaust, Ex- haust: Precautions for the repair, page 19B-6) . WARNING Make sure: - that the sleeve nut-bolt tightening assembly is vertical, with the nut facing downwards, to pre- vent any risk of underbody contact, - that you position the new component in a way...

  • Page 365: Silencer: Removal - Refitting

    EXHAUST Silencer: Removal - Refitting 4X2 TRANSMISSION a Remove the rubber pad from the silencer using the Special tooling required tool (Mot. 1857). Mot. 1199-01 Exhaust pipe cutter (diame- ter 35/50 mm and diameter Note: 50/65mm). Complete kit in a If the rubber pad is damaged, replace the rubber case.

  • Page 366: 19C

    TANK Fuel tank: Draining II - DRAINING OPERATION Special tooling required Mot. 1311-08 Union for taking fuel pres- sure measurements. a Disconnect the fuel supply union from the injector rail (1) . Equipment required pneumatic transfer pump for fuels IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area,...
  • Page 367 TANK Fuel tank: Draining a Drain the fuel tank. REFITTING a Proceed in the reverse order to removal. 144823 a Remove: - the front right-hand wheel arch liner bolts (4) , - the clip of the wheel arch liner (5) , - the diesel filter protector (see ) .

  • Page 368: Fuel Tank: Removal - Refitting

    TANK Fuel tank: Removal - Refitting 4X2 TRANSMISSION REMOVAL Tightening torquesm I - REMOVAL PREPARATION OPERATION fuel tank bolts 21 N.m a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). exhaust pipe bolts on 21 N.m a Disconnect the battery (see Battery: Removal - Re- the catalytic converter...
  • Page 369 TANK Fuel tank: Removal - Refitting 4X2 TRANSMISSION 109185 108424 a Remove the body earth cable at (2) . a Remove the oxygen sensor connector by sliding it from its support (in the direction of the arrow). a Disconnect the oxygen sensor connector. 109183 a Remove: - the heat shield pins (4) ,...
  • Page 370 TANK Fuel tank: Removal - Refitting 4X2 TRANSMISSION 116557 114121 a Remove the catalytic converter mountings (6) on the a Remove the exhaust pipe mountings (8) from the exhaust manifold. catalytic converter. a Detach the exhaust line assembly on the left-hand a Place the exhaust line assembly on the left-hand side.
  • Page 371 TANK Fuel tank: Removal - Refitting 4X2 TRANSMISSION II - OPERATION FOR REMOVAL OF PART CONCERNED 109181 Note: This operation requires two people. a Remove the bolts (11) from the fuel tank. a Lower the tank slightly. 118344 a Remove the bolts (9) from the filler neck. a Remove the fuel tank.
  • Page 372 TANK Fuel tank: Removal - Refitting 4X2 TRANSMISSION a Refit the fuel tank. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). a Refit the fuel tank bolts. a Torque tighten the fuel tank bolts (21 N.m). a Refit the external fuel filter (if fitted to the vehicle) (see Fuel filter: Removal - Refitting) .

  • Page 373: Fuel Level Sensor Module: Removal - Refitting

    TANK Fuel level sensor module: Removal - Refitting K4M or K9K Special tooling required Car. 1363 Set of trim removal levers. Mot. 1397 Universal spanner for remov- ing fuel gauge nuts. IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the union.
  • Page 374 TANK Fuel level sensor module: Removal - Refitting K4M or K9K 109176 a Remove the nut from the fuel level sensor module using the tool (Mot. 1397) (5) , 144825 a Let the fuel drain from the fuel level sensor module. a Disconnect: a Remove: - the connector (3) ,...
  • Page 375 TANK Fuel level sensor module: Removal - Refitting K4M or K9K II - REFITTING OPERATION the mark (8) on the fuel level sensor module must be positioned opposite the mark on the fuel tank (10) . a Press the fuel level sensor module by hand (to pre- vent the seal from moving) and finger tighten the nut on the fuel tank.

  • Page 376: 19D

    ENGINE MOUNTING Suspended engine mounting: Tightening torque 103236 Description Tightening torque (N.m) Right-hand suspended mounting support bolt on the body Right-hand suspended mounting support bolt on the engine Left-hand mounting bolt on the gearbox Left-hand rubber pad mounting bolt on the body Left-hand rubber pad bolt on the mounting Stud on the gearbox mounting Gearbox mounting nut on the rubber pad...

  • Page 377: Left-Hand Suspended Engine Mounting: Removal - Refitting

    ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting Special tooling required Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. Tightening torquesm bolts mounting the left- 62 N.m hand suspended mount- ing on the gearbox bolt power- 21 N.m assisted steering pipe 107930...
  • Page 378 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the bolts (3) from the left-hand rubber pad mount- - the battery tray, ing on the body, - the battery (see Battery: Removal - Refitting) (80A, Battery), - the left-hand rubber pad mounting, - the air intake sleeve.

  • Page 379: Right-Hand Suspended Engine Mounting: Removal - Refitting

    ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting Special tooling required Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. Tightening torquesm right-hand suspended 62 N.m engine mounting bolts on the engine right-hand suspended 62 N.m engine mounting bolts on the body REMOVAL I - REMOVAL PREPARATION OPERATION...
  • Page 380 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting II - REMOVAL OPERATION REFITTING I - REFITTING OPERATION 145429 a Mark the position of the right-hand suspended en- gine mounting on the body. a Remove: 145429 a Refit: - the bolts (6) from the right-hand suspended engine mounting on the engine, - the right-hand suspended engine mounting observ- - the right-hand suspended engine mounting bolts...
  • Page 381 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting II - REMOVAL OPERATION Special tooling required Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. Tightening torquesm right-hand suspended 62 N.m engine mounting bolts on the engine right-hand suspended 62 N.m engine mounting bolts on the body...
  • Page 382 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting II - FINAL OPERATION a Remove the engine support tool (Mot. 1453). a Refit the engine cover. 19D-7...

  • Page 383: Lower Engine Tie-Bar: Removal - Refitting

    ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting REFITTING Tightening torquesm I - REFITTING OPERATION rear suspended engine 105 N.m a Refit: mounting bolt on the subframe - the rear suspended engine mounting, - the rear suspended engine mounting bolts. rear suspended engine 105 N.m a Torque tighten:...
  • Page 384 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 385 DUSTER - Chapitre 2 DUSTER - Chapitre 2ContentsPages Contents Pages CLUTCH DRIVESHAFTS Clutch: Precautions for the Front left-hand driveshaft: repair 20A-1 Removal - Refitting 29A-1 Clutch: Specifications 20A-2 Front right-hand driveshaft: Removal - Refitting 29A-4 Pressure plate - Disc: Removal - Refitting 20A-4 Relay shaft bearing: Removal - Refitting...

  • Page 386: Clutch

    CLUTCH Clutch: Precautions for the repair Before removing the clutch, check: - The direction of fitting for the clutch plate. Before refitting the clutch, check: - The flywheel friction track (no scratches or blue stains), - The crankshaft bearing (no sticking), - The engine and gearbox seals (replace if necessary), - The sliding action of the clutch plate on the output shaft,...

  • Page 387: Clutch: Specifications

    CLUTCH Clutch: Specifications K4M or K9K 107918 Drive plate 105680 Plate external diameter: 200 mm Plate thickness: 7.5 mm Number of splines: 26 Spring colour (1) : Grey Spring colour (2) : Green Spring colour (3) : Lilac blue Pressure plate 20A-2...
  • Page 388 CLUTCH Clutch: Specifications K4M or K9K Colours of the springs (4) : Red and black. Colour of spring (5) : Grey. Pressure plate 108795 Drive plate 102142 Plate outer diameter: 215 mm. Plate thickness: 6.9 mm. Number of grooves: 26. 20A-3...

  • Page 389: Pressure Plate - Disc: Removal - Refitting

    CLUTCH Pressure plate - Disc: Removal - Refitting REFITTING IMPORTANT I - REFITTING PREPARATION OPERATION a Replace any faulty parts. To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- a Use SURFACE CLEANER (see Vehicle: Parts tion recommendations before carrying out any and consumables for the repair) (04B, Consuma- repair:...
  • Page 390 CLUTCH Pressure plate - Disc: Removal - Refitting REFITTING Tightening torquesm I - REFITTING PREPARATION OPERATION pressure plate bolts 15 N.m a Replace any faulty parts. a Use SURFACE CLEANER (see Vehicle: Parts IMPORTANT and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: To avoid all risk of damage to the systems, apply - the flywheel friction face,...

  • Page 391: Clutch Thrust Bearing: Removal - Refitting

    CLUTCH Clutch thrust bearing: Removal - Refitting Tightening torquesm clutch thrust bearing 21 N.m bolts on the clutch hous- The thrust bearing is connected to the clutch slave cyl- inder. REMOVAL I - REMOVAL PREPARATION OPERATION a Drain the brake reservoir using a syringe to remove the clutch thrust bearing and control.

  • Page 392: Manual Gearbox

    MANUAL GEARBOX Manual gearbox oils: Draining - Filling Tightening torquesm drain plug 22 N.m Ty p e Capacity gearbox (litres) DRAINING a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: 18749 a Remove the filler cap (2) .

  • Page 393: Differential Output Seal: Removal - Refitting

    MANUAL GEARBOX Differential output seal: Removal - Refitting REMOVAL II - REMOVAL OPERATION I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 388, 02A, Lifting equip- ment). a Remove: - the engine undertray bolts, - the engine undertray.
  • Page 394 MANUAL GEARBOX Differential output seal: Removal - Refitting II - REFITTING OPERATION 109407 a Refit the differential output seal using the tool (1) with A on the right-hand side, and B on the left-hand side. a Tap the toolwith a copper hammer (2) to fit the new differential output seal fully.

  • Page 395: Manual Gearbox: Removal - Refitting

    MANUAL GEARBOX Manual gearbox: Removal - Refitting K9K, and JR5 REMOVAL Special tooling required Mot. 1453 Engine anchorage support I - REMOVAL PREPARATION OPERATION with multiple adjustments and a Position the vehicle on a two-post lift (see Vehicle: retaining straps. Towing and lifting) (02A, Lifting equipment).
  • Page 396 MANUAL GEARBOX Manual gearbox: Removal - Refitting K9K, and JR5 24730 24828 a Remove: a Remove: - the battery (see Battery: Removal - Refitting) - the clip (3) on the air pipe between the turbocharg- (80A, Battery), er and the intercooler, - the battery tray, - the air pipe nut (4) on the gearbox, - the earth strap nut (1) ,...
  • Page 397 MANUAL GEARBOX Manual gearbox: Removal - Refitting K9K, and JR5 24817 24810 a Press on the clip (9) and disconnect the clutch con- trol pipe on the clutch slave cylinder. WARNING Do not pull the clip. If it is incorrectly handled in any way, the pipe will need to be replaced.
  • Page 398 MANUAL GEARBOX Manual gearbox: Removal - Refitting K9K, and JR5 141720 145559 a Disconnect the reverse gear connector (10) . 24762 a Remove: - the bolt (12) from the power-assisted steering pipe on the gearbox, - the bolt (13) from the power-assisted steering pipe 24766 on the gearbox mounting, a Remove the earth strap bolts (11) on the gearbox.
  • Page 399 MANUAL GEARBOX Manual gearbox: Removal - Refitting K9K, and JR5 a Remove the steering box bolts on the subframe. II - REMOVAL OPERATION a Attach the steering rack to the body. a Remove: - the lower engine tie-bar (see Lower engine tie- bar: Removal - Refitting) (19D, Engine mount- ing), - the front axle subframe (see Front axle subframe:...
  • Page 400 MANUAL GEARBOX Manual gearbox: Removal - Refitting K9K, and JR5 - a new clutch thrust bearing (see 20A, Clutch, Clutch thrust bearing: Removal - Refitting, page 20A-6) . WARNING To avoid damaging the slave cylinder, do not coat the gearbox output shaft with grease. WARNING To avoid damaging the clutch slave cylinder, do not coat the gearbox output shaft with grease.
  • Page 401 MANUAL GEARBOX Manual gearbox: Removal - Refitting K9K, and JR5 a Couple the front left-hand wheel driveshaft, on the III - FINAL OPERATION gearbox side (see 29A, Driveshafts, Front left- a Refit: hand driveshaft: Removal - Refitting, page 29A- - the catalytic converter downstream strut (see Cata- 1) .
  • Page 402 MANUAL GEARBOX Manual gearbox: Removal - Refitting K4M, and JR5 Special tooling required IMPORTANT Mot. 1453 Engine anchorage support with multiple adjustments and To avoid all risk of damage to the systems, apply retaining straps. the safety and cleanliness instructions and opera- tion recommendations before carrying out any Equipment required repair:...
  • Page 403 MANUAL GEARBOX Manual gearbox: Removal - Refitting K4M, and JR5 118882 24810 a Press the clip (5) and disconnect the clutch control pipe on the clutch slave cylinder by pressing on the retaining clip. WARNING Do not pull the clip. If it is incorrectly handled in any way, the pipe will need to be replaced.
  • Page 404 MANUAL GEARBOX Manual gearbox: Removal - Refitting K4M, and JR5 141720 24766 a Disconnect the reverse gear connector (6) . 24762 a Remove: - the earth strap bolts (7) on the gearbox, - the bolt (8) from the power-assisted steering pipe on the gearbox, - the bolt (9) from the power-assisted steering pipe on the gearbox mounting,...
  • Page 405 MANUAL GEARBOX Manual gearbox: Removal - Refitting K4M, and JR5 2 - RIGHT SIDE OF VEHICLE 116657 a Remove: 116640 a Remove: - the bolts (13) from the steering box heat-resistant - the front right-hand wheel arch side liner, protector, - the mountings (11) of the stay between the exhaust - the heat shield, manifold and the cylinder block,...
  • Page 406 MANUAL GEARBOX Manual gearbox: Removal - Refitting K4M, and JR5 II - REMOVAL OPERATION 107930 a Fit the engine support tool (Mot. 1453) with the re- taining belt, taking the flywheel end lifting eye as an anchoring point. 107936 a Remove: - the gearbox lower bolts (17) , - the gearbox stud nuts (18) , - the gearbox.
  • Page 407 MANUAL GEARBOX Manual gearbox: Removal - Refitting K4M, and JR5 - a new clutch thrust bearing (see 20A, Clutch, - the front axle subframe (see Front axle subframe: Clutch thrust bearing: Removal - Refitting, page Removal - Refitting) (31A, Front axle compo- 20A-6) .
  • Page 408 MANUAL GEARBOX Manual gearbox: Removal - Refitting K4M, and JR5 a Refit the front bumper (see Front bumper assem- bly: Exploded view) . a Top up the gearbox (see 21A, Manual gearbox, Manual gearbox oils: Draining - Filling, page 21A-1) . a Refit the engine undertray.

  • Page 409: 5Th Gear Housing: Removal - Refitting

    MANUAL GEARBOX 5th gear housing: Removal - Refitting Equipment required oil recovery tray Tightening torquesm 5th gear housing bolts 25 N.m front left-hand axle sub- 21 N.m frame tie-rod bolt the nut of the front left- 21 N.m hand axle subframe tie- IMPORTANT 145884 To avoid all risk of damage to the systems, apply...
  • Page 410 MANUAL GEARBOX 5th gear housing: Removal - Refitting 141720 141719 a Disconnect the connector (5) from the reverse gear a Remove: switch. - the bolt (8) of the 5th gear housing, - the 5th gear housing, II - REMOVAL OPERATION - the seal of the 5th gear housing.
  • Page 411 MANUAL GEARBOX 5th gear housing: Removal - Refitting a Proceed in the reverse order to removal. a Torque tighten: - the front left-hand axle subframe tie-rod bolt (21 N.m), - the nut of the front left-hand axle subframe tie- rod (21 N.m). III - FINAL OPERATION a Fill and check the gearbox oil level (see 21A, Manu- al gearbox, Manual gearbox oils: Draining - Fill-...

  • Page 412: 5Th Gear Sprockets And Synchronisers: Removal - Refitting

    MANUAL GEARBOX 5th gear sprockets and synchronisers: Removal - Refitting II - REMOVAL OPERATION Special tooling required Bvi. 1170 Extractor tool for 5th gear hub on primary shaft. Bvi. 1175 Fixed 5th gear mounting bolt. Tightening torquesm input shaft nut 190 N.m output shaft bolt 80 N.m...
  • Page 413 MANUAL GEARBOX 5th gear sprockets and synchronisers: Removal - Refitting 141715 141714 a Engage fifth gear by moving the fifth gear fork. Note: The purpose of this operation is to lock the gear- box shafts in order to facilitate loosening. a Remove: - the output shaft bolt (3) , - the input shaft nut (4) ,...
  • Page 414 MANUAL GEARBOX 5th gear sprockets and synchronisers: Removal - Refitting - the fifth idle gear fitted with its synchroniser ring (9) - the idle gear supporting ring (10) , - the lock washer (11) . 141712 a Fit the other half-shell (14) and the ringof the tool (15) .
  • Page 415 MANUAL GEARBOX 5th gear sprockets and synchronisers: Removal - Refitting a Top up the gearbox (see 21A, Manual gearbox, Manual gearbox oils: Draining - Filling, page 21A-1) . a Carry out a function test. 141711 a Refit the fifth gear pinion using the tool (16) (Bvi. 1175).

  • Page 416: Input Shaft Lip Seal: Removal - Refitting

    MANUAL GEARBOX Input shaft lip seal: Removal - Refitting a Replace the lip seal after having opened the gear- box (see Clutch housing bearing: Removal - Re- fitting) (Technical Note 6029A, 21A, Manual gearbox). 21A-25...

  • Page 417: Reverse Gear Switch: Removal - Refitting

    MANUAL GEARBOX Reverse gear switch: Removal - Refitting Special tooling required Bvi. 1934 Socket for removing/refitting reverse gear switch Tightening torquesm reverse gear switch 23 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

  • Page 418: Driveshafts

    DRIVESHAFTS Front left-hand driveshaft: Removal - Refitting II - REMOVAL OPERATION Special tooling required Emb. 880 Pin extractor tool. Tav. 1813 Extraction claw clip secured type driveshafts Tightening torquesm shock absorber base 105 N.m bolts hub nut 280 N.m track rod end nut 37 N.m WARNING In order to prevent irreversible damage to the front...
  • Page 419 DRIVESHAFTS Front left-hand driveshaft: Removal - Refitting a Remove the bolts (7) from the base of the left-hand shock absorber. a Push back the front left-hand driveshaft from the stub axle carrier using the toolsand. a Pivot the stub axle carrier to separate the driveshaft from the stub axle carrier.
  • Page 420 DRIVESHAFTS Front left-hand driveshaft: Removal - Refitting III - FINAL OPERATION a Refit: - the engine undertray, - the front left-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres). a Fill and check the manual gearbox oil level (see 21A, Manual gearbox, Manual gearbox oils: Draining - Filling, page 21A-1) .

  • Page 421: Front Right-Hand Driveshaft: Removal - Refitting

    DRIVESHAFTS Front right-hand driveshaft: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm driveshaft relay bearing 21 N.m bracket bolts shock absorber base 105 N.m bolts hub nut 280 N.m track rod ball joint nut 37 N.m WARNING In order to prevent irreversible damage to the front hub bearing: - Do not loosen or tighten the driveshaft nut when the wheels are on the ground.
  • Page 422 DRIVESHAFTS Front right-hand driveshaft: Removal - Refitting a Remove the bolts from the base of the right-hand a Refit a new right-hand differential output seal (see shock absorber (7) . 21A, Manual gearbox, Differential output seal: Removal - Refitting, page 21A-2) . a Push back the front right-hand driveshaft from the stub axle carrier using the toolsand.

  • Page 423: Relay Shaft Bearing: Removal - Refitting 29A-6

    DRIVESHAFTS Relay shaft bearing: Removal - Refitting REMOVAL REFITTING I - REFITTING PREPARATION OPERATION I - REMOVAL PREPARATION OPERATION a parts always to be replaced: Relay shaft bearing. a Position the vehicle on a two-post lift (see Vehicle: parts always to be replaced: relay bearing rub- Towing and lifting) (02A, Lifting equipment).

  • Page 424: Front Driveshaft Gaiter, Wheel Side: Removal - Refitting

    DRIVESHAFTS Front driveshaft gaiter, wheel side: Removal - Refitting II - REMOVAL OPERATION Special tooling required Emb. 880 Pin extractor tool. 109634 Big securing clip 93034 Small securing clip Driveshaft gaiter Ball hub Stub axle bowl Ball race Driveshaft Balls Lock ring IMPORTANT Wear leaktight gloves (Nitrile type) for this opera-...
  • Page 425 DRIVESHAFTS Front driveshaft gaiter, wheel side: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION WARNING Never use thinner to clean the components. Note: It is essential to use the prescribed volume of grease (see ) . 115192 a Pull out the stub axle bowl using the (11) and the ex- a parts always to be replaced: Front driveshaft tractor (Emb.
  • Page 426 DRIVESHAFTS Front driveshaft gaiter, wheel side: Removal - Refitting CAILLEAU « click » clips 109768 2910 a Tighten the small clip (13) and the big clip (14) until a Lightly lubricate the driveshaft using the GREASE they click, using the tool. supplied with the gaiter to facilitate its fitting.
  • Page 427 DRIVESHAFTS Front driveshaft gaiter, wheel side: Removal - Refitting Position 1 - Pre-tightening and positioning of the clip 2911 a Put the linkage (17) in the lower position, and close the pliers fully. The pre-tightened clip slides onto the gaiter and can be positioned. Position 2 - Tightening 2912 a Put the linkage (17) in the upper position, and close...

  • Page 428: Front Right-Hand Driveshaft Gaiter, Gearbox Side: Removal - Refitting

    DRIVESHAFTS Front right-hand driveshaft gaiter, gearbox side: Removal - Refitting II - REMOVAL OPERATION Equipment required parts washer 109767 Deflector 128487 Driveshaft Relay shaft bearing Driveshaft yoke sleeve Spider Driveshaft gaiter Small securing clip Big securing clip Lock ring IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 429 DRIVESHAFTS Front right-hand driveshaft gaiter, gearbox side: Removal - Refitting 109408 109409 a Remove the driveshaft yoke sleeve (3) . a Remove the lock ring (9) using circlip pliers (10) . Note: - Since the driveshaft yoke sleeve does not have a stop tab, it can be removed without being forced.
  • Page 430 DRIVESHAFTS Front right-hand driveshaft gaiter, gearbox side: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Front right-hand driveshaft gaiter, gearbox side. a parts always to be replaced: gearbox side front driveshaft seal locking ring. a Always replace: - the big securing clip, - the small securing clip.
  • Page 431 DRIVESHAFTS Front right-hand driveshaft gaiter, gearbox side: Removal - Refitting a Position the gaiter lip into the groove of the yoke OETIKER clips sleeve. Note: Check that the gaiter lip is correctly positioned in the groove of the driveshaft. a Fit: - the small securing clip on the driveshaft gaiter, - the big securing clip on the driveshaft gaiter.
  • Page 432 DRIVESHAFTS Front right-hand driveshaft gaiter, gearbox side: Removal - Refitting Position 2 - Tightening 2912 a Put the linkage (15) in the upper position, and close the pliers fully. III - FINAL OPERATION a Refit the front right-hand driveshaft (see 29A, Drive- shafts, Front right-hand driveshaft: Removal - Refitting, page 29A-4) .

  • Page 433: Front Left-Hand Driveshaft Gaiter, Gearbox Side: Removal - Refitting

    DRIVESHAFTS Front left-hand driveshaft gaiter, gearbox side: Removal - Refitting II - REMOVAL OPERATION Equipment required parts washer 128413 109401 Big securing clip Small securing clip Driveshaft gaiter Driveshaft yoke sleeve Lock ring Spider Cup spring Deflector (10) Driveshaft 128414 IMPORTANT a Cut the big securing clip (1) and the small securing Wear leaktight gloves (Nitrile type) for this opera-...
  • Page 434 DRIVESHAFTS Front left-hand driveshaft gaiter, gearbox side: Removal - Refitting 109408 109409 a Remove the driveshaft yoke sleeve (4) . a Remove the lock ring (5) using circlip pliers. Note: - Since the driveshaft yoke sleeve does not have a stop tab, it can be removed without being forced, - do not remove the rollers from their respective bushings as the rollers and needles are matched...
  • Page 435 DRIVESHAFTS Front left-hand driveshaft gaiter, gearbox side: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Front left-hand driveshaft gaiter, gearbox side. a parts always to be replaced: gearbox side front driveshaft seal locking ring. a Always replace: - the cup, - the cup spring,...
  • Page 436 DRIVESHAFTS Front left-hand driveshaft gaiter, gearbox side: Removal - Refitting 90392 a Insert a smooth rod with a rounded end between the gaiter and driveshaft to control the amount of air in- side the joint. a Fit: 128410 - the small securing clip on the driveshaft gaiter, a Refit: - the big securing clip on the driveshaft gaiter.
  • Page 437 DRIVESHAFTS Front left-hand driveshaft gaiter, gearbox side: Removal - Refitting OETIKER clips Position 2 - Tightening 2912 a Put the linkage (15) in the upper position, and close the pliers fully. III - FINAL OPERATION 96048 a Refit the front left-hand driveshaft (see 29A, Drive- a Tighten the small clip (13) and the big clip (14) using shafts, Front left-hand driveshaft: Removal - Re- the tool.
  • Page 438 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 439 DUSTER - Chapitre 3 DUSTER - Chapitre 3ContentsPages Contents Pages GENERAL INFORMATION FRONT AXLE COMPONENTS Brake circuit: Operating Front brake calliper: Removal diagram 30A-1 - Refitting 31A-7 Brake circuit: Precautions for Front brake calliper: Repair 31A-9 the repair 30A-2 Front brake calliper Braking circuit: Bleed 30A-4 mounting: Removal -...
  • Page 440 Contents FRONT AXLE COMPONENTS WHEELS AND TYRES Filter unit assembly: Tyre: Precautions f o r the Removal - Refitting 31A-38 repair 35A-7 Front driveshaft lower arm: Tyres: Identifi cation 35A-8 Removal - Refitting 31A-39 Tyres: Remov al - Refitting 35A-9 Front driveshaft lower arm Tyre: Repair 35A-11...
  • Page 441 Contents POWER ASSISTED STEERING MECHANICAL COMPONENT CONTROLS Power-assisted steering Clutch control: List and pump pulley: Removal - location of components 37A-31 Refitting 36B-12 Clutch pedal: Removal - Power-assisted steering Refitting 37A-33 pump assembly: Removal - Clutch pedal switch: Refitting 36B-13 Removal - Refitting 37A-35 Power-assisted steering...

  • Page 442: General Information

    GENERAL INFORMATION Brake circuit: Operating diagram « 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.

  • Page 443: Brake Circuit: Precautions For The Repair

    Use brake fluids that comply with the Renault standard (see Vehicle: Parts and consumables for the repair) IMPORTANT Check the brake fluid levels in the braking circuit and To avoid any accident, bring the pistons, brake pads the bleeding device.
  • Page 444 - 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 consumables for the repair) (04B, Consumables - Products),...

  • Page 445: Braking Circuit: Bleed

    GENERAL INFORMATION Braking circuit: Bleed Equipment required 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 the repair, page 30A-2) .
  • Page 446 Braking circuit: Bleed a Connect the brake circuit bleeding device (after a Remove the brake circuit bleeding device from having received Renault approval) to the master cyl- the master cylinder reservoir. inder reservoir (see the instructions for the equip- a Check pedal travel and resistance. If it is not correct, ment).

  • Page 447: Brake Circuit: Tightening Torque

    GENERAL INFORMATION Brake circuit: Tightening torque I - FRONT AND REAR BRAKES Description Tightening torque (N.m) Front calliper bleed screw Rear cylinder bleed screw Front calliper inlet brake hose Rear cylinder inlet brake pipes Brake hose on brake pipe Front brake guide pin bolt Brake pipe on compensator Brake pipe on master cylinder Brake pipe on hose...

  • Page 448: Rigid Brake Pipe: Repair

    GENERAL INFORMATION Rigid brake pipe: Repair Equipment required compressed air nozzle Tightening torquesm brake pipe bolts 8 N.m u n d e r b o d y u n i o n s 6 N.m (female/male) This procedure applies to copper pipes diameter 4.7 128666 Note: This procedure does not apply to:...
  • Page 449 GENERAL INFORMATION Rigid brake pipe: Repair 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 N.m). III - CHECKING THE RIVETS 128668 a Visually check that the internal diameter of the pipe is not oval-shaped.
  • Page 450 GENERAL INFORMATION Rigid brake pipe: Repair 128659 a Measure the dimensions (X3) (in mm) curve after curve, between each curve radius « centre » (1) of the old pipe. 30A-9...
  • Page 451 GENERAL INFORMATION Rigid brake pipe: Repair 128814 WARNING T o 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 alterna- tively to reach the correct curve radius.
  • Page 452 GENERAL INFORMATION Rigid brake pipe: Repair V - CHECKING BENDING VI - REFITTING THE PIPE 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.

  • Page 453: Brake Fluid: Specifications

    - 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 consumables for the repair) . 30A-12...

  • Page 454: Brake: Specifications

    GENERAL INFORMATION Brake: Specifications Front brakes (mm) Piston diameter Disc diameter Disc thickness Minimum disc thickness (1) 21.8 19.8 Maximum disc run-out 0.07 Brake lining thickness (including backplate) 17.8 17.4 Minimum brake lining thickness (including backplate) Rear brakes (mm) Piston diameter Drum diameter 228.5 Maximum drum wear diameter...

  • Page 455: Steering: Tightening Torque

    GENERAL INFORMATION Steering: Tightening torque Description Tightening torque (N.m) Steering column nut Universal joint bolt Track rod end nut Axial ball joint Description Tightening torque (N.m) Wheel alignment lock nut Steering box bolt Description Tightening torque (N.m) Pressure switch on high pressure pipe High and low pressure pipe union on steering rack...

  • Page 456: Axle Assemblies: Check

    GENERAL INFORMATION Axle assemblies: Check a Lock the slip plates of the lift. a Position the vehicle on a lift (see Vehicle: Towing and lifting) . a Check the condition of the following components: - track rods, - axial ball joint linkages, - subframe, - lower arm rubber bushes, - lower arm ball joints (see 31A, Front axle compo-...

  • Page 457: Front Axle System: Tightening Torque

    GENERAL INFORMATION Front axle system: Tightening torque 145734 Description Tightening torque (N.m Lower arm bolt Subframe tie-rod lower bolt Anti-roll bar bearing bolt Calliper support bolt Front sub-frame bolt Steering box bolt on the subframe (10) Front subframe bracket bolt Description Tightening torque (N.m) «...
  • Page 458 GENERAL INFORMATION Front axle system: Tightening torque 109719 Description Tightening torque (N.m) (12) Shock absorber nut for spring cup (14) Lower arm ball joint bolt or nut (15) Driveshaft nut (16) Wheel bolts (18) Axial ball joint mounting on the steering rack (19) Disc bolt Description...

  • Page 459: Front Axle System: Adjustment

    GENERAL INFORMATION Front axle system: Adjustment 2 - Castor angle a Not adjustable. Equipment required flywheel immobiliser 3 - Camber a Not adjustable. Tightening torquesm 4 - Pivot wheel alignment adjust- 53 N.m a Not adjustable. ment lock nuts I - ADJUSTMENT PREPARATION STAGE a Check the geometry (see 30A, General informa- tion, Axle assemblies: Check, page 30A-15) .

  • Page 460: Rear Axle System: Tightening Torque

    GENERAL INFORMATION Rear axle system: Tightening torque 109717 Description Tightening torque (N.m) Rubber bush nut Rigid brake pipe on brake cylinder Rigid pipe union on hose Description Tightening torque (N.m) Drum nut Bearing bolt Shock absorber lower bolt Brake back-plate bolts on the rear axle Wheel speed sensor bolt 30A-19...

  • Page 461: Front Axle Components

    FRONT AXLE COMPONENTS Front axle components: Precautions for the repair I - SAFETY III - GENERAL RECOMMENDATIONS 1 - Advice to be followed before any operation 1 - Bearing, hub carrier For an operation requiring the use of a lift, follow the safety advice (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 462 FRONT AXLE COMPONENTS Front axle components: Precautions for the repair 2 - Suspension spring 4 - Front axle When replacing the spring, ensure that the positioning and orientation of the spring and the tool cups are cor- WARNING rect. To prevent any damage, do not use the lower arm When replacing a spring, always replace the spring on as support for the lifting system.

  • Page 463: Front Brake Pads: Removal - Refitting

    FRONT AXLE COMPONENTS Front brake pads: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm guide pin bolt 34 N.m When replacing brake pads, be sure to replace the pads on the opposite side. IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 31A, F ront axle components, Front...
  • Page 464 FRONT AXLE COMPONENTS Front brake pads: Removal - Refitting III - FINAL OPERATION REFITTING a Refit the front wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) . I - REFITTING PREPARATION OPERATION a Check the thickness of the front brake pads (see IMPORTANT 30A, General information, Brake: Specifications, To avoid any accident, bring the pistons, brake...

  • Page 465: Front Brake Hose: Removal - Refitting

    FRONT AXLE COMPONENTS Front brake hose: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Equipment required pedal press IMPORTANT Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 31A, F ront axle components, Front axle components: Precautions for the repair, page 31A-1) .
  • Page 466 FRONT AXLE COMPONENTS Front brake hose: Removal - Refitting a Set the wheels straight ahead. a Refit the brake hose at the calliper end. a Torque tighten the brake hose (see 30A, General information, Brake circuit: Tightening torque, page 30A-6) a Clip the brake hose cap on to the base of the shock absorber, aligning the marks made using a perma- nent marker.

  • Page 467: Front Brake Calliper: Removal - Refitting

    FRONT AXLE COMPONENTS Front brake calliper: Removal - Refitting a Remove the front wheel on the side concerned (see 35A, Wheels and tyres, Wheel: Removal - Refit- Equipment required ting, page 35A-1) . pedal press II - REMOVAL OPERATION a Release the brake hose from the front brake calliper. Tightening torquesm a Remove the brake pads (see 31A, Front axle com- guide pin upper bolt...
  • Page 468 FRONT AXLE COMPONENTS Front brake calliper: Removal - Refitting a Always replace the guide pin bolts each time they are removed. II - REFITTING OPERATION a Without using a tool, screw the calliper to the brake hose as tightly as possible. a Refit the guide pin upper bolt.

  • Page 469: Front Brake Calliper: Repair

    FRONT AXLE COMPONENTS Front brake calliper: Repair II - REPAIR OPERATION FOR PART CONCERNED Equipment required pedal press IMPORTANT Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 31A, F ront axle components, Front axle components: Precautions for the repair, page 31A-1) .
  • Page 470 FRONT AXLE COMPONENTS Front brake calliper: Repair 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, - the dust seal.

  • Page 471: Front Brake Calliper Mounting: Removal - Refitting

    FRONT AXLE COMPONENTS Front brake calliper mounting: Removal - Refitting Tightening torquesm front brake calliper sup- 105 N.m port bolts guide pin upper bolt 34 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 31A, F ront axle components, Front axle components: Precautions for the repair,...
  • Page 472 FRONT AXLE COMPONENTS Front brake calliper mounting: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Clean using a wire brush and BRAKE CLEANER (see Vehicle: Parts and consumables for the re- pair) (04B, Consumables - Products): - the front brake calliper mounting, - the front brake calliper, - the hub carrier.

  • Page 473: Front Brake Disc Protector: Removal - Refitting

    FRONT AXLE COMPONENTS Front brake disc protector: Removal - Refitting WHEEL DISC PROTECTOR Tightening torquesm bolts of the front brake 7 N.m disc protector IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 31A, F ront axle components, Front axle components: Precautions for the repair,...
  • Page 474 FRONT AXLE COMPONENTS Front brake disc protector: Removal - Refitting WHEEL DISC PROTECTOR REFITTING I - REFITTING PREPARATION OPERATION a Using a wire brush and SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) clean the hub carri- II - REFITTING OPERATION a Refit the brake disc protector.

  • Page 475: Front Brake Disc: Removal - Refitting

    FRONT AXLE COMPONENTS Front brake disc: Removal - Refitting Equipment required indelible pencil parts washer 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-13) . IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera-...
  • Page 476 FRONT AXLE COMPONENTS Front brake disc: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 125059 a Remove the brake pads (see 31A, Front axle com- ponents, Front brake pads: Removal - Refitting, 125056 page 31A-3) a Remove: a Remove the "brake calliper mounting - brake calli- per"...
  • Page 477 FRONT AXLE COMPONENTS Front brake disc: Removal - Refitting III - FINAL OPERATION a Refit the "brake calliper mounting - brake calliper" assembly (see 31A, Front axle components, Front brake calliper mounting: Removal - Refitting, page 31A-11) . a Refit the brake pads (see 31A, Front axle compo- nents, Front brake pads: Removal - Refitting, page 31A-3) a Set the wheels straight ahead.

  • Page 478: Front Brake Disc: Description

    FRONT AXLE COMPONENTS Front brake disc: Description I - PREPARATION OPERATION FOR CHECK Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). Remove the wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) . II - CHECKING OPERATION FOR PART CONCERNED Note:...

  • Page 479: Hydraulic Unit - Master Cylinder Brake Pipe: Removal - Refitting

    FRONT AXLE COMPONENTS Hydraulic unit - master cylinder brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM Equipment required pedal press Tightening torquesm brake pipe unions on 14 N.m the hydraulic unit brake pipe unions on 14 N.m the master cylinder IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera-...
  • Page 480 FRONT AXLE COMPONENTS Hydraulic unit - master cylinder brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM a Bleed the brake circuit (see 30A, General informa- tion, Braking circuit: Bleed, page 30A-4) . 117829 a Undo the brake pipe unions (3) on the master cylin- der.

  • Page 481: Hydraulic Unit - Underbody Union Brake Pipe: Removal - Refitting

    FRONT AXLE COMPONENTS Hydraulic unit - underbody union brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM Equipment required pedal press Tightening torquesm brake pipe unions on 14 N.m the hydraulic unit brake pipe unions on 14 N.m the underbody unions IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera-...
  • Page 482 FRONT AXLE COMPONENTS Hydraulic unit - underbody union brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM - the brake pipe unions on the underbody unions. a Torque tighten: - the brake pipe unions on the hydraulic unit (14 N.m), - the brake pipe unions on the underbody unions (14 N.m).

  • Page 483: Hydraulic Unit - Front Left-Hand Calliper Brake Pipe: Removal - Refitting

    FRONT AXLE COMPONENTS Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM Equipment required pedal press Tightening torquesm brake pipe union on the 14 N.m hydraulic unit brake pipe union on the 14 N.m brake hose IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera-...
  • Page 484 FRONT AXLE COMPONENTS Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM a Bleed the brake circuit (see 30A, General informa- tion, Braking circuit: Bleed, page 30A-4) . a Refit the front left-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A- 117819 a Undo the brake pipe union (3) on the hydraulic unit.

  • Page 485: Hydraulic Unit - Front Right-Hand Calliper Brake Pipe: Removal - Refitting

    FRONT AXLE COMPONENTS Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM Equipment required pedal press Tightening torquesm brake pipe union on the 14 N.m hydraulic unit brake pipe union on the 14 N.m brake hose IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera-...
  • Page 486 FRONT AXLE COMPONENTS Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting ANTI-LOCK BRAKING SYSTEM a Bleed the braking circuit (see 30A, General infor- mation, Braking circuit: Bleed, page 30A-4) . a Refit the front right-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A- 1) .

  • Page 487: Front Driveshaft Hub Carrier: Removal - Refitting

    FRONT AXLE COMPONENTS Front driveshaft hub carrier: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm ANTI-LOCK BRAKING SYSTEM shock absorber base 105 N.m a Remove the wheel speed sensor (depending on the bolts vehicle equipment) (see 38C, Anti-lock braking system, Front wheel speed sensor: Removal - nut or bolt of the lower 62 N.m...
  • Page 488 FRONT AXLE COMPONENTS Front driveshaft hub carrier: Removal - Refitting WARNING In order to prevent irreversible damage to the front hub bearing: - Do not loosen or tighten the driveshaft nut when the wheels are on the ground. - Do not place the vehicle with its wheels on the ground when the driveshaft has been loosened or removed.
  • Page 489 FRONT AXLE COMPONENTS Front driveshaft hub carrier: Removal - Refitting WHEEL DISC PROTECTOR a Refit the brake disc protector (see 31A, Front axle components, Front brake disc protector: Re- moval - Refitting, page 31A-13) . a Refit: - the brake disc (see 31A, Front axle components, Front brake disc: Removal - Refitting, page 31A- 15) , - the hub nut.

  • Page 490: Front Hub Carrier Bearing: Removal - Refitting

    FRONT AXLE COMPONENTS Front hub carrier bearing: Removal - Refitting - the front driveshaft hub carrier (see 31A, Front axle components, Front driveshaft hub carrier: IMPORTANT Removal - Refitting, page 31A-27) . To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- II - REMOVAL OPERATION tion recommendations before carrying out any...
  • Page 491 FRONT AXLE COMPONENTS Front hub carrier bearing: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Front hub carrier bearing. a parts always to be replaced: Front stub axle car- rier bearing rubber ring. WARNING To ensure that the wheel speed sensor works properly, do not mark the sensor target on the...
  • Page 492 FRONT AXLE COMPONENTS Front hub carrier bearing: Removal - Refitting a Apply a fitting force of 50,000 N to ensure that the II - REFITTING OPERATION bearing is correctly fitted on the hub carrier shoulder. 141795 20789 a Refit: - the hub using a tube with an external diameter of 55 mm, - the elastic ring on the front driveshaft hub carrier.

  • Page 493: Front Shock Absorber And Spring: Removal - Refitting

    FRONT AXLE COMPONENTS Front shock absorber and spring: Removal - Refitting Equipment required indelible pencil spring compressor Tightening torquesm internal nut of the shock 62 N.m absorber rod shock absorber nut on 44 N.m the body shock absorber base 105 N.m bolts brake hose mounting 8 N.m...
  • Page 494 FRONT AXLE COMPONENTS Front shock absorber and spring: Removal - Refitting 144756 108978 a Remove the nut (5) of the anti-roll bar tie-rod on the a Remove: shock absorber. - the shock absorber cage with a male Allen key and a ring spanner, II - REMOVAL OPERATION - the cage (8) ,...
  • Page 495 FRONT AXLE COMPONENTS Front shock absorber and spring: Removal - Refitting II - REFITTING OPERATION 117228 95435 a Remove the shock absorber rod with a male Allen a Place the spring compressor in a vice. key and a ring spanner. a Separate the various components which make up Note: the «...
  • Page 496 FRONT AXLE COMPONENTS Front shock absorber and spring: Removal - Refitting 108979 a Insert the spring in the neck of the cup. 31A-36...
  • Page 497 FRONT AXLE COMPONENTS Front shock absorber and spring: Removal - Refitting III - FINAL OPERATION a Refit the brake hose mounting. a Torque tighten the brake hose mounting bolt (8 N.m). a Clip the brake hose cap onto the support. a Clip the speed sensor onto the support.
  • Page 498 FRONT AXLE COMPONENTS Filter unit assembly: Removal - Refitting II - REMOVAL OPERATION IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 31A, F ront axle components, Front axle components: Precautions for the repair, page 31A-1) .

  • Page 499: Front Axle Components

    FRONT AXLE COMPONENTS Front driveshaft lower arm: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm front and rear bolts 180 N.m mounting the lower arm on the subframe lower arm ball joint nut 62 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 31A, F ront axle components, Front...
  • Page 500 FRONT AXLE COMPONENTS Front driveshaft lower arm: Removal - Refitting - the front wheel on the side in question (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) . a Check the values of the axle assemblies (see Front axle assembly: Adjustment values) .

  • Page 501: Front Driveshaft Lower Arm Ball Joint: Check

    FRONT AXLE COMPONENTS Front driveshaft lower arm ball joint: Check 3 - Checking the play of the lower arm ball joint CHECK CHECKING THE FRONT DRIVESHAFT LOWER ARM BALL JOINT a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

  • Page 502: Front Axle Subframe: Removal - Refitting

    FRONT AXLE COMPONENTS Front axle subframe: Removal - Refitting a Disconnect the battery (see Battery: Removal - Re- Special tooling required fitting) (80A, Battery). a Remove the front wheels (see 35A, Wheels and ty- Mot. 1390 Support for removal - refitting of engine - gearbox assembly res, Wheel: Removal - Refitting, page 35A-1) .
  • Page 503 FRONT AXLE COMPONENTS Front axle subframe: Removal - Refitting 108353 116657 a Remove: a Remove the heat shield bolts (6) on the steering box. - the subframe tie-rod upper bolts (3) , a Remove: - the bolts or nuts (4) of the lower ball joints. - the steering box heat shield, a Remove the lower ball joints.
  • Page 504 FRONT AXLE COMPONENTS Front axle subframe: Removal - Refitting 144755 145808 a Remove the bolts (10) of the front axle subframe a Strap the subframe to (Mot. 1390). brackets. a Raise the lift to separate the subframe from the a Unclip the oxygen sensor wiring on the heat shield. body.
  • Page 505 FRONT AXLE COMPONENTS Front axle subframe: Removal - Refitting a Refit the rear suspended engine mounting (see Lower engine tie-bar: Removal - Refitting) (19D, Engine mounting). a Refit the power-assisted steering low pressure pipe on the subframe. a Torque tighten the power-assisted steering low pressure pipe bolt on the subframe (21 N.m).

  • Page 506: Front Anti-Roll Bar: Removal - Refitting

    FRONT AXLE COMPONENTS Front anti-roll bar: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm anti-roll bar tie rod nuts 44 N.m anti-roll bar bearing 21 N.m bolts Anti-roll bar specifications: Ø of the bar in mm Black IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 31A, F ront axle components, Front...

  • Page 507: Rear Axle Components

    REAR AXLE COMPONENTS Rear axle components: Precautions for the repair I - SAFETY 3 - Suspension spring When replacing the spring, ensure that the positioning For an operation requiring the use of a lift, follow the and orientation of the spring and the spring compres- safety advice (see Vehicle: Towing and lifting) (02A, sor tool cups are correct.

  • Page 508: Rear Brake Lining: Removal - Refitting

    REAR AXLE COMPONENTS Rear brake lining: Removal - Refitting REAR BRAKE BOSCH: 9 INCHES Replace all the brake pads on one axle at the same time. Never mix brake pads of different brands or qual- ities. IMPORTANT Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 30A, General information, Brake cir- cuit: Precautions for the repair, page 30A-2) .
  • Page 509 REAR AXLE COMPONENTS Rear brake lining: Removal - Refitting a Lightly grease the support linkage thread. Note: The brake mechanism components are different on the left and right-hand sides, so it is important not to confuse them. On the left-hand brake: the bolt has a right-hand thread.
  • Page 510 REAR AXLE COMPONENTS Rear brake lining: Removal - Refitting III - FINAL OPERATION a Refit: - the brake drums (see 33A, Rear axle compo- nents, Rear brake drum: Removal - Refitting, page 33A-7) . - the rear wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .

  • Page 511: Rear Brake Cylinder: Removal - Refitting

    REAR AXLE COMPONENTS Rear brake cylinder: Removal - Refitting a Separate the shoes. Equipment required II - REMOVAL OPERATION pedal press a Unscrew the rigid pipe union from the slave cylinder parts washer (be prepared for brake fluid running out). a Fit a cap on the brake pipe union.
  • Page 512 REAR AXLE COMPONENTS Rear brake cylinder: Removal - Refitting III - FINAL OPERATION a Attach the pin from the spring of the wear compen- sation system on the leading shoe. a Refit: - the upper return spring using brake shoe pliers (see 33A, Rear axle components, Rear brake lining: Removal - Refitting, page 33A-2) , - the side retaining springs while holding the con-...

  • Page 513: Rear Brake Drum: Removal - Refitting

    REAR AXLE COMPONENTS Rear brake drum: Removal - Refitting II - REMOVAL OPERATION Equipment required parts washer Tightening torquesm rear brake drum nut 280 N.m IMPORTANT Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 30A, General information, Brake cir- cuit: Precautions for the repair, page 30A-2) .
  • Page 514 REAR AXLE COMPONENTS Rear brake drum: Removal - Refitting a Always replace the brake drum nuts. a parts always to be replaced: rear drum cap. a Replace any faulty parts. a Using a parts washer, clean: - the brake drum linings, - the drum, - the stub axle.

  • Page 515: Rear Brake Drum: Description

    REAR AXLE COMPONENTS Rear brake drum: Description III - FINAL OPERATION Equipment required Replace the rear drums if necessary (see 33A, Rear axle components, Rear brake drum: Removal - Re- sliding calliper fitting, page 33A-7) . Refit the rear wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .

  • Page 516: Rigid Brake Pipe: Removal - Refitting

    REAR AXLE COMPONENTS Rigid brake pipe: Removal - Refitting II - REMOVAL OPERATION Equipment required 1 -Rear left-hand rigid brake pipe pedal press Tightening torquesm rigid brake pipe unions 14 N.m on the brake cylinders rigid brake pipe unions 14 N.m on the rear brake hoses The pipes have a rigid and a flexible section.
  • Page 517 REAR AXLE COMPONENTS Rigid brake pipe: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Always replace the rigid brake pipe mounting clips. II - REFITTING OPERATION a Refit the rear rigid brake pipes in their original posi- tions. a Clip the rear rigid brake pipes on the rear axle.

  • Page 518: Shock Absorber: Removal - Refitting

    REAR AXLE COMPONENTS Shock absorber: Removal - Refitting 4X2 TRANSMISSION II - REMOVAL OPERATION Equipment required component jack Tightening torquesm shock absorber lower 162 N.m bolt shock absorber upper 14 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 33A, Rear axle components, Rear...
  • Page 519 REAR AXLE COMPONENTS Shock absorber: Removal - Refitting 4X2 TRANSMISSION REFITTING I - REFITTING PREPARATION OPERATION a Always replace the rear shock absorber lower bolt . parts always to be replaced: Rear shock absorb- er upper nut. II - REFITTING OPERATION a Refit: - the shock absorber, positioning the shock absorber head in its housing,...

  • Page 520: Rear Suspension Spring: Removal - Refitting

    REAR AXLE COMPONENTS Rear suspension spring: Removal - Refitting 4X2 TRANSMISSION Equipment required component jack Tightening torquesm shock absorber lower 162 N.m bolt 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 33A, Rear axle components, Rear axle components: Precautions for the repair,...
  • Page 521 REAR AXLE COMPONENTS Rear suspension spring: Removal - Refitting 4X2 TRANSMISSION III - FINAL OPERATION a Refit the rear wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) . a Repeat these operations on the opposite side. 108924 a Remove the spring (4) with its lower mounting by re- moving the component jack.

  • Page 522: Rear Axle Rubber Bearing: Removal - Refitting

    REAR AXLE COMPONENTS Rear axle rubber bearing: Removal - Refitting II - REMOVAL OPERATION 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 33A, Rear axle components, Rear axle components: Precautions for the repair, page 33A-1) .
  • Page 523 REAR AXLE COMPONENTS Rear axle rubber bearing: Removal - Refitting 122816 122817 a Fit the joint castor (A) of the. a To refit the rear axle rubber bearings use: a Remove the rubber bearing from the rear axle by hit- - the threaded rod (B) , ting with a hammer on the bush castor (A) of the - the cover (C) ,...
  • Page 524 REAR AXLE COMPONENTS Rear axle rubber bearing: Removal - Refitting a Check that the marks (M1) and (M2) are correctly aligned. a Remove the tool. III - FINAL OPERATION a Refit: - the complete rear axle (see 33A, Rear axle com- ponents, Complete rear axle system: Removal - Refitting, page 33A-19) , - the rear brake drums (see 33A, Rear axle compo-...

  • Page 525: Complete Rear Axle System: Removal - Refitting

    REAR AXLE COMPONENTS Complete rear axle system: Removal - Refitting 4X2 TRANSMISSION Equipment required pedal press component jack safety strap(s) Tightening torquesm bearing bolts 105 N.m rigid pipe unions on the 14 N.m brake cylinders rigid pipe unions on the 14 N.m hoses 98992...
  • Page 526 REAR AXLE COMPONENTS Complete rear axle system: Removal - Refitting 4X2 TRANSMISSION 108926 108923 a Loosen the bearing bolts (8) . a Unscrew the unions of the rigid pipes on the flexible a Lower the rear axle with the component jack. brake pipes (4) .
  • Page 527 REAR AXLE COMPONENTS Complete rear axle system: Removal - Refitting 4X2 TRANSMISSION a Refit the brake drums (see 33A, Rear axle compo- nents, Rear brake drum: Removal - Refitting, page 33A-7) . a Refit the cables and the wheel speed sensors (if fit- ted to the vehicle).

  • Page 528: Wheels And Tyres

    WHEELS AND TYRES Wheel: Removal - Refitting The removal - refitting procedure is the same for all wheels. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Release the parking brake.
  • Page 529 WHEELS AND TYRES Wheel: Removal - Refitting If this procedure does not work: 124750 106089 a Coat the wheel-mating face (3) with COPPER ANTI- a Strike the inner surface of the wheel (2) using a mal- SEIZE AGENT (see Vehicle: Parts and consum- let and a wooden block to detach it.
  • Page 530 WHEELS AND TYRES Wheel: Removal - Refitting a Pretighten the wheel bolts to 30 N.m, with the wheel suspended, starting with the bolts at the bottom. a Rotate the wheel through 180˚ to bring the valve into the bottom position. a Position the vehicle on its wheels.

  • Page 531: Wheel: Balancing

    WHEELS AND TYRES Wheel: Balancing 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.
  • Page 532 WHEELS AND TYRES Wheel: Balancing 113742 105871 a The wheel is fitted on the wheel balancer as follows: Steel wheel with flange - (5) ring, Alloy wheel with flange - (6) wheel balancer back-plate, Alloy wheel without flange - (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;...
  • Page 533 WHEELS AND TYRES Wheel: Balancing a Enter the specific wheel parameters when starting the wheel balancer. a Start the wheel balancer and check the wheel bal- ance, which should be 0 g on each plane of the wheel. a If this is not the case, remove the old wheel balanc- ing weights and repeat the wheel balancing proce- dure, checking that the wheel balance equals 0 on each wheel plane.

  • Page 534: Tyre: Precautions For The Repair

    WHEELS AND TYRES Tyre: Precautions for the repair I - CLEANLINESS Clean: - the tyre bead, - the tyre bead/wheel rim contact surface. Remove any grit trapped in the tyre treads. Clean the bearing surfaces on: - the wheels, - the discs, - the hubs.

  • Page 535: Tyres: Identification

    WHEELS AND TYRES Tyres: Identification Example of a tyre identification mark: 205/65 R 15 91 Speed code table: Code Maximum s p e e d mph (km/h) above 240 101008 123448 Tyre width in mm (L) Height/width ratio Radial structure Internal diameter in inches (c) Load index Speed code...

  • Page 536: Tyres: Removal - Refitting

    WHEELS AND TYRES Tyres: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the wheel in question (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) , - the balance weights, - the valve mechanism.
  • Page 537 WHEELS AND TYRES Tyres: Removal - Refitting III - FINAL OPERATION a Refit the valve mechanism. a Inflate the tyre to the recommended pressure (see Tyre pressure: Identification) . Note: It is not necessary to drive the vehicle before and after a new wheel is balanced.

  • Page 538: Tyre: Repair

    WHEELS AND TYRES Tyre: Repair Perforation LCV load index less There are two types of perforation: than or equal to - single perforation: perforation caused by nail etc. not requiring a reinforced tyre boot and which can be re- HGV load index paired when the tyres are cold, 122 to 177 (inc.) - damage: rubber detachment etc.
  • Page 539 WHEELS AND TYRES Tyre: Repair 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 a Choose the size of plug (mushroom type plug) de- Before carrying out the repair, clean the inner surface of the tyre and the valve with water.
  • Page 540 WHEELS AND TYRES Tyre: Repair 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).

  • Page 541: Wheel Rim: Identification

    WHEELS AND TYRES Wheel rim: Identification IDENTIFICATION 2 - Installation diameter for the wheel bolts 1 - Marking There are two types of identification marking on the 3 - Rim run-out wheel rims: The maximum run-out is measured at the wheel rim edge (7) .

  • Page 542: Emergency Spare Wheel Carrier: Removal - Refitting

    WHEELS AND TYRES Emergency spare wheel carrier: Removal - Refitting 4X2 TRANSMISSION REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). II - OPERATION FOR REMOVAL OF PART CONCERNED 145187 a Unhook the handle (2) of the emergency spare...
  • Page 543 WHEELS AND TYRES Emergency spare wheel carrier: Removal - Refitting 4X2 TRANSMISSION REFITTING I - REFITTING PREPARATION OPERATION a Always replace the lock washers. II - REFITTING OPERATION FOR PART CONCERNED a Refit the arms of the emergency spare wheel carrier on the body mountings.

  • Page 544: Steering Assembly

    STEERING ASSEMBLY Steering: List and location of components 145659 Track rod Axial ball joint linkage Steering column Steering box gaiter Steering column adjustment lever 36A-1...

  • Page 545: Steering: Precautions For The Repair

    STEERING ASSEMBLY Steering: Precautions for the repair I - SAFETY 2 - Seals To ensure a sound power-assisted steering circuit 1 - Advice to be followed before any operation seal, replace the power-assisted steering pipe seals each time a pipe is removed. For an operation requiring the use of a lift, follow the safety advice (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 546 STEERING ASSEMBLY Steering: Precautions for the repair The axial ball joint limiters (1) are colour coded for fool- proofing purposes. When removing or replacing the ax- ial ball joint, check that the limiter with the correct colour code is refitted. 6 - Power-assisted steering pump Do not run the engine without steering fluid in the cir- cuit.

  • Page 547: Track Rod: Removal - Refitting

    STEERING ASSEMBLY Track rod: Removal - Refitting Tightening torquesm track rod ball joint nut 37 N.m wheel alignment adjust- 53 N.m ing lock nut IMPORTANT Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 36A, Steering assembly, Steering: Precautions for the repair, page 36A-2) .

  • Page 548: Axial Ball Joint Linkage: Removal - Refitting

    STEERING ASSEMBLY Axial ball joint linkage: Removal - Refitting Tightening torquesm axial ball joint 80 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the front wheel on the side concerned (see 35A, Wheels and tyres, Wheel: Removal - Refit- ting, page 35A-1) .
  • Page 549 STEERING ASSEMBLY Axial ball joint linkage: Removal - Refitting II - REFITTING OPERATION 108414 a Coat the threading of the axial ball joint with HIGH STRENGTH THREAD LOCK (see Vehicle: Parts and consumables for the repair) . a Refit the axial ball joint (1) . a Torque tighten the axial ball joint (80 N.m) using the tool.

  • Page 550: Steering Column: Removal - Refitting

    STEERING ASSEMBLY Steering column: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm universal joint bolt 21 N.m steering column nuts 21 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 36A, Steering assembly, Steering: Precautions for the repair, page 36A-2) .
  • Page 551 STEERING ASSEMBLY Steering column: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the ignition switch (see Ignition switch: Re- moval - Refitting) . (82A, Immobiliser). a Refit a new cam nut for the universal joint on the steering column a Lock the cam nut in its housing (opening on the uni- versal joint).

  • Page 552: Steering Box Gaiter: Removal - Refitting

    STEERING ASSEMBLY Steering box gaiter: Removal - Refitting - the retaining clip. REMOVAL a Clean the contact surfaces between the steering box and the gaiter using SURFACE CLEANER (see Ve- I - REMOVAL PREPARATION OPERATION hicle: Parts and consumables for the repair) a Position the vehicle on a two-post lift (see Vehicle: (04B, Consumables - Products).

  • Page 553: Bulkhead Seal: Removal - Refitting

    STEERING ASSEMBLY Bulkhead seal: Removal - Refitting REFITTING IMPORTANT I - REFITTING OPERATION FOR PART To avoid all risk of damage to the systems, apply CONCERNED the safety and cleanliness instructions and opera- a Fit the bulkhead seal in its original position. tion recommendations before carrying out any repair (see 36A, Steering assembly, Steering: a Clip the bulkhead seal onto the steering box.

  • Page 554: Steering Column Adjustment Handle: Removal - Refitting

    STEERING ASSEMBLY Steering column adjustment handle: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see ) (80A, Battery). a Remove: - the bolts on the steering wheel lower cover, - the half covers under the steering wheel (see In- strument panel: Removal - Refitting) (83A, In- strument panel), - the immobiliser ring.
  • Page 555 STEERING ASSEMBLY Steering column adjustment handle: Removal - Refitting a Refit: REFITTING - the immobiliser ring, I - REFITTING PREPARATION OPERATION - the half covers under the steering wheel (see In- strument panel: Removal - Refitting) (83A, In- strument panel), - the bolts on the steering wheel lower cover.

  • Page 556: Steering Wheel: Removal - Refitting

    STEERING ASSEMBLY Steering wheel: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm new steering wheel bolt 44 N.m IMPORTANT Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 36A, Steering assembly, Steering: Precautions for the repair, page 36A-2) .
  • Page 557 STEERING ASSEMBLY Steering wheel: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 105327 WARNING In order not to damage the steering wheel or steering column, the steering wheel-column fool- proofing devices must be aligned. a Refit the steering wheel. a Connect the connectors.

  • Page 558: Power Assisted Steering

    Remove the hose clamp. a Lower the vehicle. a Fill the power-assisted steering circuit with ELF RENAULT MATIC D2 oil (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). a Bleed the circuit by turning the steering wheel from lock to lock with the engine switched off in the first in- stance.
  • Page 559 (21 N.m). a Remove the hose clamp. a Fill the power-assisted steering circuit with ELF RENAULT MATIC D2 oil (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). a Bleed the circuit by turning the steering wheel from lock to lock with the engine switched off in the first in- stance.
  • Page 560 POWER ASSISTED STEERING Power-assisted steering pump pressure: Check K9K, and AIR CONDITIONING a Lower the vehicle. a Fill up the power assisted steering oil circuit (type: Tightening torquesm ELF RENAULTMATIC D2). bolt mounting the high 25 N.m a Bleed the circuit by turning the steering wheel from pressure pipe union on lock to lock with the engine switched off at first.
  • Page 561 POWER ASSISTED STEERING Power-assisted steering pump pressure: Check K9K, and AIR CONDITIONING - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection), - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front left-hand wheel (see 35A, Wheels and ty- res, Wheel: Removal - Refitting, page 35A-1) .

  • Page 562: Power-Assisted Steering Pump: Removal - Refitting

    POWER ASSISTED STEERING Power-assisted steering pump: Removal - Refitting K9K, and STANDARD HEATING RECIRCULA TION Special tooling required Ms. 583 Pipe clamps. Tightening torquesm power-assisted steering 21 N.m pump bolts power-assisted steering 21 N.m pump high pressure union power assisted steering 21 N.m pump support bolt on the sump...

  • Page 563: Power-Assisted Steering

    Fill the power-assisted steering circuit with ELF Also, do not remove the components from their RENAULT MATIC D2 oil (see Vehicle: Parts and packaging until they are to be fitted to the vehi- consumables for the repair) (see 04B, Consum- cle.
  • Page 564 POWER ASSISTED STEERING Power-assisted steering pump: Removal - Refitting K4M, and AIR CONDITIONING Special tooling required Ms. 583 Pipe clamps. Tightening torquesm power-assisted steering 21 N.m pump bolts on the multi- function support high pressure union on 21 N.m t h e p ower-assisted steering pump high pressure pipe bolt...
  • Page 565 POWER ASSISTED STEERING Power-assisted steering pump: Removal - Refitting K4M, and AIR CONDITIONING a Disconnect the power-assisted steering pump high II - REFITTING OPERATION FOR PART pressure pipe. CONCERNED a Fit plugs to the pipe and power-assisted steering a Refit: pump openings to prevent impurities from entering.
  • Page 566 Torque tighten the injector rail protector nuts (21 N.m). a Fill the power-assisted steering circuit with ELF RENAULT MATIC D2 oil (see Vehicle: Parts and consumables for the repair) (see 04B, Consum- ables - Products). a Bleed the circuit by turning the steering wheel from lock to lock with the engine switched off at first.
  • Page 567 POWER ASSISTED STEERING Power-assisted steering pump: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Ms. 583 Pipe clamps. Tightening torquesm power-assisted steering 21 N.m pump bolts on the multi- function support high pressure...
  • Page 568 Fill the power-assisted steering circuit with ELF Also, do not remove the components from their RENAULT MATIC D2 oil (see Vehicle: Parts and packaging until they are to be fitted to the vehi- consumables for the repair) (04B, Consumables - cle.
  • Page 569 POWER ASSISTED STEERING Power-assisted steering pump pulley: Removal - Refitting REMOVAL a Remove the power assisted steering pump (see 36B, Power assisted steering, Power-assisted steering pump: Removal - Refitting, page 36B-5) . a Use the press with a jaw extractor. REFITTING 90317 a Fit the pulley using the (1) until you reach the mea-...

  • Page 570: Power-Assisted Steering Pump Assembly: Removal - Refitting

    POWER ASSISTED STEERING Power-assisted steering pump assembly: Removal - Refitting K9K, and AIR CONDITIONING II - REMOVAL OPERATION Special tooling required Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm pump assembly bolts 21 N.m power-assisted steering 21 N.m pump assembly nut high pressure...
  • Page 571 24777 a Fill the power-assisted steering circuit with ELF a Unclip the power-assisted steering pump assembly wiring at (4) . RENAULT MATIC D2 oil (see Vehicle: Parts and consumables for the repair) (04B, Consumables - a Remove: Products). - the bolts (5) from the power-assisted steering...

  • Page 572: Power-Assisted Steering Pipes: Removal - Refitting

    POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting a Remove: Special tooling required - the front left-hand wheel (see 35A, Wheels and ty- Mot. 1448 Remote operation pliers for res, Wheel: Removal - Refitting, page 35A-1) , hose clips. - the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection).
  • Page 573 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting STANDARD HEATING RECIRCULA TION AIR CONDITIONING 122175 116658 a Loosen the clip (3) using tool (Mot. 1448), a Loosen the clip (5) using tool (Mot. 1448). a Disconnect the low pressure pipe on the power-as- a Disconnect the low pressure pipe on the power-as- sisted steering pump.
  • Page 574 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting STANDARD HEATING RECIRCULA TION AIR CONDITIONING 122175 116658 a Remove the high pressure pipe bolt (8) from the a Remove: multifunction support. - the high pressure pipe union (10) on the power-as- a Remove: sisted steering pump, - the high pressure pipe union (7) on the power-as-...
  • Page 575 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting - the high pressure pipe on the steering box, - the power-assisted steering high pressure pipe. 3 - Low pressure pipe between the reservoir and the steering box 24766 a Remove: - the bolt (11) on the high pressure pipe on the gear- box, - the bolt (12) on the high pressure pipe on the gear-...
  • Page 576 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting a Refit: - the steering box heat shield, - the heat-resistant protector bolts, - the low pressure pipe on the reservoir, - the clip using the (Mot. 1448). a Clip the low pressure pipe onto the fan unit mount- ing.
  • Page 577 Wheel: Removal - Refitting, page 35A-1) , - the engine undertray, a Remove the hose clamp. a Fill the power-assisted steering circuit with ELF RENAULT MATIC D2 oil (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). WARNING T o avoid damaging the power-assisted steering system, do not keep the steering at full lock.
  • Page 578 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting 1 - Low pressure pipe between the power-assisted Special tooling required steering pump and the reservoir Mot. 1448 Remote operation pliers for hose clips. STANDARD HEATING RECIRCULA TION a Drain the power-assisted steering fluid reservoir us- Tightening torquesm ing a syringe.
  • Page 579 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED AIR CONDITIONING a Drain the power-assisted steering fluid reservoir us- 1 - Low pressure pipe between the power-assisted ing a syringe. steering pump and the reservoir STANDARD HEATING RECIRCULA TION a Remove: - the front left-hand wheel (see 35A, Wheels and ty-...
  • Page 580 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting 2 - High pressure pipe between the power-assisted steering pump and the steering box AIR CONDITIONING STANDARD HEATING RECIRCULA TION 24776 a Remove: 24736 - the high pressure pipe bolt (5) on the power-assist- a Remove: ed steering pump assembly, - the high pressure pipe clamp bolt (3) on the power-...
  • Page 581 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting - the high pressure pipe between the power-assisted steering pump and the steering box. 3 - Low pressure pipe between the reservoir and the power-assisted steering box STANDARD HEATING RECIRCULA TION 24766 a Remove: 24759...
  • Page 582 POWER ASSISTED STEERING Power-assisted steering pipes: Removal - Refitting AIR CONDITIONING 125719 a Remove: - the low pressure pipe union (13) on the steering 24776 box, a Remove: - the low pressure pipe between the reservoir and the steering box. - the clip (11) using the (Mot.
  • Page 583 - the high pressure pipe union on the power-assisted a Fill the power-assisted steering circuit with ELF steering pump, RENAULT MATIC D2 oil (see Vehicle: Parts and consumables for the repair) (04B, Consumables - - the high pressure pipe clamp bolt on the power-as- Products).

  • Page 584: Mechanical Component Controls

    Prepare for the flow of fluid, and protect the sur- To avoid such risks, only ever use brake fluids which rounding components. comply with the RENAULT standard (see Vehicle: Parts and consumables for the repair) (04B, Con- sumables - Products).

  • Page 585: Master Cylinder: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Master cylinder: Removal - Refitting LEFT-HAND DRIVE II - REMOVAL OPERATION Tightening torquesm WITHOUT ANTI-LOCK BRAKING SYSTEM nuts on the brake servo 21 N.m rigid brake pipe unions 14 N.m on the master cylinder WARNING Prepare for the flow of fluid, and protect the sur- rounding components.
  • Page 586 MECHANICAL COMPONENT CONTROLS Master cylinder: Removal - Refitting LEFT-HAND DRIVE REFITTING I - REFITTING PREPARATION OPERATION 144758 a Disconnect the brake fluid level sensor connector (3) a Remove the brake fluid filler cap. 108920 a parts always to be replaced: Master cylinder seal a Drain the brake fluid reservoir with a syringe.
  • Page 587 MECHANICAL COMPONENT CONTROLS Master cylinder: Removal - Refitting LEFT-HAND DRIVE II - REFITTING OPERATION 101711 a Line up the master cylinder with the brake servo so that the pushrod goes into the master cylinder hous- ing. a Torque tighten the nuts on the brake servo (21 N.m).

  • Page 588: Master Cylinder - Front Right-Hand Calliper Brake Pipe: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Master cylinder - front right-hand calliper brake pipe: Removal - Refitting LEFT-HAND DRIVE, and WITHOUT ANTI-LOCK BRAKING SYSTEM Equipment required pedal press Tightening torquesm brake pipe union on the 14 N.m master cylinder brake pipe union on the 14 N.m brake hose REMOVAL...
  • Page 589 MECHANICAL COMPONENT CONTROLS Master cylinder - front right-hand calliper brake pipe: Removal - Refitting LEFT-HAND DRIVE, and WITHOUT ANTI-LOCK BRAKING SYSTEM II - FINAL OPERATION a Refit: - the soundproofing on the bulkhead (if fitted to the vehicle). - the soundproofing clips, - the front engine cover (if fitted to the vehicle), - the front right-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) .

  • Page 590: Master Cylinder - Front Left-Hand Calliper Brake Pipe: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Master cylinder - front left-hand calliper brake pipe: Removal - Refitting LEFT-HAND DRIVE, and WITHOUT ANTI-LOCK BRAKING SYSTEM II - OPERATION FOR REMOVAL OF PART CONCERNED Equipment required pedal press Tightening torquesm brake pipe union on the 14 N.m master cylinder brake pipe union on the...
  • Page 591 MECHANICAL COMPONENT CONTROLS Master cylinder - front left-hand calliper brake pipe: Removal - Refitting LEFT-HAND DRIVE, and WITHOUT ANTI-LOCK BRAKING SYSTEM REFITTING I - REFITTING STAGE FOR THE PART IN QUESTION a Refit the brake pipe between the master cylinder and the front left-hand brake hose.

  • Page 592: Brake Servo Non-Return Valve: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Brake servo non-return valve: Removal - Refitting LEFT-HAND DRIVE REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the engine cover. II - OPERATION FOR REMOVAL OF PART CONCERNED 24753 a Disconnect the non-return valve at (3) on the vacu- um pump.
  • Page 593 MECHANICAL COMPONENT CONTROLS Brake servo non-return valve: Removal - Refitting LEFT-HAND DRIVE a Connect the non-return valve at the vacuum pump, a Connect the non-return valve to the brake servo. III - FINAL OPERATION a Refit the engine cover. 116552 a Disconnect the non-return valve at (4) on the inlet distributor.

  • Page 594: Brake Servo: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Brake servo: Removal - Refitting LEFT-HAND DRIVE II - REMOVAL OPERATION Tightening torquesm brake servo nuts 21 N.m IMPORTANT To avoid a loss of braking efficiency, do not bend the brake servo pipe. WARNING Prepare for the flow of fluid, and protect the sur- 108348 rounding components.
  • Page 595 MECHANICAL COMPONENT CONTROLS Brake servo: Removal - Refitting LEFT-HAND DRIVE REFITTING I - REFITTING PREPARATION OPERATION 109449 a Remove the special nuts (4) for the insulating foam. a Gently move the insulating foam aside. a Remove: 109206 - the brake servo nuts (3) , on the passenger com- a Check that the brake servo seal (5) is present;...
  • Page 596 MECHANICAL COMPONENT CONTROLS Brake servo: Removal - Refitting LEFT-HAND DRIVE II - REFITTING OPERATION a Refit the brake servo. a Torque tighten the brake servo nuts (21 N.m). a The shaft connecting the brake servo pushrod and the brake pedal must be refitted from right to left, and from top to bottom.

  • Page 597: Vacuum Pump: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Vacuum pump: Removal - Refitting Tightening torquesm the vacuum pump bolts 21 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover - the air inlet duct. a Gently move the air filter box aside to access the vacuum pump.
  • Page 598 MECHANICAL COMPONENT CONTROLS Vacuum pump: Removal - Refitting III - FINAL OPERATION a Refit: - the air filter unit, - the air inlet duct, - the engine cover. 37A-15...

  • Page 599: Pedal Yoke: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Pedal yoke: Removal - Refitting LEFT-HAND DRIVE Tightening torquesm pedal yoke nuts 21 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the brake pedal switch (see 37A, Mechan- ical component controls, Brake pedal switch: Removal - Refitting, page 37A-27) . 119307 a Uncouple the master cylinder ball joint (4) from the clutch pedal.
  • Page 600 MECHANICAL COMPONENT CONTROLS Pedal yoke: Removal - Refitting LEFT-HAND DRIVE a Couple the steering column and the steering box II - OPERATION FOR REMOVAL OF PART CONCERNED (see 36A, Steering assembly, Steering column: Removal - Refitting, page 36A-7) . 109449 128483 a Remove the pedal yoke nuts (5) .
  • Page 601 MECHANICAL COMPONENT CONTROLS Pedal yoke: Removal - Refitting RIGHT-HAND DRIVE II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm pedal yoke nuts 21 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the brake pedal switch (see 37A, Mechan- ical component controls, Brake pedal switch: Removal - Refitting, page 37A-27) .
  • Page 602 MECHANICAL COMPONENT CONTROLS Pedal yoke: Removal - Refitting RIGHT-HAND DRIVE II - REFITTING OPERATION FOR PART CONCERNED a In the event of replacement, refit: - the accelerator pedal (see 37A, Mechanical com- ponent controls, Accelerator pedal: Removal - Refitting, page 37A-20) , - the brake pedal (see 37A, Mechanical compo- nent controls, Brake pedal: Removal - Refitting, page 37A-26) .

  • Page 603: Accelerator Pedal: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Accelerator pedal: Removal - Refitting K9K – K4M, and 4X4 TRANSMISSION REFITTING Equipment required I - REFITTING OPERATION FOR PART Diagnostic tool CONCERNED a Refit: Tightening torquesm - the accelerator pedal, - the accelerator pedal bolts on the pedal mounting. accelerator pedal bolts 8 N.m a Torque tighten the accelerator pedal bolts (8 N.m).
  • Page 604 MECHANICAL COMPONENT CONTROLS Accelerator pedal: Removal - Refitting K4M, and 4X2 TRANSMISSION Tightening torquesm pedal mounting nuts 21 N.m REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED LEFT-HAND DRIVE 108918 a Remove: - the accelerator cable on the pedal side by holding it upwards and sliding the end piece of the cable to- wards the centre console, - the circlip (3) using a screwdriver,...
  • Page 605 MECHANICAL COMPONENT CONTROLS Accelerator pedal: Removal - Refitting K4M, and 4X2 TRANSMISSION REFITTING RIGHT-HAND DRIVE REFITTING PREPARATION OPERATION a Coat the shaft with MOLYCOTE 33M grease (see Vehicle: Parts and consumables for the repair) (MR 388, 04B, Consumables - Products). Note: Refit the shaft in relation to the pedal mounting in the position noted during the removal operation.
  • Page 606 MECHANICAL COMPONENT CONTROLS Accelerator pedal: Removal - Refitting K4M, and 4X2 TRANSMISSION - the accelerator cable clip on the pedal. II - FINAL OPERATION a Check that the whole accelerator system operates correctly. 37A-23...

  • Page 607: Accelerator Pedal Cable: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Accelerator pedal cable: Removal - Refitting K4M, and 4X2 TRANSMISSION REMOVAL RIGHT-HAND DRIVE I - REMOVAL PREPARATION OPERATION RIGHT-HAND DRIVE a Remove the brake fluid reservoir (see 37A, Me- chanical component controls, Master cylinder: Removal - Refitting, page 37A-2) . II - OPERATION FOR REMOVAL OF PART CONCERNED LEFT-HAND DRIVE...
  • Page 608 MECHANICAL COMPONENT CONTROLS Accelerator pedal cable: Removal - Refitting K4M, and 4X2 TRANSMISSION a Remove the accelerator pedal cable via the engine compartment. RIGHT-HAND DRIVE REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Pass the accelerator pedal cable into the passenger compartment via the engine compartment.

  • Page 609: Brake Pedal: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Brake pedal: Removal - Refitting a Coat the shaft with MOLYKOTE 33M (see Vehicle: Parts and consumables for the repair) grease Tightening torquesm (MR 388, 04B, Consumables - Products). brake pedal shaft nut 16 N.m II - REFITTING OPERATION FOR PART CONCERNED REMOVAL a Refit:...

  • Page 610: Brake Pedal Switch: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Brake pedal switch: Removal - Refitting REMOVAL REFITTING I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION a Remove the dashboard lower trim (depending on the equipment level). When removing and refitting or when replacing the brake light switch II - OPERATION FOR REMOVAL OF PART CONCERNED...
  • Page 611 MECHANICAL COMPONENT CONTROLS Brake pedal switch: Removal - Refitting 136037 Note: T o adjust the position of the piston of the brake light switch, place a 2 mm thick shim (4) between the piston crown of the brake light switch and the brake pedal.

  • Page 612: Parking Brake Lever: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Parking brake lever: Removal - Refitting Tightening torquesm parking brake lever nuts 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the centre console (see Centre console: Removal - Refitting) (57A, Interior equipment). 109447 a Remove nuts (3) . a Lift the parking brake lever slightly to be able to dis- connect the parking brake switch connector (4) .

  • Page 613: Parking Brake Lever: Adjustment

    MECHANICAL COMPONENT CONTROLS Parking brake lever: Adjustment A poorly adjusted parking brake: - prevents correct operation of the automatic compen- sation system for the brake shoes, - causes premature wear of brake shoes. ADJUSTMENT I - ADJUSTMENT PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) .

  • Page 614: Clutch Control: List And Location Of Components

    MECHANICAL COMPONENT CONTROLS Clutch control: List and location of components 1. Cable clutch control Description Clutch cable Clutch pedal Clutch fork Clutch thrust bearing 109143 This control has no automatic compensation. 2. Hydraulic clutch control Description Slave cylinder supply pipe (engine compartment) Master cylinder (engine compartment/passenger compartment connection) Clutch pedal Slave cylinder (on gearbox)
  • Page 615 MECHANICAL COMPONENT CONTROLS Clutch control: List and location of components 119306 37A-32...

  • Page 616: Clutch Pedal: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Clutch pedal: Removal - Refitting LEFT-HAND DRIVE REMOVAL Tightening torquesm I - OPERATION FOR REMOVAL OF PART pedal shaft nut 21 Nm CONCERNED 108790 a Remove the nut (4) from the pedal shaft (2) . II - REFITTING OPERATION FOR PART CONCERNED a Pull the shaft (2) to free the clutch pedal.
  • Page 617 MECHANICAL COMPONENT CONTROLS Clutch pedal: Removal - Refitting RIGHT-HAND DRIVE II - REFITTING OPERATION FOR PART CONCERNED Tightening torquesm a Place the clutch pedal in position with its spring. clutch shaft nut 16 Nm Note: Do not hit the shaft with a hammer to get it to go REMOVAL back into place.

  • Page 618: Clutch Pedal Switch: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Clutch pedal switch: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION 145590 a Turn the clutch pedal switch (4) one quarter of a turn anti-clockwise. a Remove the clutch pedal switch (4) . 112629 a Remove: - the driver side dashboard lower trim clips (1) , - the driver side dashboard lower trim (2) .
  • Page 619 MECHANICAL COMPONENT CONTROLS Clutch pedal switch: Removal - Refitting a At the same time, carefully return the clutch pedal. REFITTING I - REFITTING PREPARATION OPERATION Note: The clutch pedal switch has an automatic adjust- ment feature, adapting to the pedal position. The automatic adjustment makes a clicking noise when in operation.

  • Page 620: Clutch Circuit: Bleed

    MECHANICAL COMPONENT CONTROLS Clutch circuit: Bleed There are two types of equipment used to bleed the clutch circuit: Equipment required a ARC50 via the brake fluid reservoir. brake circuit bleeding device a Syringe via the bleed hole located on the clutch slave cylinder.
  • Page 621 MECHANICAL COMPONENT CONTROLS Clutch circuit: Bleed There are several versions of bleed screw: Bleed screw with a clip. Screw type bleed screw. 112868 a To open the bleed screw, press and hold the clip (4) while pulling by one notch. 113919 a To open the bleed screw, hold the plastic union (1) using a ring spanner and undo the bleed screw (2) .
  • Page 622 Clutch circuit: Bleed a Connect the brake circuit bleeding device (after Bleed screw with two clips. having received Renault approval) to the master cyl- inder reservoir (see the instructions for the equip- ment). a Remove the bleed plug from the clutch slave cylin- der.
  • Page 623 MECHANICAL COMPONENT CONTROLS Clutch circuit: Bleed 2 - Bleed using a new syringe. IV - BLEED PROCEDURE IF PARTS OF THE HYDRAULIC CIRCUIT ARE REMOVED. a Keep the clutch pedal in the upper position using a strap attached to the steering wheel to ensure conti- nuity of the hydraulic circuit during the bleed opera- WARNING tion.
  • Page 624 MECHANICAL COMPONENT CONTROLS Clutch circuit: Bleed There are several versions of pipe with and without Filling position for pipe with filter. a filter: Pipe without filter. 141810 Filling position for pipe with filter. 141812 Filling position for pipe with filter. 141813 a Prefill the clutch pipe using the syringe.
  • Page 625 MECHANICAL COMPONENT CONTROLS Clutch circuit: Bleed V - BLEED PROCEDURE AFTER A REMOVING A COMPONENT OF THE HYDRAULIC CIRCUIT. a Keep the clutch pedal in the upper position using a strap attached to the steering wheel to ensure conti- nuity of the hydraulic circuit during the bleed opera- tion.
  • Page 626 MECHANICAL COMPONENT CONTROLS Clutch circuit: Bleed VI - FINAL OPERATION a Refit the engine undertray. a Remove the vehicle from the two-post lift (see Vehi- cle: Towing and lifting) (02A, Lifting equipment). 37A-43...

  • Page 627: Clutch Master Cylinder: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Clutch master cylinder: Removal - Refitting JR5, and LEFT-HAND DRIVE II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm expansion bottle nuts 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 628 MECHANICAL COMPONENT CONTROLS Clutch master cylinder: Removal - Refitting JR5, and LEFT-HAND DRIVE 19399 a Remove the clutch master cylinder from the bulk- head by turning it a quarter of a turn clockwise in the engine compartment (bayonet type mounting) using the tool (7) or.
  • Page 629 MECHANICAL COMPONENT CONTROLS Clutch master cylinder: Removal - Refitting JR5, and LEFT-HAND DRIVE a Press the clutch master cylinder clip. 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 pipe between the clutch master cylinder and the brake fluid reservoir.

  • Page 630: Clutch Circuit: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Clutch circuit: Removal - Refitting JR5, and LEFT-HAND DRIVE II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm expansion bottle nuts 8 N.m Note: 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 bear-...
  • Page 631 MECHANICAL COMPONENT CONTROLS Clutch circuit: Removal - Refitting JR5, and LEFT-HAND DRIVE 119304 119305 a Remove the master cylinder-slave cylinder connect- a Unclip: ing pipe retaining clip (4) on the master cylinder. - the master cylinder-slave cylinder connecting pipe a Place a cloth under the master cylinder. from the body (6) , a Disconnect the pipe (5) on the master cylinder in the - the master cylinder-slave cylinder connecting pipe...
  • Page 632 MECHANICAL COMPONENT CONTROLS Clutch circuit: Removal - Refitting JR5, and LEFT-HAND DRIVE a Connect the pipe to the slave cylinder. Note: As you lock the clutch control pipe, you should hear a safety click. III - FINAL OPERATION a Refit the expansion bottle. a Torque tighten the expansion bottle nuts (8 N.m).

  • Page 633: Gear Control Unit: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Gear control unit: Removal - Refitting II - REMOVAL OPERATION Tightening torquesm gear control unit bolts 21 N.m exhaust pipe mountings 21 N.m expansion bottle nuts 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 634 MECHANICAL COMPONENT CONTROLS Gear control unit: Removal - Refitting 114121 116557 a Remove the exhaust pipe mountings (6) from the a Remove the exhaust pipe mountings (7) . catalytic converter. a Move aside the exhaust pipe. 145186 a Remove: - the nuts (8) from the heat shield, 37A-51...
  • Page 635 MECHANICAL COMPONENT CONTROLS Gear control unit: Removal - Refitting a Torque tighten the gear control unit bolts (21 - the heat shield. N.m). a Refit the centre console (see Centre console: Re- moval - Refitting) (57A, Interior equipment). a Remove the centre console (see Centre console: Removal - Refitting) (57A, Interior equipment).

  • Page 636: Parking Brake Cables: Removal - Refitting

    MECHANICAL COMPONENT CONTROLS Parking brake cables: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the central console (see Centre console: Remov- al - Refitting) (57A, Interior equipment), - the rear wheels (see 35A, Wheels and tyres, Wheel: Removal - Refitting, page 35A-1) ,...
  • Page 637 MECHANICAL COMPONENT CONTROLS Parking brake cables: Removal - Refitting 116013 a Reattach the parking brake cable sheath onto the drum back-plate. a Refit the parking brake cable back into the lever housing using a pair of pliers and a screwdriver. a Check that the cables (5) are correctly positioned on the levers.

  • Page 638: Brake Servo: Check

    MECHANICAL COMPONENT CONTROLS Brake servo: Check Special tooling required Ms. 583 Pipe clamps. CHECKING THE SEALS 3701 a When checking the brake servo seals, ensure that If the brake servo is not operational, the braking sys- there is a perfect seal between this and the master tem will operate but the force required at the pedal to obtain the equivalent deceleration as for assisted cylinder.

  • Page 639: Anti-Lock Braking System

    ANTI-LOCK BRAKING SYSTEM ABS: List and location of components 145253 145074 145189 Hydraulic unit Steering wheel angle sensor ABS warning light on the instru- ment panel Brake lights switch 38C-1...
  • Page 640 ANTI-LOCK BRAKING SYSTEM ABS: List and location of components 107820 144829 Fuse box Lateral acceleration and yaw speed sensor ESP deactivation switch 107831 Diagnostic socket 134460 Brake disc with instrumented bearing (10) Wheel speed sensor 38C-2...
  • Page 641 ANTI-LOCK BRAKING SYSTEM ABS: List and location of components 144758 (11) Master cylinder 38C-3...

  • Page 642: Abs: Precautions For The Repair

    ANTI-LOCK BRAKING SYSTEM ABS: Precautions for the repair 2 - Hydraulic unit Equipment required WARNING pedal press Switch off the vehicle ignition so as not to activate Diagnostic tool the hydraulic unit solenoid valves when bleeding the brake circuit. I - SAFETY 3 - Wheel speed sensor - If a lift must be used for an operation, respect the safety instructions (see Vehicle: Towing and lifting)

  • Page 643: Hydraulic Brake Unit: Removal - Refitting

    ANTI-LOCK BRAKING SYSTEM Hydraulic brake unit: Removal - Refitting ANTI-LOCK BRAKING SYSTEM II - REMOVAL OPERATION Equipment required pedal press Tightening torquesm hydraulic brake unit 8 N.m bolts on the support rigid brake pipe unions 13 N.m on the hydraulic brake unit hydraulic brake...
  • Page 644 ANTI-LOCK BRAKING SYSTEM Hydraulic brake unit: Removal - Refitting ANTI-LOCK BRAKING SYSTEM - the hydraulic brake unit earth wire nut (8 N.m). a Bleed the brake circuit (see 30A, General informa- tion, Braking circuit: Bleed, page 30A-4) . 145075 a Remove: - the hydraulic brake unit bolts (6) from its mounting, - the hydraulic brake unit.

  • Page 645: Front Wheel Speed Sensor: Removal - Refitting

    ANTI-LOCK BRAKING SYSTEM Front wheel speed sensor: Removal - Refitting ANTI-LOCK BRAKING SYSTEM Tightening torquesm front wheel speed sen- 7 N.m sor bolt 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 38C, Anti-lock braking system, ABS: Precautions for the repair, page 38C-4) .
  • Page 646 ANTI-LOCK BRAKING SYSTEM Front wheel speed sensor: Removal - Refitting ANTI-LOCK BRAKING SYSTEM REFITTING WARNING T o avoid damaging the wheel speed sensor cable: - Do not tension the cable, - Do not twist the cable, - Check that there is no contact with the sur- rounding components, - Do not use tools that may damage the cable.

  • Page 647: Rear Wheel Speed Sensor: Removal - Refitting

    ANTI-LOCK BRAKING SYSTEM Rear wheel speed sensor: Removal - Refitting ANTI-LOCK BRAKING SYSTEM II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm rear wheel speed sen- 14 N.m sor protective screen nuts wheel speed sensor bolt 7 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any...
  • Page 648 ANTI-LOCK BRAKING SYSTEM Rear wheel speed sensor: Removal - Refitting ANTI-LOCK BRAKING SYSTEM a Refit: - the clips (5) from the rear wheel speed sensor pro- tective screen. - the rear wheel speed sensor protective screen on the body, - the rear wheel speed sensor protective screen nuts, - the rear wheel speed sensor protective screen clips.
  • Page 649 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 650 DUSTER - Section 5 DUSTER - Section 5 ContentsPages Contents Pages SIDE OPENING ELEMENT MECHANISMS SIDE OPENING ELEMENT MECHANISMS Front side door window Rear side door interior winder handle: Removal - opening control: Removal - Refitting 51A-1 Refitting 51A-17 Rear side door window Rear side door manual winder handle: Removal - window winder mechanism:...
  • Page 651 Contents NON-SIDE OPENING ELEMENT EXTERIOR EQUIPMENT MECHANISMS Tailgate strut: Removal - Exterior body side trim Refitting 52A-9 assembly: Exploded view 56A-1 Tailgate exterior opening Door mirror: Removal - control: Removal - Refitting 52A-10 Refitting 56A-2 Door mirror glass: Removal - Refitting 56A-3 WINDOWS...

  • Page 652: Side Opening Element Mechanisms

    SIDE OPENING ELEMENT MECHANISMS Front side door window winder handle: Removal - Refitting MANUAL FRONT WINDOW REMOVAL REMOVAL OPERATION Clipped on window winder handle 137396 133415 137398 a Pull the ring (3) towards the vehicle interior. a Unclip the clip (4) . a Remove the front side door window winder handle.

  • Page 653: Rear Side Door Window Winder Handle: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Rear side door window winder handle: Removal - Refitting MANUAL REAR WINDOW REMOVAL REMOVAL OPERATION Clipped on window winder handle 137396 145201 137398 a Pull the ring (2) towards the vehicle interior. a Unclip the clip (3) . a Remove the rear side door window winder handle.

  • Page 654: Front Side Door Check Strap: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door check strap: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening elements trim). II - REMOVAL OPERATION 108514 a Remove the front side door check strap bolts (3) .

  • Page 655: Front Side Door Striker Panel: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door striker panel: Removal - Refitting REFITTING Tightening torquesm REFITTING OPERATION front side door striker 21 N.m panel REMOVAL REMOVAL OPERATION 117368 a Refit the front side door striker panel. a Adjust the front side door striker panel. a Check whether it is possible to close the door.

  • Page 656: Front Side Door Lock: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door lock: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening element trim). - the support of the front side door run channel (see 51A, Side opening element mechanisms, Front side door slide mounting: Removal - Refitting, page 51A-21) .
  • Page 657 SIDE OPENING ELEMENT MECHANISMS Front side door lock: Removal - Refitting - the locking motor (10) . REFITTING a Proceed in the reverse order to removal. a Refit the front side door impact padding (see Front side door impact padding: Removal - Refitting) (59A, Safety accessories).

  • Page 658: Front Side Door Lock Barrel: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door lock barrel: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening elements trim). II - REMOVAL OPERATION 125479 a Remove: - the fork (1) ,...

  • Page 659: Exterior Door Handle: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Exterior door handle: Removal - Refitting Tightening torquesm the nuts of the exterior 7 N.m door handle REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front door trim (see Front side door trim: Removal - Refitting) (72A, Side opening ele- ments trim) or the rear side door trim (see Rear side door trim: Removal - Refitting) (72A, Side opening elements trim).

  • Page 660: Front Side Door Interior Opening Control: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door interior opening control: Removal - Refitting REMOVAL REMOVAL OPERATION 144631 a Remove: - the bolt (1) , - the front side door interior handle. REFITTING a Proceed in the reverse order to removal. 51A-9...

  • Page 661: Front Side Door Electric Window Mechanism: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door electric window mechanism: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening elements trim). II - REMOVAL OPERATION a Lower the window.
  • Page 662 SIDE OPENING ELEMENT MECHANISMS Front side door electric window mechanism: Removal - Refitting REFITTING I - REFITTING OPERATION a Refit the window lift mechanism. a Connect the electric window motor connector. a Refit the nuts (2) . a Position the sliding window. a Refit the bolts (1) without tightening them.

  • Page 663: Front Side Door Manual Window Winder Mechanism: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door manual window winder mechanism: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening elements trim). II - REMOVAL OPERATION a Lower the window.
  • Page 664 SIDE OPENING ELEMENT MECHANISMS Front side door manual window winder mechanism: Removal - Refitting REFITTING I - REFITTING OPERATION a Fit the window winder mechanism. a Refit the nuts (2) . a Position the sliding window. a Refit the bolts (1) without tightening them. a Raise the sliding window.

  • Page 665: Rear Side Door Striker Panel: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Rear side door striker panel: Removal - Refitting REFITTING Tightening torquesm REFITTING OPERATION rear side door striker 21 N.m panel REMOVAL REMOVAL OPERATION 108623 a Refit the rear side door striker panel. a Adjust the rear side door striker panel. a Check whether it is possible to close the door.

  • Page 666: Rear Side Door Lock: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Rear side door lock: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the rear side door trim (see Rear side door trim: Removal - Refitting) (72A, Side opening element trim), - the support of the rear side door run channel (see 51A, Side opening element mechanisms, Front side door slide mounting: Removal - Refitting, page 51A-21) .
  • Page 667 SIDE OPENING ELEMENT MECHANISMS Rear side door lock: Removal - Refitting DOOR OPENING SYSTEM 02 108311 a Remove: - the bolt (7) , - the lock motor. REFITTING a Proceed in the reverse order to removal. a Carry out a function test. 51A-16...

  • Page 668: Rear Side Door Interior Opening Control: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Rear side door interior opening control: Removal - Refitting REMOVAL REMOVAL OPERATION 145204 a Remove: - the bolt (1) , - the rear side door interior handle. REFITTING a Proceed in the reverse order to removal. 51A-17...

  • Page 669: Rear Side Door Manual Window Winder Mechanism: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Rear side door manual window winder mechanism: Removal - Refitting MANUAL REAR WINDOW REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the rear side door trim (see Rear side door trim: Removal - Refitting) (72A, Side opening ele- ment trim).
  • Page 670 SIDE OPENING ELEMENT MECHANISMS Rear side door manual window winder mechanism: Removal - Refitting MANUAL REAR WINDOW REFITTING I - REFITTING OPERATION a Fit the rear side door manual window mechanism. a Refit the nuts of the rear side door manual window mechanism.

  • Page 671: Rear Side Door Slide Mounting: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Rear side door slide mounting: Removal - Refitting REFITTING I - REMOVAL PREPARATION OPERATION a Remove the rear side door trim (see Rear side door trim: Removal - Refitting) (72A, Side opening ele- ment trim). II - REMOVAL OPERATION a Partially remove the glass run channel from its mounting.

  • Page 672: Front Side Door Slide Mounting: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Front side door slide mounting: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening elements trim). 145252 a Remove the bolts (3) . 24835 a Remove the bolts (1) from the impact padding with- out extracting it.
  • Page 673 SIDE OPENING ELEMENT MECHANISMS Front side door slide mounting: Removal - Refitting FINAL OPERATION a Proceed in the reverse order to removal. 51A-22...

  • Page 674: Rear Side Door Check Strap: Removal - Refitting

    SIDE OPENING ELEMENT MECHANISMS Rear side door check strap: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the rear side door trim (see Rear side door trim: Removal - Refitting) (72A, Side opening ele- ment trim). II - REMOVAL OPERATION 108514 a Remove the bolts (3) .

  • Page 675: Non-Side Opening Element Mechanisms

    NON-SIDE OPENING ELEMENT MECHANISMS Exterior rear opening element assembly: Exploded view 146094 (see Illustration key: Description) (01D, Mechanical introduction). 52A-1...

  • Page 676: Non-Side Opening Element Mechanisms

    NON-SIDE OPENING ELEMENT MECHANISMS Exterior rear opening element assembly: Exploded view Mark Description Information Bonnet Material: Steel (see Bonnet: Removal - Refit- ting) (48A, Non-side opening ele- ments). (see Steel bodywork compo- nent: Preparation and paint range) (Technical Note 0592A, Paint application range for panels).
  • Page 677 NON-SIDE OPENING ELEMENT MECHANISMS Exterior rear opening element assembly: Exploded view Mark Description Information Side indicator (see Side indicator: Removal - Refitting) (80B Headlights). Headlight (see Headlight assembly: Exploded view) (80B Headlights). 52A-3...
  • Page 678 NON-SIDE OPENING ELEMENT MECHANISMS Bonnet release control: Removal - Refitting REMOVAL REMOVAL OPERATION 108723 a Remove the bonnet release control (1) . REFITTING a Proceed in the reverse order to removal. 52A-4...
  • Page 679 NON-SIDE OPENING ELEMENT MECHANISMS Bonnet lock: Removal - Refitting Tightening torquesm bonnet catch nuts 21 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the front bumper (see 55A, Exterior protection, Front bumper: Removal - Refitting, page 55A-8) - the air deflector. II - REMOVAL OPERATION 145205 a Remove the bonnet catch.
  • Page 680 NON-SIDE OPENING ELEMENT MECHANISMS Bonnet release cable: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the front bumper (see 55A, Exterior protection, Front bumper: Removal - Refitting, page 55A-8) - the bonnet catch (see 52A, Non-side opening el- ement mechanisms, Bonnet lock: Removal - Refitting, page 52A-5) , - the bonnet release catch (see 5 2 A, Non-side...
  • Page 681 NON-SIDE OPENING ELEMENT MECHANISMS Bonnet strut: Removal - Refitting REMOVAL REMOVAL OPERATION 144828 a Remove the bonnet strut while holding the bonnet. REFITTING 145084 a Position the clips on the bonnet strut. a Proceed in the reverse order to removal 145085 WARNING The strut is fitted in such a way as to prevent...
  • Page 682 NON-SIDE OPENING ELEMENT MECHANISMS Tailgate lock: Removal - Refitting a Torque tighten the tailgate lock bolts (8 N.m). a Carry out a function test. Tightening torquesm tailgate lock bolts 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the tailgate trim (see Tailgate trim: Re- moval - Refitting) (73A, Tailgate trim).

  • Page 683: Tailgate Strut: Removal - Refitting

    NON-SIDE OPENING ELEMENT MECHANISMS Tailgate strut: Removal - Refitting REMOVAL REFITTING a Position the clips on the tailgate strut. a Proceed in the reverse order to removal. I - REMOVAL PREPARATION OPERATION a Note the direction in which the tailgate gas strut is fit- ted before removal.

  • Page 684: Tailgate Exterior Opening Control: Removal - Refitting

    NON-SIDE OPENING ELEMENT MECHANISMS Tailgate exterior opening control: Removal - Refitting Tightening torquesm the bolts of the tailgate 8 N.m control REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the tailgate trim (see Tailgate trim: Re- moval - Refitting) (73A, Non-side opening ele- ments trim).

  • Page 685: Windscreen: Removal - Refitting

    WINDOWS Windscreen: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the interior rear-view mirror (see 57A, Interior equipment, Interior rear-view mirror: Removal - Refitting, page 57A-12) (57A, Interior equipment), - the windscreen pillar trims (see Windscreen pillar trim: Removal - Refitting) (71A, Body internal trim).
  • Page 686 WINDOWS Windscreen: Removal - Refitting a Fit the toolon the dashboard. II - REMOVAL OPERATION a Cut the cement bead (see Technical Note 0560A). a Remove the windscreen (this operation requires two people). REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Windscreen adjust- ing shim a Fit new shims and retaining stops.

  • Page 687: Front Side Door Sliding Window: Removal - Refitting

    WINDOWS Front side door sliding window: Removal - Refitting II - REMOVAL OPERATION REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening elements trim). 107945 a Remove the bolts (1) .
  • Page 688 WINDOWS Front side door sliding window: Removal - Refitting II - REFITTING OPERATION a Refit the window. 107945 a Refit the bolts (2) without tightening them. 145089 a Tighten the bolts (2) through the holes (3) . a Carry out a function test. III - FINAL OPERATION a Proceed in the reverse order to removal.

  • Page 689: Rear Side Door Sliding Window: Removal - Refitting

    WINDOWS Rear side door sliding window: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the rear side door trim (see Rear side door trim: Removal - Refitting) (72A, Side opening ele- ment trim). 107968 a Lower the window. a Remove the exterior weatherstrip (2) .
  • Page 690 WINDOWS Rear side door sliding window: Removal - Refitting 107969 a Remove the window. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: rear side opening element sliding window bolt II - REFITTING OPERATION a Refit the window. a Refit the bolts (4) .

  • Page 691: Rear Quarter Panel Window: Removal - Refitting

    WINDOWS Rear quarter panel window: Removal - Refitting a Equal out the clearances and shut lines. REMOVAL a Remove the tabs from the stops when the adhesive has dried. I - REMOVAL PREPARATION OPERATION a Remove (see Interior body side trim assembly: III - FINAL OPERATION Exploded view) : a Proceed in the reverse order to removal.

  • Page 692: Rear Screen: Removal - Refitting

    WINDOWS Rear screen: Removal - Refitting II - REFITTING OPERATION FOR PART REMOVAL CONCERNED a Bond the rear screen (two people are required for I - REMOVAL PREPARATION OPERATION this operation). a Remove: a Equal out the clearances and shut lines. - the tailgate trim (see Tailgate trim: Removal - Re- a Remove the tabs from the stops once the adhesive fitting) (73A, Non-side opening elements trim),...

  • Page 693: Exterior Protection

    EXTERIOR PROTECTION Front bumper assembly: Exploded view 146092 (see Illustration key: Description) (01D, Mechanical introduction). Mark Description Information Front badge Front bumper upper trim Material: ABS Radiator grille Material: ASA Front bumper Material: P/E (see 5 5 A , Exterior protection, Front bumper: Removal - Refit- ting, page 55A-8) (see 5 5 A , Exterior protection,...
  • Page 694 EXTERIOR PROTECTION Front bumper assembly: Exploded view Mark Description Information Front bumper lower grille Material: P/E+EPDM Fog light mounting Fog light mounting clip Fog light (see Front fog light bulb: Removal - Refitting) (80B Head- lights). Front bumper centre trim Material: P/E 55A-2...

  • Page 695: Rear Bumper Assembly: Exploded View

    EXTERIOR PROTECTION Rear bumper assembly: Exploded view 146093 (see Illustration key: Description) (01D, Mechanical introduction). Mark Description Information Rear bumper Material: P/E (see 5 5 A , Exterior protection, Rear bumper: Removal - Refit- ting, page 55A-9) (see Polypropylene bodywork component: Preparation and paint range) (Technical Note...
  • Page 696 EXTERIOR PROTECTION Rear bumper assembly: Exploded view Mark Description Information Side pressure piece of rear bumper Rivet of side pressure piece of rear bumper 55A-4...

  • Page 697: Exterior Body Front Trim Assembly: Exploded View

    EXTERIOR PROTECTION Exterior body front trim assembly: Exploded view 146095 (see Illustration key: Description) (01D, Mechanical introduction). 55A-5...

  • Page 698: Front Bumper: Removal - Refitting

    EXTERIOR PROTECTION Exterior body front trim assembly: Exploded view Mark Description Information Bonnet Material: Steel (see Bonnet: Removal - Refit- ting) (48A, Non-side opening ele- ments). (see Steel bodywork compo- nent: Preparation and paint range) (Technical Note 0592A, Paint application range for panels). Front bumper Material: P/E (see 5 5 A , Exterior protection,...
  • Page 699 EXTERIOR PROTECTION Exterior body front trim assembly: Exploded view Mark Description Information Side indicator (see Side indicator: Removal - Refitting) (80B Headlights). Headlight (see Headlight assembly: Exploded view) (80B Headlights). 55A-7...
  • Page 700 EXTERIOR PROTECTION Front bumper: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. Location and specifications (tightening torques, parts always to be replaced, etc.) (see 55A, Exterior pro- tection, Front bumper assembly: Exploded view, page 55A-1) and (see 55A, Exterior protection, Exte- rior body front trim assembly: Exploded view, page 55A-5) .

  • Page 701: Rear Bumper: Removal - Refitting

    EXTERIOR PROTECTION Rear bumper: Removal - Refitting Location and specifications (tightening torques, parts always to be replaced, etc.) (see 55A, Exterior pro- tection, Rear bumper assembly: Exploded view, page 55A-3) . REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

  • Page 702: Front Wheel Arch Liner: Removal - Refitting

    EXTERIOR PROTECTION Front wheel arch liner: Removal - Refitting Location and specifications (tightening torques, parts always to be replaced, etc.) (see 55A, Exterior pro- tection, Exterior body front trim assembly: Explod- ed view, page 55A-5) . REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

  • Page 703: Rear Wheel Arch Liner: Removal - Refitting

    EXTERIOR PROTECTION Rear wheel arch liner: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the rear wheel on the side concerned (see Wheel: Removal - Refitting) (35A, Wheels and ty- res).

  • Page 704: Exterior Equipment

    EXTERIOR EQUIPMENT Exterior body side trim assembly: Exploded view 146188 (see Illustration key: Description) (01D, Mechanical introduction). Mark Description Information Roof bar Roof bar front trim (Car.1363) Roof bar rear trim (Car.1363) Central mounting access flap (Car.1363) Mark Description Information Sill panel extender Material: P/E Sill panel extender trim...

  • Page 705: Door Mirror: Removal - Refitting

    EXTERIOR EQUIPMENT Door mirror: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening elements trim). II - REMOVAL OPERATION 107944 a Disconnect the connector (1) (depending on equip- ment level).

  • Page 706: Door Mirror Glass: Removal - Refitting

    EXTERIOR EQUIPMENT Door mirror glass: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL 107955 a Protect the edge of the rear-view mirror (masking tape). a Use the (Car. 1363) as a lever to unclip the glass. a Disconnect the supply terminals (depending on equipment level).

  • Page 707: Rear Badges: Removal - Refitting

    EXTERIOR EQUIPMENT Rear badges: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 133399 a Unclip the rear badge using the tool (Car. 1363). REFITTING REFITTING OPERATION FOR PART CONCERNED a Clip on the rear badge.

  • Page 708: Interior Equipment

    INTERIOR EQUIPMENT Dashboard: Removal - Refitting Equipment required Diagnostic tool IMPORTANT To avoid any risk of triggering when working on or near a pyrotechnic component (airbags or preten- sioners), lock the airbag computer using the diag- nostic tool. When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).
  • Page 709 INTERIOR EQUIPMENT Dashboard: Removal - Refitting 125728 107835 a Unclip the (1) control panel on the dashboard. a Unclip the covers (3) on both sides of the dash- board. II - OPERATION FOR REMOVAL OF PART CONCERNED 107836 a Remove the bolts (4) from both sides of the dash- board.
  • Page 710 INTERIOR EQUIPMENT Dashboard: Removal - Refitting 107831 107801 a Remove the bolt (5) . 107805 a Remove the diagnostic socket (7) . 107800 a Remove the bolts (6) . 107803 a Partially remove the dashboard (this operation re- quires two people). 57A-3...
  • Page 711 INTERIOR EQUIPMENT Dashboard: Removal - Refitting 107804 109138 a Remove the rivets (11) . a Disconnect the connector (8) . a Remove: - the dashboard (this operation requires two people), - the passenger front airbag (depending on equip- ment level) (see Passenger's frontal airbag: Re- moval Refitting) (88C,...
  • Page 712 INTERIOR EQUIPMENT Dashboard: Removal - Refitting a Connect the battery (see Battery: Removal - Refit- II - REFITTING OPERATION FOR PART CONCERNED ting) (80A, Battery). a Refit: IMPORTANT - the glovebox cover, To avoid a fault with or even triggering of pyro- - the rivets, technic components (airbags or pretensioners), check the airbag computer using the diagnostic...

  • Page 713: Dashboard: Stripping - Rebuilding

    INTERIOR EQUIPMENT Dashboard: Stripping - Rebuilding STRIPPING STRIPPING OPERATION a Remove: - the dashboard trims on the driver's side (see In- strument panel: Removal - Refitting) (83A, In- strument panel), - the dashboard air vents (see 57A, Interior equip- ment, Dashboard air vent: Removal - Refitting, page 57A-7) , - the glovebox cover (see 57A, Interior equipment, Glovebox cover: Removal - Refitting, page 57A-...

  • Page 714: Dashboard Air Vent: Removal - Refitting

    INTERIOR EQUIPMENT Dashboard air vent: Removal - Refitting REMOVAL 108722 a Unclip inner band (3) . 108720 a Using a flat screwdriver, remove the air vent sur- round (1) . 108721 a Unclip grilles (2) . 57A-7...
  • Page 715 INTERIOR EQUIPMENT Dashboard air vent: Removal - Refitting 108719 108717 a Unclip clips (4) . a Withdraw the vent. REFITTING a Proceed in the reverse order to removal. 57A-8...

  • Page 716: Glovebox Cover: Removal - Refitting

    INTERIOR EQUIPMENT Glovebox cover: Removal - Refitting a Position the glove box cover with rivets. REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 120946 a Refit the rivets (2) . 120946 a Remove the rivets (1) . 120947 a Remove the glove box lid. REFITTING REFITTING OPERATION FOR PART CONCERNED a Fit the glove box cover.

  • Page 717: Centre Console: Removal - Refitting

    INTERIOR EQUIPMENT Centre console: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL REMOVAL OPERATION 2 ELECTRICALLY ADJUSTABLE EXTERNAL REAR VIEW MIRRORS 144829 a Unclip the upper section of the centre console (3) . 144830 a Remove the adjustment control for the door mirrors (1) .
  • Page 718 INTERIOR EQUIPMENT Centre console: Removal - Refitting WITH SMOKING ACCESSORIES 144832 a Remove: 144833 - the centre console nut (7) , a Disconnect the cigarette lighter connector (5) . - the central bolts of the centre console (8) , - the side bolts of the centre console (9) , - the lower section of the centre console.

  • Page 719: Interior Rear-View Mirror: Removal - Refitting

    INTERIOR EQUIPMENT Interior rear-view mirror: Removal - Refitting REMOVAL REMOVAL OPERATION 108659 a Remove interior rear view mirror (1) . REFITTING REFITTING OPERATION a Proceed in the reverse order to removal. 57A-12...

  • Page 720: Sun Visor: Removal - Refitting

    INTERIOR EQUIPMENT Sun visor: Removal - Refitting REMOVAL 108728 a Remove the bolt (1) . 108729 a Remove the sun visor. 108730 a Remove sun visor bracket (2) . REFITTING a Proceed in the reverse order to removal. 57A-13...

  • Page 721: Grab Handle: Removal - Refitting

    INTERIOR EQUIPMENT Grab handle: Removal - Refitting REMOVAL 108739 a Unclip covers (1) . 108738 a Remove the bolts (2) . a Remove the grab handle. REFITTING a Proceed in the reverse order to removal. 57A-14...
  • Page 722 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 723 DUSTER - Chapitre 6 DUSTER - Chapitre 6ContentsPages Contents Pages HEATING AIR CONDITIONING Heating: List and location of Air conditioning: List and components 61A-1 location of components 62A-1 Cabin filter: Removal - Air conditioning: Parts and Refitting 61A-8 consumables for the repair 62A-9 Front air distribution duct: Condenser: Removal -...

  • Page 724: Heating

    HEATING Heating: List and location of components 107799 VALEO distribution unit 143994 61A-1...
  • Page 725 HEATING Heating: List and location of components 143997 61A-2...
  • Page 726 HEATING Heating: List and location of components BEHR distribution unit 143995 61A-3...
  • Page 727 HEATING Heating: List and location of components 143998 61A-4...
  • Page 728 HEATING Heating: List and location of components 143996 61A-5...
  • Page 729 HEATING Heating: List and location of components 128024 121595 Control panel (see 61A, Heating, Control panel: Removal - Refitting, page 61A-29) Passenger compartment fan assembly (see 61A, Heating, Fan assembly: Removal - Refitting, page 61A-24) 61A-6...
  • Page 730 HEATING Heating: List and location of components Expansion valve (see 62A, Air conditioning, Expansion valve: Removal - Refitting, page 62A-16) Passenger compartment fan assembly control (see 61A, Heating, Passenger compartment unit fan assembly control unit: Removal - Refit- ting, page 61A-28) Heater matrix (see 61A, Heating, Heater matrix: Removal - Refitting, page 61A-21)

  • Page 731: Cabin Filter: Removal - Refitting

    HEATING Cabin filter: Removal - Refitting AIR CONDITIONING REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 112763 a Unclip the passenger compartment filter (1) . Note: Foreign bodies (leaves, insects etc.) are likely to accumulate in the passenger compartment filter. Remove the cabin filter with care so as to prevent foreign bodies getting into the evaporator.

  • Page 732: Front Air Distribution Duct: Removal - Refitting

    HEATING Front air distribution duct: Removal - Refitting 2 - Front left-hand air distribution duct REMOVAL I - REMOVAL PREPARATION OPERATION a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).

  • Page 733: Rear Air Distribution Duct: Removal - Refitting

    HEATING Rear air distribution duct: Removal - Refitting REAR SEATS AIR DUCT REMOVAL 2 - Rear right-hand air distribution duct I - REMOVAL PREPARATION OPERATION a Remove: - the central console (see Centre console: Remov- al - Refitting) (57A, Interior equipment), - the front seats (see Front seat assembly: Ex- ploded view) (75A, Front seat frames and mecha- nisms),...

  • Page 734: Recirculation Control Cable: Removal - Refitting

    HEATING Recirculation control cable: Removal - Refitting AIR CONDITIONING or STANDARD HEATING RECIRCULATION REMOVAL II - REMOVAL OPERATION I - REMOVAL PREPARATION OPERATION a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners).
  • Page 735 HEATING Recirculation control cable: Removal - Refitting AIR CONDITIONING or STANDARD HEATING RECIRCULATION 121597 a Unclip the cable sleeve stop (5) from the distribution unit. a Extract the end of the air recirculation control cable (6) . a Remove the air recirculation control cable. REFITTING a Proceed in the reverse order to removal.

  • Page 736: Air Distribution Cable: Removal - Refitting

    HEATING Air distribution cable: Removal - Refitting AIR CONDITIONING or STANDARD HEATING RECIRCULATION REMOVAL II - REMOVAL OPERATION I - REMOVAL PREPARATION OPERATION a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners).
  • Page 737 HEATING Air distribution cable: Removal - Refitting AIR CONDITIONING or STANDARD HEATING RECIRCULATION LEFT-HAND DRIVE 108093 a Unclip the cable sleeve stop (5) from the distribution unit. a Extract the end of the air distribution cable (6) . a Remove the air distribution cable. REFITTING a Proceed in the reverse order to removal.

  • Page 738: Air Mixing Cable: Removal - Refitting

    HEATING Air mixing cable: Removal - Refitting AIR CONDITIONING or STANDARD HEATING RECIRCULATION REMOVAL II - REMOVAL OPERATION I - REMOVAL PREPARATION OPERATION a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners).
  • Page 739 HEATING Air mixing cable: Removal - Refitting AIR CONDITIONING or STANDARD HEATING RECIRCULATION a Remove the air mixing cable. REFITTING a Proceed in the reverse order to removal. a Check that the air mixing control can move along its whole stroke. a Unlock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners).

  • Page 740: Distribution Unit: Removal - Refitting

    HEATING Distribution unit: Removal - Refitting Special tooling required Ms. 583 Pipe clamps. Equipment required refrigerant charging station REMOVAL I - REMOVAL PREPARATION OPERATION a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- 108112 tensioners).
  • Page 741 HEATING Distribution unit: Removal - Refitting a Remove: LEFT-HAND DRIVE - the driver's front airbag (see Driver's frontal air- bag: Removal - Refitting) (88C, Airbags and pre- a Unclip the ignition switch connector (7) from its tensioners), mounting. - the steering wheel (see Steering wheel: Removal - Refitting) (36A, Steering assembly), - the steering column switch assembly (see Steer- ing column switch assembly: Removal - Refit-...
  • Page 742 HEATING Distribution unit: Removal - Refitting a Refit on the distribution unit: - the heater matrix, REAR SEATS AIR DUCT a Separate the C-pillar air distribution ducts from the - the heater matrix pipes, distribution unit. - the passenger compartment fan assembly control unit, - the passenger compartment blower unit, a Put a container in place to recover the coolant.
  • Page 743 HEATING Distribution unit: Removal - Refitting a Remove the hose clamps (Ms. 583). III - FINAL OPERATION a Refit the floor carpet. AIR CONDITIONING a Replace the seals. Note: a Lubricate the seals using recommended air condi- Check that the floor carpet reaches under the tioning oil to make fitting easier.

  • Page 744: Heater Matrix: Removal - Refitting

    HEATING Heater matrix: Removal - Refitting LEFT-HAND DRIVE - the radio (see Radio: Removal - Refitting) (86A, Special tooling required Radio), Ms. 583 Pipe clamps. - the dashboard (see Dashboard: Removal - Refit- ting) (57A, Interior equipment). Tightening torquesm upper nuts of the strut 21 N.m lower bolts of the strut 21 N.m...
  • Page 745 HEATING Heater matrix: Removal - Refitting LEFT-HAND DRIVE - the two lower bolts (9) from the strut, - the stay. a Put a container in place to recover the coolant. II - REMOVAL OPERATION 24757 a Remove: - the heating resistor relay mounting bolt (6) , - the heating resistor relay mounting.
  • Page 746 HEATING Heater matrix: Removal - Refitting LEFT-HAND DRIVE II - REFITTING OPERATION - the instrument panel (see Instrument panel: Re- moval - Refitting) (83A, Instrument panel), a Refit the heater matrix. - the steering column switch assembly (see Steer- ing column switch assembly: Removal - Refit- ting) (84A, Control - Signals), a Refit: - the steering wheel (see Steering wheel: Removal...

  • Page 747: Fan Assembly: Removal - Refitting

    HEATING Fan assembly: Removal - Refitting II - REMOVAL OPERATION REMOVAL I - REMOVAL PREPARATION OPERATION LEFT-HAND DRIVE a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).

  • Page 748: Heating Resistor Relays: Removal - Refitting

    HEATING Heating resistor relays: Removal - Refitting Note: Do not remove the dashboard. REMOVAL I - REMOVAL PREPARATION OPERATION a Unclip the soundproofing under the dashboard using unclipping pliers. II - REMOVAL OPERATION 145077 a Remove the heating resistor relays (2) in the direc- tion of the arrows.

  • Page 749: Heating Resistors: Removal - Refitting

    HEATING Heating resistors: Removal - Refitting LEFT-HAND DRIVE Tightening torquesm lower bolts of the strut 21 N.m upper nuts of the strut 21 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners).
  • Page 750 HEATING Heating resistors: Removal - Refitting II - REMOVAL OPERATION 108102 a Partially lift the floor carpet to access the strut bolts. 128047 a Disconnect the heating resistor connector (6) in the a Make a mark between the strut and the panel weld- direction of the arrow.

  • Page 751: Passenger Compartment Fan Assembly Control Unit: Removal - Refitting

    HEATING Passenger compartment fan assembly control unit: Removal - Refitting Note: It is not necessary to remove the dashboard to remove the passenger compartment fan assembly control unit. REMOVAL REMOVAL OPERATION a Remove the lower trim of the dashboard (depending on the equipment level).

  • Page 752: Control Panel: Removal - Refitting

    HEATING Control panel: Removal - Refitting II - REMOVAL OPERATION REMOVAL I - REMOVAL PREPARATION OPERATION a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).

  • Page 753: Air Conditioning

    AIR CONDITIONING Air conditioning: List and location of components Note: The pictures show the fittings present on Logan. Fitting A 143987 62A-1...
  • Page 754 AIR CONDITIONING Air conditioning: List and location of components Fitting B 143988 62A-2...
  • Page 755 AIR CONDITIONING Air conditioning: List and location of components Fitting C 143991 62A-3...
  • Page 756 AIR CONDITIONING Air conditioning: List and location of components Fitting D 143990 62A-4...
  • Page 757 AIR CONDITIONING Air conditioning: List and location of components Fitting E 143993 62A-5...
  • Page 758 AIR CONDITIONING Air conditioning: List and location of components Fitting F 143989 62A-6...
  • Page 759 AIR CONDITIONING Air conditioning: List and location of components Fitting G 143992 Compressor (see 6 2 A , Air conditioning, Compressor: Removal - Refitting, page 62A-12) Condenser (see 6 2 A, Air conditioning, Condenser: Removal - Refitting, page 62A-10) Expansion valve (see 62A, Air conditioning, Expansion valve: Removal - Refitting, page 62A-16) Pressure sensor...
  • Page 760 AIR CONDITIONING Air conditioning: List and location of components Intermediate pipe - expansion valve connecting (see 62A, Air conditioning, Refrigerant circuit pipe (fittings A, B, and C) pipe: Removal - Refitting, page 62A-21) Condenser - expansion valve connecting pipe (fit- (see 62A, Air conditioning, Refrigerant circuit ting D) pipe: Removal - Refitting, page 62A-21)

  • Page 761: Air Conditioning: Parts And Consumables For The Repair

    AIR CONDITIONING Air conditioning: Parts and consumables for the repair AIR CONDITIONING To find out the part number of the oil used (see Vehi- Table of vehicle refrigerant capacities according to cle: Parts and consumables for the repair) (04B, their engines and various specifications: Consumables - Products).

  • Page 762: Condenser: Removal - Refitting

    AIR CONDITIONING Condenser: Removal - Refitting AIR CONDITIONING Equipment required refrigerant charging station 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 Air conditioning: Precautions for the repair) .
  • Page 763 AIR CONDITIONING Condenser: Removal - Refitting AIR CONDITIONING REFITTING I - REFITTING PREPARATION OPERATION WARNING Do not remove the blanking plugs from each component until the last moment. Also, do not remove the components from their packaging until they are to be fitted to the vehi- cle.

  • Page 764: Compressor: Removal - Refitting

    AIR CONDITIONING Compressor: Removal - Refitting AIR CONDITIONING a Remove: Equipment required - the front bumper (see Front bumper: Removal - Refitting) and (see Exterior body front trim as- refrigerant charging station sembly: Exploded view) (55A, Exterior protec- tion), - the front right-hand wheel (see Wheel: Removal - Tightening torquesm Refitting) (35A, Wheels and tyres), compressor bolts...
  • Page 765 AIR CONDITIONING Compressor: Removal - Refitting AIR CONDITIONING 145750 145191 a Remove: a Disconnect the compressor connector (5) . a Remove: - the bolt (3) from the pipe retaining clip on the com- pressor, - the compressor bolts (6) , - the pipe union bolts (4) on the compressor.
  • Page 766 AIR CONDITIONING Compressor: Removal - Refitting AIR CONDITIONING 143880 a Clean the surface and the seal of the pipe using EN- GINE CLEANER (see Vehicle: Parts and con- 145751 sumables for the repair) (04B, Consumables - a Disconnect the compressor connector (7) . Products).
  • Page 767 AIR CONDITIONING Compressor: Removal - Refitting AIR CONDITIONING II - REFITTING OPERATION a Proceed in the reverse order to removal. a Torque tighten: - the compressor bolts (21 N.m), - the pipe union bolts (8 N.m). a Torque tighten the pipe retaining bracket bolt on the compressor (21 N.m).

  • Page 768: Expansion Valve: Removal - Refitting

    AIR CONDITIONING Expansion valve: Removal - Refitting AIR CONDITIONING a Move aside the bulkhead soundproofing. Equipment required II - REMOVAL OPERATION refrigerant charging station a Remove the bolts from the pipes on the expansion valve (see 62A, Air conditioning, Air condition- ing: List and location of components, page 62A- IMPORTANT 1) .
  • Page 769 AIR CONDITIONING Expansion valve: Removal - Refitting AIR CONDITIONING II - REFITTING OPERATION a Proceed in the reverse order to removal. Note: Gradually tighten the expansion valve bolts so that the expansion valve is uniformly positioned on the pipes. a Consult the refrigerant and oil quantity values before filling the circuit (see 62A, Air conditioning, Air conditioning: Parts and consumables for the re- pair, page 62A-9) .

  • Page 770: Refrigerant Pipe Seal: Removal - Refitting

    AIR CONDITIONING Refrigerant pipe seal: Removal - Refitting REMOVAL Special tooling required Car. 1363 Set of trim removal levers. I - REMOVAL PREPARATION OPERATION Equipment required WARNING refrigerant charging station Consult the device's operating manual to avoid incorrect use. compressed air nozzle a Drain the refrigerant circuit using the refrigerant charging station (see Refrigerant circuit: Drain- IMPORTANT...
  • Page 771 AIR CONDITIONING Refrigerant pipe seal: Removal - Refitting - (see Compressor - intermediate pipe connect- ing pipe: Removal - Refitting) . II - OPERATION FOR REMOVAL OF PART CONCERNED WARNING T o avoid damaging the surface of the air condi- tioning pipes when removing the seals, do not use a tool with a metallic end piece.
  • Page 772 AIR CONDITIONING Refrigerant pipe seal: Removal - Refitting - (see Expansion valve - compressor connecting REFITTING pipe: Removal - Refitting) , - (see Expansion valve - rear expansion valve I - REFITTING PREPARATION OPERATION connecting pipe: Removal - Refitting) , a Lubricate the surface of the connecting pipe and the - (see Rear expansion valve - compressor con- seal with air conditioning oil to make fitting easier...

  • Page 773: Refrigerant Circuit Pipe: Removal - Refitting

    AIR CONDITIONING Refrigerant circuit pipe: Removal - Refitting AIR CONDITIONING Equipment required refrigerant charging station IMPORTANT Consult the safety instructions and cleanliness advice and the operation recommendations before carrying out any repairs (see Air conditioning: Precautions for repair). WARNING 145079 a Remove: To prevent moisture from entering the system, place plugs on the cold loop components which are...
  • Page 774 AIR CONDITIONING Refrigerant circuit pipe: Removal - Refitting AIR CONDITIONING REFITTING I - REFITTING PREPARATION OPERATION WARNING Do not remove the blanking plugs from each component until the last moment. Also, do not remove the components from their packaging until they are to be fitted to the vehi- cle.

  • Page 775: Pressure Sensor: Removal - Refitting

    AIR CONDITIONING Pressure sensor: Removal - Refitting AIR CONDITIONING REFITTING Tightening torquesm I - REFITTING OPERATION FOR PART pressure sensor 9 N.m CONCERNED a Refit the pressure sensor. a Torque tighten the pressure sensor (9 N.m). REMOVAL a Connect the pressure sensor. I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- II - FINAL OPERATION.
  • Page 776 Edition Anglaise "The repair procedures given by the manufacturer in this document are based on the All rights reserved by Renault s.a.s. technical specifications current when it was prepared. Copying or translating, in part or in full, of this document or use of the service part...
  • Page 777 CLIMATE CONTROL Fault finding – Introduction 1. SCOPE OF THIS DOCUMENT This document presents the fault finding procedure applicable to all computers with the following specifications: Vehicle(s): DUSTER Function concerned: Climate Control 2. PREREQUISITES FOR FAULT FINDING Documentation type Fault finding procedures (this document and the Technical Notes concerning the injection system fitted to the vehicle, and the UCH): –...
  • Page 778 CLIMATE CONTROL Fault finding – Introduction Faults Faults are declared present or stored (depending on whether they appeared in a certain context and have disappeared since, or whether they remain present but are not diagnosed within the current context). The present or stored status of the fault should be considered when the diagnostic tool is switched on after the + after ignition feed is switched on (without any action on the system components).
  • Page 779 CLIMATE CONTROL Fault finding – Introduction Special notes on the conformity check for the air conditioning function: The air conditioning system conformity check is divided into four parts. The parts relate to the four sub-functions of the air conditioning system: heating, cold loop, user selection and passenger compartment ventilation. The statuses and parameters related to these sub-functions are listed with their respective computers.
  • Page 780 CLIMATE CONTROL Fault finding – Introduction 4. FAULT FINDING PROCEDURE Perform a pre-diagnostic on the system Print the system fault finding log (available on CLIP and in Repair Manual or Technical Note) Connect CLIP Dialogue with See ALP no. 1 computer? Read the faults Faults...
  • Page 781 CLIMATE CONTROL Fault finding – Introduction 4. FAULT FINDING PROCEDURE (continued) Wiring check Note: Carry out each requested check visually. Do not remove a connector if it is not required. Note: Repeated connections and disconnections alter the functionality of the connectors and increase the risk of poor electrical contact.
  • Page 782 CLIMATE CONTROL Fault finding – Introduction Visual inspection of the sealing: (Only for watertight connectors) • Check for the seal on the connection (between the 2 parts of the connection). • Check the seal at the back of the connectors: –...
  • Page 783 CLIMATE CONTROL Fault finding – Introduction 5. FAULT FINDING LOG IMPORTANT Any fault on a complex system requires thorough fault finding with the appropriate tools. The FAULT FINDING LOG, which should be completed during the fault finding procedure, ensures a record is kept of the procedure carried out. It is an essential document when IMPORTANT! consulting the manufacturer.
  • Page 784 CLIMATE CONTROL Fault finding – List and location of components System (cold loop, hot loop and components) 1) Air conditioning unit 2) Heater matrix 3) Expansion valve and evaporator 4) Coolant circuit 5) Cold loop 6) Condenser and radiator 7) Compressor •...
  • Page 785 CLIMATE CONTROL Fault finding – List and location of components – Low pressure pipe: This pipe connects the expansion valve, buffering capacity, evaporator and compressor inlet in series (it is located in the engine compartment on the left-hand side). • HEATING COMPONENTS –...
  • Page 786 CLIMATE CONTROL Fault finding – Role of components • COLD LOOP COMPONENTS System assembly 1) Air conditioning unit 2) Heater matrix 3) Expansion valve and evaporator 4) Coolant circuit 5) Cold loop 6) Condenser and radiator 7) Compressor MR-453-X79-62C000$030.mif 62C-11...
  • Page 787 CLIMATE CONTROL Fault finding – Role of components Figure 1: System assembly – Compressor: The compressor is not activated when the exterior temperature is less than 3˚C, it is used to compress the refrigerant into gas. The pressure can reach up to 28 bar. –...
  • Page 788 CLIMATE CONTROL Fault finding – Role of components – Dehydrator reservoir: (see figure above) The dehydrator reservoir is used to: • Check the condition of the refrigerant. • Absorb the variations in volume (expansion bottle principle). • Filter impurities. • Absorb moisture (water in the circuit). –...
  • Page 789 CLIMATE CONTROL Fault finding – Role of components – High and low pressure pipes: • The High Pressure and Low Pressure pipes are composed of rigid aluminium pipes and flexible pipes which enable engine-related movements to be absorbed. • Two filler valves (on the High Pressure pipe and on the Low Pressure pipe) can be accessed in order to fill (or drain) the refrigerant loop.
  • Page 790 CLIMATE CONTROL Fault finding – Role of components – Passenger compartment heating resistors (depending on the equipment level): The passenger compartment heating resistors (RCH) are electrical heating devices in the air conditioning unit. This system is an additional heating system which operates when the engine is cold (when starting). •...
  • Page 791 CLIMATE CONTROL Fault finding – Role of components Resistive Blower Dimmer Module (MVPR) 1) Thermal fuse 2) Fan assembly connector 3) Connector to Control panel The passenger compartment fan assembly is used to vary the rate at which air is blown into the passenger compartment, depending on the requirements of the customer.
  • Page 792 CLIMATE CONTROL Fault finding – Operating diagram Summary diagram of all the components of the air conditioning system 1) Evaporator 2) Temperature sensor 3) Compressor 4) Condenser 5) Fan assembly 6) Pressure switch 7) Dehydrator reservoir 8) Expansion valve MR-453-X79-62C000$040.mif 62C-17...
  • Page 793 CLIMATE CONTROL Fault finding – Function Layout of the air conditioning function: The functions provided by the system are the thermal comfort of the occupants (warming and cooling), visibility through the windscreen, as well as the isolation of the passenger compartment in case of exterior air pollution. The heating and air conditioning system dries and purifies the air in the passenger compartment.
  • Page 794 CLIMATE CONTROL Fault finding – Function Buttons with operation indicator lamps: • Air conditioning button. Manual controls: • Mixing: rotary control on the right-hand side, with cable connection to the flap. • Distribution: rotary control on the left-hand side, with cable connection to the flap. •...
  • Page 795 CLIMATE CONTROL Fault finding – Function Exchanges between the two air conditioning computers (manual air conditioning) Switch on heated rear screen request (+ electric door mirrors) MANUAL AIR CONDITIONING CONTROL PANEL Air conditioning request INJECTION COMPUTER Engine status signal MR-453-X79-62C000$050.mif 62C-20...
  • Page 796 CLIMATE CONTROL Fault finding – Function Summary of components controlled or managed by the MANUAL AIR CONDITIONING control panel: Ventilation and air conditioning unit Passenger compartment fan Resistor unit Recirculation flap Distribution flap Mixing flap Actuator control User control panel User request management (heated rear screen button pressed)
  • Page 797 CLIMATE CONTROL Fault finding – Function Summary diagram of components controlled or managed by the UCH: Rear screen de-icing and rear-view mirror de-icer (depending on version) Vehicle wire network Actuator control Heated rear screen control management Summary diagram of components controlled or managed by the injection computer: Engine cooling Engine coolant Refrigerant...
  • Page 798 CLIMATE CONTROL Fault finding – Function Compressor control flowchart: AIR CONDITIONING REQUEST Injection Computer ET321: AIR CONDITIONING COMPRESSOR Air conditioning compressor Special notes: This flowchart shows the tracks of the compressor engagement request. Key: If the compressor does not engage (one of the requests is not transmitted): carry out a : Wire connections conformity check.
  • Page 799 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). Application conditions: Engine stopped, ignition on, AIR CONDITIONING SWITCHED OFF (Passenger compartment blower unit switched off and air conditioning NOTES compressor not activated).
  • Page 800 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). Application conditions: Engine stopped, ignition on, AIR CONDITIONING SWITCHED OFF (Passenger compartment blower unit switched off and air conditioning NOTES compressor not activated).
  • Page 801 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Application conditions: Engine stopped, ignition on, AIR CONDITIONING SWITCHED OFF (Passenger compartment blower unit switched off and air conditioning compressor not activated).
  • Page 802 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Application conditions: Engine stopped, ignition on, AIR CONDITIONING SWITCHED OFF (Passenger compartment blower unit switched off and air conditioning compressor not activated).
  • Page 803 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Application conditions: Engine at idle speed, AIR CONDITIONING OPERATING (air conditioning compressor engaged). SUB-FUNCTION: COLD LOOP Parameter or Status Computer...
  • Page 804 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Application conditions: Engine at idle speed, AIR CONDITIONING OPERATING (air conditioning compressor engaged). SUB-FUNCTION: COLD LOOP (CONTINUED) Parameter or Status Computer...
  • Page 805 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Application conditions: Engine at idle speed, AIR CONDITIONING OPERATING (air conditioning compressor engaged). SUB-FUNCTION: HEATING Parameter or Status Computer...
  • Page 806 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Application conditions: Engine at idle speed, AIR CONDITIONING OPERATING (air conditioning compressor engaged). SUB-FUNCTION: HEATING (CONTINUED) Parameter or Status Computer...
  • Page 807 CLIMATE CONTROL Fault finding – Conformity check Only carry out this conformity check after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Application conditions: Engine at idle speed, AIR CONDITIONING OPERATING (air conditioning compressor engaged). SUB-FUNCTION: USER SELECTION Parameter or Computer...
  • Page 808 CLIMATE CONTROL Fault finding – Conformity check SUMMARY TABLE OF THE VARIOUS AIR CONDITIONING COMPUTER COMMANDS NAME OF SUB- COMPUTER NAME TITLE OF COMMAND FAULT FINDING FUNCTION AC180: Air conditioning compressor relay control or AC070 Air conditioning In the event of a fault, compressor consult the interpretation of this...
  • Page 809 CLIMATE CONTROL Fault finding – Customer complaints Special notes: NOTES This section corresponds to the list of possible customer complaints. AIR DISTRIBUTION PROBLEM AIR DISTRIBUTION PROBLEM ALP 2 AIR FLOW FAULT ALP 3 INEFFICIENT WINDSCREEN DEMISTING ALP 4 NO PASSENGER COMPARTMENT VENTILATION ALP 5 HEATING FAULT NO HEATING OR LOSS OF HEATING (section 61A)
  • Page 810 CLIMATE CONTROL Fault finding – Customer complaints PASSENGER COMPARTMENT ODOURS UNPLEASANT ODOURS IN PASSENGER COMPARTMENT ALP 11 WATER IN PASSENGER COMPARTMENT WATER IS PRESENT IN PASSENGER COMPARTMENT ALP 12 CONTROL PANEL FAULT NO CONTROL PANEL LIGHTING ALP 13 COMPRESSOR NOISES COMPRESSOR NOISES ALP 14 MR-453-X79-62C000$070.mif...
  • Page 811 CLIMATE CONTROL Fault finding – Fault finding chart ALP 2 Air distribution fault Make sure that the air circuit (cabin filter, scuttle panel grille, air ducts etc.) is not NOTES blocked. Check that the air circuit (cabin filter, scuttle panel grille, air vents and extractors etc.) is not blocked. Ensure that the passenger compartment fan blades are in good condition.
  • Page 812 CLIMATE CONTROL Fault finding – Fault finding chart ALP 2 CONTINUED 1 Remove the glovebox and the centre console in order to visually check whether moving the control causes the distribution flaps to move. Check that the distribution flaps Does it move? are in good condition, the footwell distribution flap linkages are in position, and that there is no...
  • Page 813 CLIMATE CONTROL Fault finding – Fault finding chart ALP 2 CONTINUED 2 Check that the cable routing is clean and that the cables are in good condition. Repair if necessary. Make sure that the controls are in good condition and that they move the cables correctly. Repair if necessary.
  • Page 814 CLIMATE CONTROL Fault finding – Fault finding chart ALP 3 Air flow fault Only refer to this customer complaint after a complete check using the NOTES diagnostic tool Check that the customer knows how to work the air conditioning system properly. Does the passenger compartment fan operate? Check all of the speeds: Does the flow vary in accordance with the position of Repair, see ALP 5.
  • Page 815 CLIMATE CONTROL Fault finding – Fault finding chart ALP 3 CONTINUED Ensure that the blower unit is properly sealed. Also check that the air distribution ducts (right-hand and left-hand, upper and lower) are correctly connected to the housing as well as the refrigeration pipe in the glove box (if the customer complains about a feeling of cold air on the passenger's side).
  • Page 816 CLIMATE CONTROL Fault finding – Fault finding chart ALP 4 Inefficient windscreen demisting Special notes: NOTES Check that the inside of the windows are not greasy, as this reduces the demisting efficiency. Is the passenger compartment fan working? Repair, see ALP 5. Check that the air extraction vents are not blocked.
  • Page 817 CLIMATE CONTROL Fault finding – Fault finding chart ALP 4 CONTINUED Check that the condensation evacuation port (water from the evaporator) is not blocked. Repair if necessary. Is it an air distribution fault? See ALP 2. Is it an air flow fault? See ALP 3.
  • Page 818 CLIMATE CONTROL Fault finding – Fault finding chart ALP 5 No passenger compartment ventilation NOTES Check that fuses F39 and F36 are in good condition. Check that the air circuit (cabin filter, scuttle panel grille, air ducts, etc.) is not blocked. Is the air circuit in good condition? If necessary, repair, clean or replace the cabin filter (see MR 451 Mechanical, 61A, Heating, Cabin filter:...
  • Page 819 CLIMATE CONTROL Fault finding – Fault finding chart ALP 5 CONTINUED 1 Is the fault still present? END OF FAULT FINDING Check fuses F36 and F39 of component 1016. Replace the faulty fuse. Are the checks correct? Using a multimeter in the voltmeter position, check for +12 V on connection SP3 and BP1 of component 233 and earth MAM of component 233.
  • Page 820 CLIMATE CONTROL Fault finding – Fault finding chart ALP 5 CONTINUED 2 Repair the wiring. If there is a Carry out a continuity test on repair method (see Technical Check for +12 V on connection connection S1 between Note 6015A, Repairing S1 of component 319.
  • Page 821 CLIMATE CONTROL Fault finding – Fault finding chart ALP 5 CONTINUED 3 Carry out a continuity test on connection 38AH between components 319 and 164. Is the continuity correct? Fault on connection 38AH between components 319 and 164. Repair the wiring. If there is a repair procedure (see Technical Note 6015A, Carry out a continuity test on connection 38AJ Repairing electrical wiring, Wiring: Precautions for...
  • Page 822 CLIMATE CONTROL Fault finding – Fault finding chart ALP 5 CONTINUED 4 Fault on connection 38AK between components 319 and 164. Repair the wiring. If there is a repair procedure (see Technical Note 6015A, Repairing electrical wiring, Carry out a continuity test on connection 38AK Wiring: Precautions for repair), repair the wiring, between components 319 and 164.
  • Page 823 CLIMATE CONTROL Fault finding – Fault finding chart ALP 5 CONTINUED 5 Fault on connection 38DB between components 319 and 164. Repair the wiring. If there is a repair procedure (see Technical Note 6015A, Repairing electrical wiring, Wiring: Precautions for repair), repair the wiring, otherwise replace it.
  • Page 824 CLIMATE CONTROL Fault finding – Fault finding chart ALP 5 CONTINUED 6 Test the continuity on connection SP3 between component 233 and fuse F39 of component 1016. Is the continuity correct? Repair the wiring. If there is a repair method (see Technical Note 6015A, Repairing electrical wiring, Wiring: Precautions for repair), repair or replace the wiring.
  • Page 825 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 No cold air Consult this customer complaint after a complete check with the diagnostic tool (fault reading and configuration checks). Check that the engine speed is greater than 750 rpm and that the exterior temperature NOTES is above 3˚C.
  • Page 826 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 1 Replace the expansion valve (see MR 451 Mechanical, 62A, Air Is the expansion valve pipe hot at the inlet and outlet? conditioning, Expansion valve: Removal - Refitting). Is the evaporator pipe hot at the inlet and outlet? Replace the evaporator.
  • Page 827 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 2 Using the diagnostic tool statuses and parameters Carry out a conformity check: screen (Injection cold loop sub-function), check that the temperature signals are consistent (no – For the coolant temperature sensor, sensor drift resulting in incorrect measurement).
  • Page 828 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 3 Using the diagnostic tool (injection cold loop sub-function screen), display the following statuses: – ET321: Air conditioning compressor Is status ET321 ACTIVE? Carry out fault finding on the injection system to ensure that no fault is present (if faults are displayed by the injection computer, engagement of the air conditioning may be inhibited).
  • Page 829 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 4 Check that the engine cooling fan assembly is at speed 1 by viewing the following status on the cold loop sub-function screen: – Status ET298 Low-speed fan assembly should display ACTIVE.
  • Page 830 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 5 Measure the resistance of component 321 Check the continuity of connection 49C between connections 49C and 49B of between components 321 and 784. component 321. If the measured resistance is infinite, replace the fan assembly resistor Is the continuity correct? (component 321).
  • Page 831 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 6 Check the air conditioning compressor belt tension (see Technical Note 3786A, Engine and cylinder block assembly, 10A, Belt tension setting tool Hz Replace the belt. (see MR 451, measurement: tension values).
  • Page 832 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 7 Replace the air conditioning clutch (component 171) if possible, otherwise replace the compressor (see MR 451 Mechanical, 62A, Air conditioning, Compressor: Removal - Refitting). Check the continuity and insulation to earth of connection 38R between components 171 and 784.
  • Page 833 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 8 With the engine warm and the passenger Check the condition and routing of the mixing flap control compartment ventilation operating, vary cable. Eliminate any constraints on it: kinks, cable restricted the position of the mixing flap from the by plastic clips, etc.
  • Page 834 CLIMATE CONTROL Fault finding – Fault finding chart ALP 8 CONTINUED 9 Top up the refrigerant (see MR 451 Mechanical, 62A, Air conditioning, Refrigerant circuit: Draining - Filling). Is the fault still present? End of fault finding procedure. Replace the air conditioning compressor. AFTER REPAIR Carry out a full check with the diagnostic tool.
  • Page 835 CLIMATE CONTROL Fault finding – Fault finding chart ALP 9 Too much cold air Consult this customer complaint after a complete check with the diagnostic tool (fault reading and configuration checks). NOTES Check that the fuses are in good condition. Use a multimeter and a 21 W test light.
  • Page 836 CLIMATE CONTROL Fault finding – Fault finding chart ALP 9 CONTINUED 1 With the vehicle ignition Replace the air conditioning compressor (see MR 451, If there is a repair off, check that the Mechanical, 62A, Air conditioning, Compressor: procedure (see compressor clutch relay Removal - Refitting).
  • Page 837 CLIMATE CONTROL Fault finding – Fault finding chart ALP 9 CONTINUED 2 With the engine warm and the passenger compartment ventilation operating, vary the position of the mixing flap from the maximum cold position to the maximum hot position and check subjectively that there is a difference in temperature.
  • Page 838 CLIMATE CONTROL Fault finding – Fault finding chart ALP 9 CONTINUED 3 Using the diagnostic tool statuses and parameters screen (Injection cold loop sub-function), check that Carry out a conformity check: the temperature signals are consistent (no sensor drift resulting in incorrect measurement). –...
  • Page 839 CLIMATE CONTROL Fault finding – Fault finding chart ALP 10 Inefficient rear screen de-icing and demisting Carry out this conformity check after a complete check using the diagnostic tool (fault reading, especially UCH and injection faults and configuration checks). Check that the fuses are in good condition. Use a multimeter and a 21 W test light.
  • Page 840 CLIMATE CONTROL Fault finding – Fault finding chart ALP 10 CONTINUED 1 Ensure that there are no water leaks in the passenger compartment which would significantly increase the moisture and reduce the effectiveness of the demisting function (see ALP 12 if the fault is noted). Is the fault still present? End of fault finding procedure.
  • Page 841 CLIMATE CONTROL Fault finding – Fault finding chart ALP 10 CONTINUED 2 Check for earth on connection MAM of component 1456. Press the de-icing button on the control panel and check status: – ET547: Rear de-icing button Is the result of the check correct? Does status ET547 display PRESSED? Check the continuity and insulation of connection 15B...
  • Page 842 CLIMATE CONTROL Fault finding – Fault finding chart ALP 10 CONTINUED 3 Continuity fault on connection 15M. Use an ohmmeter to Press the de-icing button on the control perform a continuity test on connection 15M between panel and check for earth on connection components 235 and 645.
  • Page 843 CLIMATE CONTROL Fault finding – Fault finding chart ALP 10 CONTINUED 4 Connect a test light between connection 15LP of component 200 and a chassis earth. Does the test bulb illuminate? Check the continuity of connection 15LP between components 235 and 200. Is the connection OK? If there is a repair method (see Technical Note 6015A,...
  • Page 844 CLIMATE CONTROL Fault finding – Fault finding chart ALP 11 Unpleasant odours in the passenger compartment NOTES None. Check that the cabin filter is not blocked or damaged. End of fault finding Is the fault still present? procedure. Check that the condensate drain pipe (water from the evaporator) is not blocked.
  • Page 845 CLIMATE CONTROL Fault finding – Fault finding chart ALP 11 CONTINUED Check that the heating unit is completely sealed and there are no leaks into the engine compartment: – Foam seal on the heater matrix coolant pipes fitted and in good condition.
  • Page 846 CLIMATE CONTROL Fault finding – Fault finding chart ALP 12 Water is present in the passenger compartment NOTES None. Pressurise the cooling circuit. Is there any coolant leaking into the Repair. vehicle? Check that the condensation evacuation pipe (water from the evaporator) is not blocked. Repair if necessary.
  • Page 847 CLIMATE CONTROL Fault finding – Fault finding chart ALP 13 No lighting on the control panel in night mode Check fuse F19 or F18 (depending on model: F19 for left-hand drive and F18 for right- NOTES hand drive) of component 1016. Check fuse F19 (left-hand drive) or F18 (right-hand drive) of Replace the faulty fuse.
  • Page 848 CLIMATE CONTROL Fault finding – Fault finding chart ALP 13 CONTINUED Are the bulbs sound? Is the test correct? Fault on connection LPD or LPG between F19 (left-hand drive) or F18 (right-hand drive) of Check for earth components 1016 and Replace the air Replace the air on connection...
  • Page 849 CLIMATE CONTROL Fault finding – Fault finding chart ALP 14 Compressor noise Only address this customer complaint after a complete check with the diagnostic tool. NOTES Note: Before starting any work, check that the noise is indeed coming from the compressor. Check that the compressor belt is in good condition and check its tension (for engines without automatic tensioning) (see MR 451, Mechanical, 11A, Top and front of engine, Accessories belt: Removal - Refitting).
  • Page 850 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 851 DUSTER - Chapitre 6 DUSTER - Chapitre 6ContentsPages Contents Pages OPENING ELEMENT SEALING Side door frame seal: Removal - Refitting 65A-1 WINDOW SEALING Front side door window run channel: Removal - Refitting 66A-1 Front side door exterior weatherstrip: Removal - Refitting 66A-2 Rear side door exterior...
  • Page 852 OPENING ELEMENT SEALING Side door frame seal: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION 108662 a Remove the trim (2) . II - REMOVAL OPERATION 125529 a Remove the trim piece bolt (1) . 108661 a Remove the frame seal (3) . 108663 a Unclip the trim at (2) .
  • Page 853 OPENING ELEMENT SEALING Side door frame seal: Removal - Refitting 117828 a Remove the frame seal (4) . REFITTING a Proceed in the reverse order to removal. 65A-2...
  • Page 854 WINDOW SEALING Front side door window run channel: Removal - Refitting II - REMOVAL OPERATION REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the front side door trim (see Front side door trim: Removal - Refitting) (72A, Side opening element trim), - the front side door sliding window (see Front side door sliding window: Removal - Refitting) (54A,...
  • Page 855 WINDOW SEALING Front side door exterior weatherstrip: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL I - REMOVAL PREPARATION OPERATION a Lower the window. II - REMOVAL OPERATION 144643 a Carefully remove the exterior weatherstrip (4) using the tool (Car.
  • Page 856 WINDOW SEALING Rear side door exterior weatherstrip: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL I - REMOVAL PREPARATION OPERATION a Lower the window. II - REMOVAL OPERATION 144644 a Carefully remove the exterior weatherstrip (4) using the tool (Car.
  • Page 857 WINDOW SEALING Rear side door window run channel: Removal - Refitting REMOVAL REFITTING I - REFITTING OPERATION FOR PART REMOVAL PREPARATION OPERATION CONCERNED a Remove: a Refit the rear side door window glass run channel. - the rear side door trim (see Rear side door trim: a Refit: Removal - Refitting) (72A, Side opening element trim),...
  • Page 858 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 859 DUSTER - Chapitre 7 DUSTER - Chapitre 7ContentsPages Contents Pages FRONT SEAT FRAMES AND BODY INTERNAL TRIM MECHANISMS Interior body side trim Front seat assembly: assembly: Exploded view 71A-1 Exploded view 75A-1 Roof trim assembly: Exploded view 71A-3 Floor trim assembly: Exploded view 71A-4 Floor carpet: Removal -...

  • Page 860: Body Internal Trim

    BODY INTERNAL TRIM Interior body side trim assembly: Exploded view 145783 (see ) (01D, Mechanical introduction) Mark Description Information C-pillar upper trim (Car. 1363) Rear parcel shelf side trim bolt Rear parcel shelf side trim Rear wheel arch trim (Car. 1363) Rear wheel arch trim bolt C-pillar trim (Car.
  • Page 861 BODY INTERNAL TRIM Interior body side trim assembly: Exploded view Mark Description Information B-pillar lower trim bolt Windscreen pillar trim (Car. 1363) Front side door seal 71A-2...

  • Page 862: Roof Trim Assembly: Exploded View

    BODY INTERNAL TRIM Roof trim assembly: Exploded view 145784 (see ) (01D, Mechanical introduction) Mark Description Information Grab handle Courtesy light Sun visor Sun visor hook Sun visor bolt Headlining clip Grab handle bolt Headlining 71A-3...

  • Page 863: Floor Trim Assembly: Exploded View

    BODY INTERNAL TRIM Floor trim assembly: Exploded view 145785-1 (see ) (01D, Mechanical introduction) Mark Description Information Luggage compartment carpet Lashing hook Floor carpet clip Car. 1363 Floor carpet Floor soundproofing 71A-4...

  • Page 864: Floor Carpet: Removal - Refitting

    BODY INTERNAL TRIM Floor carpet: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the front seats (see Complete front seat: Remov- al - Refitting) , - the centre console (see Centre console: Removal - Refitting) (MR 389, 57A, Interior equipment), - the B-pillar linings (see 71A, Body internal trim, B-pillar trim: Removal - Refitting, page 71A-9) , - the side door seals partially.
  • Page 865 BODY INTERNAL TRIM Floor carpet: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 108503 a Remove clip (7) . 118629 a Remove the retaining clips (5) . 108504 a Pull away the carpet. REFITTING I - REFITTING OPERATION FOR PART 108502 CONCERNED a Remove clip (6) .
  • Page 866 BODY INTERNAL TRIM Floor carpet: Removal - Refitting a Refit: - the side door seals, - the B-pillar linings (see 71A, Body internal trim, B-pillar trim: Removal - Refitting, page 71A-9) , - the centre console (see Centre console: Removal - Refitting) (MR 389, 57A, Interior equipment), - the front seats (see Complete front seat: Remov- al - Refitting) .

  • Page 867: Windscreen Pillar Trim: Removal - Refitting

    BODY INTERNAL TRIM Windscreen pillar trim: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION 107832 a Partially remove door seal (1) . II - REMOVAL OPERATION 107833 a Remove the windscreen pillar trim by (2) and (3) . REFITTING a Proceed in the reverse order to removal.

  • Page 868: B-Pillar Trim: Removal - Refitting

    BODY INTERNAL TRIM B-pillar trim: Removal - Refitting Tightening torquesm upper and lower bolts 21 N.m for the seat belt REMOVAL I - REMOVAL PREPARATION OPERATION 108515 a Remove: - the cover, - the bolt (2) . 108517 a Remove the bolt (1) . 71A-9...
  • Page 869 BODY INTERNAL TRIM B-pillar trim: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 117826 a Remove the B-pillar upper trim. 108536 118108 108482 a Remove the B-pillar lower trim. a Remove: - the control (4) using a flat screwdriver, REFITTING - the door seals (partially).
  • Page 870 BODY INTERNAL TRIM B-pillar trim: Removal - Refitting - the door seals, - the seat belt adjustment control. II - FINAL OPERATION a Refit the upper and lower bolts for the seat belt. a Tighten to torque the upper and lower bolts for the seat belt (21 N.m).

  • Page 871: Side Opening Element Trim

    SIDE OPENING ELEMENT TRIM Front side door trim: Removal - Refitting REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 125450 a Remove: - the bolts (3) , - the speaker. 125449 a Disconnect the speaker connector. a Remove: - the bolt (1) , - the opening control, - the speaker grille (2) .
  • Page 872 SIDE OPENING ELEMENT TRIM Front side door trim: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a If necessary, replace: - the front door trim clips, - the front door trim sealing mastic (part no.: 77 01 423 330). Note: To make it easier to fit the trim, moisten the box section at the point where the seal is applied.

  • Page 873: Rear Side Door Trim: Removal - Refitting

    SIDE OPENING ELEMENT TRIM Rear side door trim: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the rear side door interior handle (see Rear side door interior opening control: Removal - Refit- ting) (51A, Side opening element mechanisms).
  • Page 874 SIDE OPENING ELEMENT TRIM Rear side door trim: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Check the condition of the clips and replace them if necessary. Note: To facilitate fitting the rear side door trim, dampen the box section where the seal is to be applied.
  • Page 875 SIDE OPENING ELEMENT TRIM Rear side door trim: Removal - Refitting 109593 109594 a Finish the operation using a conical milling cutter. 72A-5...

  • Page 876: Non-Side Opening Elements Trim

    NON-SIDE OPENING ELEMENTS TRIM Rear opening element assembly on the passenger compartment side: Exploded view 146251 (see ) (01D, Mechanical introduction). Mark Description Information T ailgate trim (Car. 1363) High level brake light bulb high level brake light bolt High level brake light cover (Car.

  • Page 877: Front Seat Frames And Mechanisms

    FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view DRIVER HEIGHT ADJUSTER 146024 (see ) Mark Description Information Front seat lumbar adjustment con- trol trim Front seat backrest tilt control Front seatback angle control trim Front seat base frame Front seat lumbar adjustment con- trol Front seat lumbar adjustment...
  • Page 878 FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view DRIVER HEIGHT ADJUSTER Mark Description Information Bolt of front seat base exterior cas- Front seat base exterior casing Front seat lumbar adjustment mechanism FRONT SIDE AIRBAG or FRONT SIDE + CUR- TAIN AIRBAG Mark Description...
  • Page 879 FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view DRIVER HEIGHT ADJUSTER 146025 (see ) Mark Description Information Seat trim clip (Car.1521) Front seatback cover (see ) Front seat base cover (see ) Front seat headrest (see ) Front seat back foam Front seat base foam FRONT SIDE AIRBAG, and FRONT SEAT WITH HEATING, and WITH SEA T BELT NOT SECURED...
  • Page 880 FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view DRIVER HEIGHT ADJUSTER Mark Description Information Front seat electrical wiring support Retaining clip FRONT SEAT WITH HEATING Mark Description Information Front seatback heated pad Front seat base heated pad 75A-4...
  • Page 881 FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view FIXED SUBFRAME 146034 (see ) Mark Description Information Front seat backrest tilt control Front seat headrest guide (see ) Front seat frame (see ) Front seatback angle control trim Front seat belt buckle (see Front seat belt buckle: Removal - Refitting) Front seat runner...
  • Page 882 FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view FIXED SUBFRAME FRONT SIDE AIRBAG or FRONT SIDE + CUR- TAIN AIRBAG Mark Description Information Front seat chest-level side airbag dummy module Bolt of front seat chest-level side airbag dummy module Front seat chest-level side airbag (see Front (chest-level) side air- bag: Removal - Refitting)
  • Page 883 FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view FIXED SUBFRAME 146035 (see ) Mark Description Information Seat trim clip (Car.1521) Front seatback cover (see ) Front seat base cover (see ) Front seat headrest (see ) Front seat back foam Front seat base foam FRONT SEAT WITH HEATING Mark...
  • Page 884 FRONT SEAT FRAMES AND MECHANISMS Front seat assembly: Exploded view FIXED SUBFRAME FRONT SIDE AIRBAG, and FRONT SEAT WITH HEATING, and WITH SEA T BELT NOT SECURED WARNING Mark Description Information Front seat electrical wiring Front seat electrical wiring support Retaining clip 75A-8...
  • Page 885 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 886 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 887 DUSTER - Chapitre 8 DUSTER - Chapitre 8ContentsPages Contents Pages BATTERY REAR LIGHTING Battery: Precautions for the Rear light assembly: repair 80A-1 Exploded view 81A-1 Battery: Removal - Refitting 80A-2 Rear wing light: Removal - Refitting 81A-2 Rear light bulb: Removal - Refitting 81A-3 HEADLIGHTS...
  • Page 888 Contents FUSES CONTROL - SIGNALS Fuses: List and location of Central door locking switch: components 81C-1 Removal - Refitting 84A-9 Remote headlight beam adjustment control: Removal - Refitting 84A-10 ENGINE IMMOBILISER Exterior rear view mirror control switch: Removal - Immobiliser system: List and Refitting 84A-12 location of components...
  • Page 889 Contents RADIO WIRING HARNESS Radio: List and location of Wiring: Precautions for the components 86A-1 repair 88A-3 Radio: Removal - Refitting 86A-3 Front bumper wiring: Removal - Refitting 88A-4 Radio aerial: Removal - Refitting 86A-4 Engine wiring: Removal - Refitting 88A-5 Front speakers: Removal - Refitting...
  • Page 890 Contents AIR BAG AND PRETENSIONERS Rear centre seat belt: Removal - Refitting 88C-23 Seat belt reminder warning light: Removal - Refitting 88C-26...

  • Page 891: Battery: Precautions For The Repair

    BATTERY Battery: Precautions for the repair I - SAFETY IMPORTANT 1 - DANGER: RISK FROM ACID LINKED TO To avoid all risk of sparks, ensure that all electrical HANDLING consumers are fully switched off. Sulphuric acid is a highly aggressive and toxic sub- When a battery is being charged inside a building, stance which corrodes most metals.

  • Page 892: Battery: Removal - Refitting

    BATTERY Battery: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm 1 - DISCONNECTING battery bracket bolt 12 Nm bolt on the positive bat- 6 N.m tery terminal negative battery termi- 6 N.m nal nut IMPORTANT Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 80A, Battery, Battery: Precautions for...
  • Page 893 BATTERY Battery: Removal - Refitting 2 - REMOVAL 24730 24729 a Remove: a Remove the cover (2) from the positive battery ter- - the battery clamp bolt (4) , minal. - the mounting clamp (5) , - the battery. 3 - REPLACEMENT a Check that the battery needs replacing (see Techni- cal Note 6014A, Checking the charging circuit, 16A, Starting-charging, Checking the charging...
  • Page 894 BATTERY Battery: Removal - Refitting a Push the positive battery terminal fully onto the bat- tery terminal post. WARNING Poor contact may cause starting or charging faults, create sparks and cause the battery to explode (see 80A, Battery, Battery: Precau- tions for the repair, page 80A-1) .

  • Page 895: Headlight Assembly: Exploded View

    HEADLIGHTS Headlight assembly: Exploded view 143999 Main beam headlight bulbs Side light bulb (see 80B, Headlights, Headlight bulb: Removal - Refitting, page 80B-5) Direction indicator bulb Dipped beam headlight bulb Headlight beam adjustment actuator (see 80B, Headlights, Remote headlight beam adjustment actuator: Removal - Refitting, page 80B-9) Headlight...

  • Page 896: Headlight: Removal - Refitting

    HEADLIGHTS Headlight: Removal - Refitting Location and specifications (tightening torques, parts always to be replaced, etc.) (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1) REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

  • Page 897: Headlight: Adjustment

    HEADLIGHTS Headlight: Adjustment III - ADJUSTMENT OPERATION Equipment required 1 - Beam adjustment headlight adjustment and checking tool ADJUSTMENT I - PREPARATION OPERATION FOR CHECK a Place the vehicle on a level horizontal working area. a Do not apply the parking brake. a Check and inflate the tyres (see ) (35A, Wheels and tyres).
  • Page 898 HEADLIGHTS Headlight: Adjustment IV - FINAL OPERATION a Close the bonnet. 80B-4...

  • Page 899: Headlight Bulb: Removal - Refitting

    HEADLIGHTS Headlight bulb: Removal - Refitting Location and specifications (tightening torques, parts always to be replaced, etc.) (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1) Note: The operation for removing - refitting the bulbs does not require the headlight to be removed. REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition.

  • Page 900: Front Fog Light Bulb: Removal - Refitting

    HEADLIGHTS Front fog light bulb: Removal - Refitting II - REMOVAL OPERATION REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). 144539 a Disconnect the front fog light connector (3) . 145207 a Remove: - the clips (1) ,...

  • Page 901: Front Fog Light: Removal - Refitting

    HEADLIGHTS Front fog light: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the front bumper (see Front bumper as- sembly: Exploded view) (55A, Exterior protection). II - REMOVAL OPERATION 145208 a Adjust the front fog lights using a screwdriver.

  • Page 902: Side Indicator: Removal - Refitting

    HEADLIGHTS Side indicator: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the side indicator using the (Car. 1363). 118608 a Disconnect the bulb holder connector (1) by turning it a quarter of a turn anti-clockwise.

  • Page 903: Remote Headlight Beam Adjustment Actuator: Removal - Refitting

    HEADLIGHTS Remote headlight beam adjustment actuator: Removal - Refitting Location and specifications (tightening torques, parts always to be replaced, etc.) (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1) REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).

  • Page 904: Rear Lighting

    REAR LIGHTING Rear light assembly: Exploded view 144000 Brake light and side light bulb (see 8 1 A , Rear lighting, Rear light bulb: Direction indicator bulb Removal - Refitting, page 81A-3) Fog or reversing light bulb Rear light (see 8 1 A, Rear lighting, Rear wing light: Removal - Refitting, page 81A-2) 81A-1...

  • Page 905: Rear Wing Light: Removal - Refitting

    REAR LIGHTING Rear wing light: Removal - Refitting Location and specifications (tightening torques, parts always to be replaced, etc.) (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1) REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition. Rear light on the wing (right-hand side) a Remove - the jack cover,...

  • Page 906: Rear Light Bulb: Removal - Refitting

    REAR LIGHTING Rear light bulb: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition. a Remove the rear light on the wing (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1) . II - REMOVAL OPERATION 145583 a Unclip the bulb holder by pressing on the clips (1) .

  • Page 907: 3Rd Brake Light: Removal - Refitting

    REAR LIGHTING 3rd brake light: Removal - Refitting - the high level brake light , REMOVAL - the high level brake light screws. OPERATION FOR REMOVAL OF PART a Connect the high level brake light connector. CONCERNED a Clip on the high level brake light cover. 125456 a Unclip the high level brake light cover by pressing at (1) .

  • Page 908: High Level Brake Light Bulb: Removal - Refitting

    REAR LIGHTING High level brake light bulb: Removal - Refitting II - FINAL OPERATION. REMOVAL a Connect the high level brake light connector. I - REMOVAL PREPARATION OPERATION a Clip on the high level brake light cover. 125456 a Unclip the high level brake light cover by pressing at (1) .

  • Page 909: Number Plate Light: Removal - Refitting

    REAR LIGHTING Number plate light: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition. II - OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the number plate light using a small flat-blade screwdriver. a Disconnect the connector for the number plate lights.

  • Page 910: Interior Lighting

    INTERIOR LIGHTING Interior lighting: List and location of components 2 - PASSENGER COMPARTMENT FUSE BOX I - LIST OF COMPONENTS Description Passenger compartment fuse box Front courtesy light (4), (5) Rear cour tesy light Storage compartment light (7), (8), (9), (10) Luggage compartment light (11), (12) Door switch...
  • Page 911 INTERIOR LIGHTING Interior lighting: List and location of components 4 - STORAGE COMPARTMENT LIGHT 6 - DOOR SWITCH 118607 108624 Storage compartment light (6) Side door switch (11) 5 - LUGGAGE COMPARTMENT LIGHT 7 - LUGGAGE COMPARTMENT SWITCH 144648 144628 Luggage compartment light (10) Luggage compartment switch (15) 81B-2...
  • Page 912 INTERIOR LIGHTING Interior light: Removal - Refitting a Refit the courtesy light. Special tooling required a Clip the translucent cover in place. Car. 1363 Set of trim removal levers. REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED Front courtesy light 108749 a Unclip the translucent cover (1) using a flat-blade screwdriver or tool (Car.
  • Page 913 INTERIOR LIGHTING Door switch: Removal - Refitting REMOVAL REFITTING REFITTING OPERATION FOR PART CONCERNED OPERATION FOR REMOVAL OF PART CONCERNED Side door switch a Connect the connector. Side door switch a Clip the switch. a Refit the sealing gaiter. 108624 a Remove the sealing gaiter.
  • Page 914 INTERIOR LIGHTING Storage compartment light: Removal - Refitting a Connect the storage compartment light switch con- Special tooling required nector. a Clip the storage compartment light connector. Car. 1363 Set of trim removal levers. a Connect the storage compartment light connector. REMOVAL a Clip on the storage compartment light.
  • Page 915 INTERIOR LIGHTING Luggage compartment light: Removal - Refitting Special tooling required Car. 1363 Set of trim removal levers. REMOVAL REMOVAL OPERATION 144648 a Unclip the luggage compartment light (4) using tool (Car. 1363). a Disconnect the luggage compartment light connec- tor.
  • Page 916 FUSES Fuses: List and location of components I - LIST OF COMPONENTS Description Passenger compartment fuse box (2),(3) Engine compartment fuse and relay II - LOCATION OF COMPONENTS 1 - PASSENGER COMPARTMENT FUSE BOX 107820 Passenger compartment fuse box (1) 2 - ENGINE COMPARTMENT FUSE AND RELAY 117677 This unit is located in the passenger compartment, on...
  • Page 917 FUSES Fuses: List and location of components 24730 107845 Engine compartment fuse and relay box Engine compartment fuse and relay box (3) 3 - OLD ENGINE COMPARTMENT FUSE AND RELAY BOX 107847 Unclip the cover to gain access to the unit. 81C-2...
  • Page 918 ENGINE IMMOBILISER Immobiliser system: List and location of components 2 - IGNITION SWITCH I - LIST OF COMPONENTS Description Antenna/Transponder ring Ignition switch Ignition key II - LOCATION OF COMPONENTS 1 - ANTENNA/TRANSPONDER RING 107851 Ignition switch (2) 3 - UCH 108537 Antenna/transponder ring (1) 107848...
  • Page 919 ENGINE IMMOBILISER Immobiliser system: List and location of components 4 - IGNITION KEY 107869 Ignition key (4) 82A-2...
  • Page 920 ENGINE IMMOBILISER Ignition switch: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting, page 80A-2) . a Remove the transponder ring (see 82A, Engine im- mobiliser, Transponder ring: Removal - Refit- ting, page 82A-5) .
  • Page 921 ENGINE IMMOBILISER Ignition switch: Removal - Refitting a Check that the ignition key is in position (5) . II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the switch, - the switch bolt. a Clip: - the connector to the switch, - the connector for the switch on its mounting.
  • Page 922 ENGINE IMMOBILISER Transponder ring: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition. Note: The steering wheel does not need to be removed. 107814 a Remove the upper half cowling. II - OPERATION FOR REMOVAL OF PART CONCERNED 107813 a Remove:...
  • Page 923 ENGINE IMMOBILISER Transponder ring: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the transponder ring. a Connect the transponder ring connector. II - FINAL OPERATION. a Refit: - the upper half-shell, - the lower half-shell, - the two lower half-shell bolts.
  • Page 924 ENGINE IMMOBILISER Battery for remote door locking control: Removal - Refitting REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 107867 a Remove the battery (3) using a flat-blade screwdriv- 107868 REFITTING a Remove the bolt (1) . I - REFITTING PREPARATION OPERATION WARNING To ensure that the remote control operates cor- rectly, take care not to damage the battery con-...
  • Page 925 HORN Audible warning: Removal - Refitting Left-hand side Tightening torquesm horn bolt 21 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front bumper (see Front bumper as- sembly: Exploded view) . II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - Monotonal horn 145584...
  • Page 926 HORN Audible warning: Removal - Refitting a Torque tighten the horn bolt (21 N.m). II - FINAL OPERATION a Refit the front bumper. 82B-2...
  • Page 927 INSTRUMENT PANEL Instrument panel: Removal - Refitting When replacing the instrument panel, the following must be noted on the warranty booklet: - that the instrument panel has been replaced, - the mileage indicated by the instrument panel removed. REMOVAL I - REMOVAL PREPARATION OPERATION a When replacing the instrument panel, read the mile- age indicated on the instrument panel and note it in 125471...
  • Page 928 INSTRUMENT PANEL Instrument panel: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 107819 a Remove the bolts (8) from the instrument panel. a Unclip the instrument panel. 107816 a Disconnect the connectors from the instrument pan- a Remove the bolts (5) of the instrument panel frame. REFITTING I - REFITTING OPERATION FOR PART CONCERNED...
  • Page 929 CONTROL - SIGNALS Rotary switch: Removal - Refitting REMOVAL REFITTING I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION a Set the wheels straight ahead. a Check that the rotary switch tape is correctly centred a Lock the airbag computer (see Fault finding - Re- (2.5 rotations on each side).
  • Page 930 CONTROL - SIGNALS Steering column switch assembly: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Set the wheels straight ahead. a Lock the airbag computer (see Fault finding - Re- placement of components) (88C, Airbags and pre- tensioners). a Switch off the ignition.
  • Page 931 CONTROL - SIGNALS Steering column switch assembly: Removal - Refitting a Connect the various connectors. a Remove the adhesive tape. Note: Continue refitting and do not tighten bolt until the two half-shells are refitted so that the stalks can be aligned with the instrument panel and dash- board.
  • Page 932 CONTROL - SIGNALS Steering column switch assembly: Removal - Refitting 84A-4...
  • Page 933 CONTROL - SIGNALS Screen wiper switch: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition. a Remove the transponder ring (see 82A, Engine im- mobiliser, Transponder ring: Removal - Refit- ting, page 82A-5) . II - OPERATION FOR REMOVAL OF PART CONCERNED 108742 a Remove the two bolts (1) from the wiping stalk.
  • Page 934 CONTROL - SIGNALS Signals and lighting switch: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition. Note: The steering wheel does not need to be removed. 107814 a Remove the upper half cowling. II - OPERATION FOR REMOVAL OF PART CONCERNED 107813 a Remove:...
  • Page 935 CONTROL - SIGNALS Signals and lighting switch: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Connect the connector. a Refit: - the lighting stalk on its support, - the two bolts on the lighting stalk. II - FINAL OPERATION a Refit: - the upper half-shell, - the lower half-shell,...
  • Page 936 CONTROL - SIGNALS Hazard warning lights switch: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REMOVAL CONCERNED I - REMOVAL PREPARATION OPERATION a Remove the radio (see 86A, Radio, Radio: Remov- al - Refitting, page 86A-3) . 125727 a Disconnect the hazard warning lights switch connec- tor (1) .
  • Page 937 CONTROL - SIGNALS Central door locking switch: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REMOVAL CONCERNED I - REMOVAL PREPARATION OPERATION a Remove the radio (see 86A, Radio, Radio: Remov- al - Refitting, page 86A-3) . 125727 a Disconnect the connector (1) from the central door locking switch.
  • Page 938 CONTROL - SIGNALS Remote headlight beam adjustment control: Removal - Refitting REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 109243 a Unclip the adjustment knob. 108639 a Retract the sealing sleeve (1) from the left-hand ac- tuator. a Unclip the end piece of the left-hand actuator sheath (2) .
  • Page 939 CONTROL - SIGNALS Remote headlight beam adjustment control: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the « control - cables - sheaths » assembly from the vehicle interior, - the adjustment control, - the adjustment control bolts. a Clip on the adjustment knob.
  • Page 940 CONTROL - SIGNALS Exterior rear view mirror control switch: Removal - Refitting 2 ELECTRICALLY ADJUSTABLE EXTERNAL REAR VIEW MIRRORS REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 107824 a Unclip the door mirror switch (1) . a Disconnect the door mirror switch connector. REFITTING REFITTING OPERATION FOR PART CONCERNED a Connect the door mirror switch connector.
  • Page 941 CONTROL - SIGNALS Heated rear screen switch: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the radio (see 86A, Radio, Radio: Remov- al - Refitting, page 86A-3) . II - OPERATION FOR REMOVAL OF PART CONCERNED 125727 a Disconnect the connector (1) from the rear screen de-icing switch.
  • Page 942 CONTROL - SIGNALS Heated seat pad switch: Removal - Refitting FRONT SEAT WITH HEATING REMOVAL I - REMOVAL PREPARATION OPERATION 24693 a Remove: - the bolt (1) from the exterior runner cover, - the exterior runner cover. II - OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the heated seat cover switch (2) .
  • Page 943 WIPING - WASHING Wiping and washing: List and location of components 2 - PASSENGER COMPARTMENT FUSE BOX I - LIST OF COMPONENTS Description Passenger compartment fuse box Windscreen wiper switch Windscreen wiper motor Rear screen wiper motor Washer pump Windscreen washer bottle II - LOCATION OF COMPONENTS 107820 Passenger compartment fuse box (2)
  • Page 944 WIPING - WASHING Wiping and washing: List and location of components 4 - WINDSCREEN WIPER MOTOR 6 - WASHER PUMP 108635 Washer pump (6) 7 - WINDSCREEN WASHER BOTTLE 145587 Windscreen wiper motor (4) 5 - REAR SCREEN WIPER MOTOR 108635 Windscreen washer bottle (7) 145807...
  • Page 945 WIPING - WASHING Windscreen wiper blade: Removal - Refitting REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED a Lift the wiper arm. a Swivel the blade so it is perpendicular to the wiper arm. 118618 a Squeeze the clips (1) and move downwards at the same time (2) .
  • Page 946 WIPING - WASHING Windscreen wiper arm: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm wiper arm nuts 16 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Switch on the ignition. WARNING T o ensure that the wiper arms can travel smoothly , the wiper motor must be initialised.
  • Page 947 WIPING - WASHING Windscreen wiper motor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm windscreen wiper motor 8 N.m LEFT-HAND DRIVE bolts windscreen wiper motor 16 N.m shaft nut REMOVAL I - REMOVAL PREPARATION OPERATION WARNING T o ensure that the wiper arms can travel smoothly , the wiper motor must be initialised.
  • Page 948 WIPING - WASHING Windscreen wiper motor: Removal - Refitting REFITTING RIGHT-HAND DRIVE I - REFITTING PREPARATION OPERATION a Connect: - the windscreen wiper motor, - the battery (see 80A, Battery, Battery: Removal - Refitting, page 80A-2) . WARNING To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.
  • Page 949 WIPING - WASHING Windscreen wiper motor: Removal - Refitting LEFT-HAND DRIVE RIGHT-HAND DRIVE 108001 121577 a Position the linkages as shown in the above illustra- a Position the linkages as shown in the above illustra- tion. tion. a Refit the windscreen wiper motor shaft nut. a Torque tighten the windscreen wiper motor shaft nut (16 N.m).
  • Page 950 WIPING - WASHING Windscreen wiper mechanism: Removal - Refitting RIGHT-HAND DRIVE Tightening torquesm windscreen wiper mech- 8 N.m anism bolts windscreen wiper mech- 8 N.m anism nuts REMOVAL I - REMOVAL PREPARATION OPERATION WARNING T o ensure that the wiper arms can travel 121522 smoothly , the wiper motor must be initialised.
  • Page 951 WIPING - WASHING Windscreen wiper mechanism: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED LEFT-HAND DRIVE 107997 a Remove: - the two scuttle half-grille bolts (4) , - the right-hand scuttle half-grille (5) . 107999 a Disconnect the windscreen wiper motor connector (7) .
  • Page 952 WIPING - WASHING Windscreen wiper mechanism: Removal - Refitting - the two scuttle panel grille side bolts, - the engine compartment seal, RIGHT-HAND DRIVE - the windscreen wiper mechanism bolt covers. a Connect the battery (see 80A, Battery, Battery: Re- moval - Refitting, page 80A-2) .
  • Page 953 WIPING - WASHING Rear screen wiper arm: Removal - Refitting REAR SCREEN WIPER REFITTING Special tooling required Ele. 1781 Tool for removing windscreen I - REFITTING PREPARATION OPERATION wiper arms a Switch on the ignition. REMOVAL WARNING To ensure that the wiper arms can travel I - REMOVAL PREPARATION OPERATION smoothly, the wiper motor must be initialised.
  • Page 954 WIPING - WASHING Rear screen wiper motor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REMOVAL CONCERNED I - REMOVAL PREPARATION OPERATION a Switch on the ignition. WARNING T o ensure that the wiper arms can travel smoothly , the wiper motor must be initialised. a Move the wiper stalk from (0) to (1), then from (1) to (0).
  • Page 955 WIPING - WASHING Rear screen wiper motor: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION 125465 a Replace the seal (3) if necessary. II - REFITTING OPERATION FOR PART CONCERNED a Position and rivet the rear screen wiper motor (see MR 400, 40A, General information).
  • Page 956 WIPING - WASHING Screen washer pump: Removal - Refitting LEFT-HAND DRIVE a Check that the assembly works correctly. REMOVAL Note: I - REMOVAL PREPARATION OPERATION Adjust the position of the windscreen washer jets a Remove the windscreen washer bottle (see 85A, if necessary using a needle.
  • Page 957 WIPING - WASHING Front screen washer jet: Removal - Refitting REMOVAL REFITTING I - REMOVAL PREPARATION OPERATION I - REFITTING OPERATION FOR PART CONCERNED a Clip the washer jet. II - FINAL OPERATION a Connect the jet supply pipe. a Check that the assembly works correctly. a Adjust the position of the rear windscreen washer jet if necessary using a needle.
  • Page 958 WIPING - WASHING Rear screen washer jet: Removal - Refitting REAR SCREEN WIPER Special tooling required Car. 1363 Set of trim removal levers. REMOVAL I - REMOVAL PREPARATION OPERATION II - REMOVAL OPERATION 126625 a Unclip the rear screen washer jet (2) using tool (Car. 1363).
  • Page 959 WIPING - WASHING Windscreen washer reservoir: Removal - Refitting LEFT-HAND DRIVE REMOVAL - the right-hand scuttle half-grille (4) . II - OPERATION FOR REMOVAL OF PART I - REMOVAL PREPARATION OPERATION CONCERNED 108636 108635 a Detach the pipe at (1) . a Disconnect the connector (5) from the windscreen washer pump.

  • Page 960: Radio: List And Location Of Components

    RADIO Radio: List and location of components RADIO NO. 01 or RADIO NO. 02 2 - AERIAL I - LIST OF COMPONENTS Description Radio Aerial Front speakers (4),(5) Rear speakers II - LOCATION OF COMPONENTS 127943 The radio aerial (2) is located on the roof 1 - RADIO 3 - FRONT SPEAKERS 107821...
  • Page 961 RADIO Radio: List and location of components RADIO NO. 01 or RADIO NO. 02 4 - REAR SPEAKERS 118610 86A-2...

  • Page 962: Radio: Removal - Refitting

    RADIO Radio: Removal - Refitting RADIO NO. 01 or RADIO NO. 02 REMOVAL REFITTING I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION a Switch off the ignition. Note: II - OPERATION FOR REMOVAL OF PART Ensure that the ignition is switched off. CONCERNED II - REFITTING OPERATION FOR PART CONCERNED...

  • Page 963: Radio Aerial: Removal - Refitting

    RADIO Radio aerial: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION Note: The radio aerial is located on the front roof. a Remove: - front courtesy light (see 81B, Interior lighting, In- terior light: Removal - Refitting, page 81B-3) , - the headlining partially (see Headlining: Removal - Refitting) (MR 389, 71A, Body internal trim).

  • Page 964: Front Speakers: Removal - Refitting

    RADIO Front speakers: Removal - Refitting RADIO NO. 01 or RADIO NO. 02 REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION 107940 a Remove: 107939 a Unclip the front speaker grille (1) . - the bolts (2) from the front speaker, - the front speaker.

  • Page 965: Rear Speakers: Removal - Refitting

    RADIO Rear speakers: Removal - Refitting RADIO NO. 01 or RADIO NO. 02 REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION 107940 a Remove: 118610 a Unclip the rear speaker grille (1) . - the bolts (2) , - the speaker.

  • Page 966: Radio Control Satellite: Removal - Refitting

    RADIO Radio control satellite: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Switch off the ignition. 144762 a Remove the radio control satellite bolt (2) . a Disconnect the radio control satellite connector. a Remove the radio control satellite. 144761 a Remove the bolts (1) from the shells under the steer- REFITTING...

  • Page 967: Passenger Compartment Connection Unit

    PASSENGER COMPARTMENT CONNECTION UNIT UCH: Removal - Refitting Equipment required Diagnostic tool REMOVAL I - REMOVAL PREPARATION OPERATION Note: If replacing the UCH, it is essential to display the configurations using Diagnostic tool. a Switch off the ignition. a Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting, page 80A-2) .

  • Page 968: Electric Windows - Sunroof

    ELECTRIC WINDOWS - SUNROOF Electric window: List and location of components ELECTRIC FRONT WINDOW or FRONT ONE-TOUCH ELECTRIC WINDOW – ELECTRIC FRONT WINDOW or FRONT ONE-TOUCH ELECTRIC WINDOW , and ELECTRIC REAR WINDOW 2 - FRONT WINDOW WINDER SWITCHES I - LIST OF COMPONENTS Description Passenger compartment fuse box Front window winder switches...

  • Page 969: Front Electric Window Switch: Removal - Refitting

    ELECTRIC WINDOWS - SUNROOF Front electric window switch: Removal - Refitting ELECTRIC FRONT WINDOW or FRONT ONE-TOUCH ELECTRIC WINDOW REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION a Remove the radio (see 86A, Radio, Radio: Remov- al - Refitting, page 86A-3) .

  • Page 970: Rear Electric Window Switch: Removal - Refitting

    ELECTRIC WINDOWS - SUNROOF Rear electric window switch: Removal - Refitting ELECTRIC REAR WINDOW REMOVAL REFITTING I - REFITTING OPERATION FOR PART I - REMOVAL PREPARATION OPERATION CONCERNED a Clip on the rear window winder switch. a Reconnect the rear window winder switch connec- tor.

  • Page 971: Engine Compartment Connection Unit

    ENGINE COMPARTMENT CONNECTION UNIT Engine compartment connection unit: List and location of components I - LIST OF COMPONENTS Description New engine compartment connection unit Old engine compartment connection unit II - LOCATION OF COMPONENTS 1 - NEW ENGINE COMPARTMENT FUSE AND RELAY BOX Vehicles concerned: B90 or F90 or K90 or U90 - L90, with a sales release...
  • Page 972 ENGINE COMPARTMENT CONNECTION UNIT Engine compartment connection unit: List and location of components 107845 Engine compartment connection unit (2) 87G-2...

  • Page 973: Wiring Harness

    WIRING HARNESS Computers: List and location of components Description Procedure Passenger compartment fuse box (see 8 7 B, P assenger compartment connection unit, UCH: Removal - Refitting, page 87B-1) (13B, Diesel injec- tion) Engine compartment fuse and relay ABS-ESP computer Airbag computer (see 88C, Air bag and Pretensioners, Airbag computer: Removal - Refitting, page 88C-4)

  • Page 974: Diagnostic Socket: List And Location Of Components

    WIRING HARNESS Diagnostic socket: List and location of components I - LIST OF COMPONENTS Mark Description Diagnostic socket II - LOCATION OF COMPONENTS DIAGNOSTIC SOCKET 107831 The diagnostic socket (1) is located in the glovebox. 88A-2...

  • Page 975: Wiring: Precautions For The Repair

    WIRING HARNESS Wiring: Precautions for the repair I - SAFETY II - GENERAL RECOMMENDATIONS Do not connect an earth to a stud with insulating pro- tection (paint,etc.). 1 - Potentially dangerous components Do not use more than two earth terminals on the same Do not leave any unused +12V connectors exposed to point.

  • Page 976: Front Bumper Wiring: Removal - Refitting

    WIRING HARNESS Front bumper wiring: Removal - Refitting a Unclip the front bumper wiring at (2) . IMPORTANT WARNING To avoid all risk of damage to the systems, apply To prevent any damage during the removal oper- the safety and cleanliness instructions and opera- ation, check that the wiring is free from its mount- tion recommendations before carrying out any ings (retaining clip, plastic clip, adhesive tape,...

  • Page 977: Engine Wiring: Removal - Refitting

    WIRING HARNESS Engine wiring: Removal - Refitting Equipment required WARNING To prevent any damage to the connectors, consult indelible pencil the disconnection procedures (see Connectors: Diagnostic tool Disconnection and reconnection) (Technical Note 6015A, 88A, Wiring). Tightening torquesm manual gearbox earth 24 N.m Note: cable bolt...
  • Page 978 WIRING HARNESS Engine wiring: Removal - Refitting 145231 a Remove: - the air resonator (1) (see Air resonator: Removal - Refitting) (12A, Fuel mixture), - the cover to access the engine compartment fuse and relay box (2) , - the closure component (3) of the engine compart- ment fuse and relay box, - the engine undertray bolts, - the engine undertray.
  • Page 979 WIRING HARNESS Engine wiring: Removal - Refitting II - REMOVAL OPERATION 145233 88A-7...
  • Page 980 WIRING HARNESS Engine wiring: Removal - Refitting 145234 88A-8...
  • Page 981 WIRING HARNESS Engine wiring: Removal - Refitting 145235 a Disconnect all the connectors. a Unclip the engine wiring where indicated. 88A-9...
  • Page 982 WIRING HARNESS Engine wiring: Removal - Refitting STANDARD HEATING RECIRCULA TION 145237 a Disconnect all the connectors. a Unclip the engine wiring where indicated. 88A-10...
  • Page 983 WIRING HARNESS Engine wiring: Removal - Refitting AIR CONDITIONING 145232 a Disconnect all the connectors. a Unclip the engine wiring where indicated. Note: Before removing the earth terminal, mark its position using a indelible pencil by drawing a line on the earth terminal and on the gearbox casing.
  • Page 984 WIRING HARNESS Engine wiring: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION If replacing the engine wiring a Refit the fuses. a If replacing with a complete wiring harness, lock the unused connectors (see Connectors: Sealing and locking) (Technical Note 6015A, 88A, Wiring). II - REFITTING OPERATION a Proceed in the reverse order to removal.
  • Page 985 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 Equipment required WARNING To prevent any damage to the connectors, consult indelible pencil the disconnection procedures (see Connectors: Diagnostic tool Disconnection and reconnection) (Technical Note 6015A, 88A, Wiring). Tightening torquesm manual gearbox earth 24 N.m Note:...
  • Page 986 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 145238 a Remove: If replacing the engine wiring a Remove the fuses. - the cover to access the engine compartment fuse and relay box (1) , - the closure component (2) of the engine compart- ment fuse and relay box, - the front bumper (see Front bumper assembly: Exploded view) (55A, Exterior protection),...
  • Page 987 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 II - REMOVAL OPERATION 145243 a Disconnect all the connectors. a Unclip the engine wiring where indicated. 88A-15...
  • Page 988 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 STANDARD HEATING RECIRCULA TION 145245 88A-16...
  • Page 989 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 145246 88A-17...
  • Page 990 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 145247 88A-18...
  • Page 991 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 145248 a Disconnect all the connectors. a Unclip the engine wiring where indicated. 88A-19...
  • Page 992 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 AIR CONDITIONING 145239 88A-20...
  • Page 993 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 145240 88A-21...
  • Page 994 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 145241 88A-22...
  • Page 995 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 145242 a Disconnect all the connectors. REFITTING a Unclip the engine wiring where indicated. I - REFITTING PREPARATION OPERATION If replacing the engine wiring a Refit the fuses. Note: a If replacing with a complete wiring harness, lock the Before removing the earth terminal, mark its unused connectors (see Connectors: Sealing and position using a indelible pencil by drawing a...
  • Page 996 WIRING HARNESS Engine wiring: Removal - Refitting K9K, and 796 - the earth cable nuts (8 N.m). a Connect the battery (see 80A, Battery, Battery: Re- moval - Refitting, page 80A-2) (80A, Battery). III - TEST OPERATION a Switch on the ignition. a Connect the Diagnostic tool.

  • Page 997: Passenger Compartment Front Wiring: Removal - Refitting

    WIRING HARNESS Passenger compartment front wiring: Removal - Refitting Equipment required Note: Diagnostic tool For information on instrument connectors (see Visu-Schéma). Tightening torquesm earth nuts 8 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair: - (See Wiring: Precautions for repair) (88A, Wir-...
  • Page 998 WIRING HARNESS Passenger compartment front wiring: Removal - Refitting 144392 1 - Passenger compartment front wiring section on the dashboard cross member Passenger compartment front wiring section on the dashboard a Remove the dashboard (see Dashboard: Removal cross member - Refitting) (57A, Interior equipment). Passenger compartment front wiring section in the engine 2 - Passenger compartment front wiring section in...
  • Page 999 WIRING HARNESS Passenger compartment front wiring: Removal - Refitting 3 - Passenger compartment front wiring section on 5 - Passenger compartment front wiring section in the floor the roof a Remove: a Remove: - the windscreen pillar trim (see Interior body side - the front seats (see Front seat assembly: Ex- trim assembly: Exploded view) (71A, Body inter- ploded view) (75A, Front seat frames and mecha-...
  • Page 1000 WIRING HARNESS Passenger compartment front wiring: Removal - Refitting 2 - Passenger compartment front wiring section in the engine compartment 144397 88A-28...

Table of Contents