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Renault Latitude 2014 Service And Repair Manual

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2011-2014 RENAULT LATITUDE

SERVICE AND REPAIR MANUAL

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Summary of Contents for Renault Latitude 2014

Page 1 2011-2014 RENAULT LATITUDE SERVICE AND REPAIR MANUAL...
Page 2 1/3 AND 2/3 REAR BENCH SEATBACK: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the rear bench seat base (see 76A, Rear seat frames and mechanisms Rear bench seat base: Removal - Refitting 2. REMOVAL OPERATION Remove: the bolts (1) , - 1 -...
Page 3 the side trims of the 1/3 and 2/3 rear bench seatback (2) , the bolts (3) , the bolt of the rear seat belt buckle (4) . Tilt the 1/3 and 2/3 rear bench seatback. - 2 -...
Page 4 Remove the 1/3 rear bench seatback at ( ) and ( Remove the 2/3 rear bench seatback at ( ) and ( REFITTING 1. REFITTING OPERATION - 3 -...
Page 5 Proceed in the reverse order to removal. 44 N.m Tighten to torque the 1/3 and 2/3 rear bench seatback bolts Repair-70x13x02x14-01x37-1-6-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 6 3RD BRAKE LIGHT: REMOVAL - REFITTING Special tooling required Set of trim removal levers. Car. 1363 REMOVAL 1. OPERATION FOR REMOVAL OF PART CONCERNED Remove: the bolt covers (1) using a flat blade screwdriver, the bolts. - 1 -...
Page 7 Note: Take care not to damage the clips ( Unclip the third brake light at ( ) using the tool Set of trim removal levers. ( Car. 1363 Disconnect the connector. - 2 -...
Page 8 Remove the third brake light. REFITTING 1. REFITTING PREPARATION OPERATION Note: If the LEDs are faulty, replace the complete third brake light. 2. REFITTING OPERATION FOR PART CONCERNED Connect the connector. Clip the third brake light onto the headlining. Refit: the bolts, the bolt covers.
Page 9 EDITION ANGLAISE "The repair methods given by the Manufacturer in this document are based on the All copyrights reserved by RENAULT. 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 10 NOISES AND VIBRATIONS NOISES AND VIBRATIONS 109A Shock absorber noises Fault finding Fault finding FOREWORD 1 - Replacing each shock absorber must be justified by the fault finding attached. 2 - Noises heard when descending a pavement ("Cannon shot") are linked to the shock absorber definition: The shock absorber is compliant: do not replace the shock absorbers.
Page 11 NOISES AND VIBRATIONS Shock absorber noises Fault finding GURGLING from shock absorbers Origin: Noise caused by shock absorber piston valves reversing their direction. Check tightness and clearance for all the mountings, linkage and ball joints of the front and rear axles and the shock absorbers as well as the state of the sub-frame rubber mountings. Do a road test on a bad or deformed road at low speed (6-19 mph (10-30 km/h)).
Page 12 NOISES AND VIBRATIONS Shock absorber noises Fault finding BANGING/KNOCKING from shock absorbers Origin: Noise caused by a faulty component or incorrect assembly of the suspension. Check tightness and clearance for all the mountings, linkage and ball joints from the front and rear axles and the shock absorbers as well as the state of the sub-frame rubber mountings.
Page 13 NOISES AND VIBRATIONS Shock absorber noises Fault finding GRATING of shock absorbers Origin: Noise caused by contact between a metallic part and a rubber part. Check tightness and clearance for all the mountings, linkage and ball joints from the front and rear axles and the shock absorbers as well as the state of the sub-frame rubber mountings.
Page 15 Contents Page ENGINE AND PERIPHERALS Overhauling the engine General information 10A-1 Tooling required for fitting old type elastomer seals 10A-2 Method for fitting old type elastomer seals 10A-4 Tooling required for fitting new type elastomer seals 10A-5 Tooling required for removing new type elastomer seals 10A-5 Method for removing elastomer seals...
Page 16 110A ENGINE AND PERIPHERALS ENGINE AND PERIPHERALS Overhauling the engine Overhauling the engine GENERAL INFORMATION Old and new seals are easily recognized. Developments in engine elastomer seals (fitted to the The old elastomer seal is fitted with a spring (1) and camshafts, relay shaft and crankshaft).
Page 17 ENGINE AND PERIPHERALS Overhauling the engine Tooling required for fitting old type elastomer seals. Tool for the camshaft seal Tool for the crankshaft seal Tool for the Engine type relay shaft seal Timing end Flywheel end Timing end Flywheel end Mot.
Page 18 ENGINE AND PERIPHERALS Overhauling the engine Tool for the camshaft seal Tool for the crankshaft seal Tool for the Engine type relay shaft seal Timing end Flywheel end Timing end Flywheel end Mot. 1127-01 Mot. 1385 Mot. 1129-01 Mot. 1491 Mot.
Page 19 ENGINE AND PERIPHERALS Overhauling the engine Method for fitting old type elastomer seals The seal lip is very delicate, so be careful when fitting. Do not oil the external diameter of the ring before fitting. There are two scenarios: the tool has a spring in its housing with a retractable mandrel; by lightly tapping on the end of the tool, the mandrel fits flush with its matched face.
Page 20 ENGINE AND PERIPHERALS Overhauling the engine Tooling required for fitting new type elastomer seals Tool for the camshaft seal Tool for the crankshaft seal Tool for the Engine type relay shaft seal Timing end Flywheel end Timing end Flywheel end Mot.
Page 21 ENGINE AND PERIPHERALS Overhauling the engine Method for removing elastomer seals Tighten knurled back-plate (3) until it locks on knurled back-plate (2) to keep the plungers correctly adjusted This method can be used for the following seals: on the shaft. –...
Page 22 ENGINE AND PERIPHERALS Overhauling the engine Method for fitting new type elastomer seals. IMPORTANT: this type of seal is extremely FRAGILE. Only touch protector part (1) when handling the gasket. It is strictly forbidden to touch seal (2). This is to ensure that there will be no oil leaks once the gasket is fitted on the engine.
Page 23 ENGINE AND PERIPHERALS DXX ENGINE Overhauling the engine Camshaft elastomer seal (timing end) Fit cup (4) and collar nut (5) from Mot. 1587. Screw the threaded rod (3) from tool Mot. 1587 into the camshaft. Tighten the collar nut until the cup touches the cylinder head.
Page 24 ENGINE AND PERIPHERALS DXX ENGINE Overhauling the engine Remove the nut, the cup, the protector and the threaded rod. 10A-9...
Page 25 ENGINE AND PERIPHERALS DXX ENGINE Overhauling the engine Crankshaft elastomer seal (timing end) Fit cup (7) and collar nut (8) from Mot. 1626. Screw threaded rod (6) of Mot. 1626 into the crankshaft. Fit the seal and protector on the crankshaft, taking care not to touch the seal.
Page 26 ENGINE AND PERIPHERALS DXX ENGINE Overhauling the engine Tighten the collar nut until the cup touches the Remove the nut, the cup, the protector and the crankshaft locking panel. threaded rod. 10A-11...
Page 27 ENGINE AND PERIPHERALS DXX ENGINE Overhauling the engine Crankshaft elastomer seal, flywheel end Fit cup (10) and nut (11) (putting threaded hole (12) of the nut on the side facing away from the engine) of Install tool Mot. 1625 on the crankshaft, attaching it Mot.
Page 28 ENGINE AND PERIPHERALS DXX ENGINE Overhauling the engine Tighten the nut until the cup makes contact with the Remove the nut, the cup, the protector and the base cylinder block. plate. 10A-13...
Page 29 ENGINE AND PERIPHERALS FXX ENGINE Overhauling the engine Crankshaft elastomer seal (timing end) Fit the protector complete with the seal onto the spacer, taking care not to touch the seal. Screw threaded rod (22) of Mot. 1636 into the crankshaft. Fit cup (24) and nut (25) (putting threaded hole (26) of the nut on the side facing away from the engine) of Fit spacer (23) to the crankshaft Mot.
Page 30 ENGINE AND PERIPHERALS FXX ENGINE Overhauling the engine Tighten the nut until the cup touches the spacer. Remove the nut, the cup, the protector, the spacer and the threaded rod. 10A-15...
Page 31 ENGINE AND PERIPHERALS FXX ENGINE Overhauling the engine Crankshaft elastomer seal, flywheel end Fit cup (28) and nut (29) (putting the threaded hole (30) of the nut on the side facing away from the Install tool Mot. 1635 on the crankshaft, attaching it engine) of Mot.
Page 32 ENGINE AND PERIPHERALS KXX ENGINE Overhauling the engine Camshaft elastomer seal (timing end) Fit cup (34) and collar nut (35) from Mot. 1632. Tighten stud (31) of tool Mot. 1632 onto the camshaft. Tighten the collar nut until the cup touches the cylinder head.
Page 33 ENGINE AND PERIPHERALS KXX ENGINE Overhauling the engine Crankshaft elastomer seal (timing end) Fit the protector complete with the seal onto the spacer, taking care not to touch the seal. Screw threaded rod (13) of Mot. 1586 into the crankshaft. Fit cup (15) and nut (16) (putting threaded hole (17) of the nut on the side facing away from the engine) of tool Position the spacer (14) of tool Mot.
Page 34 ENGINE AND PERIPHERALS KXX ENGINE Overhauling the engine Tighten the nut until the cup touches the spacer. Remove the nut, the cup, the protector and the threaded rod. 10A-19...
Page 35 ENGINE AND PERIPHERALS KXX ENGINE Overhauling the engine Crankshaft elastomer seal, flywheel end Fit cup (19) and nut (20) (putting threaded hole (21) of the nut on the side facing away from the engine) of tool Install tool Mot. 1585 on the crankshaft, attaching it Mot.
Page 36 ENGINE AND PERIPHERALS KXX ENGINE Overhauling the engine Screw the nut until the cup makes contact with the Remove the nut, the cup, the protector and the base cylinder block. plate. 10A-21...
Page 37 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Camshaft elastomer seal (timing end) Fit the cup (23) and the collar nut (24) from Mot. 1562. Screw the threaded rod (22) of tool Mot. 1562 into the camshaft. Fit the seal gasket and protector on the camshaft. Be careful not to touch the seal.
Page 38 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Screw the collar nut until the cup touches the cylinder Remove the nut, the cup, the protector and the head. threaded rod. 10A-23...
Page 39 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Relay shaft elastomer seal Fit the protector complete with seal on the relay shaft, taking care not to touch the seal. Remove the bolt (25). Fit the cup (27) and nut (28) (putting the threaded part Screw threaded rod (26) of Mot.
Page 40 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Screw in the nut until the cup makes contact with the Remove the nut, the cup, the protector and the timing cover. threaded rod. Refit the sprocket and tighten to torque. 10A-25...
Page 41 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Crankshaft elastomer seal (timing end) Screw the threaded rod (30) of Mot. 1560 into the crankshaft. Fit the cup (33) and nut (34) (putting the threaded part (35) of the nut on the side facing away from the engine) of Mot.
Page 42 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Screw in the nut until the cup makes contact with the Remove the nut, the cup, the protector and the timing cover. threaded rod. 10A-27...
Page 43 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Crankshaft elastomer seal, flywheel end Fit cup (37) and nut (38) (putting the threaded hole (39) of the nut on the side facing away from the Install tool Mot. 1564 on the crankshaft, attaching it engine) of Mot.
Page 44 ENGINE AND PERIPHERALS G9X ENGINE Overhauling the engine Screw the nut until the cup makes contact with the Remove the nut, the cup, the protector and the base cylinder block. plate. 10A-29...
Page 45 - 1 -...
Page 46 (1) Hydraulic unit (2) Steering wheel angle sensor (3) ESP warning light on the instrument panel (4) UCH (5) Yaw speed and lateral acceleration sensor (6) Brake disc with instrumented bearing (7) Wheel speed sensor (8) ESP deactivation switch (9) Master cylinder Repair-13x03x10-02x51-1-10-1.xml XSL version : 3.02 du 22/07/11 - 2 -...
Page 47 ACCELERATOR PEDAL: REMOVAL - REFITTING Note, one or more warnings are present in this procedure WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 37A, Mechanical component controls, Brake mechanism: Precautions for the repair ) (37A, Mechanical component controls), Vehicle: Precautions for the repair...
Page 48 Disconnect the accelerator pedal potentiometer connector ( Remove: the accelerator pedal bolts (2) , the accelerator pedal. - 2 -...
Page 49 REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Refit the accelerator pedal. Connect the accelerator pedal connector. Repair-30x03x03x02-01x37-1-32-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 50 ACCESSORIES BELT: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required brush with non abrasive bristles parts always to be replaced: Accessories belt Accessories belt tensioning roller Accessories fixed roller WARNING Wear cut-resistant gloves during the operation. CAUTION Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley.
Page 51 Remove: the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection). 2. REMOVAL OPERATION 3 mm Place a Allen key ( ) in the tensioning roller hole. - 2 -...
Page 52 Turn the tensioning roller clockwise and push on the key at the same time until the tensioning roller locks. Remove the accessories belt. Turn the tensioning roller slightly in a clockwise direction. 3 mm Remove the Allen key. Turn the tensioning roller anti-clockwise until it locks. - 3 -...
Page 53 Remove: the tensioning roller bolts (2) , the tensioning roller. - 4 -...
Page 54 Remove: the fixed roller protector (3) , the fixed roller bolt (4) , the fixed roller. - 5 -...
Page 55 REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: Accessories belt parts always to be replaced: Accessories belt tensioning roller parts always to be replaced: Accessories fixed roller CAUTION Only use brushes with plastic or non-corrosive metal (brass) bristles. Note: Clean the V-grooves on all accessories pulleys using a brush with non abrasive bristles...
Page 56 Check that the fixed roller anti-dust deflector ( ) is correctly positioned. Refit: the fixed roller, the fixed roller bolt. - 7 -...
Page 57 44 N.m Torque tighten the fixed roller bolt Refit: the fixed roller guard, the new tensioning roller, the tensioning roller bolts. 25 N.m Torque tighten the tensioning roller bolts Refit a new accessories belt. Turn the tensioning roller slightly in a clockwise direction. Remove the tensioning roller locking pin.
Page 58 ACCESSORIES BELT: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required brush with non abrasive bristles parts always to be replaced: Accessories belt Accessories belt tensioning roller Accessories fixed roller WARNING Wear cut-resistant gloves during the operation. CAUTION Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley.
Page 59 Remove: the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection). 2. REMOVAL OPERATION 3 mm Place a Allen key ( ) in the tensioning roller hole. - 2 -...
Page 60 Turn the tensioning roller clockwise and push on the key at the same time until the tensioning roller locks. Remove the accessories belt. Turn the tensioning roller slightly in a clockwise direction. 3 mm Remove the Allen key. Turn the tensioning roller anti-clockwise until it locks. - 3 -...
Page 61 Remove: the tensioning roller bolts (2) , the tensioning roller. - 4 -...
Page 62 Remove: the fixed roller protector (3) , the fixed roller bolt (4) , the fixed roller. - 5 -...
Page 63 REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: Accessories belt parts always to be replaced: Accessories belt tensioning roller parts always to be replaced: Accessories fixed roller CAUTION Only use brushes with plastic or non-corrosive metal (brass) bristles. Note: Clean the V-grooves on all accessories pulleys using a brush with non abrasive bristles...
Page 64 Check that the fixed roller anti-dust deflector ( ) is correctly positioned. Refit: the fixed roller, the fixed roller bolt. - 7 -...
Page 65 44 N.m Torque tighten the fixed roller bolt Refit: the fixed roller guard, the new tensioning roller, the tensioning roller bolts. 25 N.m Torque tighten the tensioning roller bolts Refit a new accessories belt. Turn the tensioning roller slightly in a clockwise direction. Remove the tensioning roller locking pin.
Page 66 AIR CONDITIONING: PARTS AND CONSUMABLES FOR THE REPAIR For the oil part number (04B, Consumables - Products). (see Vehicle: Parts and consumables for the repair) TABLE OF VEHICLE REFRIGERANT CAPACITIES ACCORDING TO THEIR ENGINES AND VARIOUS FEATURES. Refrigerant capacity Type of Quantity of oil Engine Type of oil...
Page 67 Operation on the air conditioning Quantity of oil (ml or cm circuit Measure the volume recovered and add the same quantity Circuit oil change of new oil Split pipe or other rapid leak Replacement of a pipe Quantity recovered Replacement of a condenser Quantity recovered Replacement of an evaporator Quantity recovered...
Page 68 AIR FILTER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure REMOVAL 1. REMOVAL PREPARATION OPERATION - 1 -...
Page 69 Unclip the turbocharger control solenoid valve ( ) by pulling it upwards. Move the turbocharger control solenoid valve to one side. Unclip the air filter unit cover at ( 2. OPERATION FOR REMOVAL OF PART CONCERNED - 2 -...
Page 70 Move aside the air filter unit cover. Remove the filter element ( REFITTING 1. REFITTING PREPARATION OPERATION Clean the air filter housing. 2. REFITTING OPERATION FOR PART CONCERNED CAUTION If the air filter is fitted incorrectly in the air filter unit, unfiltered air may enter the engine. Refit the filter element correctly in the air filter box.
Page 71 AIR FILTER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure REMOVAL 1. REMOVAL PREPARATION OPERATION - 1 -...
Page 72 Unclip the turbocharger control solenoid valve ( ) by pulling it upwards. Move the turbocharger control solenoid valve to one side. Unclip the air filter unit cover at ( 2. OPERATION FOR REMOVAL OF PART CONCERNED - 2 -...
Page 73 Move aside the air filter unit cover. Remove the filter element ( REFITTING 1. REFITTING PREPARATION OPERATION Clean the air filter housing. 2. REFITTING OPERATION FOR PART CONCERNED CAUTION If the air filter is fitted incorrectly in the air filter unit, unfiltered air may enter the engine. Refit the filter element correctly in the air filter box.
Page 74 AIR FLOWMETER: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Disconnect the air flowmeter connector ( - 1 -...
Page 75 Loosen the air outlet pipe clip ( ) on the air filter unit. Unclip the turbocharger control solenoid valve ( ) by pulling it upwards. Move the turbocharger control solenoid valve to one side. Unclip the air filter cover ( Disconnect the "air filter cover - air flowmeter"...
Page 76 Remove: the bolts (5) from the air flowmeter, the air flowmeter, the air flowmeter seal. - 3 -...
Page 77 REFITTING 1. REFITTING PREPARATION OPERATION Always replace the air flowmeter seal. 2. REFITTING OPERATION FOR PART CONCERNED Refit: a new air flowmeter seal, the air flowmeter on the air filter cover, the air flowmeter bolts. 3. FINAL OPERATION Connect the "air filter cover - air flowmeter" assembly to the air filter air outlet pipe. Refit the "air filter cover - air flowmeter"...
Page 78 AIR FRESHENER: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the upper centre front panel (57A, Interior equipment). Centre front panel: Removal - Refitting 2. REMOVAL OPERATION - 1 -...
Page 79 Unclip the air freshener by pressing on the clips at ( Remove the air freshener from the upper centre front panel. REFITTING 1. REFITTING OPERATION - 2 -...
Page 80 Position the centring pins ( ) on the upper centre front panel. Refit the air freshener on the upper centre front panel. 2. FINAL OPERATION Refit the upper centre front panel (57A, Interior equipment). Centre front panel: Removal - Refitting Repair-30x02x06-01x37-1-1-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 81 AIR RESONATOR: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift Vehicle: Towing and lifting Remove: the front wheels Wheel: Removal - Refitting (35A, Wheels and tyres), the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front bumper (55A, Exterior protection).
Page 82 Remove the battery cover ( - 2 -...
Page 83 Remove the right-hand side section ( ) of the battery tray. - 3 -...
Page 84 Remove the air filter unit air inlet pipe ( 2. REMOVAL OPERATION - 4 -...
Page 85 Remove: the bolts (4) of the front bumper side support, the front bumper side support (5) , the air resonator air inlet pipe (6) from the body. - 5 -...
Page 86 Remove: the air resonator nut (7) , the air resonator (8) . REFITTING - 6 -...
Page 87 1. REFITTING OPERATION FOR PART CONCERNED Refit: the air resonator (8) , the air resonator nut (7) . 8 N.m Torque tighten the air resonator nut Refit: the air resonator (6) on the body, the front bumper side support (5) . 8 N.m Torque tighten the bolts of the front bumper side support Connect the inlet pipe to the air filter unit.
Page 88 the air inlet pipe (6) of the air filter unit the right-hand side section (2) from the battery tray. Clip on the clip of the air resonator air inlet pipe ( ) on the body side. Refit the battery cover at the front, ensuring that the clips are unlocked by a quarter of a turn. - 8 -...
Page 89 Ensure that the clips are properly fitted into the notches ( Align the back of the battery cover on the battery tray. Ensure that the battery cover is properly fitted on the battery tray at ( Clip on the back of the battery cover. - 9 -...
Page 90 Lock the battery cover clips by a quarter of a turn. Refit: the front bumper (55A, Exterior protection), the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front wheels Wheel: Removal - Refitting (35A, Wheels and tyres).
Page 91 AIRBAG AND PRETENSIONERS: LIST AND LOCATION OF COMPONENTS 1. LIST OF COMPONENTS 1- THE AIRBAG AND PRETENSIONER SYSTEM CONSISTS OF: an airbag computer a driver's front airbag a passenger's front airbag front side (chest-level) airbags a front seat lap belt pretensioner an inhibitor switch front seat belt buckles rear seat belt buckles...
Page 92 DRIVER'S FRONTAL AIRBAG PASSENGER FRONTAL AIRBAG - 2 -...
Page 93 FRONT (CHEST-LEVEL) SIDE AIRBAG - 3 -...
Page 94 CURTAIN SIDE AIRBAG - 4 -...
Page 95 FRONT SEAT LAP BELT PRETENSIONER - 5 -...
Page 96 FRONT SEAT BELT BUCKLE - 6 -...
Page 97 REAR SEAT BELT BUCKLES - 7 -...
Page 98 FRONT SIDE SEAT BELT - 8 -...
Page 99 - 9 -...
Page 100 REAR SIDE SEAT BELT - 10 -...
Page 101 - 11 -...
Page 102 REAR CENTRE SEAT BELT - 12 -...
Page 103 - 13 -...
Page 104 SIDE IMPACT SENSOR - 14 -...
Page 105 Front impact sensor - 15 -...
Page 106 Central impact sensor INHIBITOR SWITCH - 16 -...
Page 107 SEAT BELT REMINDER WARNING LIGHT - 17 -...
Page 108 - 18 -...
Page 109 Repair-31x02x01x04-02x51-1-19-1.xml XSL version : 3.02 du 22/07/11 - 19 -...
Page 110 AIRBAG COMPUTER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required Diagnostic tool WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 88C, Airbags and pretensioners, Airbag and pretensioners: Precautions for the repair) Vehicle: Precautions for the repair...
Page 111 go to repair mode, display the "Before/After repair procedure" for the computer selected, carry out the operations described in the "Before repair procedure" section. Disconnect the battery . Remove: the central console Centre console: Removal - Refitting (57A, Interior equipment), the front section of the rear central air distribution duct Rear air distribution duct: Removal - Refitting (61A,...
Page 112 Detach the velcro mounting ( ) from the carpet. Remove the soundproofing ( - 3 -...
Page 113 Move aside the electrical wiring of the airbag computer protector. Remove the airbag computer protector ( 2. OPERATION FOR REMOVAL OF PART CONCERNED - 4 -...
Page 114 Mark the wiring routing. CAUTION To prevent any risk of noise, premature wear, short circuits, etc. after the refitting operation, mark the wiring routing and how to connect the connectors. - 5 -...
Page 115 Remove the parking brake lever bolt ( Pull the parking brake lever in the direction of the arrow ( Unlock the airbag computer connector ( Disconnect the airbag computer connectors. Remove: the airbag computer nuts (7) , the airbag computer. REFITTING 1.
Page 116 Refit the wiring in the position marked during removal. Check that the earth wire and the earth terminal are correctly positioned. Connect the airbag computer connectors. Lock the airbag computer connector. Refit the parking brake lever bolt. 3. FINAL OPERATION Refit a new airbag computer protector.
Page 117 Connect the battery . Unlock the airbag computer by applying the "After repair procedure" using the Diagnostic tool : connect the Diagnostic tool , select "Airbag computer" , go to repair mode, display the "Before/After repair procedure" for the computer selected, carry out the operations described in the "After repair procedure"...
Page 118 ALTERNATOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure WARNING Wear cut-resistant gloves during the operation. REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Disconnect the battery (80A, Battery).
Page 119 WITHOUT PAS PUMP ASSEMBLY TYPE 1(SSGEP) Remove the power-assisted steering pump (36B, Power-assisted steering pump: Removal - Refitting Power-assisted steering). Remove the clip ( ) from the intercooler air outlet pipe at the intercooler end. Disconnect the intercooler air outlet pipe at the intercooler end. - 2 -...
Page 120 Loosen the clip ( ) for the intercooler air outlet pipe at the damper valve end. Disconnect the intercooler air outlet pipe at the damper valve end. Remove the intercooler air outlet pipe. - 3 -...
Page 121 2. REMOVAL OPERATION Remove: the alternator protector bolt (3) , the alternator protector, the nut (4) from the alternator positive terminal. - 4 -...
Page 122 Disconnect the connector ( ) from the alternator regulator. Unclip the wiring from the alternator positive terminal at ( Move aside: the alternator wiring to the side, the "compressor - intermediate pipe" connecting pipe to the front of the vehicle. - 5 -...
Page 123 Remove the alternator upper bolt ( Loosen the alternator lower bolt ( ) completely. Note: The alternator lower bolt cannot be removed alone, due to the position of the body. - 6 -...
Page 124 Rotate the alternator towards the front of the vehicle. Remove: the alternator with its lower bolt, the alternator lower bolt. REFITTING 1. REFITTING PREPARATION OPERATION - 7 -...
Page 125 Push in the alternator rings ( ) using a vice to facilitate fitting. 2. REFITTING OPERATION Refit: the alternator lower bolt on the alternator, - 8 -...
Page 126 the alternator with its lower bolt. Rotate the alternator back to its original position. Refit the alternator upper bolt. 25 N.m Torque tighten the alternator bolts Clip on the wiring of the alternator positive terminal at ( Connect the alternator regulator connector. Fit the alternator positive terminal wiring.
Page 127 Push down on the new intercooler air outlet pipe clip at the intercooler end. Connect the intercooler air outlet pipe to the intercooler until it clicks into place. Gently pull the pipe to check that the union is locked. WITHOUT PAS PUMP ASSEMBLY TYPE 1(SSGEP) Refit the power-assisted steering pump (36B, Power-assisted steering pump: Removal - Refitting...
Page 128 14-8 The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault. 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 129 To carry out these measurements, has approved the " " opacimeter from RENAULT OPTIMA 4030 SAGEM This equipment is available as a standalone version or as an option for the "...
Page 130 ANTI-POLLUTION Diesel smoke opacity PRECAUTIONS TO BE TAKEN : VEHICLE PREPARATION ATTENTION : It is essential that the vehicle is correctly prepared for the test. The engine must be warm to prevent damaging the engine or the automatic gearbox. The engine oil temperature must be greater than 80°C. Do NOT run the vehicle at idle speed to warm the engine prior to carrying out the test as this leads to fouling of the exhaust line (and will affect the test results).
Page 131 ANTI-POLLUTION Test procedure CARRYING OUT AN ANTI-POLLUTION TEST There are two test procedures : Procedure for technical inspection (MOT in UK) and road test (A) (to determine the pollution level of the vehicle). For UK Market, please always refer to the MOT Inspection Manual for the method in case of any updates).
Page 132 ANTI-POLLUTION Test procedure A - Test procedure for technical inspection (MOT in UK) and road test Vehicle preparation phase Check the exhaust system for leaks. Gearbox selector lever in neutral. Any accessories which affect rotation of the engine must not be switched on. ≥...
Page 133 ANTI-POLLUTION Test procedure B - Procedure for determining the level of pollution for the workshop Vehicle preparation phase The preparation phase and phases 1 and 2 are the same as for the procedure described on the previous pages. Only the measuring phase is different. Phase 3 : measuring All of the instruments needed to test the vehicle must be used (for example, engine oil temperature mea- surement sensor, rev counter).
Page 134 ANTI-POLLUTION Fault-finding OPERATIONS TO BE CARRIED OUT IF A VEHICLE FAILS TO MEET THE ANTI-POLLUTION TEST STANDARDS Order of Incident Operation to be carried out operations Engine coked Carry out a road test. Accelerate/decelerate continuously between 3 600 rpm and 4 000 rpm in 3 gear.
Page 135 ANTI-POLLUTION Fault-finding Order of Incident Operations to be carried out operations Exhaust Check : that the exhaust line is correct to specification, the value of counter-pressure at the exhaust (with the oxidation box plugged). Injection pump Check the injection pump timing. Injector Check : conformity,...
Page 136 ANTI-POLLUTION Soundproofing the test area PROTECTION AGAINST NOISE The average noise levels obtained during an anti-pollution test are approximately 95 dB with a maximum value of 100 to 103 dB obtained during the maximum engine speed regulation section of the test. The scale of noise levels measured in dB is a logarithmic scale and not a linear scale.
Page 137 ANTI-POLLUTION Soundproofing the test area CAPAM 16 ILLBRUCK Product definition This equipment is aimed at treated noise levels relating to the measurement of diesel smoke opacity in the workshop. Product design This equipment is a mobile unit comprising a silencer (acoustic baffle with flexible segments), dimensions 1 800 x 750 x 750 mm and can be placed in contact with the vehicle radiator grille panel.
Page 138 ANTI-POLLUTION Soundproofing the test area Installation : The absorption cover on the mobile hinged support frame is fitted at the front of the vehicle, totally covering the vehicle up to the base of the windscreen. The equipment also has an anti-noise mat which is fitted under- neath the engine compartment.
Page 139 ANTI-POLLUTION Soundproofing the test area OPASON REST’AGRAF Product definition Designed to reduce noise levels when carrying out diesel smoke emissions testing using an opacimeter. Product design • A mobile unit mounted on small wheels and supplied with a handle which enables the equipment to be moved from one vehicle to another.
Page 140 ANTI-POLLUTION Soundproofing the test area Installation : This solution guarantees a reduction in noise pressure levels of 8 dB. NOTE : This type of equipment is only suitable for short test procedures (of the technical inspection (MOT test) type). As a result, when test measuring is over an extended period of time, watch the temperature indicator and take precautions to prevent any risk of the engine overheating.
Page 141 AUDIBLE WARNING: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the radiator grille (56A, Exterior equipment). 2. OPERATION FOR REMOVAL OF PART CONCERNED - 1 -...
Page 142 Disconnect the horn connector ( Remove: the horn nut (2) , the horn. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Refit the horn. 21 N.m Torque tighten the horn nut Connect the horn connector. 2. FINAL OPERATION Refit the radiator grille (56A, Exterior equipment). Repair-80x03x02-01x37-1-27-1.xml XSL version : 3.02 du 22/07/11 - 2 -...
Page 143 AUTOMATIC GEARBOX OIL: SPECIFICATIONS 1. GEARBOX TYPE/OIL TYPE CORRELATIONS: - 1 -...
Page 144 GEARBOX TYPE TYPE OF OIL FOR GEARBOX DP0/DP2/DP8/RWX RENAULTMATIC D3 SYN MBX/AD4/AD8/AR4 RENAULTMATIC ESSO ATF LT 71141 CLIP SU0/SU1/SU4 ELF MATIC ELF MATIC DC4 gearbox oil DW6 gearbox oil DW5 gearbox oil (pentosin FFL-5) - 2 -...
Page 145 Component identification: The third character corresponds to the figure written on the identification plate and therefore covers the entire automatic gearbox range. Note: ELF RENAULTMATIC D3 SYN oil is not a substitute for ELF RENAULTMATIC D2. 2. STANDARDS AND PART NUMBERS OF THE VARIOUS RECOMMENDED OILS: - 3 -...
Page 146 Designation Standard Part number 77 01 402 037 RENAULTMATIC DEXRON II D (2 litres) RENAULTMATIC DEXRON III May be ordered from ELF D3 SYN CLIP 77 11 218 368 (2 litres) ELF MATIC May be ordered from ELF ELF MATIC May be ordered from ELF (1 litre) ESSO...
Page 147 77 11 579 594 DW5 gearbox oil (pentosin FFL-5) (1 litre) Repair-12x07x01x01-02x08-1-1-1.xml XSL version : 3.02 du 22/07/11 - 5 -...
Page 148 BALANCER SHAFT: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Flywheel locking tool. Mot. 1431 Top dead centre locating pin. Mot. 1766 Balance shaft setting tool Mot. 1802 Equipment required component support compressed air nozzle REMOVAL 1.
Page 149 Drain the oil from the engine Engine oil: Draining - Refilling Remove: the oil filter unit Oil filter unit: Removal - Refitting the accessories belt Accessories belt: Removal - Refitting the coolant pump Coolant pump: Removal - Refitting Immobilise the flywheel or the drive plate while fitting the Flywheel locking tool. ( ) on the Mot.
Page 150 Remove: the clutch plate and pressure plate Pressure plate - Disc: Removal - Refitting the flywheel Flywheel: Removal - Refitting the Flywheel locking tool. (Mot. 1431 Remove: the gearbox side crankshaft seal Crankshaft seal, gearbox end: Removal - Refitting the sump Lower cover: Removal - Refitting the cylinder block base plate (see 10A, Engine and cylinder block assembly, Cylinder block base plate:...
Page 151 Position the pistons at mid-stroke by turning the crankshaft in a clockwise direction. - 4 -...
Page 152 Tighten the Top dead centre locating pin. ( ) until contact with the cylinder block. Mot. 1766 Turn the crankshaft anticlockwise until contact with the Top dead centre locating pin. ( Mot. 1766 - 5 -...
Page 153 Set the balance shafts using the pin ( ) from kit Balance shaft setting tool ( Mot. 1802 Note: The balance shaft weights ( ) must be directed towards the side opposite the crankshaft. - 6 -...
Page 154 Remove: the bolts (4) from the balance shaft assembly, the balance shaft assembly, the adjustment shims from the balance shaft assembly. - 7 -...
Page 155 WARNING Wear cut-resistant gloves during the operation. REFITTING 1. REFITTING PREPARATION OPERATION Always replace the balance shaft assembly bolts. Remove the tool Top dead centre locating pin. ( Mot. 1766 WARNING Wear goggles with side protectors for this operation. Clean with Surface Cleaner and dry using a compressed air nozzle : the balance shaft drive ring on the crankshaft, the balance shaft assembly, the adjustment shims from the balance shaft assembly,...
Page 156 When replacing the balance shaft assembly, identify the thickness of the permanent shim always to refit between the cylinder block and the balance shaft assembly to guarantee a teeth clearance between the input shaft pinion and the crankshaft crown within tolerances, before refitting the balance shaft assembly (see 10A, Engine and cylinder block assembly...
Page 157 Note: A teeth clearance outside the tolerances between the input shaft pinion and crankshaft crown may lead to: -abnormal engine noise (excessive clearance), -engine damage (insufficient clearance). the width of the permanent shims is indicated at ( 2. BALANCE SHAFT REFITTING OPERATION - 10 -...
Page 158 Refit the permanent shims on the cylinder block. Note: When replacing the balance shaft assembly, fit the new shims using the table. selected (see 10A, Engine and cylinder block assembly Balancer shaft: Check - 11 -...
Page 159 Set the crankshaft to Top Dead Centre using the Top dead centre locating pin. ( Mot. 1766 Check that the balance shafts are correctly locked using the pin ( ) of the Balance shaft setting tool ( Mot. 1802 - 12 -...
Page 160 Note: The balance shaft weights ( ) should be positioned on the opposite side to the crankshaft. Fit: the balance shaft assembly, the new balance shaft assembly bolts. Screw in without tightening the balance shaft assembly bolts. - 13 -...
Page 161 Position the permanent shims ( ) against the balance shaft assembly bolts. 15 N.m + 85 ± 5 Torque tighten to angle in order the balance shaft assembly bolts 3. FINAL OPERATION - 14 -...
Page 162 Refit: the cylinder block base plate (see 10A, Engine and cylinder block assembly, Cylinder block base plate: Removal - Refitting) the sump Lower cover: Removal - Refitting Fit the joint of the crankshaft on the gearbox side Crankshaft seal, gearbox end: Removal - Refitting Refit: the flywheel Flywheel: Removal - Refitting...
Page 163 the new accessories belt Accessories belt: Removal - Refitting the oil filter unit Oil filter unit: Removal - Refitting Remove the engine from (see 10A, component support Engine and cylinder block assembly Engine support equipment: Use Refit the engine - gearbox assembly . Fill up the engine oil Engine oil: Draining - Refilling Repair-10x03x01x10-01x37-1-1-1.xml...
Page 164 BODY SIDE FRONT SECTION REINFORCEMENT: REPLACEMENT Note, one or more warnings are present in this procedure 1. COMPOSITION OF THE SPARE PART - 1 -...
Page 165 Description Type Thickness (mm) A-pillar reinforcement Sill panel reinforcement Windscreen pillar lining Windscreen pillar lining reinforcement B-pillar upper lining B-pillar reinforcement UHLE - 2 -...
Page 166 - 3 -...
Page 167 Description Type Thickness (mm) A-pillar reinforcement APFC390 Sill panel reinforcement APFCY380 Windscreen pillar lining APFCY380 Windscreen pillar lining reinforcement APFC390 B-pillar upper lining APFCY380 B-pillar reinforcement 22MNB5 2. IN THE EVENT OF REPLACEMENT There is only one way of replacing this part: complete replacement.
Page 168 2)POSITION OF ELECTRIC EARTHS CAUTION To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness near the weld area must be disconnected. Position the earth of the welding machine as close as possible to the weld area Earth (MR 400, 40H, Bolted connections).
Page 169 Locate the earths located near to the weld area Earths on body: List and location of components 3)PARTS ALWAYS TO BE REPLACED Replace: the inserts for the hollow parts of the B-pillar and A-pillar Hollow section inserts: List and location of components Hollow section inserts: Precautions for the repair 4)IRREMOVABLE BODYWORK COMPONENTS-STRUCTURES TO BE REMOVED IN ORDER TO CARRY OUT THE REPLACEMENT OPERATION Remove the sill panel...
Page 170 BODY SIDE TRIM: REMOVAL - REFITTING Special tooling required Set of trim removal levers. Car. 1363 parts always to be replaced: Clip of rear wing panel trim REMOVAL 1. REMOVAL OPERATION - 1 -...
Page 171 Push the clips ( Remove the front section of the body side trim ( ) using the tool Set of trim removal levers. ( Car. 1363 - 2 -...
Page 172 Remove the rear section of the body side trim ( ) using the tool Set of trim removal levers. ( Car. 1363 REFITTING 1. REFITTING PREPARATION OPERATION - 3 -...
Page 173 parts always to be replaced: Clip of rear wing panel trim 2. REFITTING OPERATION Refit: the rear section of the body side trim (3) . the front section of the body side trim (2) . Repair-50x07x04x08-01x37-1-6-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 174 BODY SIDE TRIM: REMOVAL - REFITTING Special tooling required Set of trim removal levers. Car. 1363 parts always to be replaced: Clip of rear wing panel trim REMOVAL 1. REMOVAL OPERATION - 1 -...
Page 175 Push the clips ( Remove the front section of the body side trim ( ) using the tool Set of trim removal levers. ( Car. 1363 - 2 -...
Page 176 Remove the rear section of the body side trim ( ) using the tool Set of trim removal levers. ( Car. 1363 REFITTING 1. REFITTING PREPARATION OPERATION - 3 -...
Page 177 parts always to be replaced: Clip of rear wing panel trim 2. REFITTING OPERATION Refit: the rear section of the body side trim (3) . the front section of the body side trim (2) . Repair-50x07x04x08-01x37-1-6-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 178 BODY SIDE, FRONT SECTION: REPLACEMENT Note, one or more warnings are present in this procedure 1. COMPOSITION OF THE SPARE PART - 1 -...
Page 179 Description Type Thickness (mm) 0.95 Sill front blanking cover Mild steel 0.65 Body side Mild steel 2. IN THE EVENT OF REPLACEMENT The options for replacing this part are as follows: complete replacement A-B, partial replacement C-D, partial replacement B-D-E, partial replacement A-B-D-F.
Page 180 1- COMPLETE REPLACEMENT A-B 1)PART IN POSITION - 3 -...
Page 181 - 4 -...
Page 182 DETAILED VIEW A - 5 -...
Page 183 DETAILED VIEW B - 6 -...
Page 184 2)POSITION OF ELECTRIC EARTHS CAUTION To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness near the weld area must be disconnected. Position the earth of the welding machine as close as possible to the weld area Earth (MR 400, 40H, Bolted connections).
Page 185 Locate the earths located near to the weld area Earths on body: List and location of components 3)PARTS ALWAYS TO BE REPLACED Replace: the inserts for the hollow parts of the B-pillar and A-pillar Hollow section inserts: List and location of components Hollow section inserts: Precautions for the repair 4)IRREMOVABLE BODYWORK COMPONENTS - STRUCTURAL COMPONENTS TO BE REMOVED IN ORDER TO CARRY OUT THE REPLACEMENT OPERATION Remove the roof...
Page 186 - 9 -...
Page 187 DETAILED VIEW C - 10 -...
Page 188 DETAILED VIEW D - 11 -...
Page 189 2)POSITION OF ELECTRIC EARTHS CAUTION To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness near the weld area must be disconnected. Position the earth of the welding machine as close as possible to the weld area Earth (MR 400, 40H, Bolted connections).
Page 190 Locate the earths located near to the weld area Earths on body: List and location of components 3)PARTS ALWAYS TO BE REPLACED Replace: the inserts for the hollow parts of the A-pillar Hollow section inserts: List and location of components Hollow section inserts: Precautions for the repair 4)SPECIAL NOTES ON MATING CAUTION...
Page 191 DETAILED VIEW E - 14 -...
Page 192 DETAILED VIEW D - 15 -...
Page 193 DETAILED VIEW B - 16 -...
Page 194 2)POSITION OF ELECTRIC EARTHS CAUTION To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness near the weld area must be disconnected. Position the earth of the welding machine as close as possible to the weld area Earth (MR 400, 40H, Bolted connections).
Page 195 Locate the earths located near to the weld area Earths on body: List and location of components 3)PARTS ALWAYS TO BE REPLACED Replace: the inserts for the hollow parts of the B-pillar Hollow section inserts: List and location of components Hollow section inserts: Precautions for the repair 4)SPECIAL NOTES ON MATING CAUTION...
Page 196 DETAILED VIEW F - 19 -...
Page 197 DETAILED VIEW A - 20 -...
Page 198 DETAILED VIEW B - 21 -...
Page 199 DETAILED VIEW D - 22 -...
Page 200 2)POSITION OF ELECTRIC EARTHS CAUTION To avoid damaging the vehicles electric and electronic components, the earths of any wiring harness near the weld area must be disconnected. Position the earth of the welding machine as close as possible to the weld area Earth (MR 400, 40H, Bolted connections).
Page 201 Locate the earths located near to the weld area Earths on body: List and location of components 3)PARTS ALWAYS TO BE REPLACED Replace: the inserts for the hollow parts of the B-pillar Hollow section inserts: List and location of components Hollow section inserts: Precautions for the repair 4)IRREMOVABLE BODYWORK COMPONENTS - STRUCTURAL COMPONENTS TO BE REMOVED IN ORDER TO CARRY OUT THE REPLACEMENT OPERATION Remove the roof...
Page 202 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 203 Bodywork fault finding - Water sealing Bodywork fault finding - Water sealing tests ContentsPages tests Contents Pages GENERAL INFORMATION GENERAL INFORMATION General sealing information: Rear section of the vehicle: Contents 60A-1 Sealing repair 60A-44 Vehicle sealing: General Underside of the vehicle: information 60A-2 Sealing repair...
Page 204 GENERAL INFORMATION General sealing information: Contents X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 205 GENERAL INFORMATION Vehicle sealing: General information X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 206 GENERAL INFORMATION Vehicle sealing: General information X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 207 GENERAL INFORMATION Sealing tools: Description X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 208 GENERAL INFORMATION Sealing tools: Description X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 209 GENERAL INFORMATION Sealing tools: Use X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 210 GENERAL INFORMATION Sealing tools: Use X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 211 GENERAL INFORMATION Sealing tools: Use X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 212 GENERAL INFORMATION Bodywork sealing products: Description X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 213 GENERAL INFORMATION Vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 214 GENERAL INFORMATION Vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 215 GENERAL INFORMATION Windows: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 216 GENERAL INFORMATION Windows: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 217 GENERAL INFORMATION Windows: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 218 GENERAL INFORMATION Side opening elements: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 219 GENERAL INFORMATION Side opening elements: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 220 GENERAL INFORMATION Front section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 221 GENERAL INFORMATION Front section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 222 GENERAL INFORMATION Front section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 223 GENERAL INFORMATION Rear section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 224 GENERAL INFORMATION Rear section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 225 GENERAL INFORMATION Rear section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 226 GENERAL INFORMATION Rear section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 227 GENERAL INFORMATION Rear section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 228 GENERAL INFORMATION Rear section of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 229 GENERAL INFORMATION Roof: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 230 GENERAL INFORMATION Roof: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 231 GENERAL INFORMATION Roof: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 232 GENERAL INFORMATION Roof: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 233 GENERAL INFORMATION Retractable roof: Sealing check X95 – X84 – X33 SEALING CHECK Note: I - PREPARATION OPERATION FOR CHECKING Below you will ﬁnd the detailed operating procedure THE SEALING for performing a sealing test on the retractable roof with "gardener type" water jets. 1 - Conditions to respect before performing a The sealing test is used during repairs to check the sealing test on the retractable roof...
Page 234 GENERAL INFORMATION Retractable roof: Sealing check X95 – X84 – X33 II - OPERATION FOR CHECKING THE SEALING X84, and E84 Note: You will ﬁnd the logical spraying order for the retractable roof. If testing a speciﬁc point (for example: retract- able roof front frame), directly consult the instructions on this point.
Page 235 GENERAL INFORMATION Retractable roof: Sealing check X95 – X84 – X33 X84, and E84 X95 – X84 Checking the sealing of the retractable roof front section a - a) Spraying by sweeping X95, and E95 149725 a Visually inspect for the presence of water inside the vehicle (see 60A, General information, Vehicle sealing: General information, page 60A-2) .
Page 236 GENERAL INFORMATION Retractable roof: Sealing check X95 – X84 – X33 X95, and E95 X84, and E84 149610 149724 a Visually inspect for the presence of water inside the a Visually inspect for the presence of water inside the vehicle (see 60A, General information, Vehicle vehicle (see 60A, General information, Vehicle sealing: General information, page 60A-2) .
Page 237 GENERAL INFORMATION Retractable roof: Sealing check X95 – X84 – X33 b - b) Static spraying X33, and E33 Note: Checking the sealing of the retractable roof Static spraying is used to conﬁrm and locate water ingress. a - a) Spraying by sweeping a Spray each of the peripheral joins of the retractable roof front frame.
Page 238 GENERAL INFORMATION Underside of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 239 GENERAL INFORMATION Underside of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 240 GENERAL INFORMATION Underside of the vehicle: Sealing check X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 241 GENERAL INFORMATION Windows: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 242 GENERAL INFORMATION Windows: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 – X63 – X64 – X65 – X66 – X70 – X73 – X74 – X76 – X77 – X79 – X81 – X83 – X84 – X85 – X90 – X91 – X94 –...
Page 243 GENERAL INFORMATION Side opening elements: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 244 GENERAL INFORMATION Side opening elements: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 245 GENERAL INFORMATION Front section of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 246 GENERAL INFORMATION Front section of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 247 GENERAL INFORMATION Rear section of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 248 GENERAL INFORMATION Rear section of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 249 GENERAL INFORMATION Rear section of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 250 GENERAL INFORMATION Underside of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 251 GENERAL INFORMATION Underside of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 252 GENERAL INFORMATION Underside of the vehicle: Sealing repair X06 – X11 – X24 – X29 – X33 – X35 – X38 – X40 – X43 – X44 – X45 – X48 – X53 – X54 – X56 – X57 – X61 – X62 –...
Page 253 BONDING SUNROOF OPERATING MECHANISMS: DESCRIPTION 1. PREPARATION AND BONDING PROCEDURE Special notes on the preparation and bonding operation for sunroof mechanisms. For cutting operations (see the MR for the vehicle concerned On sunroof mechanism (Parts Department) Procedure 1 New sunroof mechanism (with residual beading) Procedure 2 Removed sunroof mechanism...
Page 254 1 to 2 mm Level the residual beading (leave a thickness of of beading). Place indexing guides and positioning shims onto the sunroof mechanism. Carry out a test assembly of the sunroof mechanism on the vehicle. Note: If there is an area without residual beading on the sunroof mechanism (e.g.: difficulty in adhering): apply the glass cleaner/activator using a pre-soaked wipe along the bonding line, wipe with a dry cloth.
Page 255 BONNET: ADJUSTMENT ADJUSTMENT VALUES For information on the adjustment values for the bonnet (01C, Vehicle Vehicle panel gaps: Adjustment value bodywork specifications). ADJUSTMENT Observe the correct adjustment order for the bonnet (MR 400, 48A, Non-side opening elements: Adjustment Non-side opening elements). There are two options for adjusting the bonnet: by means of the bonnet bolts, by means of the bonnet hinge bolts.
Page 256 Symbols A, B, C and D show the adjustment options. The black dot in the centre represents the body of the bolt. The grey section represents the component to be adjusted. The white section represents the adjustment area. 1. ADJUSTMENT BY MEANS OF THE BONNET BOLTS - 2 -...
Page 257 Loosen the bolts. Adjust the bonnet panel gaps. 2. ADJUSTMENT USING THE BONNET HINGE BOLTS - 3 -...
Page 258 Loosen the bolts. Adjust the bonnet panel gaps. 3. ADJUSTING THE BONNET STRIKER PANEL - 4 -...
Page 259 Note: When adjusting the bonnet striker plate, it is essential to remove the striker panel and fill in the paintwork to protect the bonnet from corrosion. Remove: the bonnet striker panel bolts, - 5 -...
Page 260 the bonnet striker panel. Fill in the paintwork. Refit the striker panel and the bolts. Adjust the bonnet striker panel with the bonnet lock. Repair-40x10x08-01x67-1-12-1.xml XSL version : 3.02 du 22/07/11 - 6 -...
Page 261 BONNET LOCK: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the radiator grille (55A, Exterior protection). 2. REMOVAL OPERATION - 1 -...
Page 262 Remove: the bolts (1) , the tamper-proof protector (2) . Remove: - 2 -...
Page 263 the bonnet catch nuts (3) , the bonnet catch (4) . Unclip the bonnet release cable ( ) onto the bonnet catch. REFITTING 1. REFITTING OPERATION Refit: the bonnet release cable (5) , the bonnet catch (4) , the bonnet catch nuts (3) (without tightening them). Carry out a function test.
Page 264 2. FINAL OPERATION Refit the radiator grille (55A, Exterior protection). Repair-50x03x02x04-01x37-1-16-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 265 BONNET LOCK: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the radiator grille (55A, Exterior protection). 2. REMOVAL OPERATION - 1 -...
Page 266 Remove: the bolts (1) , the tamper-proof protector (2) . Remove: - 2 -...
Page 267 the bonnet catch nuts (3) , the bonnet catch (4) . Unclip the bonnet release cable ( ) onto the bonnet catch. REFITTING 1. REFITTING OPERATION Refit: the bonnet release cable (5) , the bonnet catch (4) , the bonnet catch nuts (3) (without tightening them). Carry out a function test.
Page 268 2. FINAL OPERATION Refit the radiator grille (55A, Exterior protection). Repair-50x03x02x04-01x37-1-16-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 269 BONNET RELEASE CABLE: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove: the battery (80A, Battery), the battery tray Battery tray: Removal - Refitting (80A, Battery). the air filter unit Air filter unit: Removal - Refitting (12A, Fuel mixture), the bonnet catch (see 52A, Non-side opening element mechanisms, Bonnet lock: Removal - Refitting) the front sill panel trim Front door sill lining: Removal - Refitting...
Page 270 Remove the bolt ( Unclip: the cap (2) , the clip (3) . - 2 -...
Page 271 Note the route of the bonnet release cable. Remove the bonnet release cable from inside the vehicle. REFITTING 1. REFITTING OPERATION Refit the bonnet release cable through the inside of the vehicle. Refit: the clip (3) , the cap (2) , the bolt (1) .
Page 272 the battery tray Battery tray: Removal - Refitting (80A, Battery), the battery (80A, Battery). Repair-50x03x02x16-01x37-1-13-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 273 BONNET: REMOVAL - REFITTING This operation can be carried out in two ways: removal without the hinges: method used for replacing the bonnet. removal with the hinges: this method allows the initial adjustments to be kept and prevents the original paintwork from coming off between the hinges and the bonnet lining.
Page 274 Remove: the bolts (1) , the bonnet (this operation requires two people). 2. REFITTING WITHOUT BONNET HINGES - 2 -...
Page 275 1- REFITTING OPERATION Refit: the bonnet (this operation requires two people), the bolts (1) . Adjust the opening clearances and flush fitting (see 48A, Non-side opening elements Bonnet: Adjustment 2- FINAL OPERATION Connect the screen washer pipe. Refit the bonnet soundproofing (68A, Soundproofing).
Page 276 the front wings Front wing: Removal - Refitting the bonnet soundproofing Bonnet soundproofing: Removal - Refitting (68A, Soundproofing). Disconnect the screen washer pipe. Remove the bonnet struts. 2- REMOVAL OPERATION - 4 -...
Page 277 Remove: the bolts (2) , the bonnet (this operation requires two people). 4. REFITTING WITH THE BONNET HINGES - 5 -...
Page 278 1- REFITTING OPERATION Refit: the bonnet (this operation requires two people), the bolts (2) . Adjust the opening clearances and flush fitting (see 48A, Non-side opening elements Bonnet: Adjustment 2- FINAL OPERATION Refit the bonnet struts. Connect the screen washer pipe. Refit: the bonnet soundproofing Bonnet soundproofing: Removal - Refitting...
Page 279 BONNET SOUNDPROOFING: REMOVAL - REFITTING REMOVAL 1. REMOVAL OPERATION Remove: the clips (1) using an unclipping tool, the bonnet soundproofing. REFITTING 1. REFITTING PREPARATION OPERATION Replace the clips ( ) if necessary. - 1 -...
Page 280 2. REFITTING OPERATION Position the bonnet soundproofing at ( Refit the clips ( Repair-60x05x02-01x37-1-12-1.xml XSL version : 3.02 du 22/07/11 - 2 -...
Page 281 B-PILLAR UPPER TRIM: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Unclip the front side seat belt ( Front side seat belt: Removal - Refitting - 1 -...
Page 282 Push the front seat as far back as possible. 2. REMOVAL OPERATION Note: When removing the B-pillar upper trim, take care not to deform the headlining in that area. - 2 -...
Page 283 Carefully unclip the B-pillar upper trim at ( ) and ( REFITTING Proceed in the reverse order to removal. Repair-70x02x08x08-01x37-1-16-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 284 Using a mixture of two incompatible brake fluids in the brake circuit may give rise to: significant risk of leaks mainly due deterioration of the cups, impaired operation of the ESP system. To avoid such risks, it is essential to only use RENAULT standard approved brake fluids Vehicle: Parts and consumables for the repair Repair-13x03x01x02-02x08-1-20-1.xml...
Page 285 HYDRAULIC BRAKE UNIT: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required Diagnostic tool pedal press WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 38C, Anti-lock braking system, ABS: Precautions for the repair) Vehicle: Precautions for the repair...
Page 286 Unclip the following from around the hydraulic brake unit: the expansion valve - condenser connecting pipe Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting (62A, Air conditioning), the expansion valve - intermediate pipe connecting pipe Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting (62A, Air conditioning).
Page 287 Disconnect the connector ( Loosen the brake pipe unions ( ) on the hydraulic unit. Unclip the wiring harness ( Remove: - 3 -...
Page 288 the hydraulic unit bolts (4) , the hydraulic unit. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Refit: the hydraulic unit on its mounting, the brake pipe unions on the hydraulic unit. Torque tighten: 8 N.m the hydraulic unit bolts on the support 6 N.m + 40 the brake pipe unions on the hydraulic unit Connect the connector.
Page 289 the expansion valve outlet: Removal - Refitting (62A, Air conditioning). Refit: the bulkhead insulation giving access to the hydraulic unit Bulkhead insulation: Removal - Refitting (68A, Soundproofing), the front axle subframe . Remove the from the brake pedal. pedal press Connect the battery (80A, Battery).
Page 290 BRAKE SERVO NON-RETURN VALVE: REMOVAL - REFITTING Note, one or more warnings are present in this procedure WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 37A, Mechanical component controls, Brake mechanism: Precautions for the repair ) Vehicle: Precautions for the repair...
Page 291 - 2 -...
Page 292 Remove the cooling pipe bolts ( Move aside the cooling pipe. 2. OPERATION FOR REMOVAL OF PART CONCERNED - 3 -...
Page 293 Remove the non-return valve ( ) from the brake servo, turning the non-return valve to extract it from the rubber washer. - 4 -...
Page 294 Disconnect the non-return valve pipe ( ) from the vacuum pump. Remove the non-return valve. - 5 -...
Page 295 REFITTING 1. REFITTING PREPARATION OPERATION Check the condition of the sealing washer and the non-return valve. Replace any faulty parts. 2. REFITTING OPERATION FOR PART CONCERNED Refit the non-return valve. Connect: the non-return valve pipe to the vacuum pump, the non-return valve on the brake servo. 3.
Page 296 BRAKE SERVO: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 Lower engine support. Mot. 1672 Pipe clamps. Ms. 583 Engine stand. Mot. 1720 Conversion support studs for Mot. 1720 tool Mot.
Page 297 the engine undertray bolts, the engine undertray, the engine cover, the air filter unit Air filter unit: Removal - Refitting (12A, Fuel mixture). Remove the air filter unit air outlet pipe from the turbocharger (see Throttle valve: Removal - Refitting) (12A, Fuel mixture).
Page 298 Remove the bolt ( ) from the max fuse box ( Unclip the clip ( ) by pushing the clips inside the wheel arch. Move aside the max fuse box. - 3 -...
Page 299 Remove the master cylinder (see 37A, Mechanical component controls Master cylinder: Removal - Refitting Remove: the bulkhead insulation partially to remove the brake servo (68A, Soundproofing), the brake pedal switch (see 37A, Mechanical component controls, Brake pedal switch: Removal - Refitting) Fit the tools: Conversion support studs for Mot.
Page 300 Disconnect the brake servo non-return valve ( LEFT-HAND DRIVE - 5 -...
Page 301 RIGHT-HAND DRIVE - 6 -...
Page 302 - 7 -...
Page 303 Remove: the double safety connecting piece (15) between the brake servo pushrod and the brake pedal, the brake servo nuts (16) . Remove the brake servo. - 8 -...
Page 304 REFITTING 1. REFITTING PREPARATION OPERATION Check the presence and condition of the brake servo seal ( Replace the brake servo seal if necessary. - 9 -...
Page 305 The shaft of the double safety connecting piece between the brake servo pushrod and the brake pedal must be replaced. Before refitting, check dimension 167.3 mm for left-hand drive vehicles, - 10 -...
Page 306 118.5 mm for right-hand drive vehicles. If the dimension is not correct, replace the brake servo. 2. REFITTING OPERATION FOR PART CONCERNED Refit the brake servo. 21 N.m Torque tighten the brake servo nuts Refit the double safety connecting piece between the brake servo pushrod and the brake pedal. Connect the non-return valve onto the brake servo.
Page 307 Refit the max fuse box. Clip on the clip ( ) by pushing the clips into the wheel arch. Refit the bolt ( ) on the max fuse box ( Refit the air filter unit air outlet pipe on the turbocharger (12A, (see Throttle valve: Removal - Refitting) Fuel mixture).
Page 308 Bleed the clutch circuit (see 37A, Mechanical component controls Clutch circuit: Bleed Repair-13x03x06-01x37-1-78-1.xml XSL version : 3.02 du 22/07/11 - 13 -...
Page 309 BULKHEAD PLATE: REPLACEMENT 1. COMPOSITION OF THE SPARE PART - 1 -...
Page 310 Description Type Thickness (mm) 1.5/0.8 Bulkhead plate 2. IN THE EVENT OF REPLACEMENT The option for replacing this part is as follows: complete replacement. 1- COMPLETE REPLACEMENT 1)PART IN POSITION - 2 -...
Page 311 Note: For refitting, the bonding procedure is identical to that for replacing the bonded Technical Note 0560A) windscreen (see SECTION A - 3 -...
Page 312 Repair-40x06x14x10-02x49-1-1-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 313 CABIN FILTER: REMOVAL - REFITTING LEFT HAND DRIVE parts always to be replaced: Passenger compartment filter REMOVAL 1. REMOVAL PREPARATION OPERATION Remove: the glovebox Glovebox: Removal - Refitting ( 57A, Interior equipment), the lower cover under the glovebox, the front right-hand footwell air distribution duct (see 61A, Heating, Front footwell air distribution duct: Removal - Refitting) - 1 -...
Page 314 Remove: the side trim of the centre console upper panel (1) , the centre console trim (2) . 2. REMOVAL OPERATION - 2 -...
Page 315 Remove the bolt from the cabin filter access flap ( Unclip the cabin filter access flap ( Remove the cabin filter access flap. Note: Foreign bodies (leaves, insects, etc.) are likely to accumulate in the cabin filter. Remove the passenger compartment filter with care to prevent foreign bodies getting into the evaporator.
Page 316 REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: Passenger compartment filter Check for foreign bodies in the cabin filter housing, and clean thoroughly if necessary. Note: The TOP marks must be on top of the filters and the arrows must be pointing towards the evaporator.
Page 317 Refit: the After-Sales cabin filters (6) at (7) and (8) , the After-Sales cabin filters (9) at (10) , the cabin filter access flap, the cabin filter access flap bolt. - 5 -...
Page 318 3. FINAL OPERATION Refit: the centre console trim, the side trim of the centre console upper panel, the front right-hand footwell air distribution duct (see 61A, Heating, Front footwell air distribution duct: Removal - Refitting) the lower cover under the glovebox, the glovebox Glovebox: Removal - Refitting (57A, Interior equipment).
Page 319 CABIN FILTER: REMOVAL - REFITTING RIGHT HAND DRIVE parts always to be replaced: Passenger compartment filter REMOVAL 1. REMOVAL PREPARATION OPERATION Remove: the glovebox Glovebox: Removal - Refitting ( 57A, Interior equipment), the lower cover under the glovebox, the front left-hand footwell air distribution duct (see 61A, Heating, Front footwell air distribution duct: Removal - Refitting) Remove:...
Page 320 Remove the protector under the dashboard ( 2. REMOVAL OPERATION - 2 -...
Page 321 Remove the bolt from the cabin filter access flap ( Unclip the cabin filter access flap ( Remove the cabin filter access flap. - 3 -...
Page 322 Note: Foreign bodies (leaves, insects, etc.) are likely to accumulate in the cabin filter. Remove the passenger compartment filter with care to prevent foreign bodies getting into the evaporator. Remove the cabin filter. REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: Passenger compartment filter Check for foreign bodies in the cabin filter housing, and clean thoroughly if necessary.
Page 323 Refit: the After-Sales cabin filters (7) at (8) and (9) , the After-Sales cabin filters (10) at (11) , the cabin filter access flap, the cabin filter access flap bolt. - 5 -...
Page 324 3. FINAL OPERATION Remove the protector under the dashboard. Refit: the centre console trim, the side trim of the centre console upper panel, the front left-hand footwell air distribution duct (see 61A, Heating, Front footwell air distribution duct: Removal - Refitting) the lower cover under the glovebox, the glovebox Glovebox: Removal - Refitting...
Page 325 CAMSHAFT POSITION SENSOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure parts always to be replaced: camshaft sensor seal WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 13B, Diesel injection Diesel injection: Precautions for the repair...
Page 326 Disconnect the connector ( ) from the camshaft position sensor. Remove: the bolt (2) from the camshaft position sensor, the camshaft position sensor, the camshaft position sensor seal. - 2 -...
Page 327 REFITTING 1. REFITTING PREPARATION OPERATION Use surface cleaner (04B, Consumables - Products) to clean and degrease: the camshaft position sensor seal housing in case of reuse, the camshaft position sensor seal housing in the rocker cover. parts always to be replaced: camshaft sensor seal Lubricate the camshaft position sensor seal with engine oil.
Page 328 CAMSHAFT POSITION SENSOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure parts always to be replaced: camshaft sensor seal WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 13B, Diesel injection Diesel injection: Precautions for the repair...
Page 329 Disconnect the connector ( ) from the camshaft position sensor. Remove: the bolt (2) from the camshaft position sensor, the camshaft position sensor, the camshaft position sensor seal. - 2 -...
Page 330 REFITTING 1. REFITTING PREPARATION OPERATION Use surface cleaner (04B, Consumables - Products) to clean and degrease: the camshaft position sensor seal housing in case of reuse, the camshaft position sensor seal housing in the rocker cover. parts always to be replaced: camshaft sensor seal Lubricate the camshaft position sensor seal with engine oil.
Page 331 CATALYTIC CONVERTER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required roller-type stud removal tool WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 19B, Exhaust Exhaust: Precautions for the repair...
Page 332 Note: Apply Super releasing agent (04B, Consumables - Products) to the turbocharger studs to prevent the studs from breaking when the catalytic converter nuts are undone. Remove: the catalytic converter nuts (1) on the turbocharger, the engine undertray bolts, the engine undertray, the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres),...
Page 333 the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection). Drain the gearbox (21A, Manual gearbox). Manual gearbox oils: Draining - Filling Move the heat insulating material ( ) away from the oil level sensor connector. Disconnect the connector from the oil level sensor ( Remove: - 3 -...
Page 334 Remove: the front right-hand wheel driveshaft Front right-hand driveshaft: Removal - Refitting (29A, Driveshafts), the right-hand differential output seal Differential output seal: Removal - Refitting (21A, Manual gearbox), the lower engine tie-bar Lower engine tie-bar: Removal - Refitting Remove: - 4 -...
Page 335 the intermediate pipe nuts (4) , the seal between the intermediate pipe and the catalytic converter. Move aside the intermediate pipe to facilitate removal of the catalytic converter. 2. REMOVAL OPERATION - 5 -...
Page 336 Remove: the bolt (5) from the catalytic converter strut, the strut nuts (6) on the catalytic converter, the strut nuts (7) on the cylinder block, the catalytic converter strut. - 6 -...
Page 337 Remove: the bolts (8) from the front right-hand wheel driveshaft relay bearing, the front right-hand wheel driveshaft relay bearing. Remove: - 7 -...
Page 338 the catalytic converter half-clip bolts (9) , the half-clips of the catalytic converter (10) by unclipping the rear half-clips (11) and (12) . Move the engine towards the front of the vehicle using a lever. Note: This operation requires two people. Turn the catalytic pre-converter back by to remove it.
Page 339 Remove: the mounting half-clip bolts (13) on the cylinder block, the mounting half-clips. REFITTING - 9 -...
Page 340 1. REFITTING PREPARATION OPERATION Using surface cleaner (04B, Consumables - Products), clean and degrease the bearing faces of: of the turbocharger, on the exhaust pipe, on the catalytic converter in case of reuse. part always to be replaced: catalytic converter stud on the turbocharger part always to be replaced: catalytic converter nut part always to be replaced: seal between the turbocharger and the catalytic converter part always to be replaced: seal between the catalytic converter and the intermediate pipe...
Page 341 Note: This operation requires two people. Move the engine towards the front of the vehicle using a lever. Refit the catalytic converter in the engine compartment, inserting the lower section first. Turn the catalytic converter over once in the engine compartment. Fit: the catalytic converter on the turbocharger, new catalytic converter nuts onto the turbocharger,...
Page 342 catalytic converter strut, the strut bolt on the catalytic converter, the strut nuts on the catalytic converter, the strut nuts on the cylinder block. Torque tighten in order: 8 N.m the catalytic converter strut bolt 44 N.m the strut nuts on the catalytic converter 44 N.m the strut nuts on the cylinder block 3.
Page 343 Refit: the right-hand differential output seal Differential output seal: Removal - Refitting (21A, Manual gearbox), the front right-hand wheel driveshaft Front right-hand driveshaft: Removal - Refitting (29A, Driveshafts), the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front right-hand wheel Wheel: Removal - Refitting...
Page 344 CATALYTIC PRE-CONVERTER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required roller-type stud removal tool WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 19B, Exhaust Exhaust: Precautions for the repair...
Page 345 Note: Apply Super releasing agent (04B, Consumables - Products) to the turbocharger studs to prevent the studs from breaking when the catalytic pre-converter nuts are loosened. Remove: the catalytic pre-converter nuts (1) on the turbocharger, - 2 -...
Page 346 the engine undertray bolts, the engine undertray, the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection). Move the heat insulating material ( ) away from the connector of the oil level sensor.
Page 347 Disconnect the oil level sensor connector ( Remove: the front right-hand wheel driveshaft Front right-hand driveshaft: Removal - Refitting (29A, Driveshafts), the lower engine tie-bar Lower engine tie-bar: Removal - Refitting - 4 -...
Page 348 Remove: the connecting hose nuts (4) , the catalytic pre-converter studs using a roller-type stud removal tool , the seal between the connecting hose and the catalytic pre-converter, Move aside the connecting hose to facilitate removal of the catalytic pre-converter. 2.
Page 349 Remove: the catalytic pre-converter strut bolt (5) , the strut nuts (6) on the catalytic pre-converter, the strut nuts (7) on the cylinder block, the catalytic pre-converter strut. - 6 -...
Page 350 Remove: the bolts (8) from the relay bearing of the front right-hand wheel driveshaft, the relay bearing of the front right-hand wheel driveshaft. - 7 -...
Page 351 Remove: the bolts (9) from the catalytic pre-converter half-clips, the half-clips of the catalytic pre-converter (10) by unclipping the rear half-clips (11) and (12) . Move the engine towards the front of the vehicle using a lever. - 8 -...
Page 352 Note: This operation requires two people. Turn the catalytic pre-converter back by to remove it. Remove: the catalytic pre-converter, the catalytic pre-converter seal, the turbocharger studs using a roller-type stud removal tool or using the stud recesses. - 9 -...
Page 353 Remove: the mounting half-clip bolts (13) on the cylinder block, the mounting half-clips. REFITTING - 10 -...
Page 354 1. REFITTING PREPARATION OPERATION Using surface cleaner (04B, Consumables - Products), clean and degrease the bearing faces of: of the turbocharger, on the exhaust pipe, of the catalytic pre-converter if reused. part always to be replaced: catalytic pre-converter stud on the turbocharger part always to be replaced: catalytic pre-converter nut part always to be replace: seal between the turbocharger and the catalytic pre-converter part always to be replaced: seal between the catalytic pre-converter and the connecting hose...
Page 355 Move the engine towards the front of the vehicle using a lever. Note: This operation requires two people. Refit the catalytic pre-converter in the engine compartment, inserting the lower section first. Turn the catalytic pre-converter over once in the engine compartment. Fit: the catalytic pre-converter on the turbocharger, new catalytic pre-converter nuts on the turbocharger,...
Page 356 the catalytic pre-converter strut, the strut bolt on the catalytic pre-converter, the strut nuts on the catalytic pre-converter, the strut nuts on the cylinder block. Torque tighten in order: 8 N.m the catalytic pre-converter strut bolt 44 N.m the strut nuts on the catalytic pre-converter 44 N.m the strut nuts on the cylinder block 3.
Page 357 Refit: the front right-hand wheel driveshaft Front right-hand driveshaft: Removal - Refitting (29A, Driveshafts), the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the engine undertray, the exhaust gas pressure sensor (see 19B, Exhaust , Exhaust gas pressure sensor: Removal - Refitting)
Page 358 CENTRAL DOOR LOCKING SWITCH: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Switch off the ignition. Remove the centre front panel (57A, Interior equipment). Centre front panel: Removal - Refitting 2. REMOVAL OPERATION - 1 -...
Page 359 Remove: the bolts (1) , the hazard warning lights and door locking switch. - 2 -...
Page 360 REFITTING 1. REFITTING PREPARATION OPERATION Note: The hazard warning lights switch cannot be separated from the door locking switch. In the event of a replacement, replace the entire unit. 2. REFITTING OPERATION Refit: the hazard warning lights and door locking switch, the bolts (1) .
Page 361 CENTRE CONSOLE: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove: the side trims of the centre console upper front panel (1) , the centre front panel side trims (2) . - 1 -...
Page 362 Unclip the gear lever trim ( Remove the gear lever knob by ( - 2 -...
Page 363 Partially unclip the handbrake lever gaiter ( - 3 -...
Page 364 Carefully remove the centre front panel side trims ( - 4 -...
Page 365 Remove: the bolts (10) , the dashboard lower centre trims (11) , the control panel Control panel: Removal - Refitting (61A, Heating). - 5 -...
Page 366 Remove: the bolts (12) , the card reader (13) , the centre console upper front panel (14) . - 6 -...
Page 367 Disconnect the connectors. Remove the centre console rear trim ( Disconnect the connectors. 2. REMOVAL OPERATION - 7 -...
Page 368 Remove the bolts ( Move the front seat forwards. - 8 -...
Page 369 - 9 -...
Page 370 Remove the rear bolts ( Remove the centre console at ( ) then at ( REFITTING 1. REFITTING OPERATION Refit the centre console. Refit the centre console bolts ( ) and ( - 10 -...
Page 371 2. FINAL OPERATION Connect the connectors. Refit: the centre console rear trim (15) , the centre console upper front panel (14) , the card reader (13) , the bolts (12) , the control panel Control panel: Removal - Refitting (61A, Heating), the dashboard lower centre trims (11) , the bolts (10) , the centre front panel side trims (9) .
Page 372 the side trims of the centre console upper front panel (1) . Repair-50x08x04x02-01x37-1-21-1.xml XSL version : 3.02 du 22/07/11 - 12 -...
Page 373 CENTRE FRONT PANEL: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Carefully remove the dashboard central trims ( 2. REMOVAL OPERATION - 1 -...
Page 374 2. REMOVAL OPERATION Remove the lower section of the centre front panel ( Remove the radio navigation system (83C, On-board telematics Radio navigation: Removal - Refitting system). - 2 -...
Page 375 Remove: the bolts (3) , the upper section of the centre front panel (4) . Disconnect the connectors. Remove the hazard warning lights and door locking switch - 3 -...
Page 376 Remove the hazard warning lights and door locking switch Hazard warning lights and central door (84A, Controls - Signalling). control: Removal - Refitting Remove the air freshener (61A, Heating system). (see Air freshener: Removal - Refitting) - 4 -...
Page 377 REFITTING Proceed in the reverse order to removal. Repair-50x08x02x17-01x37-1-15-1.xml XSL version : 3.02 du 22/07/11 - 5 -...
Page 378 CIGARETTE LIGHTER: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the centre console upper panel (57A, Interior equipment). Centre console: Removal - Refitting 2. OPERATION FOR REMOVAL OF PART CONCERNED Disconnect the cigarette lighter connector. - 1 -...
Page 379 Unclip the socket using a flat-blade screwdriver at ( ) and ( Remove the cigar lighter ( - 2 -...
Page 380 Keep the plastic support unlocked at ( Pull the cigarette lighter support in the direction of ( Unclip the plastic support from the centre console upper panel. - 3 -...
Page 381 REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Clip the plastic support onto the centre console upper panel. Refit: the cigarette lighter mounting, the cigarette lighter. Clip the socket onto the cigarette lighter. Connect the cigarette lighter connector. 2. FINAL OPERATION Refit the centre console upper panel (57A, Interior equipment).
Page 382 CLUTCH CIRCUIT: BLEED Note, one or more warnings are present in this procedure Equipment required brake circuit bleeding device hydraulic circuit bleed syringe WARNING Before carrying out any operation on a vehicle fitted with the Stop & Start system, always follow the safety instructions Vehicle: Precautions for the repair Bleed in the event of: dead travel,...
Page 383 1- CLEANING CLOTHS Use lint-free cleaning cloths (04B, Consumables - Products). Each cloth must only be used once. 1- THERE ARE TWO TYPES OF EQUIPMENT USED TO BLEED THE CLUTCH CIRCUIT: ARC50 via the brake fluid reservoir. Syringe via the bleed hole located on the clutch slave cylinder. 1- THERE ARE TWO PROCEDURES USED TO BLEED THE CLUTCH CIRCUIT: If parts of the hydraulic clutch circuit are removed: Carry out the bleed operation using the ARC50 via the brake fluid reservoir or using a new syringe via the bleed...
Page 384 1- THERE ARE SEVERAL VERSIONS OF BLEED SCREW: SCREW TYPE BLEED SCREW To open the bleed screw, hold the plastic union ( ) using a ring spanner and undo the bleed screw HALF-TURN BLEED SCREW - 3 -...
Page 385 To open the bleed screw, fully turn the bleed screw ( ) by hand. BLEED SCREW WITH A CLIP - 4 -...
Page 386 To open the bleed screw, press and hold the clip ( ) while pulling by one notch. BLEED SCREW WITH A CLIP - 5 -...
Page 387 To open the bleed screw, lift the clip ( ) while pulling by one notch. BLEED SCREW WITH TWO CLIPS - 6 -...
Page 388 To open the bleed screw, lower the clip ( ) and lift the clip ( ) while pulling by one notch. 3. BLEED PROCEDURE IF NO PARTS OF THE HYDRAULIC CIRCUIT ARE REMOVED 1- BLEED USING THE ARC50 Keep the clutch pedal in the upper position using a strap attached to the steering wheel to ensure continuity of the hydraulic circuit during the bleed operation.
Page 389 Note: Take care not to disrupt the adjustment of the clutch start of travel switch. Connect the (after having received Renault approval) to the master brake circuit bleeding device cylinder reservoir (see the instructions for the equipment). Remove the bleed plug from the clutch slave cylinder.
Page 390 Top up the brake fluid level in the master cylinder reservoir after disconnecting the bleed device. Disengage and engage the clutch quickly around twenty times. Check that the clutch system is operating correctly. Repeat the bleed operation if necessary. Check the adjustment of the clutch pedal switch (see 37A, Mechanical component controls Clutch...
Page 391 Note: The transparent pipe must remain at the same height as the master cylinder reservoir to prevent air from entering inside the clutch circuit. 60 ml Connect a new to the end of the transparent pipe filled with hydraulic circuit bleed syringe approved brake fluid.
Page 392 4. BLEED PREPARATION PROCEDURE IF PARTS OF THE HYDRAULIC CIRCUIT ARE REMOVED CAUTION Prepare for the flow of fluid and protect the surrounding components. Note: The master cylinder pipe must be disconnected from its take-off point on the brake fluid reservoir, to avoid any foreign matter penetrating inside the hydraulic brake circuit. Note: Prefill the hydraulic circuit pipe equipped with a filter.
Page 393 FILLING POSITION FOR PIPE WITH FILTER - 12 -...
Page 394 FILLING POSITION FOR PIPE WITH FILTER - 13 -...
Page 395 FILLING POSITION FOR PIPE WITH FILTER - 14 -...
Page 396 Prefill the clutch pipe using the syringe. Plug the prefilled pipe on the master cylinder end to stop any brake fluid from escaping. - 15 -...
Page 397 Prefill the hydraulic tappet by gravity using the syringe. Refit the part(s) concerned. 5. BLEED OPERATION AFTER REMOVING A HYDRAULIC CIRCUIT PART - 16 -...
Page 398 Keep the clutch pedal in the upper position using a strap attached to the steering wheel to ensure continuity of the hydraulic circuit during the bleed operation. Note: Take care not to disrupt the adjustment of the clutch start of travel switch. Remove the bleed plug from the clutch slave cylinder.
Page 399 Refit the bleed plug. Top up the brake fluid level in the master cylinder reservoir. Disengage and engage the clutch quickly around twenty times. Check that the clutch system is operating correctly. Repeat the bleed operation if necessary. Check the adjustment of the clutch pedal switch (see 37A, Mechanical component controls Clutch...
Page 400 CLUTCH CIRCUIT: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Disconnect the battery (80A, Battery). Remove the air filter unit (12A, Fuel mixture). Air filter unit: Removal - Refitting - 1 -...
Page 401 Remove the bolt ( ) from the max fuse box ( Unclip the clip ( ) while pushing the clips into the wheel arch. Move the max fuse box to one side. Remove: the engine protection plate bolts, the engine protection plate. 2.
Page 402 Remove the bleed plug ( Connect a transparent pipe to the bleed hole running to an empty container placed under the bleed hole. Slightly loosen the bleed screw ( - 3 -...
Page 403 Manually depress the clutch pedal (to empty the reservoir, the master cylinder and the clutch pipe). Remove the clip ( ) from the connecting pipe between the master cylinder and the clutch slave cylinder. Disconnect the hydraulic clutch control pipe from the clutch slave cylinder. Insert the plugs into each opening.
Page 404 Lift the retaining clip ( ) of the hydraulic clutch control pipe on the master cylinder. Disconnect the hydraulic clutch control pipe ( Fit plugs into the openings. - 5 -...
Page 405 Unclip the clutch control pipe. Gently remove the hydraulic clutch control pipe taking care not to damage anything. REFITTING 1. REFITTING PREPARATION OPERATION Check the condition of the seals. The blanking cover caps must be removed when connecting the adjacent parts. 2.
Page 406 Refit the engine protection plate. Fit the max fuse box. Refit: the max fuse box bolt, the air filter unit Air filter unit: Removal - Refitting (12A, Fuel mixture). Connect the battery (80A, Battery). Repair-12x04x02x04-01x37-1-40-1.xml XSL version : 3.02 du 22/07/11 - 7 -...
Page 407 CLUTCH CONTROL: LIST AND LOCATION OF COMPONENTS Description Clutch slave cylinder (clutch thrust bearing) Hydraulic clutch control pipe Clutch master cylinder Brake fluid supply duct Clutch pedal - 1 -...
Page 408 Repair-12x03x01x06-02x51-1-13-1.xml XSL version : 3.02 du 22/07/11 - 2 -...
Page 409 CLUTCH MASTER CYLINDER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure CAUTION Prepare for the flow of fluid, and protect the surrounding components. REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment).
Page 410 Remove the bolt ( ) from the max fuse box ( Unclip the clip ( ) while pushing the clips into the wheel arch. Move the max fuse box to one side. - 2 -...
Page 411 Remove: the engine protection plate bolts, the engine protection plate, the bleed plug (4) . Connect a transparent pipe to the bleed hole running to an empty container placed under the - 3 -...
Page 412 bleed hole. Slightly loosen the bleed screw ( Manually depress the clutch pedal (to empty the reservoir, the master cylinder and the clutch pipe). 2. OPERATION FOR REMOVAL OF PART CONCERNED - 4 -...
Page 413 Lift the retaining clip ( ) of the hydraulic clutch control pipe on the master cylinder. Disconnect the hydraulic clutch control pipe ( Fit plugs into the openings. Disconnect the supply pipe ( ) from the master cylinder. - 5 -...
Page 414 Disconnect the clutch master cylinder ball joint ( ) from the clutch pedal. Remove the clutch master cylinder by turning it a quarter of turn clockwise. - 6 -...
Page 415 Disconnect the supply pipe from the master cylinder at ( Note: Avoid exerting any force at ( - 7 -...
Page 416 REFITTING 1. REFITTING PREPARATION OPERATION Check the condition of the seals. The cut that receives the "bayonet" connection on the bulkhead must be clean, free of grease and without any burrs. The routing of the supply pipe must always ascend from the master cylinder to the reservoir, as any low points may cause air pockets.
Page 417 Connect the clutch master cylinder ball joint to the clutch pedal. Connect the supply pipe at the master cylinder. 3. FINAL OPERATION Bleed the circuit (see 37A, Mechanical component controls Clutch circuit: Bleed Refit the engine protection plate. Refit: the max fuse box, the air filter box Air filter unit: Removal - Refitting (12A, Fuel mixture).
Page 418 CLUTCH PEDAL POSITION SENSOR: REMOVAL - REFITTING Equipment required Diagnostic tool REMOVAL 1. REMOVAL PREPARATION OPERATION Switch off the ignition. 2. OPERATION FOR REMOVAL OF PART CONCERNED - 1 -...
Page 419 Disconnect the position sensor connector from the clutch pedal ( Unlock: the section connected to the pedal by undoing lock (2) , the sensor body by moving the lock (3) . - 2 -...
Page 420 Tilt the sensor to the left, taking care not to damage the lower mounting support of the sensor ( REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Refit the clutch pedal position sensor. - 3 -...
Page 421 Lock: the sensor body by using the lock, the section connected to the pedal by moving the lock. Connect the clutch pedal position sensor connector. 2. FINAL OPERATION Apply the after repair procedure using the Diagnostic tool : connect the Diagnostic tool , select "Electronic parking brake computer"...
Page 422 CLUTCH PEDAL SWITCH: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Switch off the ignition. 2. OPERATION FOR REMOVAL OF PART CONCERNED - 1 -...
Page 423 Disconnect the clutch pedal switch connectors. Turn the clutch pedal switches ( ) a quarter of a turn anti-clockwise. Remove the clutch pedal switches ( REFITTING 1. REFITTING PREPARATION OPERATION - 2 -...
Page 424 Note: In order not to damage the multifunction switch ( -handle the switch ( ) with care, -only activate the piston ( ) during the adjustment phase, -do not perform more than 3 adjustments of the dimension ( -do not separate the piston ( ) from the switch ( Replace the switch: -if the piston (...
Page 425 Note: The clutch pedal switches have an automatic adjustment feature which adapts to the pedal position. The automatic adjustment makes a clicking noise when in operation. Connect the clutch pedal switch connectors. Repair-30x03x01x04-01x37-1-12-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 426 CLUTCH PEDAL: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Disconnect the battery (80A, Battery). Remove the driver's side A-pillar air distribution duct Front footwell air distribution duct: Removal - (61A, Heating system). Refitting - 1 -...
Page 427 Unclip the fuse box at ( Move aside the fuse box. 2. OPERATION FOR REMOVAL OF PART CONCERNED - 2 -...
Page 428 Remove: the clutch start of travel switch (2) (see 37A, Mechanical component controls, Clutch pedal switch: Removal - Refitting) the clutch end of travel switch (3) (see 37A, Mechanical component controls, Clutch pedal switch: Removal - Refitting) Unclip the wiring from the clutch pedal plate. - 3 -...
Page 429 Remove: the clutch master cylinder ball joint (5) , the clutch pedal plate nuts (6) . Remove: - 4 -...
Page 430 the clutch pedal plate, the clutch pedal plate spacers. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Replace the clips if they are damaged. Refit: the clutch pedal plate spacers, the clutch pedal plate. Clip on the wiring of the clutch pedal plate. Refit the clutch pedal plate nuts 21 N.m Torque tighten the clutch pedal plate nuts...
Page 431 the clutch start of travel switch (see 37A, Mechanical component controls, Clutch pedal switch: Removal - Refitting) 2. FINAL OPERATION Clip the fuse box at ( Refit the driver's side A-pillar air distribution duct Front footwell air distribution duct: Removal - Refitting (61A, Heating system).
Page 432 CLUTCH THRUST BEARING: REMOVAL - REFITTING Note, one or more warnings are present in this procedure parts always to be replaced: Clutch thrust bearing WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see Clutch: Precautions for the repair) REMOVAL...
Page 433 Remove: the bolts (1) from the clutch thrust bearing, the clutch thrust bearing. REFITTING - 2 -...
Page 434 1. REFITTING PREPARATION OPERATION parts always to be replaced: Clutch thrust bearing Note: To obtain optimum bleeding, pre-fill the clutch thrust bearing when refitting the thrust bearing. 2. REFITTING OPERATION Refit: a new clutch thrust bearing, the clutch thrust bearing bolts (1) . 21 N.m Torque tighten the clutch thrust bearing bolts 3.
Page 435 COMPLETE FRONT SEAT: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Disconnect the battery (80A, Battery). - 1 -...
Page 436 Unclip the front seat belt ( (88C, Airbag and pretensioners). Front side seat belt: Removal - Refitting Remove the front headrest. 2. REMOVAL OPERATION Move the front seat as far back as possible. - 2 -...
Page 437 Carefully remove the front seat bolts ( Move the front seat forwards as far as possible. Carefully remove the front seat bolts ( - 3 -...
Page 438 Disconnect the connectors under the front seat (depending on equipment level). Remove the complete front seat (this operation requires two people). REFITTING 1. REFITTING PREPARATION OPERATION Always replace the front seat bolts. 2. REFITTING OPERATION Proceed in the reverse order to removal. 35 N.m Torque tighten the front seat bolts Carry out a function test.
Page 439 COMPLETE REAR AXLE SYSTEM: REMOVAL - REFITTING Equipment required component jack pedal press safety strap(s) REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Release the parking brake. Remove the rear wheels Wheel: Removal - Refitting K9K M9R, 811(811) Remove the "expansion chamber - silencer"...
Page 440 Disconnect the rear brake pipe ( ) from the rear brake calliper (see 33A, Rear axle components Rear brake calliper: Removal - Refitting Remove the rear brake hose at ( Fit blanking plugs on the ends of the openings. - 2 -...
Page 441 Remove the parking brake cables at the brake callipers ( Unclip the parking brake cables at ( - 3 -...
Page 442 Disconnect: the wheel speed sensor connector (7) , the connector of the headlight beam adjustment rear sensor (8) . Unclip the wiring harness clips ( Remove the linkage of the headlight beam adjustment rear sensor from the rear lower longitudinal (80B, Headlights).
Page 443 Refitting Remove the upper nuts of the shock absorber ( Position the at the centre of the rear axle. component jack Place a in order to secure the rear axle to the safety strap(s) component jack - 5 -...
Page 444 Note: This operation requires two people. Remove the nuts from the rear axle ( Slowly lower the to remove the rear axle. component jack - 6 -...
Page 445 Remove the complete rear axle. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Refit the complete rear axle. Note: This operation requires two people. - 7 -...
Page 446 Refit the nuts of the rear axle. 140 N.m Torque tighten the rear axle nuts Remove the from the rear axle. safety strap(s) Refit the upper nuts of the shock absorber. 21 N.m Torque tighten the upper nuts of the shock absorber Refit the linkage of the headlight beam adjustment rear sensor on the rear lower longitudinal arm (80B, Headlights).
Page 447 Connect the rear brake pipe to the rear brake calliper (see 33A, Rear axle components Rear brake calliper: Removal - Refitting 2. FINAL OPERATION Remove the pedal press L43, K9K M9R, 811(L43) AND (811) Refit the "expansion chamber - silencer" assembly Expansion chamber: Removal - Refitting Silencer: (19B, Exhaust).
Page 448 COMPRESSOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required refrigerant charging station parts always to be replaced: refrigerant pipe seal WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 62A, Air conditioning, Air conditioning: Precautions for the repair) CAUTION...
Page 449 CAUTION Consult the device's operating manual to avoid incorrect use. Drain the refrigerant circuit using the (see 62A, refrigerant charging station Air conditioning Refrigerant circuit: Draining - Filling Disconnect the battery (80A, Battery). Remove: the engine protection plate, the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the front wheel arch liners...
Page 450 Remove the bolts ( ) from the connecting pipes of the air conditioning compressor. CAUTION In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. Disconnect the connecting pipes from the air conditioning compressor. - 3 -...
Page 451 Remove the connecting pipe seals. Insert the blanking plugs. Disconnect the connector from the air conditioning compressor ( - 4 -...
Page 452 Remove: the air conditioning compressor bolts (3) , the air conditioning compressor downwards. REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: refrigerant pipe seal CAUTION 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 vehicle.
Page 453 2. REFITTING OPERATION Refit the air conditioning compressor. 25 N.m Torque tighten the air conditioning compressor bolts Connect the connecting pipes to the air conditioning compressor. 8 N.m Torque tighten the connecting pipe mounting bolts on the compressor Connect the air conditioning compressor connector. 3.
Page 454 Refit: the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the engine protection plate. Repair-30x02x02x14-01x37-1-59-1.xml XSL version : 3.02 du 22/07/11 - 7 -...
Page 455 COMPUTER AUTOMATIC CONFIGURATION PROCEDURE This Technical Note concerns the on-board computer Automatic Configuration operations using a RENAULT.NET connection or the Reprogramming CD (part no.: 77 11 298 859). Edition 1 - XXX 2007 Edition Anglaise "The repair procedures given by the manufacturer in this document are based on the All rights reserved by RENAULT.
Page 456 Contents Page VEHICLE FAULT FINDING SPECIFICATIONS Computer automatic configuration 01B-1...
Page 457 This procedure is detailed in the after repair documents of this computer. The reprogramming data available via RENAULT.NET is always more up to date than that available on the CD (Part No. 77 11 298 859).
Page 458 VEHICLE FAULT FINDING SPECIFICATIONS Computer automatic configuration OPERATIONAL PROCEDURE The automatic configuration operation is accessible only from the "after repair" documentation of the computer. CLIP displays for access to "after repair" documentation Screen Step Notes Fault finding of the vehicle is complete. Repairs can begin. Fault finding Select the button depicting an open-jawed spanner Select the button depicting 2 books.
Page 459 Otherwise, screen 4 is displayed. Searching for the If CLIP is configured in disconnected mode, screen 8 is displayed. configuration file on Otherwise, CLIP will start the interface to communicate with Renault Net. Renault.Net Interrogating Renault.Net CLIP interrogates Renault.Net to receive the configuration file...
Page 460 1-Follow the procedure to be implemented after repair. Click on "AUTOMATIC CONFIGURATION" when this 1- Select "Continue" step is reached patch Find a patch supplied by Techline during an assistance Searching for the configuration file on procedure. Renault Net Patch found Interrogating Renault.Net 01B -4...
Page 461 VEHICLE FAULT FINDING SPECIFICATIONS Computer automatic configuration Interrogation of Renault.Net complete 1: Select "OK" File found on Renault 1- Select "OK" File not found File found on CD Select "YES" to initiate the 1: Insert the latest updated CD/DVD automatic configuration of the computer.
Page 462 VEHICLE FAULT FINDING SPECIFICATIONS Computer automatic configuration Preparing computer data Sending the data to the computer Transmission complete 1: select "OK" Reopening the documentation 01B -6...
Page 463 VEHICLE FAULT FINDING SPECIFICATIONS Computer automatic configuration ASSISTANCE PROCEDURE The ASSISTANCE PROCEDURE must be applied in the event that automatic configuration is interrupted, i.e. if screen 12 is not displayed. The ASSISTANCE PROCEDURE consists of ACTIS completing a CUSTOMER INCIDENT REPORT (CIR) to be sent to Techline, stating the following details: The VIN of the vehicle.
Page 464 COMPUTER REPROGRAMMING AND CALIBRATION PROCEDURE This Technical Note relates to onboard computer Reprogramming and Calibration operations using a RENAULT.NET connection or a Reprogramming CD (Part No.: 77 11 298 859). 77 11 338 820 Edition 4 - OCTOBER 2007 EDITION ANGLAISE "The repair procedures given by the manufacturer in this document are based on the...
Page 465 Tooling required............................... 1 Calibration ................................2 Reprogramming ............................... 2 OPERATING PROCEDURE (Programming and reprogramming a computer)............3 Preparing the RENAULT CLIP diagnostic tool......................3 Preparing the vehicle ............................... 3 Programming phase - reprogramming........................4 Returning the vehicle ............................... 4 CLIP screens depending on programming - reprogramming step................5 Linking the screens..............................
Page 466 These operations apply to all vehicles and all types of (re)programmable computer (e.g: Injection, Gearbox, Air conditioning, Instrument panel, Parking brake, UCH). The two types of operation are carried out with the RENAULT CLIP diagnostic tool using either RENAULT.NET, or the Calibration - Reprogramming CD Part No. 77 11 298 859.
Page 467 COMPUTER TO BE PROGRAMMED Reprogramming The operation consists of exchanging the software and/or calibration for the most recent version using the RENAULT CLIP diagnostic tool. This relates to computers already fitted to the vehicle as well as computers supplied as operational (also called "full".
Page 468 Programming – Reprogramming the computers OPERATING PROCEDURE (Programming and reprogramming a computer) The operating procedure for Calibration and Reprogramming operations is strictly identical. The operation is carried out using the RENAULT CLIP diagnostic tool, either connected to RENAULT.NET or with the reprogramming CD. WARNING To prevent any computer malfunctioning or locking, the following operations must be carried out before (re)programming.
Page 469 Programming – Reprogramming the computers Programming - reprogramming phase Enter the exact VIN of the vehicle in the RENAULT CLIP diagnostic tool main menu. WARNING Using a VIN which is not allocated to the vehicle risks compromising the correct running of the programming - reprogramming operation, as well as the conformity of the vehicle Apply the correct pre-reprogramming Procedure for the vehicle and for the system to be reprogrammed.
Page 470 Select the reprogramming mode Choose the technical resource: either RENAULT.NET or CD. RENAULT.NET CLIP finds the technical data to download to the computer. Finding the file(s) In RENAULT.NET mode, a password is needed for authentication.
Page 471 VEHICLE GENERAL INFORMATION Programming – Reprogramming the computers Order of the screens 1: Obtain vehicle VIN automatically. 1: Select the reprogramming page. 1: Enter the repair order. 2: Enter the repair order. See Interface 2 See New Interface 01B-6...
Page 472 VEHICLE GENERAL INFORMATION Programming – Reprogramming the computers New Interface 1: Select the Validate button. Multiplex network test. 1: Select the Continue button. Analyse data and Read faults. 1: Select the Computer button. 1: Select the system to be reprogrammed. 01B-7...
Page 473 VEHICLE GENERAL INFORMATION Programming – Reprogramming the computers 1: Select Repair mode. 1: Select the Reprogramming page. 1: Select the Validate button Step 15 opens simultaneously. See reprogramming interface 01B-8...
Page 474 VEHICLE GENERAL INFORMATION Programming – Reprogramming the computers Interface 2 Select the system to be reprogrammed. 1: Select the Reprogramming button. 1: Select the Validate button. See reprogramming interface 01B-9...
Page 475 Identification of computer data. requested. 2: Select the Validate button. Automatic battery voltage check. IMPORTANT: Adhere to the instructions. 1: Select the OK button. 2: Select the next button. RENAULT.NET Select the reprogramming mode. Enter the Renault.Net password. CD-ROM RENAULT.NET 01B-10...
Page 476 VEHICLE GENERAL INFORMATION Programming – Reprogramming the computers CD-ROM RENAULT.NET CD-ROM Software reference search. 1: Select the software reference. CD-ROM 2: Select the Validate button. RENAULT.NET 1: Enter the reprogramming code. Downloading of the file. (CODE SERVER PROCEDURE) 2: Select the Validate button IMPORTANT: Adhere to the instructions.
Page 477 Check that the wireless connection device is working. After the battery voltage has TO CARRY OUT REPROGRAMMING If the fault is still present, contact the CLIP VIA RENAULT.NET … been checked After-Sales service, or use the latest version of the reprogramming CD. 01B-12...
Page 478 After-Sales Service ERROR 651 If the fault is still present, contact your IT representative or the mode CLIP After-Sales Service. CLIP integrity error (in RENAULT.NET mode) or reprogramming After-Sales Service ERROR 652 CD error (in CD mode). After-Sales Service ERROR 653 In mode RENAULT.NET mode, reinstall CLIP...
Page 479 Programming – Reprogramming the computers SCREE CLIP ERROR MESSAGE ORIGIN PROCEDURE TO FOLLOW RENAULT.NET mode: the computer does not need to be reprogrammed. COMPUTER ALREADY CD mode: Restart the operation using the latest available REPROGRAMMED, CANNOT Whilst finding a file version of the CD.
Page 480 This code is provided by the code management server on RENAULT.NET after having entered the VIN and the reprogramming code displayed on screen 24 of the RENAULT CLIP diagnostic tool.
Page 481 Following Techline's analysis of the fault, a 10 character code (e.g: 0000CD347B) should be sent back to you. Repeat the Calibration - reprogramming procedure and enter the Vehicle Technical Definition code in screen 17 of the RENAULT CLIP diagnostic tool. 1: Enter the repair order.
Page 482 MULTIPLEX NETWORK TEST/COMPUTER FAULT FINDING/IDENTIFICATION FRAME Print screen Press the button on the top right of the keypad of the RENAULT CLIP diagnostic tool. Syst Open WORDPAD(Start → → → → Programs→ → → → Accessories→ → → → WordPad),...
Page 483 EMERGENCY PROCEDURE. the recovery of CODECAL from the last reprogramming operations carried out. This log enables the last 50 reprogramming operations stored in the RENAULT CLIP diagnostic tool to be consulted, displayed in chronological order with the most recent first.
Page 484 Then select (double left click) the following: Local disc (C:) / CLIP / DATA / USER / LOGS. Send this file to your Techline by e-mail. Note: For all RENAULT CLIP diagnostic tools under Windows XP, compress the file "clip.log": Select the clip.log trace file. Right click the on the clip.log file, and select Properties.
Page 485 CONDENSER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required refrigerant charging station parts always to be replaced: refrigerant pipe seal WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 62A, Air conditioning, Air conditioning: Precautions for the repair) CAUTION...
Page 486 Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting CAUTION Consult the device's operating manual to avoid incorrect use. Drain the refrigerant circuit using the (see 62A, refrigerant charging station Air conditioning Refrigerant circuit: Draining - Filling Disconnect the battery (80A, Battery).
Page 487 Remove the right-hand air deflector ( - 3 -...
Page 488 Remove the nuts ( ) from the condenser connecting pipes. Unclip the clip from the condenser connecting pipe at ( Disconnect the connecting pipes from the condenser. Remove the connecting pipe seals. - 4 -...
Page 489 Insert the blanking plugs. Unclip the air pipe ( ) from the left-hand air deflector. Remove the left-hand air deflector ( - 5 -...
Page 490 Unclip the condenser at ( Remove the condenser in the direction of ( ) and ( REFITTING 1. REFITTING PREPARATION OPERATION - 6 -...
Page 491 parts always to be replaced: refrigerant pipe seal CAUTION 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 vehicle. CAUTION To avoid any leaks, check that the pipe surface is sound before positioning the new seal.
Page 492 the left-hand air deflector, the air pipe on the left-hand air deflector. Connect the connecting pipes to the condenser. 8 N.m Torque tighten the connecting pipe nuts Clip on: the clip of the condenser connecting pipe at (3) , the right-hand air deflector. 3.
Page 493 Refit: the front end panel Front end panel: Removal - Refitting (42A, Upper front structure), the audible warning Audible warning: Removal - Refitting (82B, Horn), the bonnet catch Bonnet lock: Removal - Refitting (52A, Non-side opening element mechanisms), the headlights Headlight: Removal - Refitting (80B, Headlights), the front bumper (55A, Exterior protection),...
Page 494 CONNECTING HOSE: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Pliers for removing exhaust pipe rubber mounting bushes Mot. 1857 Equipment required component jack WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 19B, Exhaust Exhaust: Precautions for the repair...
Page 495 Remove the particle filter bolt ( ) on the rubber mounting bush. Unclip the particle filter temperature sensor wiring from its clip ( Remove the nuts ( ) from the connecting hose on the catalytic pre-converter. - 2 -...
Page 496 Note: Place a under the silencer to prevent it from falling. component jack Remove the silencer nuts ( Unclip the expansion chamber from the rubber mounting bush ( ) using the tool Pliers for removing exhaust pipe rubber mounting bushes ( Mot.
Page 497 Move the "connecting hose - particle filter - expansion chamber - silencer" assembly slightly towards the back of the vehicle. 2. REMOVAL OF THE PART CONCERNED Remove: the particle filter upstream pressure pipe (7) from the connecting hose, the particle filter temperature sensor (8) from the connecting hose. Note: This operation requires two people.
Page 498 Remove: the particle filter nuts (9) on the connecting hose, the connecting hose from the "particle filter - expansion chamber - silencer" assembly, the seal between the flexible pipe and the particle filter. REFITTING 1. REFITTING PREPARATION OPERATION part always to be replaced: seal between the connecting hose and the particle filter part always to be replaced: seal between the catalytic pre-converter and the connecting hose Using SURFACE CLEANER (04B, Consumables - Products), clean and degrease the bearing faces of: between the catalytic pre-converter and the connecting hose,...
Page 499 a new seal between the connecting hose and the particle filter, the connecting hose to the "particle filter - expansion chamber - silencer" assembly. 21 N.m Torque tighten the particle filter nuts on the connecting hose Note: This operation requires two people. Lift the "connecting hose - particle filter - expansion chamber - silencer"...
Page 500 Refit the engine undertray. Check: that all the exhaust pipe heat shields are in place and properly attached, that there is no contact with the underbody, that there are no leaks. Repair-10x08x02x05-01x37-1-46-1.xml XSL version : 3.02 du 22/07/11 - 7 -...
Page 501 CONTROL PANEL: REMOVAL - REFITTING Equipment required Diagnostic tool REMOVAL 1. REMOVAL PREPARATION OPERATION Disconnect the battery (80A, Battery). - 1 -...
Page 502 Remove the dashboard centre trims ( Remove: the bolts (2) , - 2 -...
Page 503 the dashboard lower centre trims. (3) 2. REMOVAL OPERATION Remove the control panel bolts ( Squeeze the centring pins ( ) while pushing the control panel. - 3 -...
Page 504 Tilt the control panel. Disconnect the connectors ( ) and ( ) from the control panel. Remove the control panel. - 4 -...
Page 505 REFITTING 1. REFITTING OPERATION Connect the connectors ( ) and ( ) to the control panel. Refit the control panel in its housing. Clip on the centring pins. Refit the control panel bolts ( 2. FINAL OPERATION Refit: the dashboard lower centre trims (3) , the bolts (2) , the dashboard centre trims (1) .
Page 506 display the "Before/after repair procedure" for the computer selected, select "Air conditioning control panel" in the "List of components controlled by this computer" section, carry out the operations described in the "After repair procedure" section. Repair-30x02x01x11-01x37-1-33-1.xml XSL version : 3.02 du 22/07/11 - 6 -...
Page 507 COOLANT PUMP INLET PIPE: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 parts always to be replaced: seal between coolant pump inlet pipe and coolant pump inlet union WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair:...
Page 508 CAUTION When carrying out a repair that requires a complete change, it is essential to flush the circuit with clean water, blast compressed air through the circuit to drive out the water, fill and bleed the circuit and then measure the effective protection. The criteria to be met are: -25 C ±...
Page 509 Drain the cooling system (see 19A, Cooling Cooling system: Draining - Refilling Remove: the inlet distributor Inlet distributor: Removal - Refitting the exhaust gas recirculation rigid pipe Exhaust gas recirculation rigid pipe: Removal - Refitting the starter Starter: Removal - Refitting the exhaust gas heat exchanger Exhaust gas cooler: Removal - Refitting Unclip the alternator wiring.
Page 510 Remove the bolt of the coolant pump inlet pipe ( Separate the coolant pump inlet pipe from the coolant pump. Remove: the clip (2) between the exhaust gas heat exchanger and the coolant pump inlet pipe using the tool Remote operation pliers for hose clips. (Mot.
Page 511 the hose between the exhaust gas heat exchanger and the coolant pump inlet pipe, the clip (3) between the coolant outlet union and the coolant pump inlet pipe using the tool Remote operation pliers for hose clips. (Mot. 1448 Disconnect the coolant outlet union hose and the coolant pump inlet pipe. Remove: the coolant pump inlet pipe, the coolant pump inlet pipe seal.
Page 512 Refit: a new coolant pump inlet pipe seal, the hose between the exhaust gas heat exchanger and the coolant pump inlet pipe, the clip between the exhaust gas heat exchanger and the coolant pump inlet pipe using the tool Remote operation pliers for hose clips.
Page 513 the damper valve Damper valve: Removal - Refitting the air filter unit Air filter unit: Removal - Refitting the battery tray Battery tray: Removal - Refitting (80A, Battery), the battery Battery: Removal - Refitting (80A, Battery). Fill and bleed the cooling system (see 19A, Cooling Cooling system: Draining - Refilling...
Page 514 COOLANT PUMP: REMOVAL - REFITTING Note, one or more warnings are present in this procedure parts always to be replaced: coolant pump seal WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 19A, Cooling, Engine cooling: Precautions for the repair) Vehicle: Precautions for the repair...
Page 515 CAUTION Prepare for the flow of fluid, and protect the surrounding components. CAUTION When carrying out a repair that requires a complete change, it is essential to flush the circuit with clean water, blast compressed air through the circuit to drive out the water, fill and bleed the circuit and then measure the effective protection.
Page 516 the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the accessories belt Accessories belt: Removal - Refitting 2. REMOVAL OF THE PART CONCERNED Remove: the bolts of the coolant pump pulley (1) with a screwdriver, - 3 -...
Page 517 the coolant pump pulley. Remove: the coolant pump bolts (2) , the coolant pump, - 4 -...
Page 518 the coolant pump seal. REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: coolant pump seal CAUTION Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. WARNING Wear goggles with side protectors for this operation.
Page 519 2. REFITTING PART CONCERNED Refit: a new coolant pump seal, the coolant pump. 25 N.m Torque tighten in order the coolant pump bolts - 6 -...
Page 520 Refit the water pump pulley. 21 N.m Torque tighten the coolant pump pulley bolts 3. FINAL OPERATION Refit: the accessories belt Accessories belt: Removal - Refitting the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front wheels Wheel: Removal - Refitting (35A, Wheels and tyres).
Page 521 COOLANT PUMP: REMOVAL - REFITTING Note, one or more warnings are present in this procedure parts always to be replaced: coolant pump seal WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 19A, Cooling, Engine cooling: Precautions for the repair) Vehicle: Precautions for the repair...
Page 522 CAUTION When carrying out a repair that requires a complete change, it is essential to flush the circuit with clean water, blast compressed air through the circuit to drive out the water, fill and bleed the circuit and then measure the effective protection. The criteria to be met are: -25 C ±...
Page 523 Remove: the bolts of the coolant pump pulley (1) with a screwdriver, the coolant pump pulley. - 3 -...
Page 524 Remove: the coolant pump bolts (2) , the coolant pump, the coolant pump seal. - 4 -...
Page 525 REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: coolant pump seal CAUTION Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. WARNING Wear goggles with side protectors for this operation. WARNING Wear leaktight gloves (Nitrile type) for this operation.
Page 526 Refit: a new coolant pump seal, the coolant pump. 25 N.m Torque tighten in order the coolant pump bolts Refit the water pump pulley. - 6 -...
Page 527 21 N.m Torque tighten the coolant pump pulley bolts 3. FINAL OPERATION Refit: the accessories belt Accessories belt: Removal - Refitting the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front wheels Wheel: Removal - Refitting (35A, Wheels and tyres).
Page 528 COOLING RADIATOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 Equipment required refrigerant charging station parts always to be replaced: turbocharger air cooler air inlet pipe seal turbocharger air cooler air outlet pipe seal refrigerant pipe seal WARNING...
Page 529 CAUTION When carrying out a repair that requires a complete change, it is essential to flush the circuit with clean water, blast compressed air through the circuit to drive out the water, fill and bleed the circuit and then measure the effective protection. The criteria to be met are: -25 C ±...
Page 530 M9R, 811(811) Unclip the coolant hoses at ( - 3 -...
Page 531 Pull the clip ( ) of the intercooler air outlet pipe on the intercooler side using a flat-blade screwdriver. Disconnect the intercooler air outlet pipe from the intercooler. - 4 -...
Page 532 - 5 -...
Page 533 Rotate the clip on the intercooler air inlet pipe ( Disconnect the intercooler air inlet pipe from the intercooler. - 6 -...
Page 534 Unclip the cooling fan assembly wiring at ( - 7 -...
Page 535 Mark the position of the wiring clips. Unclip the expansion bottle cooling hose clip ( ) on the cooling radiator using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the expansion bottle cooling hose from the cooling radiator. - 8 -...
Page 536 Unclip: the cooling fan assembly wiring at (6) , the expansion bottle cooling hose clip (7) with the hose from the cooling fan. Mark the position of the wiring clips. - 9 -...
Page 537 Unclip the cooling fan assembly wiring at ( Disconnect the cooling fan assembly connectors ( Remove: the air deflectors from the cooling radiator, - 10 -...
Page 538 the nuts (10) of the condenser connecting pipes. Unclip the clip of the condenser connecting pipe at ( CAUTION To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air. CAUTION In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe.
Page 539 Separate the clip of the cooling radiator bottom hose ( ) using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the bottom hose from the cooling radiator. - 12 -...
Page 540 Separate the clip of the cooling radiator top hose ( ) using the tool Remote operation pliers for hose clips. ( Mot. 1448 Note: When disconnecting the hose, pay attention to the cooling radiator top hose retaining bracket. - 13 -...
Page 541 Disconnect the cooling radiator top hose. 2. REMOVAL OF THE PART CONCERNED CAUTION To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air. - 14 -...
Page 542 Remove the "condenser - cooling radiator - cooling fan assembly - intercooler" assembly. Remove the fan assembly in the direction of the arrow by pressing on the retaining brackets ( - 15 -...
Page 543 Unclip the condenser by pulling it at a right angle in relation to the cooling radiator ( Pull the condenser horizontally in relation to the cooling radiator ( - 16 -...
Page 544 Press on the intercooler tabs at ( Remove the intercooler ( ) from the cooling radiator by turning it in the direction of the arrow. REFITTING - 17 -...
Page 545 1. REFITTING PREPARATION OPERATION Clean and degrease with surface cleaner (04B, Consumables - Products) the following components if they are full of oil: the cooling radiator, the condenser, the intercooler. parts always to be replaced: turbocharger air cooler air inlet pipe seal parts always to be replaced: turbocharger air cooler air outlet pipe seal parts always to be replaced:...
Page 546 Remove: the intercooler air inlet pipe seal, the intercooler air outlet pipe seal. - 19 -...
Page 547 Note: Check that the seal is fitted the right way round. Fit new seals, taking care to fit them the right way round. 2. REFITTING PART CONCERNED - 20 -...
Page 548 Refit the following components on the cooling radiator: the intercooler, the condenser, the fan assembly. Note: Check that the components are correctly fitted. Refit the "condenser - cooling radiator - cooling fan assembly - intercooler" assembly. 3. FINAL OPERATION CAUTION To avoid any leaks, check that the pipe surface is sound before positioning the new seal.
Page 549 8 N.m Torque tighten the nuts on the condenser connecting pipes Clip on the condenser connecting pipe. Refit the air deflectors. Connect: the cooling radiator top hose to the cooling radiator, the cooling radiator bottom hose to the cooling radiator. Refit: the cooling radiator top hose clip using the tool Remote operation pliers for hose clips.
Page 550 clips. ( Mot. 1448 Rotate the intercooler air inlet pipe clip in order to fit the clip into the neck of the intercooler air inlet pipe. Connect the intercooler air inlet pipe to the intercooler. Note: Check that the intercooler air inlet pipe is correctly clipped onto the intercooler. Connect the intercooler air outlet pipe on the intercooler.
Page 551 the front bumper (55A, Exterior protection), the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front wheels Wheel: Removal - Refitting (35A, Wheels and tyres). Connect the battery (80A, Battery). Battery: Removal - Refitting Refill: the coolant circuit (see 19A, Cooling, Cooling system: Draining - Refilling)
Page 552 COOLING SYSTEM: DRAINING - REFILLING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 Instrument for testing the cooling circuit and the expansion bottle valve. Contains caps 554-01, 554-04, 554-06 Ms.
Page 553 CAUTION The coolant helps to keep the engine running properly (heat exchange). The system does not operate using pure water. CAUTION Drain with the engine warm. Flush and refill with the engine cold or warm. Never flush a hot engine (risk of major thermal shock). CAUTION When carrying out a repair that requires a complete change, it is essential to flush the circuit with clean water, blast compressed air through the circuit to drive out the...
Page 554 Remove: the clip (1) from the oil filter unit coolant outlet hose using the tool Remote operation pliers for hose clips. (Mot. 1448 the oil filter unit coolant outlet hose using the tool Set of trim removal levers. (Car. 1363 Drain the cooling system.
Page 555 Fault finding and filling - bleeding the cooling circuit. (Mot. 1700 ) recommended by Renault. It saves a considerable amount of time because it does not require the cooling system bleed screws to be opened, the procedure without a special tool.
Page 556 the turbocharging pressure regulation hose on the turbocharger from the oil vapour rebreathing hose, the oil vapour rebreathing hose from the oil decanter, the brake servo vacuum pipe from the air filter unit air outlet pipe, the turbocharging pressure regulation hose on the air filter unit air outlet pipe. Loosen the air filter unit air outlet pipe clip on the turbocharger side.
Page 557 Move aside the engine wiring ( Remove: the bleed screw (3) of the coolant outlet unit, the bleed screw of the heater matrix pipe. Fill the cooling system with engine coolant recommended by the manufacturer (see 19A, Cooling and (04B, Consumables - Products) via the expansion bottle until it Engine cooling system: Specifications overflows.
Page 558 CAUTION Do not open the bleed screw whilst the engine is running; this would damage the engine. Start the engine and check that the air conditioning system is off. Note: Because of the layout of the cooling system, it is more difficult to prime the coolant pump on this engine.
Page 559 COURTESY LIGHT: REMOVAL - REFITTING REMOVAL 1. OPERATION FOR REMOVAL OF PART CONCERNED - 1 -...
Page 560 Unclip the vanity light ( ) from the headlining using a trim removal tool. Note: Take care not to remove the plastic support ( ) from the vanity light in the headlining. Disconnect the vanity light connector. Remove the vanity light. Note: When replacing the bulb, use an approved bulb.
Page 561 REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Connect the vanity light connector. Clip the vanity light onto the headlining. Repair-80x02x08x25-01x37-1-12-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 562 CRANKSHAFT ACCESSORIES PULLEY: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Crankshaft pulley locking tool. Mot. 1770 parts always to be replaced: Crankshaft accessories pulley bolts REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment).
Page 563 Immobilise the crankshaft accessories pulley using the Crankshaft pulley locking tool. ( Mot. 1770 Remove the crankshaft accessories pulley bolt. - 2 -...
Page 564 Remove: the washer of the crankshaft accessories pulley (2) , the crankshaft accessories pulley (3) . REFITTING - 3 -...
Page 565 1. REFITTING PREPARATION OPERATION parts always to be replaced: Crankshaft accessories pulley bolts CAUTION Only use brushes with plastic or non-corrosive metal (brass) bristles. CAUTION Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley. In case of reuse, clean the crankshaft accessories V-pulley using a brush to get rid of any deposit.
Page 566 3. FINAL OPERATION Refit: the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting) the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres).
Page 567 CRANKSHAFT: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 Dial gauge support. Mot. 251-01 Flywheel locking tool. Mot. 1431 Equipment required component support puller (from inside) depth gauge indelible pencil compressed air nozzle...
Page 568 Immobilise the flywheel or the drive plate while fitting the Flywheel locking tool. ( ) on the cylinder block. Mot. 1431 Remove: the crankshaft accessories pulley Crankshaft accessories pulley: Removal - Refitting the crankshaft seal on the timing side Crankshaft seal on timing end: Removal - Refitting Remove the timing chain (see 10A, Engine and cylinder block assembly...
Page 569 X43, M9R, 804 817 839 844(804 OR 817 OR 839 OR 844) AND (830 OR 832 OR 833 OR 835 OR 836 OR 838 OR 850 OR 855 OR 856 OR 864 OR 865 OR 866) AND (760) AND (760 OR 761 OR 762 OR 763) AND (721 OR 724) AND (800 OR 805 OR 809 OR 816 OR 820 OR 828) Remove the balance shaft assembly (see 10A,...
Page 570 Note: Always mark the position of each thrust washer using an indelible marker pen, in relation to the cylinder block. Remove the crankshaft thrust washers ( 2- REMOVE THE CRANKSHAFT POSITION SENSOR TARGET Operation only to be carried out when replacing the crankshaft or the crankshaft position sensor target. Remove: the bolts (9) from the crankshaft position sensor target, the target (10) from the crankshaft position sensor.
Page 571 17 mm Remove the bearing using the for bearing inner diameter. puller (from inside) REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: crankshaft bearing bolt 1- CLEANING PARTS Note: Avoid any impact or pressure to: -the mating faces of the seal and bearing of the crankshaft or cylinder block, -the mating faces of the crankshaft bearing caps.
Page 572 Refit: the crankshaft position sensor target by aligning the crankshaft centring pin (13) with the target hole, the bolts from the crankshaft position sensor target. Torque tighten in order the crankshaft position sensor target bolts 17 N.m 2. CRANKSHAFT REFITTING OPERATION Note: If not being replaced, refit following the marks made at the time of the removal: -the crankshaft bearing shells,...
Page 573 Centre the on bearing No. 1 of the cylinder block while aligning the groove of the bearing shell with the groove of the bearing ( grooved bearing shell Secure the flush bearing shell at ( ) and push from the opposite side to position the bearing shell flush with the bearing. - 7 -...
Page 574 Measure the distance ( ) between the bearing face ( ) and the edge of the bearing shell at points ( ) , ( ) and ( ) using a depth gauge If necessary, adjust the position of the bearing shell to the value ( 182.71 ±...
Page 575 Place: a rectified shim (18) against the mating face of the crankshaft thrust washer on bearing No. 3 (e.g.: the tool Dial gauge support. (Mot. 251-01) ), the grooved bearing shell against the rectified shim. Secure the flush bearing shell at ( ) and push from the opposite side to position the bearing shell flush with the bearing.
Page 576 Centre the grooved bearing shell on the bearing, aligning the bearing shell with the bearing groove. Adjust the position of the bearing shell at points ( ) , ( ) and ( ) using the rectified shim ( ) and a (thickness of the shim ( X3: 2 ±...
Page 577 the non-grooved bearing shell on the bench. Secure the flush bearing shell with the bearing cap at ( ) and push from the opposite side to bring the bearing shell flush with the bearing cap. Measure the distance ( ) between the edge of the bearing shell and the wall of the bearing cap at points ( ) , ( ) and ( ) using a...
Page 578 Repeat the previous operations for the other bearing caps. Position the crankshaft thrust washers on the cylinder block (washer lug ( ) in the cylinder block notch). Use engine oil to lubricate the crankshaft journal bearing shells and thrust washers (only the face making contact with the crankshaft). Note: Ensure the bearing shells and the thrust washers do not move when refitting the crankshaft and bearing caps.
Page 579 the new crankshaft bearing bolts. Note: Check that the bearing caps are in contact with the cylinder block before tightening the bearing cap bolts. 20 N.m + 70 ± 6 Tighten to torque, to angle and in order the crankshaft bearing bolts Check that the crankshaft turns freely, with no resistance.
Page 580 10A, Engine and cylinder block assembly Piston - Con rod: Check Note: A piston protrusion outside the tolerances in relation to the cylinder block can lead to: -an engine malfunction (incorrect start, pollution, poor performance), - engine damage (piston in contact with the cylinder head or valves). X43, M9R, 804 817 839 844(804 OR 817 OR 839 OR 844) AND (830 OR 832 OR 833 OR 835 OR 836 OR 838 OR 850 OR 855 OR 856 OR 864 OR 865 OR 866) AND (760) AND (760 OR 761 OR 762 OR 763) AND (721 OR 724) AND (800 OR 805 OR 809 OR 816 OR 820 OR 828) If replacing the crankshaft, always identify the thickness of the permanent shims to refit between the cylinder block and the balance shaft assembly to guarantee the teeth...
Page 581 the oil decanter Oil decanter: Removal - Refitting a new high pressure pipe between the pump and the rail High pressure pipe between pump and rail: Removal - Refitting the vacuum pump Vacuum pump: Removal - Refitting (37A, Mechanical component controls), new turbocharger oil pipes Turbocharger oil pipe: Removal - Refitting depending on version, the turbocharger outlet catalytic pre-converter or catalytic converter...
Page 582 CRANKSHAFT SEAL ON TIMING END: REMOVAL - REFITTING Note, one or more warnings are present in this procedure parts always to be replaced: Crankshaft seal on timing end REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment).
Page 583 Remove the crankshaft seal on the timing end ( ) using the tool supplied in the spare parts kit for the new seal. REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: Crankshaft seal on timing end - 2 -...
Page 584 2. REFITTING OPERATION Clean and degrease the mating face of the crankshaft seal using surface cleaner (04B, Consumables - Products). CAUTION To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks). - 3 -...
Page 585 Position the lugs ( ) of the new crankshaft seal opposite the timing cover notches ( - 4 -...
Page 586 Engage the new crankshaft seal lugs in the timing cover notches. Manually tighten the crankshaft seal using the tool supplied in the spare parts kit for the new crankshaft seal. - 5 -...
Page 587 47 N.m Torque tighten the crankshaft seal using the ( ) supplied in the spare parts kit for the new crankshaft seal. - 6 -...
Page 588 Remove the crankshaft seal protector ( 3. FINAL OPERATION Refit: the crankshaft accessories pulley Crankshaft accessories pulley: Removal - Refitting the accessories belt Accessories belt: Removal - Refitting the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A, Exterior protection), - 7 -...
Page 589 the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres). Repair-10x03x03x04-01x37-1-59-1.xml XSL version : 3.02 du 22/07/11 - 8 -...
Page 590 CRANKSHAFT SEAL, GEARBOX END: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required refrigerant charging station REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Drain the gearbox (21A, Manual gearbox).
Page 591 Note: The crankshaft seal on the gearbox side cannot be separated from the crankshaft cover. Remove: the crankshaft cover bolts (1) , - 2 -...
Page 592 the crankshaft "seal - cover" assembly. REFITTING 1. REFITTING PREPARATION OPERATION CAUTION To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks). Use SURFACE CLEANER (04B, Consumables - Products) to clean and degrease: the joint face of the crankshaft cover on the cylinder block, the crankshaft seal mating face.
Page 593 Note: Touching the lip of the seal is strictly forbidden. Any contact with it will result in the lip being permanently damaged, which will cause an oil leak. Fit: the "seal protector - seal - new cover" assembly on the crankshaft, - 4 -...
Page 594 90 mm the bolts (2) ( long) to guide the crankshaft "seal - cover" assembly. Move the "seal - cover" assembly evenly by hand until it makes contact with the cylinder block. Remove: the seal protector (3) , - 5 -...
Page 595 the guide bolts (4) . 5 N.m Pretighten to torque and in order the crankshaft cover bolts (initial torque) 10 N.m Torque tighten in order the crankshaft cover bolts 3. FINAL OPERATION - 6 -...
Page 596 Refit: the flywheel (see 10A, Engine and cylinder block assembly, Flywheel: Removal - Refitting) the clutch pressure plate Pressure plate - Disc: Removal - Refitting (20A, Clutch), the gearbox Manual gearbox: Removal - Refitting (21A, Manual gearbox). Fill and top up the gearbox oil (21A, Manual gearbox).
Page 597 CRANKSHAFT: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 Dial gauge support. Mot. 251-01 Flywheel locking tool. Mot. 1431 Equipment required component support puller (from inside) depth gauge indelible pencil compressed air nozzle...
Page 598 Immobilise the flywheel or the drive plate while fitting the Flywheel locking tool. ( ) on the cylinder block. Mot. 1431 Remove: the crankshaft accessories pulley Crankshaft accessories pulley: Removal - Refitting the crankshaft seal on the timing side Crankshaft seal on timing end: Removal - Refitting Remove the timing chain (see 10A, Engine and cylinder block assembly...
Page 599 X43, M9R, 804 817 839 844(804 OR 817 OR 839 OR 844) AND (830 OR 832 OR 833 OR 835 OR 836 OR 838 OR 850 OR 855 OR 856 OR 864 OR 865 OR 866) AND (760) AND (760 OR 761 OR 762 OR 763) AND (721 OR 724) AND (800 OR 805 OR 809 OR 816 OR 820 OR 828) Remove the balance shaft assembly (see 10A,...
Page 600 Note: Always mark the position of each thrust washer using an indelible marker pen, in relation to the cylinder block. Remove the crankshaft thrust washers ( 2- REMOVE THE CRANKSHAFT POSITION SENSOR TARGET Operation only to be carried out when replacing the crankshaft or the crankshaft position sensor target. Remove: the bolts (9) from the crankshaft position sensor target, the target (10) from the crankshaft position sensor.
Page 601 17 mm Remove the bearing using the for bearing inner diameter. puller (from inside) REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: crankshaft bearing bolt 1- CLEANING PARTS Note: Avoid any impact or pressure to: -the mating faces of the seal and bearing of the crankshaft or cylinder block, -the mating faces of the crankshaft bearing caps.
Page 602 Refit: the crankshaft position sensor target by aligning the crankshaft centring pin (13) with the target hole, the bolts from the crankshaft position sensor target. Torque tighten in order the crankshaft position sensor target bolts 17 N.m 2. CRANKSHAFT REFITTING OPERATION Note: If not being replaced, refit following the marks made at the time of the removal: -the crankshaft bearing shells,...
Page 603 Centre the on bearing No. 1 of the cylinder block while aligning the groove of the bearing shell with the groove of the bearing ( grooved bearing shell Secure the flush bearing shell at ( ) and push from the opposite side to position the bearing shell flush with the bearing. - 7 -...
Page 604 Measure the distance ( ) between the bearing face ( ) and the edge of the bearing shell at points ( ) , ( ) and ( ) using a depth gauge 182.71 ± 0.1 mm If necessary, adjust the position of the bearing shell to the value ( Repeat the previous operations for the bearing shells of bearings No.
Page 605 Place: a rectified shim (18) against the mating face of the crankshaft thrust washer on bearing No. 3 (e.g.: the tool Dial gauge support. (Mot. 251-01) ), the grooved bearing shell against the rectified shim. Secure the flush bearing shell at ( ) and push from the opposite side to position the bearing shell flush with the bearing.
Page 606 Centre the grooved bearing shell on the bearing, aligning the bearing shell with the bearing groove. Adjust the position of the bearing shell at points ( ) , ( ) and ( ) using the rectified shim ( ) and a (thickness of the shim ( X3: 2 ±...
Page 607 the non-grooved bearing shell on the bench. Secure the flush bearing shell with the bearing cap at ( ) and push from the opposite side to bring the bearing shell flush with the bearing cap. Measure the distance ( ) between the edge of the bearing shell and the wall of the bearing cap at points ( ) , ( ) and ( ) using a...
Page 608 Repeat the previous operations for the other bearing caps. Position the crankshaft thrust washers on the cylinder block (washer lug ( ) in the cylinder block notch). Use engine oil to lubricate the crankshaft journal bearing shells and thrust washers (only the face making contact with the crankshaft). Note: Ensure the bearing shells and the thrust washers do not move when refitting the crankshaft and bearing caps.
Page 609 the new crankshaft bearing bolts. Note: Check that the bearing caps are in contact with the cylinder block before tightening the bearing cap bolts. 20 N.m + 70 ± 6 Tighten to torque, to angle and in order the crankshaft bearing bolts Check that the crankshaft turns freely, with no resistance.
Page 610 10A, Engine and cylinder block assembly Piston - Con rod: Check Note: A piston protrusion outside the tolerances in relation to the cylinder block can lead to: -an engine malfunction (incorrect start, pollution, poor performance), - engine damage (piston in contact with the cylinder head or valves). X43, M9R, 804 817 839 844(804 OR 817 OR 839 OR 844) AND (830 OR 832 OR 833 OR 835 OR 836 OR 838 OR 850 OR 855 OR 856 OR 864 OR 865 OR 866) AND (760) AND (760 OR 761 OR 762 OR 763) AND (721 OR 724) AND (800 OR 805 OR 809 OR 816 OR 820 OR 828) If replacing the crankshaft, always identify the thickness of the permanent shims to refit between the cylinder block and the balance shaft assembly to guarantee the teeth...
Page 611 the oil decanter Oil decanter: Removal - Refitting a new high pressure pipe between the pump and the rail High pressure pipe between pump and rail: Removal - Refitting the vacuum pump Vacuum pump: Removal - Refitting (37A, Mechanical component controls), new turbocharger oil pipes Turbocharger oil pipe: Removal - Refitting depending on version, the turbocharger outlet catalytic pre-converter or catalytic converter...
Page 612 CYLINDER BLOCK: REMOVAL - REFITTING Special tooling required Seal extractor tool Mot. 587 Engine lifting ring. Mot. 923 Flywheel locking tool. Mot. 1431 Equipment required workshop hoist REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the timing chain (see 10A, Engine and cylinder block assembly Timing chain: Removal - Refitting X43, M9R, 804 817 824 839 844 846(804 OR 817 OR 824 OR 839 OR 844 OR 846) AND (670 OR 678 OR 680 OR 690 OR 696 OR 698 OR 880 OR 896 OR 898) AND (760) AND (760 OR 761 OR 762 OR 763 OR 812 OR 814 OR 815 OR 858 OR 859)
Page 613 the high pressure pipe between the pump and the rail High pressure pipe between pump and rail: Removal - Refitting the oil decanter Oil decanter: Removal - Refitting the injector fuel return rail Diesel injector fuel return rail: Removal - Refitting the high pressure pipes between the rail and the injectors High pressure pipe between rail and injector: Removal - Refitting...
Page 614 Removal - Refitting) X43, M9R, 804 811 817 839 844(804 OR 811 OR 817 OR 839 OR 844) AND (830 OR 832 OR 833 OR 835 OR 836 OR 838 OR 850 OR 855 OR 856 OR 864 OR 865 OR 866) AND (760) AND (760 OR 761 OR 762 OR 763 OR 812) AND (721 OR 724) AND (800 OR 805 OR 806 OR 808 OR 809 OR 816 OR 820 OR 828) AND (610 OR 615) Remove the balance shaft assembly (see 10A,...
Page 615 Remove the centring dowels ( ) from the cylinder head using the Seal extractor tool ( ) or Mot. 587 a slide hammer. Remove: the crankshaft position sensor Crankshaft position sensor: Removal - Refitting the oil level sensor Oil level sensor: Removal - Refitting - 4 -...
Page 616 the EGR cooler , the coolant pump inlet pipe . X43, M9R, 756 811(756 OR 811) AND (754 OR 800 OR 802 OR 803 OR 805 OR 806 OR 808 OR 809 OR 814 OR 815 OR 816 OR 820 OR 828 OR 854 OR 857) Remove the power assisted steering pump Power-assisted steering pump: Removal - Refitting Remove:...
Page 617 Position the Engine lifting ring. ( ) on the cylinder block. Mot. 923 Remove the cylinder block from the component support using a (see 10A, workshop hoist Engine and cylinder block assembly Engine support equipment: Use Clean the cylinder block (see 10A, Engine and cylinder block assembly Cylinder block: Cleaning...
Page 618 Refit the cylinder block on the component support using a (see 10A, workshop hoist Engine and cylinder block assembly Engine support equipment: Use 2. CYLINDER BLOCK REFITTING OPERATION Refit: the multifunction support , the alternator Alternator: Removal - Refitting X43, M9R, 756 811(756 OR 811) AND (754 OR 800 OR 802 OR 803 OR 805 OR 806 OR 808 OR 809 OR 814 OR 815 OR 816 OR 820 OR 828 OR 854 OR 857) Refit the power assisted steering pump Power-assisted steering pump: Removal - Refitting...
Page 619 Note: Any clearances exceeding the tolerances of the crankshaft journals can cause engine damage. Refit the crankshaft (see 10A, Engine and cylinder block assembly Crankshaft: Removal - Refitting If replacing the cylinder block, always identify the piston height category to refit in each cylinder to guarantee the piston protrusion in relation to the cylinder block remains within the tolerances, before refitting the conrod - piston assemblies (see 10A,...
Page 620 X43, M9R, 804 811 817 839 844(804 OR 811 OR 817 OR 839 OR 844) AND (830 OR 832 OR 833 OR 835 OR 836 OR 838 OR 850 OR 855 OR 856 OR 864 OR 865 OR 866) AND (760) AND (760 OR 761 OR 762 OR 763 OR 812) AND (721 OR 724) AND (800 OR 805 OR 806 OR 808 OR 809 OR 816 OR 820 OR 828) AND (610 OR 615) If replacing the cylinder block, always identify the thickness of the permanent shims to refit between the cylinder block and the balance shaft assembly to guarantee the teeth clearance between...
Page 621 the clutch plate and pressure plate Pressure plate - Disc: Removal - Refitting Refit: the oil filter unit Oil filter unit: Removal - Refitting the cylinder head (see 10A, Engine and cylinder block assembly, Cylinder head: Removal - Refitting) the rocker cover (see 10A, Engine and cylinder block assembly, Rocker cover: Removal - Refitting) the diesel injectors Diesel injector: Removal - Refitting...
Page 622 Refit the timing chain (see 10A, Engine and cylinder block assembly Timing chain: Removal - Refitting Repair-10x03x01x07-01x37-1-27-1.xml XSL version : 3.02 du 22/07/11 - 11 -...
Page 623 DAMPER VALVE: REMOVAL - REFITTING Equipment required Diagnostic tool REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the front engine cover. - 1 -...
Page 624 Undo the clip ( ) from the intercooler outlet pipe. Disconnect: the intercooler air outlet pipe from the damper valve, the damper valve connector (2) , - 2 -...
Page 625 the turbocharging pressure sensor connector (3) . Unclip the clips of the damper valve wiring harness and the turbocharging pressure sensor housing. Move the intercooler air outlet pipe to one side. Remove: the bolts of the engine oil filler neck (4) , the engine oil filler neck (5) .
Page 626 Note: Be careful not to drop the "damper valve - turbocharging pressure sensor housing" assembly while removing the long bolts of the damper valve strut. Remove the short bolts ( ) of the damper valve strut. Completely loosen the long bolts ( ) of the damper valve strut.
Page 627 Remove: the "damper valve strut - damper valve - turbocharging pressure sensor housing" assembly, the seal between the turbocharging pressure sensor housing and the exhaust gas recirculation solenoid valve, the turbocharging pressure sensor housing, the seal between the damper valve and the turbocharging pressure sensor housing. REFITTING 1.
Page 628 the damper valve strut, the damper valve, a new seal between the damper valve and the turbocharging pressure sensor housing, the turbocharger pressure sensor housing, a new seal between the turbocharging pressure sensor housing and the exhaust gas recirculation solenoid valve.
Page 629 the intercooler air outlet pipe. 6 N.m Torque tighten the clip of the intercooler air outlet pipe Refit the engine cover. Apply the after repair procedure using the Diagnostic tool : connect the Diagnostic tool , select "Injection computer" , go to repair mode, display the "before/after repair procedure"...
Page 630 DASHBOARD AIR VENT: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the centre front panel (see 57A, Interior equipment Centre front panel: Removal - Refitting 2. REMOVAL OPERATION - 1 -...
Page 631 Remove the ioniser control panel ( (61A, Heating system). Ioniser unit: Removal - Refitting Remove the dashboard air vent ( REFITTING - 2 -...
Page 632 Proceed in the reverse order to removal. Repair-50x08x02x03-01x37-1-13-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 633 DASHBOARD CROSS MEMBER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Bolt for repositioning the play compensation bushes of the dashboard cross member Car. 1765 Equipment required Diagnostic tool REMOVAL WARNING To avoid any risk of damaging the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out the repair Airbag and (88C, Airbags and pretensioners).
Page 634 1. REMOVAL PREPARATION OPERATION Lock the airbag computer using the (see ) (88C, Diagnostic tool Fault finding - Replacement of components Airbags and pretensioners). Disconnect the battery (80A, Battery). Remove: the front side doors (see Front side opening element: Removal - Refitting) , the dashboard Dashboard: Removal - Refitting (57A, Interior equipment),...
Page 635 Remove: the nuts (1) , the bolts (2) , the dashboard flange. - 3 -...
Page 636 Remove the bolts from the cross member ( - 4 -...
Page 637 Remove: the side bolts using the tool Bolt for repositioning the play compensation bushes of the dashboard cross member (Car. 1765 ) (4) , the dashboard cross member with the help of a second person. - 5 -...
Page 638 REFITTING 1. REFITTING OPERATION Refit: the dashboard cross member with the help of a second person, the side bolts using the tool Bolt for repositioning the play compensation bushes of the dashboard cross member (Car. 1765 the cross member bolts (3) , the dashboard flange, the bolts (2) , the nuts (1) .
Page 639 Connect the battery (80A, Battery). Unlock the airbag computer using the (see Diagnostic tool Fault finding - Replacement of components (88C, Airbags and pretensioners). Repair-40x06x12x02-01x37-1-19-1.xml XSL version : 3.02 du 22/07/11 - 7 -...
Page 640 DASHBOARD LOWER TRIM: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Press the clip ( ) of the driver's glovebox. - 1 -...
Page 641 Remove the driver's storage compartment ( Remove the switch side plate ( Disconnect the connectors from the switch side plate. - 2 -...
Page 642 2. REMOVAL OPERATION Remove the dashboard lower trim bolt ( Unclip the dashboard lower trim ( REFITTING - 3 -...
Page 643 Proceed in the reverse order to removal. Repair-50x08x02x07-01x37-1-7-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 644 DASHBOARD SIDE AIR VENT: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Disconnect the battery (80A, Battery). Remove the dashboard (see 57A, Interior equipment Dashboard: Removal - Refitting 2. REMOVAL OPERATION - 1 -...
Page 645 Remove: the bolts (1) of the dashboard side air vent, the dashboard side air vent (2) . REFITTING - 2 -...
Page 646 Proceed in the reverse order to removal. Repair-50x08x02x06-01x37-1-3-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 647 DASHBOARD: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Disconnect the battery (80A, Battery). Remove: the windscreen pillar trims Windscreen pillar trim: Removal - Refitting (71A, Body internal trim), the driver's frontal airbag Driver's frontal airbag: Removal - Refitting (88C, Airbags and pretensioners), the steering wheel Steering wheel: Removal - Refitting (36A, Steering assembly),...
Page 648 Remove the dashboard side trims ( Unclip the under-dashboard light ( Remove: the bolts (3) , the dashboard lower centre trims (4) . Remove the trim ( - 2 -...
Page 649 Remove: the bolts (6) , the trim (7) , the trim (8) . Unclip the under-dashboard light ( - 3 -...
Page 650 Remove: the dashboard bolt the dashboard bolts (11) . Disconnect the connector ( ) from the passenger frontal airbag. Remove the front passenger airbag bolts ( Note: Mark the position of the various wiring before removing the dashboard. Partially remove the dashboard. Remove the dashboard (this operation requires two people).
Page 651 Proceed in the reverse order to removal. Torque tighten the passenger frontal airbag bolts 4 N.m Carry out a function test on all functions. Repair-50x08x02x02-01x37-1-31-1.xml XSL version : 3.02 du 22/07/11 - 5 -...
Page 652 DAYTIME RUNNING LIGHT: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove: the bolts (1) , - 1 -...
Page 653 the clips (2) . 2. OPERATION FOR REMOVAL OF PART CONCERNED Disconnect the connector ( Remove: the bolts (4) , the daytime running light. REFITTING - 2 -...
Page 654 1. REFITTING OPERATION FOR PART CONCERNED Refit: the daytime running light, the daytime running light mounting bolts. Connect the daytime running light connector. 2. FINAL OPERATION Refit: the front bumper lower mounting clips, the front bumper lower mounting bolts. 4 N.m Torque tighten the front bumper lower mounting bolts Repair-80x02x02x11-01x37-1-5-1.xml XSL version : 3.02 du 22/07/11...
Page 655 DETACHMENT OF THE ROOF FRAMES: DESCRIPTION Note, one or more warnings are present in this procedure Special tooling required Wire insertion tool for removing bonded mirror glass. Car. 1033 (1) Cement bead (2) Piercing area of cement bead 1. PREPARATION - 1 -...
Page 656 WARNING Wear protective gloves and goggles when cutting the window or sunroof operating mechanism. Use an appropriate work station when replacing a sunroof operating mechanism. Protect the vehicle interior. Open the mobile panel halfway. Remove the headlining (see MR for the vehicle concerned Protect the area around the sunroof operating mechanism with masking tape.
Page 657 2.5 mm Insert the cutting wire in the wire insertion tool, or in a small diameter tube. - 3 -...
Page 658 Using the Wire insertion tool for removing bonded mirror glass. ( ) , pierce the cement bead of the Car. 1033 sunroof operating mechanism at the most accessible place ( - 4 -...
Page 659 Insert the cutting wire in the Wire insertion tool for removing bonded mirror glass. ( Car. 1033 - 5 -...
Page 660 Pass the cutting wire from the exterior towards the interior using the Wire insertion tool for removing bonded mirror glass. ( Car. 1033 - 6 -...
Page 661 Fit the first pulling handle on the section of the cutting wire inside the vehicle. - 7 -...
Page 662 Using the wire insertion tool, slide the cutting wire between the sunroof operating mechanism and the panelwork around the entire edge outside the vehicle. Cut a sufficient length of cutting wire. Remove the cutting wire insertion tool. Note: When passing the cutting wire into the vehicle interior, be careful not to cross the 2 wires.
Page 663 Pass the Wire insertion tool for removing bonded mirror glass. ( ) near the first piercing of the Car. 1033 cement bead. - 9 -...
Page 664 Pass the cutting wire from the exterior towards the interior using the Wire insertion tool for removing bonded mirror glass. ( Car. 1033 - 10 -...
Page 665 Fit the second pulling handle on the other section of the cutting wire inside the vehicle. - 11 -...
Page 666 Pull on the first pulling handle until you reach the central cross member. Note: Gradually reduce the length of the cutting wire as you cut. - 12 -...
Page 667 Remove the pulling handle. - 13 -...
Page 668 Pass the cutting wire between the central cross member and the sunroof operating mechanism. - 14 -...
Page 669 Continue cutting the cement bead with the pulling handle. - 15 -...
Page 670 Gently separate the panel in the area of the centring guide for the sunroof operating mechanism, in order to pass the cutting wire through. - 16 -...
Page 671 Leave the pulling handle in place at the central cross member. - 17 -...
Page 672 Resume cutting using the second pulling handle. - 18 -...
Page 673 Cut the cement bead of the central cross member using the two pulling handles. - 19 -...
Page 674 Remove the sunroof operating mechanism (this operation requires two people) using the specific supports: Support: PARV 202 , set of arch supports: APARV 200 ESP . Repair-50x04x01x06-02x21-1-1-1.xml XSL version : 3.02 du 22/07/11 - 20 -...
Page 675 The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault. 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 676 DIESEL EQUIPMENT Fuel supply pipes REPLACING THE DIESEL FUEL SUPPLY PIPES Certain pipes have an opening to enable the die- sel supply circuit to be bled at the factory. A plug (A) seals this opening (any plug which is locked in position cannot be removed without carrying a risk of breaking).
Page 677 DIESEL INJECTION: LIST AND LOCATION OF COMPONENTS (1) Manual priming pump (2) Fuel pressure regulator on the injector rail (3) Diesel injectors (4) Rail pressure sensor (5) Camshaft position sensor. (6) Fuel temperature sensor. (7) High pressure pump (8) Air flowmeter (9) Diesel injection computer (10) Turbocharger control solenoid valve (11) EGR cooler control solenoid valve...
Page 678 (2) Pressure regulator on the fuel injector rail (4) Rail pressure sensor (5) Camshaft position sensor - 2 -...
Page 679 (6) Fuel temperature sensor (7) High pressure pump - 3 -...
Page 680 (8) Air flowmeter (9) Diesel injection computer - 4 -...
Page 681 (10) Turbocharger control solenoid valve (11) EGR cooler control solenoid valve - 5 -...
Page 682 (12) EGR solenoid valve (13) Turbocharger pressure sensor (14) Damper valve (16) Preheating unit Repair-11x05x01-02x51-1-67-1.xml XSL version : 3.02 du 22/07/11 - 6 -...
Page 683 DIESEL INJECTION: LIST AND LOCATION OF COMPONENTS (1) Manual priming pump (2) Fuel pressure regulator on the injector rail (3) Diesel injectors (4) Rail pressure sensor (5) Camshaft position sensor. (6) Fuel temperature sensor. (7) High pressure pump (8) Air flowmeter (9) Diesel injection computer (10) Turbocharger control solenoid valve (11) EGR cooler control solenoid valve...
Page 684 (2) Pressure regulator on the fuel injector rail (4) Rail pressure sensor (5) Camshaft position sensor - 2 -...
Page 685 (6) Fuel temperature sensor (7) High pressure pump - 3 -...
Page 686 (8) Air flowmeter (9) Diesel injection computer - 4 -...
Page 687 (10) Turbocharger control solenoid valve (11) EGR cooler control solenoid valve - 5 -...
Page 688 (12) EGR solenoid valve (13) Turbocharger pressure sensor (14) Damper valve (16) Preheating unit Repair-11x05x01-02x51-1-67-1.xml XSL version : 3.02 du 22/07/11 - 6 -...
Page 689 DIESEL INJECTION: PRECAUTIONS FOR THE REPAIR Note, one or more warnings are present in this procedure 1. RISKS RELATING TO CONTAMINATION The high-pressure direct injection system is highly sensitive to contamination. The risks caused by contamination are: damage to or destruction of the high pressure injection system, a component seizing, a component not being properly sealed.
Page 690 CAUTION Do not clean the engine with a high pressure cleaner to prevent damaging the connections. 1- CLEANING CLOTHS Use lint-free cleaning cloths Vehicle: Parts and consumables for the repair It is prohibited to use cloths or ordinary paper towels: these produce lint and lose fibres, which then contaminate the fuel circuit.
Page 691 4- CLEANING PRODUCTS Two cleaning products can be used: an injector cleaner , an aerosol spray brake cleaner . To use the injector cleaner, be sure to have a clean brush in good condition (the brush must not lose any bristles) as well as a clean container which has no impurities in it. Note: Use a new injector cleaner each time work is carried out (a used cleaning agent will contain impurities).
Page 692 Note: When using leather protective gloves, wear a pair of leaktight protective gloves (Nitrile type) over the top. 5) Before carrying out work on the injection system, use plastic bags or clean cloths, for example, to protect: the accessories and timing belts, the electrical accessories (starter, alternator, power-assisted steering pump, sensors and electrical connectors), the flywheel face.
Page 693 1- CLEANING USING INJECTOR CLEANER Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see the relevant Workshop Repair Manual). Protect sections which are sensitive to fuel leaks. Pour the injector cleaning agent into a container which is free from impurities. WARNING Wear leaktight gloves (Nitrile type) for this operation.
Page 694 Protect sections which are sensitive to fuel leaks. WARNING Wear leaktight gloves (Nitrile type) for this operation. WARNING Wear goggles with side protectors for this operation. Spray the brake cleaner onto the unions to be opened. Clean the unions carefully using fresh cleaning cloths. Blast the components that have been cleaned with compressed air (tools, workbench, and also parts, unions and around the injection system).
Page 695 DIESEL INJECTOR FUEL RETURN RAIL: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required tweezers WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 13B, Diesel injection Diesel injection: Precautions for the repair...
Page 696 1. REMOVAL PREPARATION OPERATION Disconnect the battery (80A, Battery). Remove the front engine cover. Remove: the nut (1) from the cooling radiator top hose on the intercooler air inlet pipe, the bolts (2) from the intercooler air inlet pipe on the inlet distributor. Move aside the cooling radiator top hose.
Page 697 Rotate the intercooler air inlet pipe clip ( Disconnect the intercooler air inlet pipe from the turbocharger. Move aside the intercooler air inlet pipe. Remove: the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting) the oil decanter Oil decanter: Removal - Refitting 2.
Page 698 CAUTION To prevent impurities from entering the circuit, place protective plugs on all fuel circuit components exposed to the open air. Disconnect the quick-release union ( ) between the fuel return pipe and the injector fuel return rail. Place blanking plugs: on the fuel return pipe, on the injector fuel return rail.
Page 699 - 5 -...
Page 700 Remove the bolt ( ) from the injector fuel return rail union. Lift up the clips ( ) between the fuel return rail and the injectors using a flat-blade screwdriver. Disconnect the injector fuel return rail. Remove: the injector fuel return rail, - 6 -...
Page 701 the seal between the diesel injector and the diesel injector fuel return rail for each injector. Fit blanking plugs onto the injectors. REFITTING 1. REFITTING PREPARATION OPERATION Always replace: the seal between the diesel injector and the diesel injector fuel return rail, the intercooler air inlet pipe seal.
Page 702 Remove the intercooler air inlet pipe seal at the turbocharger end using a tweezers - 8 -...
Page 703 Refit the new intercooler air inlet pipe seal. Note: Check that the seal ( ) on the intercooler air inlet pipe at the turbocharger end is fitted the correct way round. - 9 -...
Page 704 2. REFITTING OPERATION CAUTION 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 vehicle. Remove the blanking plugs. Refit: the new seal between the diesel injector and the injector fuel return rail for each injector, the injector fuel return rail.
Page 705 Refit the oil decanter Oil decanter: Removal - Refitting Connect the battery (80A, Battery). Refit the intercooler air inlet pipe on the turbocharger temporarily. Prime the fuel circuit using the manual pump. Start the engine. Accelerate several times under no load. Check that there are no fuel leaks.
Page 706 Refit the intercooler air inlet pipe bolts on the inlet distributor. 8 N.m Torque tighten the intercooler air inlet pipe bolts on the intake distributor Fit the cooling radiator top hose to the intercooler air inlet pipe. Refit the cooling radiator top hose nut on the intercooler air inlet pipe. 8 N.m Torque tighten the nut of the cooling radiator top hose on the intercooler air inlet pipe Refit the engine cover.
Page 707 DIESEL INJECTOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Injector well cleaning kit Mot. 1817 M9R/M9T injector extractor Mot. 1966 Equipment required Diagnostic tool tweezers indelible pencil WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 13B, Diesel injection...
Page 708 WARNING 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. CAUTION To avoid any corrosion or damage, protect the areas on which fuel is likely to run. CAUTION Dismantling the interior of the high pressure pump and the injectors is prohibited.
Page 709 Remove: the nut (1) from the cooling radiator top hose on the intercooler air inlet pipe, the bolts (2) from the intercooler air inlet pipe on the inlet distributor. Move aside the cooling radiator top hose. - 3 -...
Page 710 Rotate the intercooler air inlet pipe clip ( Disconnect the intercooler air inlet pipe from the turbocharger. Move aside the intercooler air inlet pipe. Remove: the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting) the oil decanter Oil decanter: Removal - Refitting the diesel injector fuel return rail (see 13B, Diesel injection, Diesel injector fuel return rail: Removal -...
Page 711 the high pressure pipes between the rail and the injector (see 13B, Diesel injection, High pressure pipe between rail and injector: Removal - Refitting) CAUTION To prevent impurities from entering the circuit, place protective plugs on all fuel circuit components exposed to the open air. - 5 -...
Page 712 Insert the blanking plugs. 2. REMOVAL OPERATION Mark the injectors in relation to the cylinders using a indelible pencil Note: Cylinder number 1 is located on the timing end. Disconnect the injector connectors. Remove: - 6 -...
Page 713 the injector clamp bolts (4) , the injector clamps. the injectors one by one, the heat protection washer, the seal between the diesel injector and the diesel injector fuel return rail from each injector. Note: If it sticks, remove the injector using the tool M9R/M9T injector extractor ( Mot.
Page 714 - 8 -...
Page 715 CAUTION It is strictly forbidden to clean the injectors with: a wire brush, an emery cloth, an ultrasonic cleaner. Always clean the well of the removed injector (see 13B, Diesel injection Injector well cleaning tool: (Technical Note 6040, 13B, Diesel injection). If reusing the removed injector: clean the injector using a cloth soaked in productnettoyant injecteurornettoyant frein, if necessary, leave the injector nozzle to soak in the productnettoyant injecteur,...
Page 716 Remove the intercooler air inlet pipe seal at the turbocharger end using a tweezers - 10 -...
Page 717 Refit the new intercooler air inlet pipe seal. Note: Check that the seal ( ) on the intercooler air inlet pipe is fitted the correct way round. 2. REFITTING OPERATION - 11 -...
Page 718 CAUTION 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 vehicle. Fit new seals to the injectors. Refit: the seal between the diesel injector and the diesel injector fuel return rail on each injector, a new heat protection washer on each injector, the "injector - heat protection washer"...
Page 719 If an injector is replaced, note the injector IMA code and the corresponding cylinder number. Note: IMA codes are from X1 to XN. After connecting the battery, program the injectors using the Diagnostic tool - 13 -...
Page 720 3. FINAL OPERATION Connect the connectors for injector numbers (2), (3) and (4). Refit: the high pressure pipes between the rail and the injector (see 13B, Diesel injection, High pressure pipe between rail and injector: Removal - Refitting) the diesel injector fuel return rail (see 13B, Diesel injection, Diesel injector fuel return rail: Removal - Refitting) the oil decanter...
Page 721 carry out the operations described in the "After repair procedure" section. Check that there are no leaks. Disconnect the intercooler air inlet pipe. Move the intercooler inlet air pipe to one side. Refit the injector rail protector (see 13B, Diesel injection Injector rail protector: Removal - Refitting Fit the intercooler air inlet pipe.
Page 722 the cooling radiator top hose on the intercooler air inlet pipe, the nut of the cooling radiator top hose on the intercooler air inlet pipe. 8 N.m Torque tighten the nut of the cooling radiator top hose on the intercooler air inlet pipe Refit the engine cover.
Page 723 DISTRIBUTION MOTOR: REMOVAL - REFITTING Equipment required Diagnostic tool REMOVAL 1. REMOVAL PREPARATION OPERATION Activate the air distribution in "face" mode. Disconnect the battery (80A, Battery). 1- FRONT DISTRIBUTION MOTOR Remove the glovebox (57A, Interior equipment). Glovebox: Removal - Refitting 2.
Page 724 Disconnect the front distribution motor connector ( Remove: the mounting bolts of the front distribution motor (4) , the front distribution motor. REFITTING 1. REFITTING OPERATION 1- FRONT DISTRIBUTION MOTOR - 2 -...
Page 725 Refit the front distribution motor. Connect the front distribution motor connector. 2. FINAL OPERATION 1- FRONT DISTRIBUTION MOTOR Refit the glovebox (57A, Interior equipment). Glovebox: Removal - Refitting Connect the battery (80A, Battery). Apply the after repair procedure using the Diagnostic tool : connect the Diagnostic tool , select "Climate control computer", go to repair mode,...
Page 726 DOOR AIRBAG MODULE: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove: the rear side door trim Rear side door trim: Removal - Refitting (72A, Side opening element trim), the door sealing film Door sealing film: Removal - Refitting (65A, Opening element sealing). 2.
Page 727 Remove: the bolts (1) of the door airbag module, the door airbag module (2) . 2- REAR SIDE DOOR - 2 -...
Page 728 Remove: the bolts (1) of the door airbag module, the door airbag module (2) . - 3 -...
Page 729 REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Refit: the door airbag module, the bolts of the door airbag module. 4 N.m Torque tighten the bolts of the door airbag module 2. FINAL OPERATION Refit the door sealing film (65A, Opening element sealing). Door sealing film: Removal - Refitting Carry out a sealing test (see Technical Note 0653A...
Page 730 DOOR MIRROR CASING: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the door mirror glass (see 56A, Exterior equipment Door mirror glass: Removal - Refitting Remove the side indicator . 2. REMOVAL OPERATION - 1 -...
Page 731 Unclip the door mirror casing at ( Remove the door mirror casing. REFITTING 1. REFITTING OPERATION - 2 -...
Page 732 Proceed in the reverse order to removal. Repair-50x07x08x04-01x37-1-20-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 733 DOOR MIRROR GLASS: REMOVAL - REFITTING Special tooling required Set of trim removal levers. Car. 1363 REMOVAL 1. OPERATION FOR REMOVAL OF PART CONCERNED - 1 -...
Page 734 Unclip the door mirror glass using the Set of trim removal levers. ( Car. 1363 Disconnect the connectors (depending on equipment level). REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Connect the connectors (depending on equipment level). Clip the exterior door mirror glass into place. 2.
Page 735 DOOR MIRROR: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION Unclip the door mirror trim ( - 1 -...
Page 736 2. REMOVAL OPERATION Disconnect the door mirror connector ( - 2 -...
Page 737 Place a cloth at ( ) to prevent the bolt from being lost. Remove: the door mirror bolts (4) , the door mirror. - 3 -...
Page 738 REFITTING 1. REFITTING OPERATION Proceed in the reverse order to removal. 4 N.m Torque tighten the door mirror bolts Carry out a function test. Repair-50x07x08x02-01x37-1-24-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 739 DOOR SEALING FILM: REMOVAL - REFITTING Note, one or more warnings are present in this procedure parts always to be replaced: Door sealing film REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the front side door trim (72A, Side opening elements Front side door trim: Removal - Refitting trim) or remove the rear side door trim (72A, Side opening elements Rear side door trim: Removal - Refitting...
Page 740 Detach the front side door sealing film ( REAR SIDE DOOR - 2 -...
Page 741 Detach the rear side door sealing film ( 1- FRONT OR REAR SIDE DOOR Carefully remove the mastic bead from the door box section around the edges of the sealing film. - 3 -...
Page 742 Note: If the mastic bead offers too much resistance, use a hot air gun set to approximately 20 cm held approximately away from the sealing film to ease its removal. REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: Door sealing film Note: Remove the adhesive residue from the door box section by applying wide masking...
Page 743 Remove the paper protecting the door sealing film mastic bead. Note: Do not touch the mastic bead. Position the sealing film correctly around the outside edge without applying any pressure. Firmly attach the sealing film around its entire edge. 3. FINAL OPERATION Carry out a sealing test (see Technical Note 0653A Refit the rear side door trim...
Page 744 DRIVER'S FRONTAL AIRBAG: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Equipment required Diagnostic tool WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 88C, Airbags and pretensioners, Airbag and pretensioners: Precautions for the repair) Vehicle: Precautions for the repair...
Page 745 Lock the airbag computer by applying the "Before repair procedure" using the Diagnostic tool : connect the Diagnostic tool , select "Airbag computer" , go to repair mode, display the "Before/After repair procedure" for the computer selected, carry out the operations described in the "Before repair procedure" section. Disconnect the battery .
Page 746 Remove: the lower bolts (1) of the cowlings under the steering wheel, the lower cowling (2) under the steering wheel. 2. OPERATION FOR REMOVAL OF PART CONCERNED - 3 -...
Page 747 - 4 -...
Page 748 CAUTION To ensure the airbag is not damaged during removal, do not use a tool with a point or a sharp edge. Insert a flat-blade screwdriver into the hole ( ) located behind the steering wheel. - 5 -...
Page 749 Unclip the driver's frontal airbag by pushing it in the direction of the arrow ( Unlock the driver's frontal airbag connector by ( Disconnect the connector ( ) from the driver's frontal airbag. Remove the driver's frontal airbag. - 6 -...
Page 750 WARNING To prevent the any component from being thrown upwards, store the airbag with the inflatable cushion facing upwards. REFITTING 1. REFITTING PREPARATION OPERATION WARNING After a seat belt pyrotechnic component is triggered, it is essential to replace certain parts. (see 88C, Airbags and pretensioners Airbag and pretensioners: Precautions for the repair...
Page 751 Refit: the lower cowling under the steering wheel, the lower bolts for the cowlings under the steering wheel. Connect the battery . Unlock the airbag computer by applying the "After repair procedure" using the Diagnostic tool : connect the Diagnostic tool , select "Airbag computer"...
Page 752 DRIVESHAFT: PRECAUTIONS FOR THE REPAIR Note, one or more warnings are present in this procedure 1. GENERAL RECOMMENDATIONS 1- ADVICE TO BE FOLLOWED BEFORE ANY OPERATION For an operation requiring the use of a lift, follow the safety advice (02A, Lifting Vehicle: Towing and lifting equipment).
Page 753 EARTHS ON BODY: LIST AND LOCATION OF COMPONENTS Note, one or more warnings are present in this procedure For the welding operations (example: resistance welding, GMAW, or spot welding): lock the airbag computer Airbag and pretensioners: Precautions for the repair (88C, Airbags and pretensioners), disconnect the battery and the vehicle's electrical circuit earths located near the area to be welded Battery: Removal - Refitting...
Page 754 1. DETAILED VIEW OF THE POSITION OF EARTHS ON THE VEHICLE - 2 -...
Page 755 Earth studs on the front left-hand side member ( Earth studs on the front left-hand scuttle side panel ( Earth studs on the centre floor tunnel ( - 3 -...
Page 756 Earth studs on the quarter panel lining ( ) and on the left-hand rear inner wheel arch ( Earth studs on the quarter panel lining ( ) and on the right-hand rear inner wheel arch ( Repair-40x01x16-02x51-1-15-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 757 ELECTRIC COOLANT PUMP: REMOVAL - REFITTING Special tooling required Remote operation pliers for hose clips. Mot. 1448 Pipe clamps. Ms. 583 REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Disconnect the battery (80A, Battery).
Page 758 - 2 -...
Page 759 Remove the bolt from the fuse box ( Note: Unclip the clip ( ) , accessing it through the front left-hand wheel arch to avoid any damage. - 3 -...
Page 760 Unclip the clip from the fuse box ( ) by pressing the clip. Remove the fuse box. 2. OPERATION FOR REMOVAL OF PART CONCERNED Disconnect the electric coolant pump connector ( - 4 -...
Page 761 Remove the mounting bolt from the electric coolant pump ( Squeeze the hoses ( ) using the tool Pipe clamps. ( Ms. 583 Undo the hose clips on the electric coolant pump ( ) using the tool Remote operation pliers for hose clips.
Page 762 Disconnect the electric coolant pump hoses. Remove the electric coolant pump with its support Remove: the clips (7) from the electric coolant pump on its support, - 6 -...
Page 763 the electric coolant pump. REFITTING 1. REFITTING PREPARATION OPERATION Always replace the clips of the electric coolant pump. 2. REFITTING OPERATION FOR PART CONCERNED Refit: the electric coolant pump to its mounting, the new electric coolant pump clips on its mounting, the electric coolant pump.
Page 764 3. FINAL OPERATION Refit the fuse box. 8 N.m Torque tighten the fuse box bolt Refit: the front left-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the air filter unit Air filter unit: Removal - Refitting Connect the battery (80A, Battery).
Page 765 ELECTRIC DIESEL FUEL HEATER: REMOVAL - REFITTING Note, one or more warnings are present in this procedure WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: Diesel injection: Precautions for the repair (13B, Diesel injection), Vehicle: Precautions for the repair...
Page 766 CAUTION Keep the pipe unions away from contaminated areas. REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Remove: the front right-hand wheel Wheel: Removal - Refitting (35A, Wheels and tyres), the front section of the front right-hand wheel arch liner Front wheel arch liner: Removal - Refitting (55A,...
Page 767 Remove the electric diesel fuel heater from the diesel filter. REFITTING 1. REFITTING PREPARATION OPERATION - 3 -...
Page 768 CAUTION 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 vehicle. 2. REFITTING OPERATION FOR PART CONCERNED Refit the electric diesel fuel heater on the fuel filter. 3.
Page 769 ELECTRIC SUNROOF: LIST AND LOCATION OF COMPONENTS 1. LIST OF COMPONENTS 1- THE ELECTRIC SUNROOF SYSTEM CONSISTS OF: an electric sunroof switch (1) an electric sunroof motor (2) 2. LOCATION OF COMPONENTS 1- ELECTRIC SUNROOF SWITCH - 1 -...
Page 770 2- ELECTRIC SUNROOF MOTOR AND ELECTRIC SUNROOF COMPUTER - 2 -...
Page 771 The electric sunroof motor ( ) and the electric sunroof computer ( ) cannot be separated. To remove the electric sunroof computer (see 52A, Non-side opening element mechanisms Sunroof opening motor: Removal - Refitting Repair-80x06-02x51-1-11-1.xml XSL version : 3.02 du 22/07/11 - 3 -...
Page 772 ELECTRIC WINDOW MOTOR: REMOVAL - REFITTING Equipment required Diagnostic tool REMOVAL 1. REMOVAL PREPARATION OPERATION Switch off the ignition. 1- FRONT ELECTRIC WINDOW MOTOR Remove the front side door trim (72A, Side opening elements trim). Front side door trim: Removal - Refitting 2- REAR ELECTRIC WINDOW MOTOR Remove the rear side door trim (72A, Side opening element trim).
Page 773 Disconnect the connectors ( ) from the front electric window motor. Remove: the front electric window motor bolts (2) , the front electric window motor. 2- REAR ELECTRIC WINDOW MOTOR - 2 -...
Page 774 Disconnect the connectors ( ) from the rear electric window motor. Remove: the rear electric window motor bolts (4) , the rear electric window motor. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED When replacing the front electric window mechanism, activate the motor with no load. - 3 -...
Page 775 Note: Activating with no load deinitialises the front electric window motor, so that the motor then operates in stepping mode. If the front electric window motor has been activated with no load, it must be initialised after repair. Refit: the electric window motor, the electric window motor bolts.
Page 776 When replacing a front electric window motor, apply the after repair procedure using the Diagnostic tool : connect the diagnostic tool, select "Driver's door electric window computer" if the motor is fitted on the driver's side front door, select "Passenger door electric window computer" if the engine is fitted on the passenger side front door, go to repair mode, display the "before/after repair procedure"...
Page 777 ELECTRIC WINDOW: LIST AND LOCATION OF COMPONENTS 1. LIST OF COMPONENTS 1- THE ELECTRIC WINDOW SYSTEM CONSISTS OF: front electric window switches on the driver's door, a front electric window switch on the passenger door, rear electric window switches 2. LOCATION OF COMPONENTS 1- FRONT ELECTRIC WINDOW SWITCHES ON THE DRIVER'S DOOR - 1 -...
Page 778 2- FRONT ELECTRIC WINDOW SWITCH ON THE PASSENGER DOOR - 2 -...
Page 779 3- REAR ELECTRIC WINDOW SWITCH - 3 -...
Page 780 Repair-80x05-02x51-1-19-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 781 ELECTRICAL ACCESSORIES SOCKET: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION 1- ON THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) Remove the centre console (57A, Interior equipment). Centre console: Removal - Refitting 2- REAR OF THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) - 1 -...
Page 782 Unclip the centre console rear panel ( Disconnect the connectors. 2. OPERATION FOR REMOVAL OF PART CONCERNED - 2 -...
Page 783 Unclip the clips from the electrical accessories socket at ( Remove the electrical accessories socket. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Clip on the electrical accessories socket. 2. FINAL OPERATION 1- ON THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) - 3 -...
Page 784 Refit the centre console (57A, Interior equipment). Centre console: Removal - Refitting 2- REAR OF THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) Connect the connectors of the centre console rear panel. Clip the centre console rear panel in place. Repair-30x04x11x01-01x37-1-10-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 785 ELECTRICAL ACCESSORIES SOCKET: REMOVAL - REFITTING REMOVAL 1. REMOVAL PREPARATION OPERATION 1- ON THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) Remove the centre console (57A, Interior equipment). Centre console: Removal - Refitting 2- REAR OF THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) - 1 -...
Page 786 Unclip the centre console rear panel ( Disconnect the connectors. 2. OPERATION FOR REMOVAL OF PART CONCERNED - 2 -...
Page 787 Unclip the clips from the electrical accessories socket at ( Remove the electrical accessories socket. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED Clip on the electrical accessories socket. 2. FINAL OPERATION 1- ON THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) - 3 -...
Page 788 Refit the centre console (57A, Interior equipment). Centre console: Removal - Refitting 2- REAR OF THE CENTRE CONSOLE (DEPENDING ON THE EQUIPMENT LEVEL) Connect the connectors of the centre console rear panel. Clip the centre console rear panel in place. Repair-30x04x11x01-01x37-1-10-1.xml XSL version : 3.02 du 22/07/11 - 4 -...
Page 789 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 790 ELECTRICAL WIRING REPAIR Contents Page WIRING Wiring: Precautions for repair 88A-1 Wiring repair kit: General information 88A-8 Wiring repair kit: Description 88A-9 Wiring repair kit: Use 88A-12 Wiring: Repair 88A-18 Wiring: Check 88A-27 Connector: Repair 88A-30 Connector: Sealing and immobilisation 88A-34 Connector: Check 88A-36...
Page 791 188A WIRING WIRING Wiring: Precautions for repair Wiring: Precautions for repair WARNING WARNING This note authorises the repair of electrical If the damaged section is located less than 10 cm wiring in very specific cases only and under from the connector, replace the defective wiring, certain conditions.
Page 792 WIRING Wiring: Precautions for repair 2 - Specific procedures reference table. Guidelines for reading the tables below: ● – If not otherwise stated, consider all components or electrical connections to have a link with the functions or equipment listed. For example: For the electric power assisted steering, the function is not specified. It is prohibited to carry out operations on any wire attached to the electric power assisted steering.
Page 793 WIRING Wiring: Precautions for repair General cases: ● Functions or equipment Precisions Instructions Wiring harness Number of damaged wires 10 or (see Wiring: Repair) fewer Number of damaged wires more Change the wiring than 10 Equipment and Change the wiring predispositions specific to commercial vehicles and conversions...
Page 794 WIRING Wiring: Precautions for repair Specific cases: ● Lines Device Instructions 4-wheel steering Change the wiring Other ABS lines Change the wiring ABS sensor Change the wiring Airbag Other airbag lines (see Airbag and pretensioner wiring: Repair) Airbag Airbag sensor (see Airbag and pretensioner wiring: Repair) Airbag Airbag computer connector...
Page 795 WIRING Wiring: Precautions for repair Specific cases (cont. 1): ● Lines Device Instructions Injection computer Manifold pressure sensor Change the wiring (Petrol) Injection computer Particle filter differential pressure Change the wiring (Diesel) sensor Injection computer Rail pressure sensor Change the wiring (Diesel) Injection computer Turbocharging pressure sensor...
Page 796 WIRING Wiring: Precautions for repair Specific cases (cont. 2): ● Lines Device Instructions Injection computer Oil level and temperature sensor Change the wiring (Diesel/particle filter) Injection computer Nitrogen oxide (Nox) Change the wiring (Diesel) Injection computer Upstream oxygen sensor Change the wiring (Petrol and Diesel) Injection computer Downstream oxygen sensor...
Page 797 WIRING Wiring: Precautions for repair 3 - Summary flowchart of the operating procedure defined in this section. Identify a fault on the wiring. Disconnect the battery (see MR corresponding to the vehicle, 80A, Battery, Battery: Removal - Refitting) Access the area concerned. Case of referral to Technical Note 6015A from a MR, a Sufficient accessibility?
Page 798 WIRING Wiring repair kit: General information Wiring repair kit: General information 1 - Purpose and applications. 2 - Terminology. Description of the content of the Wiring repair kit case Wiring-connector kit. ● as well as the procedure and the field of application. Kit usually made up of a connector the cells of which are populated with crimped wires along with sleeves for The kit enables wiring which is damaged or has cut...
Page 799 WIRING Wiring repair kit: Description Wiring repair kit: Description 1 - Case and label. 2 - Tools. Case (77 11 420 544). Stripping pliers (77 11 230 416). ● ● Part no. 77 11 420 544 corresponds to the new electrical repair case.
Page 800 WIRING Wiring repair kit: Description The crimping pliers have three sizes of jaw (red, blue 3 - Consumables. and yellow) which correspond to the crimping sleeves. These pliers are recommended for the crimping the Self-solder sleeves. ● sleeves provided in the kit. The operating instructions for this kit are described in this document (see Wiring repair kit: Use).
Page 801 WIRING Wiring repair kit: Description Crimping sleeve. Adhesive PVC tape (77 11 170 331). ● ● Use the adhesive PVC tape for taping the wires. Do not use it to protect or insulate electrical parts. It is a contact-adhesive high temperature tape. Coil of twisted wires (77 11 229 425).
Page 802 WIRING Wiring repair kit: Use Wiring repair kit: Use Stripping a wire: ● Note: This section is an abridged version of the This pair of stripping pliers is automatic. It does not instructions for use of the tools in the kit. need adjusting to the cross-section of wire to be stripped (6 mm maximum).
Page 803 WIRING Wiring repair kit: Use 2 - Crimping pliers. Crimping operation: ● Squeeze the handles fully together to unlock the pliers and open the jaws. On the pliers, find the crimping jaws which correspond to the sleeve being used. Insert the wire(s) into one end of the sleeve. Position the pliers' jaws in the middle of the half of the metal shaft where the wire(s) are.
Page 804 WIRING Wiring repair kit: Use 3 - Heat gun. Accessories: ● (R) = Concentrator nozzle. (S) = Deflector nozzle. Note: The concentrator nozzle (R) is recommended when using the heat gun on the crimp or self-solder sleeves in the kit. WARNING The heat shield nozzle (S) can be used for contracting single heat shrinkable sheaths.
Page 805 WIRING Wiring repair kit: Use Switching on the gun: ● Connect the appliance to the mains electricity supply (230 Vac - 50 Hz or 60 Hz), respecting all precautions. Push the switch (I) on (1). The appliance will come on using the programs and settings most recently used.
Page 806 WIRING Wiring repair kit: Use Temperature and air flow settings: ● To change the program settings (the FREE program is recommended), carry out the following operation: – press menu selection button (K) twice, – temperature field (U) on display field (J) flashes, –...
Page 807 WIRING Wiring repair kit: Use Special modes (COOL/PAUSE): ● After use and before pushing switch (A) off (0), cool the gun. Similarly, during brief pauses or for lower power consumption, switch the gun to PAUSE mode by carrying out the following operation. Before switching off the heat gun: –...
Page 808 WIRING Wiring: Repair Wiring: Repair If 2 wires and 1 wire (2-to-1), only use crimp sleeves. Note: In this case, the seal can no longer be guaranteed. Do This relates to the generic repair procedure. not use this solution when a tight seal is needed (engine and underbody areas and damp areas of the doors and boot).
Page 809 WIRING Wiring: Repair Identifying the settings. ● Note: This is stage 3 when using the label. After having found your case in question, follow the corresponding line to find the setting parameters. The settings correspond to the lengths to be stripped and the temperature of the heat gun.
Page 810 WIRING Wiring: Repair Case of a wire joint between 1 wire and 1 wire Case of a wire joint between 2 wires and 1 wire ● ● (most common situation). (less common situation). Conditions for self-solder sleeves: Conditions for crimp sleeves: Add together the 2 wire cross-sections (copper Add together the 2 wire cross-sections (copper strands):...
Page 811 WIRING Wiring: Repair Settings table (taken from the label). ● Sleeves Self-solder Crimp clear blue blue yellow ≤ A+B≤ 1.5 ≤ A+B≤ 2.5 ≤ A+B≤ 6 ≤ A+C≤ 0.8 ≤ A+C≤ 2 ≤ A+C≤ 3 ≤ C≤ 1.5 ≤ C≤ 2.5 ≤...
Page 812 WIRING Wiring: Repair 2 - Preparation. 3 - Self-solder sleeves. To start the preparatory stage, check that the wiring is Note: sufficiently accessible and that the sleeves have been Fit the self-solder sleeves (connection and heating) chosen. line by line, sleeve by sleeve. –...
Page 813 WIRING Wiring: Repair WARNING When twisting the wires, make sure that your hands are not greasy so that the solder adheres. WARNING When the sleeve is positioned, check that all the copper strands remain flat and subsequently are not at risk of perforating the sleeve. Start the operation to join the wires again if necessary.
Page 814 WIRING Wiring: Repair When joining 2 wires to 1 wire, first connect the 2 wires WARNING from the same end in the following way: Wait for the sleeve to cool before manipulating it to maintain the quality of the solder (minimum –...
Page 815 WIRING Wiring: Repair Crimping. Repeat the crimping operation on the other end of the ● sleeve to obtain the result below. The equipment necessary and the wires are ready for the crimping operation: – Take the crimping pliers. Squeeze the handles fully together to unlock the pliers and open the jaws (see Wiring repair kit: Use).
Page 816 WIRING Wiring: Repair Heating the crimping sleeve. ● Note: Spend the majority of the recommended time on the – Switch on the heat gun fitted with the concentrator metal barrel and the rest of the time on the ends of nozzle after familiarising yourself with the the sleeve.
Page 817 WIRING Wiring: Check Wiring: Check 1 - Visual checks. Result of a correctly applied crimp sleeve. The insulation of the wires is within the sleeve. ● (Self-solder sleeves) The sealing rings must be ● clearly located on the insulated section of the wires.
Page 818 WIRING Wiring: Check The protruding strands of the wire have pierced the WARNING self-solder sleeve at (K) during contraction. The various struck-through cases are strictly forbidden. The self-solder sleeve has not been correctly shrunk. At (I), the sealing ring has not contracted around the insulation of the wire.
Page 819 WIRING Wiring: Check The sleeve and the insulation of the wire show signs of 4 - Fitting and protections. damage at (N) cause by overheating. After the operation: reposition the wires concerned in the main ● harness, tape up the main harness using adhesive tape, ●...
Page 820 WIRING Connector: Repair Connector: Repair 2 - Using a wiring-connector kit. WARNING Except in the specific outlined cases, use the wiring- Apply this procedure when there is a connector connector kits as follows: - wiring kit or wire kit. Unless the kit is linked to one of the sensitive lines listed in the specific check that the kit is complete, ●...
Page 821 WIRING Connector: Repair 4 - Applying a wire kit. 6 - Final check. After any operation on wiring, check for the absence of NOTE faults using the diagnostic tools (Clip, etc.). Access the electric documentation for the vehicle on Infotech to obtain the part number of the wire kit Refer to the corresponding fault finding procedure.
Page 822 WIRING KANGOO Connector: Repair This section deals with an electrical contact fault on Note: the connector between the dashboard wiring and the Using the Wiring Diagrams Technical Note or pedal wiring on KANGOO. applying a continuity check, check that it concerns gangs B1, B2, B3, B4, B5 and B6.
Page 823 WIRING KANGOO Connector: Repair After having shunted all of the wires concerned: 3 - Repair check. Protect the shunted electrical wires (C) with wiring Continuity: ● protective sheath with a diameter of 18 mm (77 11 237 839). Check the continuity of each of the shunted lines. ●...
Page 824 WIRING Connector: Sealing and immobilisation Connector: Sealing and immobilisation This section explains how to insulate and immobilise – Adhesive 7703 397 035 (cracked cylinder of solid an unused connector when changing the wiring. adhesive). – Wiring repair kit (see Wiring Repair Kit: 2 cases are dealt with: Description).
Page 825 WIRING Connector: Sealing and immobilisation Connector: Sealing and immobilisation Fitting the plugs: Note: When replacing the wiring, preferably carry out the operation before refitting the new wiring. – Mark the unused connector. – Mark the wire couplings on this connector (wires connected together in the same connector opening).
Page 826 WIRING Connector: Check Connector: Check This section describes how to visually inspect a 4 - Visual inspection of the metal contacts: connector. Check that there are no bent contacts (the contact ● is not inserted correctly and can come out of the Note: back of the connector).
Page 827 188B MULTIPLEXING MULTIPLEXING Multiplex network: Repair Multiplex network: Repair 2 - Necessary equipment. WARNING This procedure is relates to the repair of the For repairing the multiplex network, use the multiplex network alone (twisted wires). components of the wiring repair kit (see Wiring repair kit: Description).
Page 828 MULTIPLEXING Multiplex network: Repair 3 - Repairing the multiplex line. WARNING Do not untwist the harness to be repaired more WARNING than 100 mm (D). The wires at (E) must be Before starting to repair a multiplex line, it is twisted uniformly along the repaired length.
Page 829 MULTIPLEXING Multiplex network: Repair To join the wires, working wire by wire: Refer to the precautions for use which relate to using slip the self-solder sleeve onto the wire, self-solder sleeves (see Wiring: Repair). ● twist the end of the wires together. ●...
Page 830 MULTIPLEXING Multiplex network: Repair 4 - Checking the multiplex line. No turns (twists) at (H). WARNING After repairing the multiplex line, always check the multiplex network using the diagnostic tool. Note: During the check with the diagnostic tool, move the lines forwards and backwards slightly.
Page 831 288C AIRBAGS AND PRETENSIONERS AIRBAGS AND PRETENSIONERS Airbag and pretensioner wiring: Repair Airbag and pretensioner wiring: Repair WARNING This procedure relates repairing airbag and pretensioner wiring only. Note: Apply all the precautions and recommendations shown in the MR. WARNING All work on airbag and pretensioner systems must be carried out by qualified trained personnel. WARNING The pyrotechnic systems (pretensioners or airbags) must not be handled near to a heat source or flame;...
Page 832 AIRBAGS AND PRETENSIONERS Airbag and pretensioner wiring: Repair 2 - Under seat connector. Example of a connector on a seat runner (A): Note: For a connector on a seat runner, the wiring must be replaced. When fault finding identifies a under seat connector fault, shunt the under seat connector following the procedure below: Cut the electrical wires either side of the connector.
Page 833 AIRBAGS AND PRETENSIONERS Airbag and pretensioner wiring: Repair Example of an angled SQUIB connector. Carry out the specific airbag and pretensioner line repair checks. See Airbag line repair check and Final check in this section. 5 - Airbag lines repair check. Confirm the airbag line repair to ensure that the repair is correct: Check the quality of the operation by reading the...
Page 834 ELECTRONIC PARKING BRAKE: LIST AND LOCATION OF COMPONENTS 1. LIST OF COMPONENTS Description Control unit Emergency handle Lever Clutch pedal position sensor 2. LOCATION OF COMPONENTS 1- CONTROL UNIT - 1 -...
Page 835 2- EMERGENCY HANDLE - 2 -...
Page 836 The emergency handle is integrated into the control unit. The emergency handle must only be used if there is a battery fault or major assisted parking brake fault (red warning light). Using the emergency handle: put the vehicle in first gear, chock the front wheels, - 3 -...
Page 837 raise the rear left-hand wheel Vehicle: Towing and lifting (02A, Lifting equipment), remove the cap and pull on the cable. 3- LEVER 4- CLUTCH PEDAL POSITION SENSOR - 4 -...
Page 838 Repair-13x03x11x08-02x51-1-9-1.xml XSL version : 3.02 du 22/07/11 - 5 -...
Page 839 ENGINE - GEARBOX ASSEMBLY: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 Support for removal - refitting of engine - gearbox assembly Mot. 1390 Equipment required refrigerant charging station tweezers...
Page 840 Disconnect the connectors of the Protection and Switching Unit Protection and Switching Unit: Removal - (87G, Engine compartment connection unit). Refitting Remove: the battery tray Battery tray: Removal - Refitting (80A, Battery), the diesel injection computer Diesel injection computer: Removal - Refitting the air filter unit Air filter unit: Removal - Refitting the front wheels...
Page 841 Unclip the fuel pipes ( ) from the expansion bottle and from the right-hand suspended engine mounting. Drain the gearbox (21A, Manual gearbox). Manual gearbox oils: Draining - Filling Drain: the cooling system Cooling system: Draining - Refilling the refrigerant circuit using a refrigerant charging station Refrigerant circuit: Draining - Filling (62A, Air conditioning).
Page 842 Disconnect: the water detection sensor connector (3) , the fuel supply pipe quick-release union (4) from the fuel filter. Disconnect the sensor Unclip the fuel filter wiring at ( - 4 -...
Page 843 Disconnect the air conditioning pressure sensor connector ( Unclip the engine cooling fan assembly wiring at ( - 5 -...
Page 844 Mark the position of the wiring clips. Unclip the expansion bottle cooling hose clip ( ) on the cooling radiator using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the expansion bottle cooling hose from the cooling radiator. - 6 -...
Page 845 Unclip: the cooling fan assembly wiring at (9) , the expansion bottle cooling hose clip (10) with the hose from the cooling fan assembly. Mark the position of the wiring clips. - 7 -...
Page 846 Unclip the cooling fan assembly wiring at ( Disconnect the cooling fan assembly connectors ( Move aside the engine cooling fan assembly wiring. Move aside the cooling radiator bottom hose clip ( ) using the tool Remote operation pliers for - 8 -...
Page 847 hose clips. ( Mot. 1448 Disconnect the cooling radiator bottom hose. Move aside the cooling radiator top hose clip ( ) using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the cooling radiator top hose. - 9 -...
Page 848 Pull the clip ( ) of the intercooler air outlet pipe at the intercooler end using a flat-blade screwdriver. Disconnect the intercooler air outlet pipe from the intercooler. - 10 -...
Page 849 - 11 -...
Page 850 Rotate the intercooler air inlet pipe clip ( Disconnect the intercooler air inlet pipe from the intercooler. - 12 -...
Page 851 Remove the clip ( ) from the hose between the cooling radiator and the expansion bottle using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the hose between the cooling radiator and the expansion bottle on the cooling radiator side.
Page 852 Remove the clip ( ) from the cooling radiator top hose using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the cooling radiator top hose. - 14 -...
Page 853 Rotate the clip ( ) of the intercooler air inlet pipe at the intercooler end. Disconnect the air-air intercooler air inlet pipe at the air-air intercooler end. - 15 -...
Page 854 Pull the clip ( ) from the intercooler air outlet pipe at the intercooler end. Disconnect the intercooler air outlet pipe at the intercooler end. - 16 -...
Page 855 Remove air deflectors ( - 17 -...
Page 856 - 18 -...
Page 857 CAUTION To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air. CAUTION In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. - 19 -...
Page 858 Remove the nuts ( ) from the air conditioning hoses on the condenser. Disconnect the air conditioning hoses on the condenser. Insert the blanking plugs. - 20 -...
Page 859 Remove the nut ( ) from the air conditioning hose on the compressor. Disconnect the air conditioning hose on the compressor. Insert the blanking plugs. Remove the cooling assembly. - 21 -...
Page 860 Remove: the fuse holder cover (10) , the strut nuts (11) , the strut from the left-hand suspended engine mounting. - 22 -...
Page 861 Remove: the fuse holder bolt (12) , the fuse holder clip (13) . - 23 -...
Page 862 Remove the main supply fuses ( - 24 -...
Page 863 Cut the fuse holder unit wiring clip. Move aside the fuse holder unit ( Remove the fuse holder unit. - 25 -...
Page 864 Separate the fuse holder ( ) from the fuse holder plate. - 26 -...
Page 865 Unclip: the computer wiring (24) from the engine wiring mounting, the supply unit wiring (25) from the engine wiring mounting. - 27 -...
Page 866 - 28 -...
Page 867 Remove the nuts ( ) from the earth wires on the side members. Move aside the earth wires. - 29 -...
Page 868 Attach the engine wiring mounting ( ) onto the engine. Disconnect: the fuel heater connector, the windscreen washer pump connector. - 30 -...
Page 869 - 31 -...
Page 870 Disconnect: the cooling hoses (28) from the heater matrix by pressing each side of the quick-release union, the fuel return pipe quick-release union from the tank return pipe, the fuel supply pipe quick-release union from the fuel filter unit. - 32 -...
Page 871 Insert the blanking plugs. Remove the radiator mounting cross member (41A, Radiator mounting cross member: Removal - Refitting Front lower structure). Remove: the connecting hose nuts (29) , - 33 -...
Page 872 the connecting hose seal. Note: Prepare for the flow of power-assisted steering fluid. Fit a oil recovery tray Remove the bolt ( ) from the power-assisted steering pipes on the power-assisted steering box. - 34 -...
Page 873 Remove the lower power-assisted steering pipe. Insert the blanking plugs. - 35 -...
Page 874 - 36 -...
Page 875 Position the engine and the gearbox against the rubber pads of the tool Support for removal - refitting of engine - gearbox assembly ( Mot. 1390 2. OPERATION FOR REMOVAL OF PART CONCERNED Remove: the right-hand suspended engine mounting Right-hand suspended engine mounting: Removal - Refitting the left-hand suspended engine mounting , the engine - gearbox assembly.
Page 876 Move aside the "engine - gearbox" assembly. REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: turbocharger air cooler air inlet pipe seal parts always to be replaced: turbocharger air cooler air outlet pipe seal - 38 -...
Page 877 Remove: the intercooler air outlet pipe seal at the intercooler end using a tweezers , the intercooler air inlet pipe seal at the intercooler end using a tweezers . - 39 -...
Page 878 Note: Check that the intercooler air inlet pipe seals are fitted the right way round. Refit: a new seal for the intercooler air outlet pipe at the intercooler end, - 40 -...
Page 879 a new seal for the intercooler air inlet pipe at the intercooler end. 2. REFITTING OPERATION FOR PART CONCERNED Position the "engine - gearbox" assembly under the vehicle. Lower the vehicle. Refit: the left-hand suspended engine mounting , the right-hand suspended engine mounting Right-hand suspended engine mounting: Removal - Refitting 3.
Page 880 the exhaust intermediate pipe bolts. 21 N.m Torque tighten the exhaust intermediate pipe nuts Refit the radiator mounting cross member (41A, Radiator mounting cross member: Removal - Refitting Front lower structure). Connect: the fuel supply pipe quick-release union to the fuel filter, the fuel return pipe quick-release union to the tank fuel return pipe, the heater matrix hoses, the fuel heater connector,...
Page 881 L43, M9R, PK4(L43) Fit: the rigid clutch pipe, the gear control cables. Remove the blanking plugs from the rigid clutch pipe and the clutch thrust bearing union. Connect the clutch rigid pipe to the clutch thrust bearing. Clip: the rigid clutch pipe onto the gearbox, the gear selector cables onto their mounting, the gear control cables onto the gear selector ball joints.
Page 882 Refit: the fuse holders on the fuse holder plate, the fuse holder unit. Fit the fuse holder unit. Refit: a new hose clip onto the fuse holder plate wiring, the main supply fuses, the fuse holder unit clip, the fuse holder unit bolt. 8 N.m Torque tighten the fuse box mounting bolt Refit:...
Page 883 CAUTION To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free. Connect the air conditioning hose onto the compressor. Refit the air conditioning hose bolt on the compressor. 8 N.m Torque tighten the air conditioning hose bolt on the compressor Connect the air conditioning hoses to the condenser.
Page 884 Clip the intercooler air outlet pipe onto the intercooler. Rotate the intercooler air inlet pipe clip at the intercooler end so that the clip fits into the neck of the air pipe. Fit the intercooler air inlet pipe on the intercooler. Note: Check that the intercooler air inlet pipe is correctly clipped onto the intercooler by checking that a click can be heard.
Page 885 Clip on the engine cooling fan wiring. Connect: the engine cooling fan connectors, the engine cooling fan resistor connector. the pressure switch connector. Refit: the front end panel Front end panel: Removal - Refitting (42A, Upper front structure), the headlights Headlight: Removal - Refitting (80B, Headlights), the front bumper (55A, Exterior protection),...
Page 886 Refit: the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the front wheels Wheel: Removal - Refitting (35A, Wheels and tyres), the air filter unit Air filter unit: Removal - Refitting the diesel injection computer Diesel injection computer: Removal - Refitting the battery tray Battery tray: Removal - Refitting...
Page 887 Note: Monitor the fluid level in the reservoir during the power-assisted steering circuit bleed operation. Top up the power-assisted steering fluid level if necessary. Check that there are no leaks. Refit: the engine undertray, the engine cover. Repair-10x01x01-01x37-2-188-1.xml XSL version : 3.02 du 22/07/11 - 49 -...
Page 888 ENGINE - GEARBOX ASSEMBLY: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 Support for removal - refitting of engine - gearbox assembly Mot. 1390 Equipment required refrigerant charging station tweezers...
Page 889 WARNING Wear cut-resistant gloves during the operation. REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Remove: the engine cover, the battery (80A, Battery), the battery disconnection unit Battery disconnection unit: Removal - Refitting (80A, Battery).
Page 890 CAUTION To prevent impurities from entering the circuit, place protective plugs on all fuel circuit components exposed to the open air. Disconnect: the fuel return pipe quick-release union at (1) , the fuel supply pipe quick-release union from the fuel filter. Insert the blanking plugs.
Page 891 the refrigerant circuit using a refrigerant charging station Refrigerant circuit: Draining - Filling (62A, Air conditioning), the engine cooling system Cooling system: Draining - Refilling Disconnect the bottom hose from the expansion bottle Expansion bottle: Removal - Refitting Remove: the front left-hand wheel driveshaft Front left-hand driveshaft: Removal - Refitting (29A, Driveshafts), the front right-hand wheel driveshaft...
Page 892 Disconnect: the water detection sensor connector (3) , the fuel supply pipe quick-release union (4) from the fuel filter. Unclip the fuel filter wiring at ( - 5 -...
Page 893 Disconnect the pressure switch connector ( Unclip the engine cooling fan assembly wiring at ( - 6 -...
Page 894 Mark the position of the wiring clips. Unclip the expansion bottle cooling hose clip ( ) on the cooling radiator using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the expansion bottle hose from the cooling radiator. Unclip: the cooling fan assembly wiring at (9) , the expansion bottle cooling hose clip (10) from the cooling fan assembly.
Page 895 Mark the position of the wiring clips. Unclip the cooling fan assembly wiring at ( Disconnect the cooling fan assembly connectors ( Move aside the wiring of the engine cooling fan assembly. - 8 -...
Page 896 Separate the clip ( ) on the cooling radiator bottom hose using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the cooling radiator bottom hose. - 9 -...
Page 897 Separate the clip ( ) on the cooling radiator top hose using the tool Remote operation pliers for hose clips. ( Mot. 1448 Disconnect the cooling radiator top hose. - 10 -...
Page 898 Pull the intercooler air outlet pipe clip ( ) using a flat-blade screwdriver. Disconnect the intercooler air outlet pipe from the intercooler. - 11 -...
Page 899 - 12 -...
Page 900 Rotate the clip of the intercooler air inlet pipe by Disconnect the intercooler air inlet pipe. - 13 -...
Page 901 Remove air deflectors ( - 14 -...
Page 902 CAUTION To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air. CAUTION In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. - 15 -...
Page 903 Remove the nuts ( ) from the condenser connecting pipes. Unclip the clip of the condenser connecting pipe at ( Disconnect the condenser connecting pipes. Remove the condenser connecting pipe seals. Insert the blanking plugs. - 16 -...
Page 904 Remove the air conditioning pipe bolts ( ) from the compressor. Disconnect the air conditioning pipes from the compressor. Remove: the compressor - intermediate pipe connecting pipe, - 17 -...
Page 905 the connecting pipe seals. Insert the blanking plugs. Remove the "condenser - cooling radiator - motor-driven fan assembly - intercooler" assembly. - 18 -...
Page 906 - 19 -...
Page 907 Remove the fuse holder unit bolt ( Note: Unclip the clip ( ) by accessing it through the front left-hand wheel arch to avoid damaging it. - 20 -...
Page 908 Unclip the fuse box clip ( ) by pressing on top. Remove the fuse holder unit cover. Remove the main supply fuses ( - 21 -...
Page 909 Cut the clip of the fuse holder unit wiring at ( Move aside the fuse holder unit ( - 22 -...
Page 910 Unclip the fuse holders ( ) from the fuse holder unit by pressing the clips ( ) inside the fuse holders. Disconnect the passenger compartment wiring with the fuse holders from the fuse holder unit. - 23 -...
Page 911 Unclip: the diesel injection computer wiring (32) from the engine wiring support, the battery disconnection unit wiring (33) from the engine wiring support. - 24 -...
Page 912 Remove the nuts ( ) of the earth cables on the side members (depending on the equipment level). Move aside the earth cables. - 25 -...
Page 913 Unclip the engine wiring clips from the wiring support ( Move and fasten the engine wiring support on the engine. - 26 -...
Page 914 Unclip: the gearbox control cables from the gear selector ball joints (36) , the control cables from their support (37) . Disconnect the reverse gear sensor connector ( - 27 -...
Page 915 CAUTION Prepare for the flow of fluid, and protect the surrounding components. Remove the clutch control pipe (37A, Mechanical component Clutch circuit: Removal - Refitting controls). - 28 -...
Page 916 Disconnect: the cooling hoses (41) from the heater matrix by pressing each side of the quick-release union, the fuel return pipe quick-release union from the tank return pipe, the fuel supply pipe quick-release union from the fuel filter unit. - 29 -...
Page 917 Insert the blanking plugs. Remove: the radiator mounting cross member Radiator mounting cross member: Removal - Refitting (31A, Front axle components), the front axle subframe (31A, Front axle components). - 30 -...
Page 918 Remove: the connecting hose nuts (42) , the connecting hose seal. - 31 -...
Page 919 - 32 -...
Page 920 Position the engine and the gearbox against the rubber pads of the tool Support for removal - refitting of engine - gearbox assembly ( Mot. 1390 2. REMOVAL OPERATION Remove: the right-hand suspended engine mounting Right-hand suspended engine mounting: Removal - Refitting the left-hand suspended engine mounting , the engine - gearbox assembly.
Page 921 Move aside the "engine - gearbox" assembly. REFITTING 1. REFITTING PREPARATION OPERATION parts always to be replaced: turbocharger air cooler air inlet pipe seal parts always to be replaced: turbocharger air cooler air outlet pipe seal parts always to be replaced: seal between catalytic converter and exhaust downpipe hose - 34 -...
Page 922 Remove: the intercooler air outlet pipe seal using a tweezers , the intercooler air inlet pipe seal using a tweezers . - 35 -...
Page 923 Note: Check that the air pipe seals are fitted the right way round. Refit new seals, taking care to fit them the right way round. 2. REFITTING OPERATION - 36 -...
Page 924 Position the "engine - gearbox" assembly under the vehicle. Lower the vehicle. Refit: the left-hand suspended engine mounting , the right-hand suspended engine mounting Right-hand suspended engine mounting: Removal - Refitting 3. FINAL OPERATION Remove the tool Support for removal - refitting of engine - gearbox assembly ( Mot.
Page 925 Refit the clutch control pipe (37A, Mechanical component controls). Clutch circuit: Removal - Refitting Clip: the manual gearbox control cables on their support, the gearbox control cables onto the gear selector ball joints. Connect the reversing sensor connector. Bleed the clutch circuit (37A, Mechanical component controls). Refit the earth cables on the side members (depending on the equipment level).
Page 926 the fuse holders of the fuse holder unit Fit the fuse holder unit. Refit: a new wiring clip, the main supply fuses, the fuse holder unit clip. 8 N.m Torque tighten the fuse holder unit bolt Refit: the cover of the fuse holder unit, the "condenser - cooling radiator - motor-driven fan assembly - intercooler"...
Page 927 Connect the connecting pipes to the compressor. 8 N.m Torque tighten the bolt of the air conditioning connecting pipes on the compressor Connect the air conditioning connecting pipes to the condenser. 8 N.m Torque tighten the nuts of the air conditioning connecting pipes on the condenser Refit the air deflectors.
Page 928 Note: Check that the intercooler air inlet pipe is correctly clipped onto the intercooler by checking that a click can be heard. Clip the intercooler air inlet pipe onto the intercooler. Connect: the cooling radiator top hose to the cooling radiator, the cooling radiator bottom hose to the cooling radiator.
Page 929 Connect: the engine cooling fan assembly connectors, the pressostat connector, the water detection sensor connector, the fuel pipe quick-release union to the fuel filter. Note: Check the connection of the quick-release union by pulling on the part. Clip on the fuel filter wiring. Refit: the front end panel Front end panel: Removal - Refitting...
Page 930 Refit: the front right-hand wheel driveshaft Front right-hand driveshaft: Removal - Refitting (29A, Driveshafts), the front left-hand wheel driveshaft Front left-hand driveshaft: Removal - Refitting (29A, Driveshafts). Fill the gearbox (21A, Manual gearbox). Manual gearbox oils: Draining - Filling Connect the expansion bottle bottom hose Expansion bottle: Removal - Refitting Clip the fuel pipes onto the expansion bottle and onto the right-hand suspended engine mounting.
Page 931 the air filter unit Air filter unit: Removal - Refitting the diesel injection computer Diesel injection computer: Removal - Refitting the battery tray Battery tray: Removal - Refitting (80A, Battery). Connect the connectors of the Protection and Switching Unit Protection and Switching Unit: Removal - (87G, Engine compartment connection unit).
Page 932 Repair-10x01x01-01x37-2-181-1.xml XSL version : 3.02 du 22/07/11 - 45 -...
Page 933 ENGINE COOLING FAN ASSEMBLY: REMOVAL - REFITTING Note, one or more warnings are present in this procedure WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 19A, Cooling, Engine cooling: Precautions for the repair) Vehicle: Precautions for the repair (01D, Mechanical introduction).
Page 934 Disconnect the battery (80A, Battery). Battery: Removal - Refitting Remove: the engine protection plate, the front wheels Wheel: Removal - Refitting (35A, Wheels and tyres), the front wheel arch liners Front wheel arch liner: Removal - Refitting (55A, Exterior protection), the radiator grille (56A, Exterior equipment), the front bumper (55A, Exterior protection), the audible warning...
Page 935 Mark the position of the wiring clips. Unclip: the cooling fan assembly wiring at (1) , the expansion bottle cooling hose clip (2) with the hose from the cooling fan assembly. - 3 -...
Page 936 Mark the position of the wiring clips. Unclip the cooling fan assembly wiring at ( Disconnect the cooling fan assembly connectors ( Move aside the cooling fan assembly wiring. - 4 -...
Page 937 2. OPERATION FOR REMOVAL OF PART CONCERNED Note: Insert a cardboard protector between the cooling radiator and the fan assembly to protect the cooling radiator vanes. - 5 -...
Page 938 Unclip the cooling fan assembly by pressing the retaining brackets ( Remove the cooling fan assembly by pulling it upwards in a zigzag manner. REFITTING 1. REFITTING OPERATION FOR PART CONCERNED - 6 -...
Page 939 Refit the cooling fan assembly in the direction of the arrow in a zigzag manner. Note: Check that the component is correctly fitted. 2. FINAL OPERATION - 7 -...
Page 940 Position the wiring of the cooling fan assembly in relation to the marks made when it was unclipped. Connect the cooling fan assembly connectors. Clip: the cooling fan assembly wiring, the expansion bottle cooling hose clip with the hose onto the cooling fan assembly. Refit: the front end panel Front end panel: Removal - Refitting...
Page 941 Copying or translating, in part or in full, of this document or use of the service part The procedures may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of Renault manufacturer in the production of the various component units and accessories from s.a.s.
Page 942 ENGINE IMMOBILISER Code delivery CONTENTS Page Introduction ............................... 2 Access to code management..........................5 Searching for a code in GDC ..........................5 2.1 Immobiliser code .............................. 5 2.1.1 Old procedure ............................6 2.1.2 New procedure............................7 2.1.3 Error messages and procedures to follow ....................8 2.1.4 Emergency procedure..........................
Page 943 • Engine immobiliser • Radio • Video network • Reprogramming key (NRE) This service is Code Management (GDC) on RENAULT NET or importers' RENAULT NET. Information required for use: Immobiliser code: VIN (17 characters) number marked on the key head (old vehicles, 8 characters maximum)
Page 944 ENGINE IMMOBILISER Code delivery Reprogramming key (only in disconnected mode): *Note: this key is an authorisation code provided by the diagnostic tool to the operator in order to obtain the reprogramming key from the code server. VIN of the vehicle (17 characters) Reprogramming key supplied by the diagnostic tool WARNING Access to the "code management"...
Page 945 ENGINE IMMOBILISER Code delivery Using the Code Management server to find codes: 1) Main menu in Renault Net, under Applications you will find Code Management: PUBLICATIONS PERSONNEL APPLICATIONS ACTIVE Code Management Immobiliser codes Radio codes Reprogramming codes Video codes ICM Assistance...
Page 946 ENGINE IMMOBILISER Code delivery Code Management Help CODE MANAGEMENT Code Management IMMOBILISER CODE VIN (17 characters) Number marked on key head or programming key provided by the diagnostic tool Search Versions of Code Management The immobiliser code for this vehicle is: 2.1.1 Old procedure –...
Page 947 ENGINE IMMOBILISER Code delivery 2.1.2 New procedure: This new procedure affects vehicles from LAGUNA II, and new vehicles. This has been compulsory since June 2006. In disconnected mode: – Enter the VIN + programming key supplied by the diagnostic tool. –...
Page 948 ENGINE IMMOBILISER Code delivery 2.1.3 Error messages and procedure to follow MANAGEMENT CODE ERROR MESSAGE PROCEDURE TO FOLLOW All vehicles Re-enter the VIN. The VIN is not found on the World Vehicle Database If the fault is still present, contact the Techline. The vehicle corresponding to the VIN entered is subject The diagnostic tool programming key is compulsory.
Page 949 France with with the vehicle's VIN. the VIN (new procedure). The Renault cards and keys can only be used with the 3. Check that the Renault card (or key) corresponds VIN for which they have been ordered.
Page 950 ENGINE IMMOBILISER Code delivery 2.1.4 Emergency procedure From 2007, the help mail will be replaced by a text file. Once the code has been requested, a button will appear: "create a text file". This creates a text file which can be saved to the hard drive or to a mobile device. In the event of a fault, this text file contains all the information needed by the Techline : The VIN the key head code or programming key...
Page 951 ENGINE IMMOBILISER Code delivery 2.2 Radio code: – Enter the VIN only – Confirm with the "Search" button – Radio code supplied Code Management Help CODE MANAGEMENT RADIO CODE Code Management Enter the VIN to obtain the radio code. Entry of the pre-code is optional. Radio pre-code Search Versions of...
Page 952 ENGINE IMMOBILISER Code delivery 2.2.1 "Enter pre-code" error screen Code Management Help CODE MANAGEMENT Code Management RADIO CODE The VIN alone cannot be used to obtain the radio code. We request that you enter the radio pre-code in addition to the VIN. (1 letter + 3 figures).
Page 953 Model No: Serial No: 6200178157 The pre-code is found after the Renault part number (8200 XXX XXX or 7700 XXX XXX) and the letter T Example above: 8200178157TN557 2.2.3 The code supplied is not correct If the code supplied from the first request with the vehicle VIN alone is not accepted by the radio, resend your request with the radio pre-code (paragraph 2.2.2).
Page 954 ENGINE IMMOBILISER Code delivery 2.2.4 Old radios without pre-code: To find a radio code using the radio part number (old minitel and voice server procedures), select: "Find radio code using its part number (old server procedure)". Code Management Help CODE MANAGEMENT Code Management RADIO CODE A similar search has already been performed for this vehicle in the last 12 hours...
Page 955 ENGINE IMMOBILISER Code delivery Code Management Help CODE MANAGEMENT RADIO CODE Code Management You must enter the radio part number. The part number is the string of characters (letters and digits) which appears on the radio unit. If you cannot obtain this information, please send the Help procedure message to the assistance unit.
Page 956 ENGINE IMMOBILISER Code delivery 2.3 Video network code – Enter the VIN of the vehicle – Enter the four-digit code generated by the vehicle's video control – Confirm with the "Calculate" button – Four-digit code supplied by the code server Code Management Help CODE MANAGEMENT...
Page 957 ENGINE IMMOBILISER Code delivery 2.4 Tool reprogramming key: – Enter the VIN of the vehicle – Enter the six-digit code generated by the diagnostic tool – Confirm with the "Calculate" button – Six-character (letters and digits) reprogramming key supplied, to be entered in the diagnostic tool. Code Management Help CODE MANAGEMENT...
Page 958 ENGINE: NEW REPLACEMENT Note, one or more warnings are present in this procedure 1. NEW ENGINE REPLACEMENT 1- PARTS TO BE CHECKED 1)CHECKING THE HEATER PLUGS ON THE OLD ENGINE. CAUTION Failure to observe the following procedure can lead to the destruction of the heater plugs.
Page 959 Operations to perform: Check the colour of the ring (1) on the heater plugs of the old engine, -If the ring is BLACK, when refitting the new engine, and before connecting the heater plug connectors: Reprogram the injection computer ( see MR DIAG, Section 13B, Fault Finding or Replacement of components, Replacing or Reprogramming the computer), Reconfigure the type of heater plugs to "rapid"...
Page 960 Drain the oil and coolant from the used engine. Secure the old engine to the stand and under the same conditions as for new engine replacement: fit the plastic plug welds and covers, fit the cardboard cover over the whole assembly. 3- PARTS TO LEAVE ON THE OLD ENGINE OR TO INCLUDE IN THE RETURN BOX: Parts to leave on the old engine or to include in the return box: the dipstick,...
Page 961 the inlet distributor, the exhaust manifold, the turbocharger, the exhaust gas recirculation solenoid valve, the damper valve, the exhaust gas recirculation rigid pipe heat shield at the exhaust manifold outlet, the exhaust gas cooler, the exhaust gas recirculation solenoid valve rigid pipe downstream of the intercooler, the catalytic converter, the multifunction support, the oil pressure sensor,...
Page 962 X43, M9R, 804 811 817 824 839 844 846(804 OR 811 OR 817 OR 824 OR 839 OR 844 OR 846) AND (760) AND (760 OR 761 OR 762 OR 763 OR 812 OR 814 OR 815) AND (630 OR 692) AND (721 OR 722 OR 724) AND (800 OR 802 OR 803 OR 805 OR 806 OR 808 OR 809 OR 814 OR 815 OR 816 OR 820 OR 828 OR 845 OR 849 OR 854 OR 857 OR 858) Do not forget to remove the exhaust gas temperature sensor from the old engine.
Page 963 the catalytic converter mounting half-clamps, the turbocharger strut. the turbocharger strut bolt, the turbocharger studs, the turbocharger nuts, the inlet distributor studs, the exhaust manifold studs, the exhaust manifold nuts, the accessories belt, the accessories belt tensioning roller, the accessories belt fixed roller, the exhaust gas recirculation solenoid valve seal, the damper valve seal, the dipstick guide tube seal,...
Page 964 the crankshaft position sensor seal, the camshaft position sensor seal, the coolant temperature sensor seal. Always replace the turbocharger oil "return pipe - supply pipe" assembly. Always replace the EGR solenoid valve rigid pipe at the exhaust manifold outlet. Refit the parts removed from the old engine on the new engine. Repair-10x01-01x91-1-1-1.xml XSL version : 3.02 du 22/07/11 - 7 -...
Page 965 ENGINE OIL: DRAINING - REFILLING Note, one or more warnings are present in this procedure Special tooling required 8 mm square engine drain plug spanner. Mot. 1018 Equipment required oil recovery tray parts always to be replaced: Drain plug seal on engine oil sump CAUTION Always check the oil level using the dipstick.
Page 966 Remove the "filler cap - dipstick" assembly ( Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Remove the engine undertray. - 2 -...
Page 967 Place the under the engine oil drain plug ( oil recovery tray Remove the drain plug ( ) from the engine oil sump using the 8 mm square engine drain plug spanner. ( Mot. 1018 Let the engine oil run into the oil recovery tray - 3 -...
Page 968 2. FILLING parts always to be replaced: Drain plug seal on engine oil sump Consumable : Engine oil (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). Clean: the engine oil drain plug, the engine oil sump. - 4 -...
Page 969 Refit: the new seal on the drain plug (3) (orient the groove (4) towards the plug), the drain plug on the engine oil sump. 44 N.m Torque tighten the drain plug using the tool 8 mm square engine drain plug spanner. ( Mot.
Page 970 Remove the oil recovery tray Refit the engine undertray. Fill the engine with engine oil, observing: the quantity Maintenance values: Description the type of the engine oil Engine oil: Specifications Note: 10 minutes When filling up the engine oil, always leave at least for the oil to drain down before checking the level on the dipstick Refit the "oil filler cap - dipstick"...
Page 971 ENGINE SUPPORT EQUIPMENT: USE Note, one or more warnings are present in this procedure Special tooling required Engine support, can be adapted for Desvil stand. Mot. 1723 Equipment required component support workshop hoist 1. PREPARING TO INSTALL THE ENGINE ON THE COMPONENT SUPPORT - 1 -...
Page 972 WARNING To work on the engine in complete safety, it is essential to use a component support. - 2 -...
Page 973 CAUTION It is strictly forbidden to apply any pressure to the engine oil sump. Damage to the sump may also damage the engine by: blocking the strainer, raising the oil level above maximum, with a risk of engine racing. Remove the engine - gearbox assembly Disconnect the gearbox from the engine Manual gearbox: Removal - Refitting - 3 -...
Page 974 Fit the pins of the tool Engine support, can be adapted for Desvil stand. ( ) on the cylinder Mot. 1723 block on the flywheel end. - 4 -...
Page 975 Position the mounting plate of the Engine support, can be adapted for Desvil stand. ( ) on Mot. 1723 the support studs (holes ( ) , ( ) , ( ) and ( ) ). Tighten the support stud nuts on the stand plate. - 5 -...
Page 976 fit the support bars component support on the pins, fit the support bar nuts, without tightening them. 2. FITTING THE ENGINE ON THE COMPONENT SUPPORT - 6 -...
Page 977 Position the "engine - pins - mounting plate" assembly or the "engine - pins - support bar" assembly on the component stand using the and a load positioner. workshop hoist Tighten the stand plate studs or the support bars on the component stand. Remove the load positioner.
Page 978 3. REMOVING THE ENGINE FROM THE COMPONENT SUPPORT Maintain the "engine - pins - mounting plate" assembly or the "engine - pins - support bar" assembly on the component stand using the workshop hoist and load positioner. Remove the mounting plate studs or the retaining bars from the component support. Separate the "engine - pins - mounting plate"...
Page 979 EVAPORATOR SENSOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 62A, Air conditioning, Refrigerant circuit: Draining - Filling) REMOVAL 1.
Page 980 Remove: the upper side trim of the centre console front panel (1) , the side trim of the centre front panel (2) , the centre console trim (3) , the dashboard lower trim Dashboard lower trim: Removal - Refitting (57A, Interior equipment), - 2 -...
Page 981 the front left-hand footwell air distribution duct Front footwell air distribution duct: Removal - Refitting the steering wheel Steering wheel: Removal - Refitting (36A, Steering assembly), the steering column switch assembly Steering column switch assembly: Removal - Refitting (84A, Controls - Signalling), the steering column Steering column: Removal - Refitting...
Page 982 Unclip the evaporator sensor ( ) from the air distribution unit. Disconnect the evaporator sensor connector ( REFITTING - 4 -...
Page 983 1. REFITTING OPERATION Clip the evaporator sensor onto the air distribution unit. Connect the evaporator sensor connector. 2. FINAL OPERATION Refit: the brake pedal Brake pedal: Removal - Refitting (37A, Mechanical component controls), the accelerator pedal Accelerator pedal: Removal - Refitting (37A, Mechanical component controls), the steering column Steering column: Removal - Refitting...
Page 984 EXHAUST GAS COOLER: REMOVAL - REFITTING Special tooling required Remote operation pliers for hose clips. Mot. 1448 REMOVAL 1. REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (02A, Lifting equipment). Vehicle: Towing and lifting Remove: the battery Battery: Removal - Refitting (80A, Battery), the battery tray Battery tray: Removal - Refitting...
Page 985 - 2 -...
Page 986 Separate the cooling hose clips ( ) on the exhaust gas cooler using the tool Remote operation pliers for hose clips. ( Mot. 1448 Remove the bolts from the exhaust gas cooler. Disconnect: - 3 -...
Page 987 the exhaust gas cooler hoses, the vacuum pipe from the exhaust gas cooler (4) . Remove the exhaust gas cooler. REFITTING 1. REFITTING PREPARATION OPERATION Clean and degrease the joint faces of the exhaust gas cooler using SURFACE CLEANER (see Vehicle: (04B, Consumables - Products).
Page 988 25 N.m Torque tighten in order the exhaust gas cooler bolts Fill and bleed the cooling system Cooling system: Draining - Refilling Repair-11x07x01x05-01x37-1-61-1.xml - 5 -...
Page 989 EXHAUST GAS PRESSURE SENSOR: REMOVAL - REFITTING Note, one or more warnings are present in this procedure Special tooling required Remote operation pliers for hose clips. Mot. 1448 WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: (see 19B, Exhaust , Exhaust: Precautions for the repair) Vehicle: Precautions for the repair...
Page 990 Disconnect the connector from the exhaust gas pressure sensor ( - 2 -...
Page 991 Remove the exhaust gas pressure sensor bolt ( ) from the lifting eye. Move aside the exhaust gas pressure sensor mounting. - 3 -...
Page 992 Unclip the clip of the exhaust gas pressure sensor pipe ( ) using the tool Remote operation pliers for hose clips. ( Mot. 1448 Remove the clip from the exhaust gas pressure sensor ( Disconnect the exhaust gas pressure sensor pipe ( Remove the exhaust gas pressure sensor from its mounting.
Page 993 Refit the exhaust gas pressure sensor on its mounting. Connect the exhaust gas pressure sensor pipe. Refit: the clip of the exhaust gas pressure sensor, the exhaust gas pressure sensor pipe clip using the tool Remote operation pliers for hose clips. (Mot.
Page 994 EXHAUST GAS RECIRCULATION SOLENOID VALVE: REMOVAL - REFITTING Equipment required Diagnostic tool tweezers REMOVAL 1. REMOVAL PREPARATION OPERATION Remove the front engine cover. - 1 -...
Page 995 Remove: the nut (1) from the cooling radiator top hose on the intercooler air inlet pipe, the bolts (2) from the intercooler air inlet pipe on the inlet distributor. Move aside the cooling radiator top hose. - 2 -...
Page 996 Rotate the intercooler air inlet pipe clip ( Disconnect the intercooler air inlet pipe from the turbocharger. Move aside the intercooler air inlet pipe. Remove: the damper valve Damper valve: Removal - Refitting the exhaust gas recirculation rigid pipe between the EGR solenoid valve and the exhaust gas cooler (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting) 2.
Page 997 Disconnect the connector ( ) from the EGR solenoid valve. Remove: the EGR solenoid valve strut (5) , the EGR solenoid valve, - 4 -...
Page 998 the EGR solenoid valve seal. REFITTING 1. REFITTING PREPARATION OPERATION Use SURFACE CLEANER (04B, Consumables - (see Vehicle: Parts and consumables for the repair) Products) to clean and degrease the bearing faces of the EGR solenoid valve. Always replace: the EGR solenoid valve seal, the exhaust gas recirculation rigid pipe seals, the intercooler air inlet pipe seal.
Page 999 Remove the intercooler air inlet pipe seal at the turbocharger end using a tweezers - 6 -...
Page 1000 Refit the new intercooler air inlet pipe seal. Note: Check that the seal on the intercooler air inlet pipe is fitted the correct way round. 2. REFITTING OPERATION - 7 -...
Page 1001 Refit: the new seal to the EGR solenoid valve, the EGR solenoid valve, the EGR solenoid valve bolts. 21 N.m Torque tighten the EGR solenoid valve bolts Connect the EGR solenoid valve connector. 3. FINAL OPERATION Refit: the exhaust gas recirculation rigid pipe between the EGR solenoid valve and the exhaust gas cooler (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting) the damper valve...