© Renault s.a.s 2008

"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.

MAY 2009

Edition Anglaise

X95

3

Chassis

30A

GENERAL INFORMATION

31A

FRONT AXLE COMPONENTS

33A

REAR AXLE COMPONENTS

35A

WHEELS AND TYRES

35B

TYRE PRESSURE MONITOR

36A

STEERING ASSEMBLY

37A

MECHANICAL COMPONENT CONTROLS

37B

ELECTRONIC PARKING BRAKE

38C

ANTI-LOCK BRAKING SYSTEM

MEGANE III - Section 3

Contents

Page

MEGANE III - Section 3ContentsPage

30A

GENERAL INFORMATION

Brake circuit Operating
diagram

30A-1

Brake circuit Precautions for
repair

30A-2

Brake circuit Bleeding

30A-4

Brake circuit Tightening
torque

30A-6

Rigid brake pipe: Repair

30A-10

Brake fluid: Specifications

30A-15

Brake: Specifications

30A-16

Steering: Tightening torque

30A-18

Axle assemblies: Check

30A-20

Underbody height:
Adjustment values

30A-21

Front axle: Tightening torque

30A-25

Front axle: Adjustment
values

30A-27

Front axle: Adjusting

30A-31

Rear axle: Tightening torque

30A-33

Rear axle: Adjustment values

30A-34

31A

FRONT AXLE COMPONENTS

Front axle assemblies:
Precautions for repair

31A-1

Front brake pads: Removal -
Refitting

31A-3

Front brake hose: Removal -
Refitting

31A-6

Front brake calliper: Removal
- Refitting

31A-8

Front brake calliper: Repair

31A-10

Front brake calliper support:
Removal - Refitting

31A-12

Front brake disc shield:
Removal - Refitting

Front brake disc: Removal -
Refitting

31A-14

Front brake disc: Description

31A-16

Hydraulic unit - master
cylinder brake pipe: Removal
- Refitting

31A-17

Hydraulic unit - underbody
union brake pipe: Removal -
Refitting

31A-25

Hydraulic unit - front left-
hand calliper brake pipe:
Removal - Refitting

31A-34

Hydraulic unit - front right-
hand calliper brake pipe:
Removal - Refitting

31A-43

Front driveshaft hub carrier:
Removal - Refitting

31A-52

Contents

Front hub carrier bearing:
Removal - Refitting

31A-56

Spring and front shock
absorber: Removal - Refitting

31A-59

Filter assembly: Removal -
Refitting

31A-69

Front driveshaft lower arm:
Removal - Refitting

31A-71

Front driveshaft lower arm
ball joint: Check

31A-74

Front axle sub-frame:
Removal - Refitting

31A-75

Radiator support cross
member: Removal - Refitting

31A-83

Radiator mounting cross
member: Repair

31A-85

Front anti-roll bar: Removal -
Refitting

31A-86

33A

REAR AXLE COMPONENTS

Rear axle assemblies:
Precautions for repair

33A-1

Rear brake pads: Removal -
Refitting

33A-3

Rear brake hose: Removal -
Refitting

33A-9

Rear brake caliper: Removal
- Refitting

33A-11

Brake calipers: Repair

33A-15

Rear brake calliper
mounting: Removal -
Refitting

33A-17

Rear brake disc: Removal -
Refitting

33A-20

Rear brake disc: Description

33A-22

Shock absorber: Removal -
Refitting

33A-23

31A

FRONT AXLE COMPONENTS

Rear suspension spring:
Removal - Refitting

33A-34

Rear stub-axle carrier:
Removal - Refitting

33A-37

Rear axle rubber bearing:
Removal - Refitting

33A-39

Complete rear axle: Removal
- Refitting

33A-41

35A

WHEELS AND TYRES

Wheel: Removal - Refitting

35A-1

Wheel: Balancing

35A-4

pneumatic: Precautions for
repair

35A-7

Tyres: Identification

35A-8

Tyres: Removal - Refitting

35A-9

Tyres: Repair

35A-11

Tyre inflation pressure:
Identification

35A-14

Wheel rim: Identification

35A-17

Spare wheel winch: Removal
- Refitting

35A-18

35B

TYRE PRESSURE MONITOR

SSPP: List and location of
components

35B-1

SSPP: Precautions for repair

35B-2

Pressure sensor: Removal -
Refitting

35B-3

33A

REAR AXLE COMPONENTS

Contents

36A

STEERING ASSEMBLY

Steering: List and location of
components

36A-1

Steering: Precautions for
repair

36A-2

Steering rack: Removal -
Refitting

36A-4

Track rod: Removal -
Refitting

36A-6

Axial ball joint linkage:
Removal - Refitting

36A-8

Steering column: Removal -
Refitting

36A-10

Steering rack gaiter:
Removal - Refitting

36A-16

Bulkhead seal: Removal -
Refitting

36A-18

Intermediate shaft: Removal
- Refitting

36A-19

Steering wheel: Removal -
Refitting

36A-22

37A

MECHANICAL COMPONENT CONTROLS

Braking mechanism:
Precautions for repair

37A-1

Master cylinder: Removal -
Refitting

37A-2

Brake servo non-return
valve: Removal - Refitting

37A-4

Brake servo: Removal -
Refitting

37A-7

Vacuum pump: Removal -
Refitting

37A-18

Accelerator pedal: Removal -
Refitting

37A-29

Brake pedal: Removal -
Refitting

37A-30

Brake pedal bell crank rod:
Removal - Refitting

37A-38

Brake pedal switch: Removal
- Refitting

37A-45

Parking brake lever: Removal
- Refitting

37A-50

Parking brake lever:
Adjusting

37A-53

Braking assistance circuit:
Check

Clutch control: List and
location of components

Clutch pedal: Removal -
Refitting

37A-54

Clutch pedal switch:
Removal - Refitting

37A-58

Clutch pedal position sensor:
Removal - Refitting

37A-64

Clutch circuit: Bleeding

37A-66

Clutch master cylinder:
Removal - Refitting

37A-73

Clutch circuit: Removal -
Refitting

37A-79

Manual gearbox selector
cable: Removal - Refitting

37A-88

Mechanical gear control
cable: Adjustment

37A-97

Automatic gear control cable:
Removal - Refitting

37A-100

Gear control unit: Removal -
Refitting

37A-104

Gear control unit: Adjusting

37A-120

Parking brake cables:
Removal - Refitting

37A-128

Brake servo: Check

37A-129

37A

MECHANICAL COMPONENT CONTROLS

Contents

37B

ELECTRONIC PARKING BRAKE

Assisted parking brake: List
and location of components

37B-1

Assisted parking brake:
Precautions for repair

37B-4

Control unit: Removal -
Refitting

37B-5

Handle: Removal - Refitting

37B-7

38C

ANTI-LOCK BRAKING SYSTEM

ABS system: List and
location of components

38C-1

ABS system: Precautions for
repair

38C-4

Brake hydraulic assembly:
Removal - Refitting

38C-5

Front wheel speed sensor:
Removal - Refitting

38C-15

Rear wheel speed sensor:
Removal - Refitting

38C-17

Yaw speed and transversal
acceleration sensor:
Removal - Refitting

38C-19

30A

-

1

GENERAL INFORMATION

Brake circuit Operating diagram

30A

« X » braking system with ABS

3877

IMPORTANT

This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before
removing them.

30A

-

2

GENERAL INFORMATION

Brake circuit Precautions for repair

30A

I - SAFETY

1 - Advice to be followed before any operation

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).

The brake regulation circuit must be free of all hydrau-
lic and electrical faults.

In case of incorrect handling, the brake fluid can cause
serious injury and damage. Follow the manufacturer's
instructions for brake fluid.

To prevent dust from entering the master cylinder re-
servoir and the brake circuit, the plug must be removed
just before filling and closed immediately afterwards,

2 - Instructions to be followed during the operation

Do not press on the brake pedal during work on the
brake system.

If, during work on the brake system, any damage on
any part is observed, it must be repaired before driving
the vehicle again.

Brake fluid is highly corrosive. Ensure any brake fluid
spilt on parts of the vehicle is cleaned off.

Use brake fluids that comply with the Renault standard
(see Precautions for repair) .

Check the brake fluid levels in the braking circuit and
the bleeding device.

Check that the pressure of the bleeding device is
between 1.5 bar and 2 bar.

II - CLEANLINESS

1 - Advice to be followed before any operation

Protect any bodywork components that risk being da-
maged by brake fluid with a cover.

2 - Instructions to be followed during the operation

Clean around the braking system with BRAKE CLEA-
NER (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products).

Do not allow friction materials to come into contact with
grease, oil or other lubricants and cleaning products
which are mineral oil based.

III - GENERAL RECOMMENDATIONS

When replacing brake pads, always replace the pads
on the other side as well.

When replacing a disc, always replace the disc on the
opposite side.

When replacing brake discs, you must replace the bra-
ke pads.

Always replace the rigid brake pipe clips.

Reminder:

- The pipes between the master cylinder, callipers and

the hydraulic assembly are connected using threaded
unions with a metric thread.

- Therefore, only parts specified in the Parts Catalogue

for this vehicle should be used.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surrounding

components.

IMPORTANT

To avoid any accident, bring the pistons, brake pads
and brake discs into contact by depressing the
brake pad several times.

78491

30A

-

3

GENERAL INFORMATION

Brake circuit Precautions for repair

30A

Parts identification:

- shape of steel or copper pipe end piece (A),

- shape of connecting points on components (B),

- shape of unions (C): 11 mm hexagonal.

Precautions to be taken before and during the brake
circuit bleeding operation:

- use brake fluid which conforms to the Renault stan-

dard (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products),

- check the brake fluid levels in the brake circuit and the

bleeding device,

- the braking regulation circuit must be free from all hy-

draulic and electrical faults,

- check that the pressure of the bleeding device is

between 1.5 bars and 2 bars.

30A

-

4

GENERAL INFORMATION

Brake circuit Bleeding

30A

This procedure must be applied after one of the fol-
lowing components has been removed or replaced:

- the master cylinder,

- the brake fluid,

- the hydraulic unit,

- a rigid pipe,

- a hose,

- the reservoir,

- a calliper.

a

Use locally produced containers to collect the used
brake fluid.

Front and rear callipers:

- 2 washer fluid containers (1) (1 litre),

- 4 mm diameter transparent pipes (2) ,

- 4 pipettes (3) (part no: 00 00 081 501),

- 2 T-unions (4) .

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Switch off the vehicle ignition.

Essential equipment

pedal press

brake circuit bleeding device

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 30A, General information, Brake cir-
cuit Precautions for repair, page 30A-2) .

WARNING

Switch off the vehicle ignition so as not to activate
the hydraulic unit solenoid valves when bleeding the
brake circuit.

WARNING

The level must be between the «

MIN

» and

« MAX » markings on the reservoir.

115993

Note:

The new hydraulic unit is pre-filled.

When working on one of the following compo-
nents, position a pedal press to limit the outflow
of brake fluid and prevent any air from entering
the master cylinder and the circuits downstream
of the master cylinder:

- hydraulic unit,

- pipes between the hydraulic unit and brake cal-

lipers,

- brake hoses,

- brake calliper.

Remove the pedal press before carrying out the
braking system bleeding procedure.

30A

-

5

GENERAL INFORMATION

Brake circuit Bleeding

30A

a

Connect the brake circuit bleeding device (after
having received Renault approval) to the master cy-
linder reservoir (see the instructions for the equip-
ment).

a

Pressurise the brake circuit.

a

Adjust the pressure to between 1.5 bar < P < 2 bar
for 3 minutes to stabilise it in the braking circuit.

a

Close the circuit between the bleed screw and brake
fluid reservoir without dumping the pressure.

a

Fit the bleed containers to the four bleed screws of
the callipers.

a

Undo the calliper bleed screws:

- front left-hand,

- front right-hand,

- rear left-hand,

- rear right-hand.

a

Open the circuit between the bleed screw and brake
fluid reservoir and allow the liquid to run until all the
air bubbles have been released.

a

Tighten the bleed screws in the following order:

- front left-hand,

- front right-hand,

- rear left-hand,

- rear right-hand.

a

Undo the calliper bleed screw:

- front left-hand,

- allow the fluid to run until all the air bubbles have

been released,

- tighten the bleed screw on the calliper.

a

Carry out the previous operation on the callipers:

- front right-hand,

- rear left-hand,

- rear right-hand.

a

Close the bleed screw to dump the pressure in the
brake circuit.

a

Remove the brake circuit bleeding device from
the master cylinder reservoir.

a

Check pedal travel and resistance. If it is not correct,
finish bleeding the brake circuit with the help of a se-
cond operator. Start the bleed operation by bleeding
the calliper that is the furthest away from the master
cylinder:

- hold down the brake pedal,

- open the circuit bleed screw to release the air from

the brake circuit,

- close the circuit bleed screw,

- release the brake pedal.

a

Top up the brake fluid level in the reservoir, if neces-
sary. Check the sealing of the front and rear bleed
screws and ensure that the sealing covers are in pla-
ce (see 30A, General information, Brake circuit
Tightening torque, page 30A-6) .

a

During a road test, trigger braking regulation to con-
firm that the brake pedal travel is correct.

a

Clean off any traces of brake fluid on the vehicle
using BRAKE CLEANING PRODUCT (see Vehi-
cle: Parts and ingredients for the repairwork)

Note:

The circuit between the bleed screw and brake
fluid reservoir is closed in different ways depen-
ding on the type of equipment used:

- valve,

- switch.

30A

-

6

GENERAL INFORMATION

Brake circuit Tightening torque

30A

I - FRONT BRAKES

135773

No.

Description

T i g h t e n i n g t o rque
(N.m)

(1)

Calliper bleed screw

10

(2)

Guide pin bolts

27

(3)

Calliper support bolt

105

(4)

Brake disc protector bolts

8

(5)

Brake disc bolt

14

30A

-

7

GENERAL INFORMATION

Brake circuit Tightening torque

30A

II - REAR BRAKES

135774

No.

Description

Tightening torque (N.m)

(6)

Calliper bleed screw

11

(7)

Guide pin bolts

35

(8)

Calliper support bolt

80

(9)

Stub-axle carrier bolt

185

(10)

Brake disc protector bolts

8

(11)

Brake disc nut

220

30A

-

8

GENERAL INFORMATION

Brake circuit Tightening torque

30A

III - BRAKE CONTROL

135775

No.

Description

Tightening torque (N.m)

(12)

Master cylinder nut

27

(13)

Brake fluid reservoir bolt

4

(14)

Brake servo nut

21

(15)

Height adjuster nut

21

30A

-

9

GENERAL INFORMATION

Brake circuit Tightening torque

30A

135776

No.

Description

Tightening torque
(N.m)

(16)

Hydraulic unit bolt on its mounting

8

(17)

Hydraulic unit mounting bolts on body

8

(18)

Front wheel speed sensor bolt

6.5

(19)

Lateral acceleration and yaw sensor bolts

8

30A

-

10

GENERAL INFORMATION

Rigid brake pipe: Repair

30A

This procedure applies to copper pipes diameter 4.7
mm.

REPAIR

I - PIPE PREPARATION OPERATION

a

a

Cut the pipe to the recommended length using a
tube cutter (see Garage equipment catalogue).

a

Put the nuts or bolts on the pipe before forming the
rivets.

II - MAKING THE RIVETS

a

Essential equipment

compressed air nozzle

Tightening torques

m

brake pipe bolts

8 N.m

u n d e r b o d y u n i o n s
(female/male)

6 N.m

Note:

This procedure does not apply to:

- hybrid pipes (pipe + hose),

- pipes with diameters 6 mm and 8 mm.

WARNING

To avoid causing a breakdown in hydraulic brake
circuit , do not squash or bend the rigid pipe
when cutting.

128666

128643

128665

Note:

To make the rivets, fit the rivet press in a vice.

30A

-

11

GENERAL INFORMATION

Rigid brake pipe: Repair

30A

a

Fit the pipe in the rivet press (see Garage Equip-
ment Catalogue).

a

Adjust the length of the pipe to be shaped.

a

Torque tighten the press end piece(40 N.m).

III - CHECKING THE RIVETS

a

Visually inspect:

- the uniformity of the rivets' diameter,

- the rivet centring in relation to the pipe shaft.

a

Visually check that the internal diameter of the pipe
is not oval-shaped.

a

Check that the diameter of the end panel is not oval
shaped using a sliding calliper.

Correct diameter if (X1) = (X2)

IV - PREPARATION OF THE PIPE BEFORE
BENDING

a

a

Blow inside the pipe in both directions using a com-
pressed air nozzle.

a

Put plugs on the bolts or nuts at the ends of the pipe.

a

Put the original pipe on a flat base plate that is the
length of the pipe.

128667

128669

128668

128645

Note:

Impurities may spread inside the pipe while the
rivets are being made.

30A

-

12

GENERAL INFORMATION

Rigid brake pipe: Repair

30A

a

Measure the dimensions (X3) (in mm) curve after
curve, between each curve radius « centre » (1) of
the old pipe.

128659

30A

-

13

GENERAL INFORMATION

Rigid brake pipe: Repair

30A

a

a

Shape the pipe using a bender, curve after curve,
while respecting the original shape of the pipe.

128814

WARNING

To avoid weakening the pipe, either bend once or
bend progressively by increasing the bend (that
is, by continually decreasing the curve radius).
Do not install a rigid pipe on a vehicle that may
have been bended and then unbended alternati-
vely to reach the correct curve radius.

Note:

During the bending operation, the required angle
should be passed slightly in order to compensate
for material elasticity.

30A

-

14

GENERAL INFORMATION

Rigid brake pipe: Repair

30A

V - CHECKING BENDING

a

Check the out-of-roundness of the outer diameter at
the centre of the curve radius (2) using a sliding cal-
liper (the out-of-roundness of the outer diameter is
correct if it is less than 10% flattening):

- nominal diameter of the pipe: 4.75 mm,

- minimum diameter after bending: 4.30 mm.

VI - REFITTING THE PIPE

a

a

Torque tighten the brake pipe bolts (8 N.m).

a

Torque tighten the underbody unions (female/ma-
le) (6 N.m).

128664

128670

Note:

When refitting the rigid brake pipe:

- respect the original routing as much as possi-

ble,

- adjust the pipe routing by hand when fitting

inside the clips.

WARNING

Contact points between the rigid brake pipe and
the surrounding components could cause
damage to the pipe. In order to avoid these con-
tacts, adjust the pipe routing by hand.

128644

128646

30A

-

15

GENERAL INFORMATION

Brake fluid: Specifications

30A

BRAKE FLUID REPLACEMENT INTERVAL

Our braking technology, and in particular the disc bra-
kes (hollow pistons which conduct little heat, have a
low volume of fluid in the cylinder, sliding callipers avoi-
ding the need for a fluid reserve in the least cooled
area of the wheel), has allowed us to prevent the risk of
« vapour lock » as far as possible, even with heavy
braking (mountainous area). However, current brake
fluids are subject to minor deterioration during the first
months of use due to slight humidity intake. This is why
it is recommended that you change the brake fluid: see
maintenance booklet for the vehicle.

1 - Topping up the level

Wear of the brake pads will result in a gradual drop in
the fluid level in the reservoir.

Do not top up the fluid, as the level will rise again when
the pads are next changed. The brake fluid level must
not fall below the minimum mark.

2 - Approved brake fluid

Mixing two incompatible brake fluids in the brake circuit
may lead to:

- serious risk of leakage due mainly to deterioration of

the cups,

- deterioration in the operation of the ESP system.

To prevent such risks, it is essential to use only brake
fluids that comply with the RENAULT standard (see
Vehicle: Parts and ingredients for the repairwork) .

30A

-

16

GENERAL INFORMATION

Brake: Specifications

30A

B95 or K95 – D95, and EQT LEVEL EA1 or EQT
LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

Front brakes (mm)

Disc diameter

280

296

Disc thickness

24

26

Minimum disc thickness (1)

21.8

23.4

Piston diameter

54

57

Maximum disc run-out

0.03

Brake pad thickness (including backplate)

18

Minimum brake pad thickness (including backplate)

6

Rear brakes (mm)

Piston diameter

34

Disc diameter

260

Disc thickness

8

Minimum disc thickness (1)

7

Maximum disc run-out

0.06

Brake pad thickness (including backplate)

16

Minimum brake pad thickness (including backplate)

6

J95

Front brakes (mm)

Disc diameter

280

296

320

Disc thickness

24

26

28

Minimum disc thickness (1)

21.8

23.4

25.4

Piston diameter

54

57

60

Maximum disc run-out

0.03

0.03

0.03

Brake pad thickness (including backplate)

18

18

Minimum brake pad thickness (including backplate)

6

6

Rear brakes (mm)

Piston diameter

34

38

30A

-

17

GENERAL INFORMATION

Brake: Specifications

30A

(1) the brake discs cannot be repaired. If they are ex-
cessively worn or scratched they must be replaced.

Disc diameter

260

274

Disc thickness

8

11

Minimum disc thickness (1)

7

7

Maximum disc run-out

0.06

0.06

Brake pad thickness (including backplate)

16

Minimum brake pad thickness (including backplate)

6

Front brakes (mm)

D95, and EQT LEVEL SPORT

Front brakes (mm)

Disc diameter

340

Disc thickness

28

Minimum disc thickness (1)

26

Piston diameter

40

Maximum disc run-out

0.03

Brake pad thickness (including backplate)

Minimum brake pad thickness (including backplate)

Rear brakes (mm)

Piston diameter

38

38

Disc diameter

274

290

Disc thickness

11

Minimum disc thickness (1)

7

Maximum disc run-out

0.06

Brake pad thickness (including backplate)

Minimum brake pad thickness (including backplate)

30A

-

18

GENERAL INFORMATION

Steering: Tightening torque

30A

127570

116991

No.

Description

Tightening torque (N.m)

(1)

Steering wheel bolt

44

(2)

Steering column nuts

21

(3)

Universal joint bolts on the steering box

62

(4)

Steering rack bolt on the subframe

180

(5)

Track rod nuts

37

30A

-

19

GENERAL INFORMATION

Steering: Tightening torque

30A

(6)

Wheel alignment lock nut

53

(7)

Axial ball joint

53

-

Wheel bolts

110

No.

Description

Tightening torque (N.m)

30A

-

20

GENERAL INFORMATION

Axle assemblies: Check

30A

a

Lock the slip plates of the lift.

a

Position the vehicle on a lift (see Vehicle: Towing
and lifting) .

a

Check the condition of the following components:

- track rods,

- axial ball joint linkages,

- subframe,

- lower arm rubber bushes,

- lower arm ball joints (see 31A, Front axle compo-

nents, Front driveshaft lower arm ball joint:
Check, page 31A-74) ,

- shock absorbers,

- tyres,

a

Check:

- the tyre size (see 35A, Wheels and tyres, Tyres:

Identification, page 35A-8) ,

- the tyre inflation pressure (see 35A, Wheels and

tyres, Tyre inflation pressure: Identification,
page 35A-14) .

a

Put the vehicle in the VODM position (vehicle in run-
ning order) (see 30A, General information, Under-
body height: Adjustment values, page 30A-21) :

- tank full,

- vehicle empty (without luggage, etc.).

a

Consult:

- the front axle geometry values (see 30A, General

information, Front axle: Adjustment values,
page 30A-27) ,

- the rear axle geometry values (see 30A, General

information, Rear axle: Adjustment values,
page 30A-34) .

a

Refer to the user manual for the geometry tester.

a

Check the geometry using the geometry tester.

a

If there is an inconsistency between the manufactu-
rer's values and the measured values:

a

Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-31)

30A

-

21

GENERAL INFORMATION

Underbody height: Adjustment values

30A

I - MEASURING POINTS

Radius under load:

- (R1) : Distance between the ground and the front

wheel shaft

- (R2) : Distance between the ground and the rear

wheel shaft

1 - Front height (W1)

(W1) : Height between the ground and the rear cross
member bolt head

134817

135300

132536

30A

-

22

GENERAL INFORMATION

Underbody height: Adjustment values

30A

2 - Rear height

(W2) : Height between the ground and the shaft of the
rubber bush on the bearing

II - MEASURING PROCEDURE

Measure the heights:

- R1,

- R2,

- W1 right-hand and left-hand,

- W2 right-hand and left-hand.

Specific case:

1 - Plate higher than the lift:

Measure the heights (1) , (2) , (3) .

Example: (1) = 13 cm, (2) = 8 cm, (3) = 10 cm.

Calculate the height Wx:

Wx = height (1) + height (3) - height (2) ,

Wx =15 cm.

134347

132535

Note:

For measurements (W1) and (W2) , take into
account the height difference between the plates
and the lift.

Note:

The value of Wx to be entered into the geometry
bench is the average of the W1 heights, right-hand
and left-hand and of the W2 heights, right-hand and
left-hand.

Note:

If the measuring points are located in empty space
(between the rails of the lift), use a bar.

126087

30A

-

23

GENERAL INFORMATION

Underbody height: Adjustment values

30A

2 - Plate lower than the lift:

Measure the heights (1) , (2) , (3) .

Example: (1) = 8 cm, (2) = 10 cm, (3) = 4 cm,

Calculate the height Wx:

Wx = height (1) + height (2) + height (3) ,

Wx = 22 cm.

III - VEHICLE IN RUNNING ORDER POSITION

VODM (Vehicle in working order) position:

- Tank full,

- Empty vehicle (without luggage, etc.).

(W1) = 164 mm

(W2) = 246 mm

(W1) = 153 mm

(W2) = 234 mm

All types of tyres except 195/65 R15 or 205/55 R16 :

- (W1) = 177 mm

- (W2) = 255 mm

Tyres 195/65 R15 or 205/55 R16 :

- (W1) = 164 mm

- (W2) = 243 mm

(W1) = 177 mm

(W2) = 255 mm

(W1) = 183 mm

(W2) = 261 mm

(W1) = 176 mm

(W2) = 253 mm

(W1) = 181 mm

(W2) = 259 mm

(W1) = 164 mm

(W2) = 245 mm

126088

B95, and F9Q or H4J or K4M or K9K or M4R, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. – D95, and REINFORCED SUSPENS.

D95, and NORMAL SUSPENSION – B95, and F4R
or M9R, and NORMAL SUSPENSION

J95, and STANDARD CHASSIS, and NORMAL
SUSPENSION

J95, and STANDARD CHASSIS, and REINFOR-
CED SUSPENS. or REINFORCED SUSPENSION

J95, and STANDARD CHASSIS, and ADJUSTED
SUSPENSION

J95, and LONG CHASSIS, and NORMAL SUS-
PENSION or REINFORCED SUSPENS. or REIN-
FORCED SUSPENSION

J95, and LONG CHASSIS, and ADJUSTED SUS-
PENSION

K95, and NORMAL SUSPENSION or REINFOR-
CED SUSPENS. or REINFORCED SUSPENSION

30A

-

24

GENERAL INFORMATION

Underbody height: Adjustment values

30A

Note:

The position of the vehicle varies according to:

- the weight of the engine,

- the springs and shock absorbers,

- the tyres,

- the amount of fuel in the tank.

30A

-

25

GENERAL INFORMATION

Front axle: Tightening torque

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

30A

135771

No.

Description

Tightening torque (N.m)

(1)

Lower arm nuts

180

(2)

Tie rod bolt

21

(3)

Rear cross member bolt

62

(4)

Rear subframe bolt

180

(5)

Radiator mounting cross member bolt

180

(6)

Subframe front bolt

105

30A

-

26

GENERAL INFORMATION

Front axle: Tightening torque

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

30A

135772

No.

Description

Tightening torque (N.m)

(7)

Anti-roll bar bolts

180

(8)

Anti-roll bar tie rod nut on the base of the shock absor-
ber

44

(9)

Anti-roll bar tie rod nut on the anti-roll bar

44

(10)

Steering rack bolt

180

30A

-

27

GENERAL INFORMATION

Front axle: Adjustment values

30A

I - WHEEL ALIGNMENT: MEANING OF SYMBOLS

Toe-out: minus sign

Toe-in: plus sign

II - WHEEL ALIGNMENT

III - CASTOR ANGLE

Not adjustable.

93011

WARNING

Symbols used by RENAULT:

- toe-out: -,

- toe-in: +.

93011-1

WARNING

Symbols used by RENAULT:

- toe-out: -,

- toe-in: +.

93011

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or
EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4

Value (for two wheels)

Position of vehicle

-0˚10’

±

10’

Vehicle in running order

D95, and EQT LEVEL SPORT

Value (for two wheels)

Position of vehicle

-0˚

±

10’

Vehicle in running order

30A

-

28

GENERAL INFORMATION

Front axle: Adjustment values

30A

IV - CAMBER

Not adjustable.

93012

B95, and F9Q or H4J or K4M or K9K or M4R, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. – J95, and STANDARD CHASSIS, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. or REINFORCED SUSPENSION – J95, and
LONG CHASSIS, and NORMAL SUSPENSION or
REINFORCED SUSPENS. or REINFORCED SUS-
PENSION – D95, and EQT LEVEL EA1 or EQT
LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4, and REINFORCED SUSPENS. – K95, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. or REINFORCED SUSPENSION

Value

Position of vehicle

+5˚36’

0˚

-2˚

Vehicle in running order

D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or
EQT LEVEL EA3 or EQT LEVEL EA4, and NOR-
MAL SUSPENSION – B95, and F4R or M9R, and
NORMAL SUSPENSION

Value

Position of vehicle

+5˚42’

0˚

-2˚

Vehicle in running order

J95, and STANDARD CHASSIS, and ADJUSTED
SUSPENSION – J95, and LONG CHASSIS, and
ADJUSTED SUSPENSION

Value

Position of vehicle

+5˚30’

0˚

-2˚

Vehicle in running order

D95, and EQT LEVEL SPORT, and BASIC CHAS-
SIS

Value

Position of vehicle

+7˚19’

0˚

-2˚

Vehicle in running order

D95, and EQT LEVEL SPORT, and CUP CHASSIS

Value

Position of vehicle

+7˚21’

0˚

-2˚

Vehicle in running order

93013

30A

-

29

GENERAL INFORMATION

Front axle: Adjustment values

30A

V - PIVOT

Not adjustable.

B95, and F9Q or H4J or K4M or K9K or M4R, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. – J95, and STANDARD CHASSIS, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. or REINFORCED SUSPENSION – J95, and
LONG CHASSIS, and NORMAL SUSPENSION or
REINFORCED SUSPENS. or REINFORCED SUS-
PENSION – D95, and EQT LEVEL EA1 or EQT
LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4, and REINFORCED SUSPENS. – K95, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. or REINFORCED SUSPENSION

Value

Position of vehicle

-0˚26’

±

30’

Vehicle in running order

B95, and F4R or M9R, and NORMAL SUSPEN-
SION – D95, and F4R or M9R, and EQT LEVEL
EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or
EQT LEVEL EA4

Value

Position of vehicle

-0˚31’

±

30’

Vehicle in running order

J95, and STANDARD CHASSIS, and ADJUSTED
SUSPENSION – J95, and LONG CHASSIS, and
ADJUSTED SUSPENSION

Value

Position of vehicle

-0˚18’

±

30’

Vehicle in running order

D95, and EQT LEVEL SPORT, and BASIC CHAS-
SIS

Value

Position of vehicle

-0˚51’

±

30’

Vehicle in running order

D95, and EQT LEVEL SPORT, and CUP CHASSIS

Value

Position of vehicle

-0˚52’

±

30’

Vehicle in running order

93014

30A

-

30

GENERAL INFORMATION

Front axle: Adjustment values

30A

B95, and F9Q or H4J or K4M or K9K or M4R, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. – J95, and STANDARD CHASSIS, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. or REINFORCED SUSPENSION – J95, and
LONG CHASSIS, and NORMAL SUSPENSION or
REINFORCED SUSPENS. or REINFORCED SUS-
PENSION – D95, and EQT LEVEL EA1 or EQT
LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4, and REINFORCED SUSPENS. – K95, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. or REINFORCED SUSPENSION

Value

Position of vehicle

+12˚48’

+30’

--1˚30’

Vehicle in running order

D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or
EQT LEVEL EA3 or EQT LEVEL EA4, and NOR-
MAL SUSPENSION – B95, and F4R or M9R, and
NORMAL SUSPENSION

Value

Position of vehicle

+13˚

+30’

-1˚30’

Vehicle in running order

J95, and STANDARD CHASSIS, and ADJUSTED
SUSPENSION – J95, and LONG CHASSIS, and
ADJUSTED SUSPENSION

Value

Position of vehicle

+12˚30’

+30’

-1˚30’

Vehicle in running order

D95, and EQT LEVEL SPORT, and BASIC CHAS-
SIS

Value

Position of vehicle

+9˚28’

+30’

-1˚30’

Vehicle in running order

D95, and EQT LEVEL SPORT, and CUP CHASSIS

Value

Position of vehicle

+9˚29’

+30’

-1˚30’

Vehicle in running order

30A

-

31

GENERAL INFORMATION

Front axle: Adjusting

30A

I - ADJUSTMENT PREPARATION STAGE

a

a

Check the geometry (see 30A, General informa-
tion, Axle assemblies: Check, page 30A-20) .

II - ADJUSTMENT OPERATION

1 - Wheel alignment

a

Set the wheels straight ahead.

a

Lock the steering wheel using a steering wheel
lock.

a

Adjust the wheel alignment by rotating the track rod
sleeves.

a

Loosen the wheel alignment adjustment lock nut (1)
.

a

Turn the track rod sleeve (2) to the required value.

a

After adjustment, torque tighten the wheel align-
ment adjustment lock nuts (53 N.m).

2 - Castor angle

a

Not adjustable.

3 - Camber

a

Not adjustable.

4 - Pivot

a

Not adjustable.

a

Calibrate the steering wheel angle sensor.

a

Apply the after repair procedure:

- connect the diagnostic tool,

- select "Braking computer",

- go to repair mode,

- display the "Before/after repair procedure" for the

computer selected,

- select "Steering wheel angle sensor" in the "List of

components controlled by this computer" section,

Essential equipment

steering wheel lock

diagnostic tool

Tightening torques

m

wheel alignment adjust-
ment lock nuts

53 N.m

Note:

Throughout the axle assembly checking and
adjustment process:

- the Renault Card must remain in the reader,

- do not press the « START » button.

121364

ESP

30A

-

32

GENERAL INFORMATION

Front axle: Adjusting

30A

- carry out the operations described in the "After re-

pair procedure" section.

30A

-

33

GENERAL INFORMATION

Rear axle: Tightening torque

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

30A

135770

No.

Description

Tightening torque (N.m)

(1)

Shock absorber bolt on rear axle

105

(2)

Shock absorber bolt on body

62

(3)

Rubber bearing nut

125

(4)

Rear axle bolt

105

30A

-

34

GENERAL INFORMATION

Rear axle: Adjustment values

30A

I - WHEEL ALIGNMENT: MEANING OF SYMBOLS

II - WHEEL ALIGNMENT

WARNING

Symbols used by RENAULT:

- toe-out: -

- toe-in: +

93011

B95, and F9Q or H4J or K4M or K9K or M4R, and
NORMAL SUSPENSION or REINFORCED SUS-
PENS. – D95, and EQT LEVEL EA1 or EQT LEVEL
EA2 or EQT LEVEL EA3 or EQT LEVEL EA4, and
REINFORCED SUSPENS. – J95, and LONG
CHASSIS, and ADJUSTED SUSPENSION – K95,
and NORMAL SUSPENSION or REINFORCED
SUSPENS. or REINFORCED SUSPENSION

Value

Position of vehicle

0˚23’

±

15’

Vehicle in running order

D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or
EQT LEVEL EA3 or EQT LEVEL EA4, and NOR-
MAL SUSPENSION – B95, and F4R or M9R, and
NORMAL SUSPENSION

Value

Position of vehicle

0˚26’

±

15’

Vehicle in running order

J95, and STANDARD CHASSIS, and NORMAL
SUSPENSION or REINFORCED SUSPENS. or
REINFORCED SUSPENSION

Value

Position of vehicle

0˚24’

±

15’

Vehicle in running order

J95, and STANDARD CHASSIS, and ADJUSTED
SUSPENSION

Value

Position of vehicle

0˚22’

±

15’

Vehicle in running order

J95, and LONG CHASSIS, and NORMAL SUS-
PENSION or REINFORCED SUSPENS. or REIN-
FORCED SUSPENSION

Value

Position of vehicle

0˚25’

±

15’

Vehicle in running order

30A

-

35

GENERAL INFORMATION

Rear axle: Adjustment values

30A

III - CAMBER

D95, and EQT LEVEL SPORT, and BASIC CHAS-
SIS

Value

Position of vehicle

0˚33’

±

15’

Vehicle in running order

D95, and EQT LEVEL SPORT, and CUP CHASSIS

Value

Position of vehicle

0˚34’

±

15’

Vehicle in running order

93013-1

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or
EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4

Value

Position of vehicle

-0˚60’

±

30’

Vehicle in running order

D95, and EQT LEVEL SPORT, and BASIC CHAS-
SIS

Value

Position of vehicle

-0˚58’

±

30’

Vehicle in running order

D95, and EQT LEVEL SPORT, and CUP CHASSIS

Value

Position of vehicle

-0˚57’

±

30’

Vehicle in running order

31A

-

1

FRONT AXLE COMPONENTS

Front axle assemblies: Precautions for repair

31A

I - SAFETY

1 - Advice to be followed before any operation

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).

2 - Instructions to be followed during the operation

Do not press on the brake pedal during work on the
brake system.

If, during work on the brake system, any damage on
any part is observed, it must be repaired before driving
the vehicle again.

Brake fluid is highly corrosive. Ensure any brake fluid
spilt on parts of the vehicle is cleaned off.

In case of incorrect handling, the brake fluid can cause
serious injury and damage. Follow the manufacturer's
instructions for brake fluid.

II - CLEANLINESS

1 - Advice to be followed before any operation

Protect any bodywork components that risk being da-
maged by brake fluid with a cover.

2 - Instructions to be followed during the operation

Clean around the braking system with BRAKE CLEA-
NER (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products).

Do not allow friction materials to come into contact with
grease, oil or other lubricants and cleaning products
which are mineral oil based.

III - GENERAL RECOMMENDATIONS

1 - Bearing, hub carrier

When removing a hub, it is essential to replace the
bearing with a new one.

It is essential to check the condition of the hub and
bearing surface and the hub carrier bore before refit-
ting the bearing.

Use SURFACE CLEANER (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consumables -
Products) to clean:

- the new bearing's internal and external surfaces

which are in contact with the hub carrier and the hub,

- the hub carrier surfaces in contact with the new bea-

ring,

- the hub surfaces in contact with the new bearing.

Always check the surface condition of the hub carrier
before refitting the "hub - bearing" assembly.

Clean the surfaces of the hub carrier that are in contact
with the "hub - bearing" assembly using SURFACE
CLEANER (see Vehicle: Parts and ingredients for
the repairwork) (04B, Consumables - Products)

Replace any component whose contact surfaces have
deep scratches or cracks.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

WARNING

In order to prevent irreversible damage to the front
hub bearing:

- Do not loosen or tighten the driveshaft nut when

the wheels are on the ground.

- Do not place the vehicle with its wheels on the

ground when the driveshaft has been loosened or
removed.

WARNING

To ensure that the wheel speed sensor works pro-
perly, do not mark the sensor target on the bearing.

WARNING

Do not press the bearing's internal bush so as to
avoid damaging the bearing (very high shrink-fitting
force).

31A

-

2

FRONT AXLE COMPONENTS

Front axle assemblies: Precautions for repair

31A

2 - Suspension spring

When replacing the spring, ensure that the positioning
and orientation of the spring and the tool cups are cor-
rect.

When replacing a spring, always replace the spring on
the opposite side.

If a shock absorber is replaced, the shock absorber on
the opposite side must also be replaced.

Check that the spring compressor tool is operating cor-
rectly.

In the interests of safety, do not leave a spring com-
pressed in the spring compressor tool.

During assembly and removing operations, the surface
and the protection paint must not be damaged.

There must be no impacts during operations. Any han-
dling hooks and tightening or positioning clamps
should be equipped with rubber or plastic in order to
avoid damage on the springs.

It is recommended to replace springs if:

- the paint is damaged,

- the spring has dents in it.

They are not usually symmetrical in shape and care
should be taken to assemble them the right way round.
This can be done using the coloured marking's posi-
tion.

3 - Anti-roll bar

During assembly and removing operations, the surface
and the protection paint must not be damaged.

There must be no impacts during operations. Any han-
dling hooks, tightening or positioning clamps should be
equipped with rubber or plastic parts so as to avoid da-
maging the anti roll bar.

It is recommended to replace the anti-roll bar if:

- the paint is damaged,

- the anti-roll bar has dents in it.

4 - Front axle

WARNING

To prevent the suspension spring from prematurely
breaking, do not damage the anti-corrosion protec-
tion.

Note:

the most critical and sensitive zones are in the main
elbows.

WARNING

To prevent any damage, do not use the lower arm
as support for the lifting system.

WARNING

Check the condition of all the gaiters before refit-
ting. Always replace any damaged components
with new ones.

31A

-

3

FRONT AXLE COMPONENTS

Front brake pads: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Set the wheels straight ahead.

a

Remove the front wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the retaining spring (1) using a wide, flat-
blade screwdriver.

a

Mark the position of the cap (2) on the base of the
shock absorber using a indelible pencil.

a

Unclip the cap (2) from the base of the shock absor-
ber.

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

indelible pencil

Tightening torques

m

guide pin bolts

28 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surrounding

components.

135328

135304

31A

-

4

FRONT AXLE COMPONENTS

Front brake pads: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove:

- the guide pin bolt caps (3) ,

- the guide pin bolts.

a

Suspend the brake calliper on the subframe.

a

Remove the brake pads.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Measure the thickness of the pads and then compa-
re them to the minimum values (see 30A, General
information, Brake: Specifications, page 30A-16)
.

a

Do not allow friction materials to come into contact
with grease, oil or other lubricants and cleaning pro-
ducts which are mineral oil based.

a

parts always to be replaced: Front brake calliper
guide pin bolt (13,03,03,07).

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper supports,

- the callipers.

a

Push the piston fully into its housing using the tool
(Fre. 1190-01) part number 77 11 223 715.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the inner brake pad with the lugs (4) in the calliper
piston.

a

Refit:

- the outer brake pad on the calliper mounting,

- the calliper with the inner brake pad on the calliper

mounting.

135326

103115

114436

31A

-

5

FRONT AXLE COMPONENTS

Front brake pads: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Torque tighten the guide pin bolts (28 N.m).

a

Refit:

- the guide pin bolt caps,

- the retaining spring.

a

Set the wheels straight ahead.

a

Clip the cap on the base of the shock absorber while
aligning the marks made with a indelible pencil.

III - FINAL OPERATION

a

Refit the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surroun-

ding components.

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A

-

6

FRONT AXLE COMPONENTS

Front brake hose: Removal - Refitting

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) .

a

Set the wheels straight ahead.

a

Position a pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Remove the front wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Loosen the hose union (1) on the rigid pipe union.

a

Remove the retaining (2) fork from the hose.

a

To avoid the premature damage of the brake hose
by friction, observe the following procedure before
unclipping the hose:

a

Set the wheels straight ahead.

a

Mark the position of the cap on the base of the shock
absorber using a permanent marker.

a

Unclip the brake hose cap (3) from the shock absor-
ber base.

a

Loosen the hose union on the brake calliper.

a

Remove the brake hose.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Essential equipment

pedal press

IMPORTANT

Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

135304

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surroun-

ding components.

31A

-

7

FRONT AXLE COMPONENTS

Front brake hose: Removal - Refitting

31A

a

Set the wheels straight ahead.

a

Refit the brake hose at the calliper end.

a

Torque tighten the brake hose (see 30A, General
information, Brake circuit Tightening torque,
page 30A-6)

a

Clip the brake hose cap on to the base of the shock
absorber, aligning the marks made using a perma-
nent marker.

a

Refit:

- the brake hose on the rigid pipe union,

- the hose retaining fork.

a

Torque tighten the brake hose union on the rigid
pipe union. (see 30A, General information, Brake
circuit Tightening torque, page 30A-6)

II - FINAL OPERATION

a

Refit the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

31A

-

8

FRONT AXLE COMPONENTS

Front brake calliper: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the front wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

a

Fit a pedal press on the brake pedal to limit the out-
flow of brake fluid.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake hose union (1) slightly on the brake
calliper.

a

Remove:

- the brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) ,

- the brake hose union on the brake calliper.

a

Fit blanking plugs on the ends of the openings.

a

Remove the brake calliper.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Check:

- the condition of the calliper gaiter,

- the condition of the calliper piston; replace it if there

are deep scratches or cracks.

a

Replace any faulty parts (see 31A, Front axle com-
ponents, Front brake calliper: Repair, page 31A-
10) .

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper mounting,

- the calliper.

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

pedal press

Tightening torques

m

brake hose union

14 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

135327

31A

-

9

FRONT AXLE COMPONENTS

Front brake calliper: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Push the piston fully into its housing using the tool
(Fre. 1190-01) part number 77 11 223 715.

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Screw the brake hose union onto the calliper.

a

Refit the brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-3) .

a

Torque tighten the brake hose union (14 N.m).

a

Clean the drips using BRAKE CLEANER (see Ve-
hicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products).

III - FINAL OPERATION

a

Remove the pedal press from the brake pedal.

a

Refit the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

103115

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surroun-

ding components.

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A

-

10

FRONT AXLE COMPONENTS

Front brake calliper: Repair

31A

REPAIR

I - REPAIR PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Remove:

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the front brake calliper (see 31A, Front axle com-

ponents, Front brake calliper: Removal - Refit-
ting, page 31A-8) .

II - REPAIR OPERATION FOR PART CONCERNED

a

Remove the piston using compressed air, making
sure to insert a wooden block between the calliper
and the piston to avoid damaging it. Any trace of im-
pact on the end panel will render the piston unfit for
use.

a

Remove the dust seal.

a

Remove the rectangular section seal from the calli-
per groove with a round edged spring blade (feeler
gauge).

a

Clean the parts using methylated spirit.

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

pedal press

IMPORTANT

Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

81546

81545

WARNING

The whole calliper must systematically be repla-
ced if there are any scratches in the calliper bore.

31A

-

11

FRONT AXLE COMPONENTS

Front brake calliper: Repair

31A

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the new rectangular section seal in the calliper

groove,

- the piston (after having smeared it with the grease

supplied in the repair kit) using the (Fre. 1190-01),

- the dust seal.

II - FINAL OPERATION.

a

Refit:

- the brake calliper (see 31A, Front axle compo-

nents, Front brake calliper: Removal - Refitting,
page 31A-8) ,

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Remove the pedal press.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A

-

12

FRONT AXLE COMPONENTS

Front brake calliper support: Removal - Refitting

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the front brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the calliper mounting bolts (1) ,

- the calliper mounting.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper mounting,

- the calliper,

- the hub carrier.

a

parts always to be replaced: Front brake calliper
mounting bolt (13,03,03,08).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the calliper mounting.

a

Torque tighten the calliper mounting new bolts
(105 N.m).

Tightening torques

m

calliper mounting new
bolts

105 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

135307

31A

-

13

FRONT AXLE COMPONENTS

Front brake calliper support: Removal - Refitting

31A

III - FINAL OPERATION

a

Refit:

- the front brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) ,

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A

-

14

FRONT AXLE COMPONENTS

Front brake disc: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

Brake discs cannot be reground. If there is excessive
scoring or wear, they will need to be replaced (see
30A, General information, Brake: Specifications,
page 30A-16) .

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the brake callipers (see 31A, Front axle compo-

nents, Front brake calliper: Removal - Refitting,
page 31A-8) ,

- the brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) ,

- the calliper mountings (see 31A, Front axle com-

ponents, Front brake calliper support: Removal
- Refitting, page 31A-12) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the brake disc bolts (1) ,

- the brake discs.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean the brake discs using a parts washer.

a

Dry the surface of the discs.

a

Clean the mating faces of the disc on the hub using
a wire brush and BRAKE CLEANER (see Vehicle:
Parts and ingredients for the repairwork) (04B,
Consumables - Products).

a

Always replace the brake disc bolts.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the brake discs with new bolts.

Essential equipment

parts washer

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

135309

31A

-

15

FRONT AXLE COMPONENTS

Front brake disc: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

III - FINAL OPERATION

a

Refit:

- the calliper mountings (see 31A, Front axle com-

ponents, Front brake calliper support: Removal
- Refitting, page 31A-12) ,

- the brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) ,

- the brake callipers (see 31A, Front axle compo-

nents, Front brake calliper: Removal - Refitting,
page 31A-8) ,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A

-

16

FRONT AXLE COMPONENTS

Front brake disc: Description

31A

I - PREPARATION OPERATION FOR CHECK

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

II - CHECKING OPERATION FOR PART
CONCERNED

Position the Palmer tool (1) to measure the disc thic-
kness.

Measure the thickness of the disc at 4 points in order
(90˚ apart).

Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-16) .

III - FINAL OPERATION

Replace the discs if necessary (see 31A, Front axle
components, Front brake disc: Removal - Refitting,
page 31A-14) .

Refit the wheel (see 35A, Wheels and tyres, Wheel:
Removal - Refitting, page 35A-1) .

Note:

Use a Palmer type tool to check the thickness of the
disc.

117057

88310

31A

-

17

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position a pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side.

a

Support the exhaust pipe using a safety strap(s).

a

Remove the clips (1) from the tunnel heat shield.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

Essential equipment

pedal press

refrigerant charging station

safety strap(s)

Tightening torques

m

brake pipe unions on
the hydraulic unit

13 N.m

brake pipe unions on
the master cylinder

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

AIR CONDITIONING or CLIMATE CONTROL

137151

31A

-

18

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove:

- the bulkhead heat shield clips (2) ,

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (3) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe unions (4) on the hydraulic unit.

a

Undo the brake pipe unions (5) on the master cylin-
der.

a

Fit blanking plugs on the openings of the hydraulic
unit and brake pipes.

136467

134715

AIR CONDITIONING or CLIMATE CONTROL

134715

134359

31A

-

19

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Unclip the brake pipes from the bulkhead at (6) .

a

Remove the brake pipes.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipes.

a

Clip the brake pipes onto the bulkhead.

a

Screw on:

- the brake pipe unions on the hydraulic unit,

- the brake pipe unions on the master cylinder.

a

Torque tighten:

- the brake pipe unions on the hydraulic unit (13

N.m),

- the brake pipe unions on the master cylinder

(13 N.m).

II - FINAL OPERATION

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

a

Clip on the fuel pipes.

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield,

- the exhaust pipe,

- the exhaust connecting hose,

- the sub-frame (see 31A, Front axle components,

Front axle sub-frame: Removal - Refitting, page
31A-75) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Remove the pedal press from the brake pedal.

a

Bleed the braking circuit (see 30A, General infor-
mation, Brake circuit Bleeding, page 30A-4) .

a

Refit the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning works correctly (see
Air conditioning: Check) (62A, Air conditioning).

a

Refit the engine undertray.

134713

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

AIR CONDITIONING or CLIMATE CONTROL

31A

-

20

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

J95

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side (1) .

a

Strap the exhaust pipe to the right-hand driveshaft.

Essential equipment

pedal press

refrigerant charging station

Tightening torques

m

brake pipe unions on
the hydraulic unit

13 N.m

brake pipe unions on
the master cylinder

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

139222

31A

-

21

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

J95

31A

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (2) using an open-jawed

spanner,

- the cable sleeve stops (3) .

a

Unclip the control cable on the gearbox at:

- the anchoring ball joint (4) using an open-jawed

spanner,

- from the cable sleeve stop (5) .

a

Remove the intercooler air outlet pipe (see Inter-
cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

a

Remove the heat shield clips (6) from the tunnel.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

a

Remove:

- the bulkhead heat shield clips (7) ,

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

134676

6 SPEED AUTO GBOX

138846

F9Q or K9K or M9R

137151

136467

31A

-

22

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

J95

31A

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (8) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe unions (9) on the hydraulic unit.

a

Undo the brake pipe unions (10) on the master cylin-
der.

134716

AIR CONDITIONING or CLIMATE CONTROL

134716

134359

31A

-

23

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

J95

31A

a

Unclip the brake pipes from the bulkhead at (11) .

a

Remove the brake pipes.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: seal between cata-
lytic converter and exhaust downpipe hose (10,
08,02,21).

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipes.

a

Clip the brake pipes onto the bulkhead.

a

Screw on:

- the brake pipe unions on the hydraulic unit,

- the brake pipe unions on the master cylinder.

a

Torque tighten:

- the brake pipe unions on the hydraulic unit (13

N.m),

- the brake pipe unions on the master cylinder

(13 N.m).

III - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield.

a

Refit the intercooler air outlet pipe (see Intercooler
air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a

Clip the control cables onto the gearbox at:

- the anchoring ball joints ,

- the cable sleeve stops .

a

Clip the control cable onto the gearbox at:

- the anchoring ball joint,

134713

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

F9Q or K9K or M9R

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

6 SPEED AUTO GBOX

31A

-

24

FRONT AXLE COMPONENTS

Hydraulic unit - master cylinder brake pipe: Removal - Refitting

J95

31A

- the cable sleeve stop.

a

Refit:

- the exhaust pipe,

- the exhaust connecting hose,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment).

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning is working correctly
(see Air conditioning: Check) (62A, Air conditio-
ning).

a

Refit the engine undertray.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

25

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant circuit using the tool refrigerant
charging station (see Coolant circuit Draining -
Refilling) (62A, Air conditioning).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side.

a

Support the exhaust pipe using a safety strap(s).

a

Remove the clips (1) from the tunnel heat shield.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

Essential equipment

pedal press

refrigerant charging station

safety strap(s)

Tightening torques

m

brake pipe unions on
the hydraulic unit

13 N.m

underbody brake pipe
unions

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

AIR CONDITIONING or CLIMATE CONTROL

137151

31A

-

26

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove:

- the bulkhead heat shield clips (2) ,

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (3) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

a

Remove the bolt (4) from the « condenser - expan-
sion valve » connecting pipe bracket.

a

Remove the « condenser - expansion valve » con-
necting pipe.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe unions (5) on the hydraulic unit.

136467

134715

AIR CONDITIONING or CLIMATE CONTROL

136487

134715

31A

-

27

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Undo the brake pipe unions (6) from the underbody
union.

a

Unclip the brake pipes from the bulkhead at (7) .

a

Fit blanking plugs on the openings of the hydraulic
unit and brake pipes.

a

Remove the brake pipes.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipes.

a

Screw on:

- the brake pipe unions on the hydraulic unit,

- the brake pipe unions to the underbody unions.

a

Torque tighten:

- the brake pipe unions on the hydraulic unit (13

N.m),

- the underbody brake pipe unions (13 N.m).

a

Clip the brake pipes onto the bulkhead.

II - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

a

Refit:

- the "condenser - expansion valve" connecting pipe,

- the "expansion valve - intermediate pipe" connec-

ting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve
outlet: Removal - Refitting) (62A, Air conditio-
ning).

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield,

- the exhaust pipe,

137143

134713

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

28

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

- the exhaust connecting hose,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning works correctly (see
Air conditioning: Check) (62A, Air conditioning).

a

Refit the engine undertray.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

29

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

J95

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side (1) .

a

Strap the exhaust pipe to the right-hand driveshaft.

Essential equipment

pedal press

refrigerant charging station

Tightening torques

m

brake pipe unions on
the hydraulic unit

13 N.m

underbody brake pipe
unions

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

139222

31A

-

30

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

J95

31A

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (2) using an open-jawed

spanner,

- the cable sleeve stops (3) .

a

Unclip the control cable on the gearbox at:

- the anchoring ball joint (4) using an open-jawed

spanner,

- the cable sleeve stop (5) .

a

Remove the intercooler air outlet pipe (see Inter-
cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

a

Remove the heat shield clips (6) from the tunnel.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

a

Remove:

- the bulkhead heat shield clips (7) ,

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

134676

6 SPEED AUTO GBOX

138846

F9Q or K9K or M9R

137151

136467

31A

-

31

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

J95

31A

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (8) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

a

Remove the bolt (9) from the « condenser - expan-
sion valve » connecting pipe bracket.

a

Remove the « condenser - expansion valve » con-
necting pipe.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe unions (10) on the hydraulic
unit.

134716

AIR CONDITIONING or CLIMATE CONTROL

136487

134716

31A

-

32

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

J95

31A

a

Undo the brake pipe unions (11) from the underbody
union.

a

Unclip the brake pipes from the bulkhead at (12) .

a

Fit blanking plugs on the openings of the hydraulic
unit and brake pipes.

a

Remove the brake pipes.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: seal between cata-
lytic converter and exhaust downpipe hose (10,
08,02,21).

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipes.

a

Screw on:

- the brake pipe unions on the hydraulic unit,

- the brake pipe unions to the underbody unions.

a

Torque tighten:

- the brake pipe unions on the hydraulic unit (13

N.m),

- the underbody brake pipe unions (13 N.m).

a

Clip the brake pipes onto the bulkhead.

III - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

a

Refit:

- the "condenser - expansion valve" connecting pipe,

- the "expansion valve - intermediate pipe" connec-

ting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve
outlet: Removal - Refitting) (62A, Air conditio-
ning).

137143

134713

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

33

FRONT AXLE COMPONENTS

Hydraulic unit - underbody union brake pipe: Removal - Refitting

J95

31A

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield.

a

Refit the intercooler air outlet pipe (see Intercooler
air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a

Clip the control cables onto the gearbox at:

- the anchoring ball joints,

- the cable sleeve stops.

a

Clip the control cable onto the gearbox at:

- the anchoring ball joint,

- the cable sleeve stop.

a

Refit:

- the exhaust pipe,

- the exhaust connecting hose,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment).

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning is working correctly
(see Air conditioning: Check) (62A, Air conditio-
ning).

a

Refit the engine undertray.

F9Q or K9K or M9R

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

6 SPEED AUTO GBOX

AIR CONDITIONING or CLIMATE CONTROL

31A

-

34

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the nuts of the exhaust connecting hose.

a

Move the exhaust pipe to one side.

a

Support the exhaust pipe using a safety strap(s).

a

Remove the clips (1) from the tunnel heat shield.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

Essential equipment

pedal press

refrigerant charging station

safety strap(s)

Tightening torques

m

brake pipe union on the
hydraulic unit

13 N.m

brake pipe union on the
front left-hand brake
hose

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

AIR CONDITIONING or CLIMATE CONTROL

137151

31A

-

35

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove:

- the bulkhead heat shield clips (2) ,

- the bulkhead heat shield.

a

Unclip the fuel pipes (3) from the bulkhead.

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe union (4) on the hydraulic unit.

a

Undo the brake pipe union (5) on the front left-hand
brake hose.

136467

134715

AIR CONDITIONING or CLIMATE CONTROL

134715

135305

31A

-

36

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Unclip the brake pipe from the bulkhead at (6) .

a

Unclip the brake pipe from the left-hand side mem-
ber at (7) .

a

Fit plugs on the openings of the following:

- the hydraulic unit,

- the brake pipe,

- the front left-hand brake hose.

a

Remove the brake pipe.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipe.

a

Screw on:

- the brake pipe union on the hydraulic unit,

- the brake pipe union on the front left-hand brake

hose.

a

Torque tighten:

- the brake pipe union on the hydraulic unit (13

N.m),

- the brake pipe union on the front left-hand bra-

ke hose (13 N.m).

a

Clip the brake pipe onto the bulkhead.

II - FINAL OPERATION

a

Clip on the fuel pipes.

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield,

- the exhaust pipe,

- the exhaust connecting hose,

134713

135380

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

37

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning works correctly (see
Air conditioning: Check) (62A, Air conditioning).

a

Refit the engine undertray.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

38

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

J95

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side (1) .

a

Strap the exhaust pipe to the right-hand driveshaft.

Essential equipment

pedal press

refrigerant charging station

Tightening torques

m

brake pipe union on the
hydraulic unit

13 N.m

brake pipe union on the
front left-hand brake
hose

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

139222

31A

-

39

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

J95

31A

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (2) using an open-jawed

spanner,

- the cable sleeve stops (3) .

a

Unclip the control cable on the gearbox at:

- the anchoring ball joint (4) using an open-jawed

spanner,

- the cable sleeve stop (5) .

a

Remove the intercooler air outlet pipe (see Inter-
cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

a

Remove the heat shield clips (6) from the tunnel.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

a

Remove:

- the bulkhead heat shield clips (7) ,

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

134676

6 SPEED AUTO GBOX

138846

F9Q or K9K or M9R

137151

136467

31A

-

40

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

J95

31A

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (8) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe union (9) on the hydraulic unit.

a

Undo the brake pipe union (10) on the front left-hand
brake hose.

134716

AIR CONDITIONING or CLIMATE CONTROL

134715

135305

31A

-

41

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

J95

31A

a

Unclip the brake pipe from the bulkhead at (11) .

a

Unclip the brake pipe from the left-hand side mem-
ber at (12) .

a

Fit blanking plugs on the openings:

- the hydraulic unit,

- the brake pipe,

- the front right-hand brake hose.

a

Remove the front left-hand brake pipe.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: seal between cata-
lytic converter and exhaust downpipe hose (10,
08,02,21).

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipe.

a

Screw on:

- the brake pipe union on the hydraulic unit,

- the brake pipe union on the front left-hand brake

hose.

a

Torque tighten:

- the brake pipe union on the hydraulic unit (13

N.m),

- the brake pipe union on the front left-hand bra-

ke hose (13 N.m).

a

Clip the brake pipe onto the bulkhead.

III - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

134713

135380

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

42

FRONT AXLE COMPONENTS

Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting

J95

31A

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield.

a

Refit the intercooler air outlet pipe (see Intercooler
air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a

Clip the control cables onto the gearbox at:

- the anchoring ball joints,

- the cable sleeve stops.

a

Clip the control cable onto the gearbox at:

- the anchoring ball joint,

- the cable sleeve stop.

a

Refit:

- the exhaust pipe,

- the exhaust connecting hose,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment).

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning is working correctly
(see Air conditioning: Check) (62A, Air conditio-
ning).

a

Refit the engine undertray.

F9Q or K9K or M9R

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

6 SPEED AUTO GBOX

AIR CONDITIONING or CLIMATE CONTROL

31A

-

43

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the nuts of the exhaust connecting hose.

a

Move the exhaust pipe to one side.

a

Support the exhaust pipe using a safety strap(s).

a

Remove the clips (1) from the tunnel heat shield.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

Essential equipment

pedal press

refrigerant charging station

safety strap(s)

Tightening torques

m

brake pipe union on the
hydraulic unit

13 N.m

brake pipe union on the
front brake hose

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

AIR CONDITIONING or CLIMATE CONTROL

137151

31A

-

44

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove:

- the bulkhead heat shield clips (2) ,

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (3) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe union (4) on the hydraulic unit.

a

Undo the brake pipe union (5) on the front right-hand
brake hose.

136467

134715

AIR CONDITIONING or CLIMATE CONTROL

134715

134358

31A

-

45

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Unclip the brake pipe from the hydraulic unit support
at (6) .

a

Fit blanking plugs on the openings:

- the hydraulic unit,

- the brake pipe,

- the front right-hand brake hose.

a

Remove the brake pipe.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipe.

a

Clip the brake pipe onto the hydraulic unit support.

a

Screw on:

- the brake pipe union on the hydraulic unit,

- the brake pipe union on the front right-hand brake

hose.

a

Torque tighten:

- the brake pipe union on the hydraulic unit (13

N.m),

- the brake pipe union on the front brake hose (13

N.m).

II - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield,

- the exhaust pipe,

- the exhaust connecting hose,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit the front wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

134713

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

46

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning works correctly (see
Air conditioning: Check) (62A, Air conditioning).

a

Refit the engine undertray.

AIR CONDITIONING or CLIMATE CONTROL

31A

-

47

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

J95

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side (1) .

a

Strap the exhaust pipe to the right-hand driveshaft.

Essential equipment

pedal press

refrigerant charging station

Tightening torques

m

brake pipe union on the
hydraulic unit

13 N.m

brake pipe union on the
front right-hand brake
hose

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

139222

31A

-

48

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

J95

31A

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (2) using an open-jawed

spanner,

- the cable sleeve stops (3) .

a

Unclip the control cable on the gearbox at:

- the anchoring ball joint (4) using an open-jawed

spanner,

- from the cable sleeve stop (5) .

a

Remove the intercooler air outlet pipe (see Inter-
cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

a

Remove the heat shield clips (6) from the tunnel.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

a

Remove:

- the bulkhead heat shield clips (7) ,

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

134676

6 SPEED AUTO GBOX

138846

F9Q or K9K or M9R

137151

136467

31A

-

49

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

J95

31A

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (8) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake pipe union (9) on the hydraulic unit.

a

Undo the brake pipe union (10) on the front right-
hand brake hose.

134716

AIR CONDITIONING or CLIMATE CONTROL

134715

134358

31A

-

50

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

J95

31A

a

Unclip the brake pipe from the hydraulic unit support
at (11) .

a

Fit blanking plugs on the openings:

- the hydraulic unit,

- the brake pipe,

- the front right-hand brake hose.

a

Remove the front right-hand brake pipe.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: seal between cata-
lytic converter and exhaust downpipe hose (10,
08,02,21).

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the brake pipe.

a

Clip the brake pipe onto the hydraulic brake unit
mounting.

a

Screw on:

- the brake pipe union on the hydraulic unit,

- the brake pipe union on the front right-hand brake

hose.

a

Torque tighten:

- the brake pipe union on the hydraulic unit (13

N.m),

- the brake pipe union on the front right-hand

brake hose (13 N.m).

III - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield.

a

Refit the intercooler air outlet pipe (see Intercooler
air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a

Clip the control cables onto the gearbox at:

- the anchoring ball joints,

134713

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

F9Q or K9K or M9R

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

31A

-

51

FRONT AXLE COMPONENTS

Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting

J95

31A

- the cable sleeve stops.

a

Clip the control cable onto the gearbox at:

- the anchoring ball joint,

- the cable sleeve stop.

a

Refit:

- the exhaust pipe,

- the exhaust connecting hose,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion).

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment).

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning is working correctly
(see Air conditioning: Check) (62A, Air conditio-
ning).

a

Refit the engine undertray.

6 SPEED AUTO GBOX

AIR CONDITIONING or CLIMATE CONTROL

31A

-

52

FRONT AXLE COMPONENTS

Front driveshaft hub carrier: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) ,

- the brake calliper mounting (see 31A, Front axle

components, Front brake calliper support: Re-
moval - Refitting, page 31A-12) ,

- the brake disc (see 31A, Front axle components,

Front brake disc: Removal - Refitting, page 31A-
14) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Detach the wiring (1) from the wheel speed sensor.

a

Remove the wheel speed sensor bolt (2) .

a

Remove the wheel speed sensor from its housing.

Essential special tooling

Rou. 604-01

Hub locking tool.

Tav. 476

Ball joint extractor.

Tav. 1050-04

Universal driveshaft push
back tool (plate and claws
without ram).

Tightening torques

m

lower shock absorber
bolts

180 N.m

lower arm ball joint nut

62 N.m

track rod end nut

37 N.m

hub nut

280 N.m

bolt of the ABS wiring
support

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surrounding

components.

135310

WARNING

In order to prevent irreversible damage to the
front hub bearing:

- Do not loosen or tighten the driveshaft nut when

the wheels are on the ground.

- Do not place the vehicle with its wheels on the

ground when the driveshaft has been loosened
or removed.

31A

-

53

FRONT AXLE COMPONENTS

Front driveshaft hub carrier: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove:

- the hub nut (3) using a wheel hub locking tool

(Rou. 604-01),

- the track rod end nut (4) .

a

Detach the track rod end using the tool (Tav. 476).

a

Remove:

- the ball joint protector bolt (5) ,

- the ball joint protector.

a

Remove the nut (6) from the mounting of the headli-
ght beam adjustment sensor linkage ball joint.

135311

WITHOUT WHEEL DISC PROT

135325

XENON BULBS

135404

31A

-

54

FRONT AXLE COMPONENTS

Front driveshaft hub carrier: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove the lower ball joint nut (7) .

a

Detach:

- the lower ball joint from the hub carrier,

- the driveshaft from the hub carrier using the tool

(Tav. 1050-04).

a

Remove the bolt (8) from the ABS wiring support on
the base of the shock absorber.

a

Remove:

- the shock absorber base nuts (9) ,

- the hub carrier.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Track rod end nut
(13,04,02,03).

a

parts always to be replaced: Front driveshaft
lower arm ball joint nut (13,02,03,19).

a

parts always to be replaced: Front wheel hub nut
(13,02,03,20).

a

parts always to be replaced: front shock absor-
ber lower nut (13,02,04,11).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the hub carrier,

- the driveshaft in the hub carrier,

- the lower arm ball joint on the hub carrier,

- the track rod end.

135312

135313

135314

31A

-

55

FRONT AXLE COMPONENTS

Front driveshaft hub carrier: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Torque tighten:

- the lower shock absorber bolts (180 N.m),

- the lower arm ball joint nut (62 N.m),

- the track rod end nut (37 N.m),

- the hub nut (280 N.m) using a wheel hub locking

tool (Rou. 604-01).

a

Refit the ball joint protector.

a

Refit the mounting nut of the headlight beam adjust-
ment sensor linkage ball joint.

a

Refit:

- the ABS wiring support on the base of the shock

absorber,

- the wheel speed sensor.

a

Torque tighten the bolt of the ABS wiring support
(8 N.m).

III - FINAL OPERATION

a

Refit:

- the brake disc (see 31A, Front axle components,

Front brake disc: Removal - Refitting, page 31A-
14) ,

- the brake calliper mounting (see 31A, Front axle

components, Front brake calliper support: Re-
moval - Refitting, page 31A-12) ,

- the brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) ,

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

Adjust the front axle, if necessary (see 30A, General
information, Front axle: Adjusting, page 30A-31)
.

WARNING

In order to prevent irreversible damage to the
front hub bearing:

- Do not loosen or tighten the driveshaft nut when

the wheels are on the ground.

- Do not place the vehicle with its wheels on the

ground when the driveshaft has been loosened
or removed.

WITHOUT WHEEL DISC PROT

XENON BULBS

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A

-

56

FRONT AXLE COMPONENTS

Front hub carrier bearing: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1)

- the front wheel speed sensor (see 38C, Anti-lock

braking system, Front wheel speed sensor: Re-
moval - Refitting, page 38C-15) ,

- the front brake disc (see 31A, Front axle compo-

nents, Front brake disc: Removal - Refitting,
page 31A-14) ,

- the front driveshaft hub carrier (see 31A, Front

axle components, Front driveshaft hub carrier:
Removal - Refitting, page 31A-52) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the elastic ring (1) from the front driveshaft
hub carrier.

a

Remove the hub with a press, applying pressure
with a tube with an external diameter of 42 mm.

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surrounding

components.

WARNING

In order to prevent irreversible damage to the front
hub bearing:

- Do not loosen or tighten the driveshaft nut when

the wheels are on the ground.

- Do not place the vehicle with its wheels on the

ground when the driveshaft has been loosened or
removed.

101933

20786

31A

-

57

FRONT AXLE COMPONENTS

Front hub carrier bearing: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Place the extractor jaws (2) in the groove of the in-
ternal bush (3) .

a

Remove the internal bush from the hub, applying
pressure on the hub with a tube with an external dia-
meter of 42 mm.

a

Remove the bearing from the front hub carrier by ap-
plying pressure to the inner bush with a tube with an
external diameter of 75 mm.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Front hub carrier
bearing (13,02,03,15).

a

parts always to be replaced: Front stub axle car-
rier bearing rubber ring (13,02,03,17).

a

Use SURFACE CLEANER (see Vehicle: Parts
and consumables for repair) (04B, Consumables -
Products) to clean:

- the internal and external surfaces of the bearing, in

contact with the hub carrier and the hub,

- the hub carrier surfaces in contact with the bearing,

- the hub surfaces in contact with the bearing.

a

Check the condition of the hub surface and the bore
of the hub carrier in contact with the bearing.

a

Replace any component whose contact surfaces
have deep scratches or cracks.

101230

141794

WARNING

To ensure that the wheel speed sensor works
properly, do not mark the sensor target on the
bear ing.

WARNING

Do not press the bearing's internal bush so as to
avoid damaging the bearing (very high shrink-fit-
ting force).

31A

-

58

FRONT AXLE COMPONENTS

Front hub carrier bearing: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Position the sensor target on the bearing on the ve-
hicle interior.

a

Apply pressure to the external bush with a tube with
an outer diameter of 75 mm and an inner diameter

of 80 mm (old bearing).

a

Apply a fitting force of 50,000 N to ensure that the
bearing is correctly fitted on the hub carrier shoulder.

a

Refit:

- the hub using a tube with an external diameter of

55 mm,

- the elastic ring on the front driveshaft hub carrier.

III - FINAL OPERATION

a

Refit:

- the front driveshaft hub carrier (see 31A, Front

axle components, Front driveshaft hub carrier:
Removal - Refitting, page 31A-52) ,

- the front brake disc (see 31A, Front axle compo-

nents, Front brake disc: Removal - Refitting,
page 31A-14) ,

- the front wheel speed sensor (see 38C, Anti-lock

braking system, Front wheel speed sensor: Re-
moval - Refitting, page 38C-15) ,

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

141795

115568

WARNING

To ensure that the wheel speed sensor works
properly, do not mark the sensor target (3) on the
bearing.

20789

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A

-

59

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the windscreen wiper arms (see Windscreen wi-

per arm: Removal - Refitting) (85A, Wiping -
Washing),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Mark the position of the cap on the base of the shock
absorber using a indelible pencil.

a

Unclip:

- the wiring (1) of the wheel speed sensor from the

brake hose mounting,

- the cap (2) of the brake hose mounting.

a

Remove:

- the bolt (3) of the brake hose mounting,

- the brake hose mounting.

Essential equipment

indelible pencil

spring compressor

spanner for shock absorber rod nut

Tightening torques

m

new shock absorber rod
nut

62 N.m

filter block bolts on the
body

21 N.m

shock absorber base
bolts

180 N.m

track rod nut

37 N.m

brake hose mounting

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

135304

135315

31A

-

60

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove:

- the nut (4) of the anti-roll bar tie rod on the base of

the shock absorber,

- the track rod nut (5) ,

- the shock absorber base studs (6) .

a

Attach the hub carrier to the subframe.

a

Remove:

- the filter block bolts (7) on the body,

- the « spring - shock absorber » assembly.

a

Position the appropriate cups on the spring com-
pressor.

a

Position the spring compressor on the spring.

a

Put the « spring compressor - spring » assembly in a
vice equipped with jaws.

a

Compress the spring using the spring compressor
until the spring detaches.

a

Remove the nut cover (8) .

135317

135295

95436

135318

31A

-

61

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Remove the shock absorber rod nut using the span-
ner for shock absorber rod nut.

a

Separate the various components which make up
the « spring/shock absorber » assembly.

a

Decompress the spring.

REFITTING

I - REFITTING PREPARATION OPERATION

a

If necessary, replace any faulty filter unit compo-
nents (see 31A, Front axle components, Filter as-
sembly: Removal - Refitting, page 31A-69) .

a

parts always to be replaced: front shock absor-
ber rod nut (13,02,04,10).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Place the spring compressor in a vice equipped with
jaws.

a

Compress the spring.

96049

95435

31A

-

62

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Insert the spring in the neck of the cup.

a

Check that the spring is in contact against the stop
(9) .

102201

135316

31A

-

63

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

B95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

a

Respect the order and direction of fitting for the
constituent parts.

a

Torque tighten the new shock absorber rod nut
(62 N.m).

a

Decompress the spring.

a

Remove the spring compressor.

a

Detach the hub carrier from the subframe.

a

Refit the « spring - shock absorber » assembly.

a

Torque tighten:

- the filter block bolts on the body (21 N.m),

- the shock absorber base bolts (180 N.m).

a

Refit:

- the nut of the anti-roll bar linkage on the base of the

shock absorber,

- the track rod,

- the brake hose mounting.

a

Torque tighten:

- the track rod nut (37 N.m),

- the brake hose mounting (8 N.m).

a

Clip:

- the wiring of the wheel speed sensor on the brake

hose mounting,

- the brake hose on the brake hose mounting.

III - FINAL OPERATION

a

Refit:

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the windscreen wiper arms (see Windscreen wi-

per arm: Removal - Refitting) (85A, Wiping -
Washing).

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

Adjust the front axle, if necessary (see 30A, General
information, Front axle: Adjusting, page 30A-31)
.

101939

31A

-

64

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

J95

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the windscreen wiper arms (see Windscreen wi-

per arm: Removal - Refitting) (85A, Wiping -
Washing),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the windscreen wiper motor (see Windscreen wi-

per motor: Removal - Refitting) (85A, Wiping -
Washing),

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Mark the position of the cap on the base of the shock
absorber using a indelible pencil.

a

Unclip:

- the wiring (1) of the wheel speed sensor from the

brake hose mounting,

- the cap (2) of the brake hose mounting.

a

Remove:

- the bolt (3) of the brake hose mounting,

- the brake hose mounting.

Essential equipment

indelible pencil

spring compressor

spanner for shock absorber rod nut

Tightening torques

m

new shock absorber rod
nut

62 N.m

filter block bolts on the
body

21 N.m

shock absorber base
bolts

180 N.m

track rod nut

37 N.m

brake hose mounting

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

135304

135315

31A

-

65

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

J95

31A

a

Remove:

- the nut (4) of the anti-roll bar tie rod on the base of

the shock absorber,

- the track rod nut (5) ,

- the shock absorber base studs (6) .

a

Attach the hub carrier to the subframe.

a

Remove:

- the filter block bolts (7) on the body,

- the « spring - shock absorber » assembly.

a

Position the appropriate cups on the spring com-
pressor.

a

Position the spring compressor on the spring.

a

Put the « spring compressor - spring » assembly in a
vice equipped with jaws.

a

Compress the spring using the spring compressor
until the spring detaches.

a

Remove the nut cover (8) .

135317

138742

95436

135318

31A

-

66

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

J95

31A

a

Remove the shock absorber rod nut using the span-
ner for shock absorber rod nut.

a

Separate the various components which make up
the « spring/shock absorber » assembly.

a

Decompress the spring.

REFITTING

I - REFITTING PREPARATION OPERATION

a

If necessary, replace any faulty filter unit compo-
nents (see 31A, Front axle components, Filter as-
sembly: Removal - Refitting, page 31A-69) .

a

parts always to be replaced: front shock absor-
ber rod nut (13,02,04,10).

a

parts always to be replaced: front shock absor-
ber lower nut (13,02,04,11).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Place the spring compressor in a vice equipped with
jaws.

a

Compress the spring.

96049

95435

31A

-

67

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

J95

31A

a

Insert the spring in the neck of the cup.

a

Check that the spring is in contact against the stop.

102201

135316

31A

-

68

FRONT AXLE COMPONENTS

Spring and front shock absorber: Removal - Refitting

J95

31A

a

Respect the order and direction of fitting for the
constituent parts.

a

Torque tighten the new shock absorber rod nut
(62 N.m).

a

Decompress the spring.

a

Remove the spring compressor.

a

Detach the hub carrier from the subframe.

a

Refit the « spring - shock absorber » assembly.

a

Torque tighten:

- the filter block bolts on the body (21 N.m),

- the shock absorber base bolts (180 N.m).

a

Refit:

- the nut of the anti-roll bar linkage on the base of the

shock absorber,

- the track rod,

- the brake hose mounting.

a

Torque tighten:

- the track rod nut (37 N.m),

- the brake hose mounting (8 N.m).

a

Clip:

- the wiring of the wheel speed sensor on the brake

hose mounting,

- the brake hose on the brake hose mounting.

III - FINAL OPERATION

a

Refit:

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the windscreen wiper motor (see Windscreen wi-

per motor: Removal - Refitting) (85A, Wiping -
Washing),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the windscreen wiper arms (see Windscreen wi-

per arm: Removal - Refitting) (85A, Wiping -
Washing).

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

Adjust the front axle, if necessary (see 30A, General
information, Front axle: Adjusting, page 30A-31)
.

101939

31A

-

69

FRONT AXLE COMPONENTS

Filter assembly: Removal - Refitting

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the shock absorber (see 31A, Front axle compo-

nents, Spring and front shock absorber: Remo-
val - Refitting, page 31A-59) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Separate the various components of the « spring -
shock absorber » assembly.

a

Visually check the condition of the component parts
of the filter unit.

a

All faulty components must always be replaced.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Fit the components in the order indicated in the illus-
tration.

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

134767

(1)

Front impact stop

(2) Upper

cup

(3)

Front filter unit

(4) Nut

(5) Bolt

(6) Nut

cover

31A

-

70

FRONT AXLE COMPONENTS

Filter assembly: Removal - Refitting

31A

II - FINAL OPERATION

a

Refit:

- the shock absorber spring (see 31A, Front axle

components, Spring and front shock absorber:
Removal - Refitting, page 31A-59) ,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

31A

-

71

FRONT AXLE COMPONENTS

Front driveshaft lower arm: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the front wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

a

Remove the nut (1) from the mounting of the headli-
ght beam adjustment sensor linkage ball joint.

Essential special tooling

Tav. 476

Ball joint extractor.

Tightening torques

m

driveshaft lower arm
studs

180 N.m

lower ball joint nut

62 N.m

track rod nut

37 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

XENON BULBS

135404

31A

-

72

FRONT AXLE COMPONENTS

Front driveshaft lower arm: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the lower arm ball joint nut (2) .

a

Detach the lower ball joint from the hub carrier.

a

Extract the lower arm ball joint from the hub carrier.

a

Remove the track rod nut (3) .

a

Detach the track rod from the hub carrier using the
tool (Tav. 476).

a

Remove:

- the bolts (4) from the driveshaft lower arm,

- the driveshaft lower arm.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Front driveshaft
lower arm bolt (13,02,03,18)

a

Always replace the nuts of the driveshaft lower arm.

135329

135317

135302

135303

31A

-

73

FRONT AXLE COMPONENTS

Front driveshaft lower arm: Removal - Refitting

B95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL EA4

31A

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the driveshaft lower arm.

a

Torque tighten the driveshaft lower arm studs
(180 N.m).

a

Refit the lower ball joint into the hub carrier.

a

Torque tighten the lower ball joint nut (62 N.m).

a

Refit the track rod in the hub carrier.

a

Torque tighten the track rod nut (37 N.m).

III - FINAL OPERATION

a

Refit the mounting nut of the headlight beam adjust-
ment sensor linkage ball joint.

a

Refit the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

XENON BULBS

31A

-

74

FRONT AXLE COMPONENTS

Front driveshaft lower arm ball joint: Check

31A

CHECKING

CHECKING THE FRONT DRIVESHAFT LOWER
ARM BALL JOINT

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

1 - Check the condition of the lower arm ball joint
gaiter

a

Check:

- the gaiter crimping on the front driveshaft lower

arm ball joint,

- that the gaiter is not torn.

If the lower arm ball joint gaiter of the front driveshaft
is in poor condition or not crimped, replace the lower
arm of the front driveshaft (see 31A, Front axle
components, Front driveshaft lower arm: Remo-
val - Refitting, page 31A-71) .

2 - Check the fitting of the lower arm ball joint

a

Check:

- the "front driveshaft lower arm ball joint - front dri-

veshaft lower arm bolt - front driveshaft hub carrier"
assembly is correctly positioned,

- the tightening torque of the lower arm ball joint nut

(1) for the front driveshaft (see 30A, General infor-
mation, Front axle: Tightening torque, page
30A-25) ,

- that the rivets of the lower arm ball shaft for the

front driveshaft are held in place (2) .

3 - Checking the play of the lower arm ball joint

a

Check that there is no play in the front driveshaft
lower arm ball joint:

- from a position underneath the vehicle,

- using both hands, hold the front driveshaft lower

arm as close as possible to the wheel,

- push downwards several times.

If there is play in the front driveshaft lower arm ball
joint, replace the front driveshaft lower arm (see
31A, Front axle components, Front driveshaft
lower arm: Removal - Refitting, page 31A-71) .

122718

117494

31A

-

75

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a

Remove:

- the engine undertray bolts,

- the engine undertray,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion).

a

Remove the nut (1) from the mounting of the headli-
ght beam adjustment sensor linkage ball joint.

a

Disconnect the connector (2) from the headlight
beam adjustment sensor.

Essential special tooling

Tav. 476

Ball joint extractor.

Essential equipment

steering wheel lock

indelible pencil

component jack

diagnostic tool

Tightening torques

m

subframe front bolts

105 N.m

subframe rear bolts

180 N.m

rear cross member bolts

62 N.m

lower arm ball joint nuts

62 N.m

track rod end nuts

37 N.m

universal joint bolt

62 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

XENON BULBS

135404

31A

-

76

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Move the floor carpet on the driver's side to access
the universal joint.

a

Remove the bolt (3) from the universal joint.

a

Fit the steering wheel lock.

a

Remove the universal joint.

a

Mark the position of the cap on the brake hose
mounting using a indelible pencil.

a

Unclip:

- the cap (4) of the brake hose mounting,

- the ABS wiring (5) of the brake hose mounting.

a

Remove the track rod end nut (6) .

a

Detach the track rod end using the tool (Tav. 476).

a

Remove the nut (7) from the anti-roll bar tie rod on
the base of the shock absorber.

137147

135304

135315

135317

31A

-

77

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

a

Remove the bolt (8) from the tie rod on the radiator
mounting cross member.

a

Remove the lower ball joint nut (9) .

a

Detach the lower ball joint from the hub carrier.

a

Remove the engine tie-bar (see Lower engine tie-
bar: Removal - Refitting) (19D, Engine mounting).

a

Disconnect the connector (10) from the electric coo-
lant pump.

a

Remove the electric coolant pump from its rubber
mounting.

a

Unclip the electric coolant pump wiring from the sub-
frame.

135297

135306

F4R

135321

31A

-

78

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

a

Remove the bolt (11) from the exhaust pipe on the
subframe rubber mounting bush.

a

Unclip the downstream oxygen sensor wiring from
the subframe.

a

Remove the exhaust pipe bolt (12) on the rubber
mounting bushes of the subframe.

F4R or K4M

137150

K4M

F9Q

135299

31A

-

79

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

a

Position a component jack under the subframe.

a

Remove:

- the rear bolts (13) from the subframe,

- the rear cross member bolts (14) from the subfra-

me,

- the rear cross member from the subframe.

a

Strap the subframe to the component jack.

a

Remove:

- the subframe front bolts (15) ,

- the subframe.

III - STRIPPING THE PART CONCERNED

a

Remove:

- the steering box (see 36A, Steering assembly,

Steering rack: Removal - Refitting, page 36A-4) ,

- the anti-roll bar (see 31A, Front axle compo-

nents, Front anti-roll bar: Removal - Refitting,
page 31A-86) .

a

Remove the headlight beam adjustment sensor (see
Headlight adjustment front sensor: Removal -
Refitting) (80B, Headlights).

137152

135301

135320

XENON BULBS

31A

-

80

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

a

Remove:

- the electric coolant pump support bolt (16) ,

- the support of the electric coolant pump.

a

Remove:

- the rubber mounting bush bolt (17) on the subfra-

me,

- the rubber mounting bush.

a

Remove:

- the rubber mounting bush bolts on the subframe,

- the rubber mounting bushes.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Degrease the body surfaces that make contact with
the sub-frame and cross member using SURFACE
CLEANER (see Vehicle: Parts and consumables
for repair) (04B, Consumables - Products).

a

Check for the presence of the upper mounting
washer (18) on the subframe before refitting the bolt.

a

parts always to be replaced: Steering shaft yoke
bolt (13,04,01,07).

a

parts always to be replaced: Track rod end nut
(13,04,02,03).

a

parts always to be replaced: Front driveshaft
lower arm ball joint nut (13,02,03,19).

a

parts always to be replaced: Front sub-frame
bolt (13,02,02,03).

F4R

135322

F4R or K4M or K9K

135319

F9Q

135301

31A

-

81

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

II - REBUILDING THE PART CONCERNED

a

Refit the rubber mounting bushes on the subframe.

a

Refit the rubber mounting bush on the subframe.

a

Refit the electric coolant pump support.

a

Refit the headlight beam adjustment sensor (see
Headlight adjustment front sensor: Removal -
Refitting) (80B, Headlights).

a

Refit:

- the anti-roll bar (see 31A, Front axle compo-

nents, Front anti-roll bar: Removal - Refitting,
page 31A-86) ,

- the steering box (see 36A, Steering assembly,

Steering rack: Removal - Refitting, page 36A-4) .

III - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the radiator mounting cross member tie rods on
the subframe.

a

Refit the subframe using a component jack.

a

Remove:

- the subframe strap,

- the component jack.

a

Refit the subframe rear cross member.

a

Torque tighten:

- the subframe front bolts (105 N.m),

- the subframe rear bolts (180 N.m),

- the rear cross member bolts (62 N.m).

a

Refit the exhaust pipe on the rubber mounting
bushes.

a

Clip the downstream oxygen sensor wiring onto the
subframe.

a

Refit the exhaust pipe on the rubber mounting bush.

a

Refit the electric coolant pump into its rubber sup-
port.

a

Connect the electric coolant pump connector.

a

Clip on the electric coolant pump wiring.

a

Refit:

- the rear suspended engine mounting (see Lower

engine tie-bar: Removal - Refitting) (19D, Engi-
ne mounting),

- the lower arm ball joints,

- the anti-roll bar tie rods,

- the track rod ends.

a

Torque tighten:

- the lower arm ball joint nuts (62 N.m),

- the track rod end nuts (37 N.m).

F9Q

F4R or K4M or K9K

F4R

XENON BULBS

F9Q

K4M

F4R or K4M

F4R

31A

-

82

FRONT AXLE COMPONENTS

Front axle sub-frame: Removal - Refitting

B95 or E95 or J95 or K95 – D95, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT LEVEL
EA4

31A

a

Clip:

- the ABS wiring on the brake hose mounting,

- the cap on the brake hose mounting, aligning the

marks made using the permanent marker pen.

a

Refit the universal joint on the steering box.

a

Torque tighten the universal joint bolt (62 N.m).

a

Remove the steering wheel lock.

IV - FINAL OPERATION

a

Refit:

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the engine undertray,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

a

Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-31) .

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select the "Power-assisted steering computer",

- go to repair mode,

- apply the "Before/after repair procedure" for the

computer selected,

- select "Power-assisted steering assembly" under

"List of components stored in this computer",

- carry out the operations described in the "After re-

pair procedure" section.

a

Connect the headlight beam adjustment sensor con-
nector.

a

Refit the mounting nut of the headlight beam adjust-
ment sensor linkage ball joint.

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select “Headlight adjustment computer”,

- go to repair mode,

- apply the "Before/after repair procedure" for the

computer selected,

- select "Headlight beam adjustment front sensor" in

the "List of components controlled by this compu-
ter" section,

- carry out the operations described in the "After re-

pair procedure" section.

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

Adjust the front axle, if necessary (see 30A, General
information, Front axle: Adjusting, page 30A-31)
.

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surroun-

ding components.

137147

XENON BULBS

31A

-

83

FRONT AXLE COMPONENTS

Radiator support cross member: Removal - Refitting

31A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the degassing tube from the battery on the ra-
diator mounting cross member tie rod.

a

Remove the bolts (1) from the radiator mounting
cross member tie-rods.

a

Remove the bolts (2) from the radiator mounting
cross member on the front panel.

a

Fit a component jack under the radiator mounting
cross member.

a

Remove the bolts (3) from the radiator mounting
cross member on the side members.

Essential equipment

component jack

Tightening torques

m

radiator mounting cross
member bolts on the
side members

180 N.m

135297

135296

135293

31A

-

84

FRONT AXLE COMPONENTS

Radiator support cross member: Removal - Refitting

31A

a

Unclip the fan assembly wiring (4) from the radiator
mounting cross member.

a

Remove the nut (5) from the air conditioning pipe
bracket on the radiator mounting cross member.

a

Remove the radiator mounting cross member.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean the body surfaces that make contact with the
radiator mounting cross member using SURFACE
CLEANER (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Pro-
ducts).

a

Always replace the lower bolts of the radiator moun-
ting cross member.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the radiator mounting cross member on the com-
ponent jack.

a

Refit the air conditioning pipe bracket on the radiator
mounting cross member.

a

Clip the fan assembly wiring onto the radiator moun-
ting cross member.

a

Refit the radiator mounting cross member.

a

Torque tighten the radiator mounting cross mem-
ber bolts on the side members (180 N.m).

a

Clip the degassing tube of the battery on the radiator
mounting cross member tie rod.

a

Check the play (X) between the radiator mounting
cross member and the subframe.

The play should be 13

±±±±

1 mm.

III - FINAL OPERATION

a

Refit:

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion).

135292

F4R or F9Q

F4R or F9Q

135298

31A

-

85

FRONT AXLE COMPONENTS

Radiator mounting cross member: Repair

31A

REPAIR

I - REPAIR PREPARATION OPERATION

a

Remove the radiator mounting cross member (see

31A, Front axle components, Radiator support

cross member: Removal - Refitting, page 31A-83)

.

a

Measure the length (X) of the side members

between the pin shaft and the plate shaft.

- left-hand side member: 394

±±±±

1 mm

- right-hand side member: 398

±±±±

1 mm

a

Replace the radiator mounting cross member if the

values are incorrect.

II - REPAIR OPERATION FOR PART CONCERNED

a

Use SURFACE CLEANER (see Vehicle: Parts

and consumables for repair) (04B, Consumables -

Products) to clean:

- the side members,

- the backplates,

- the cross member.

a

Always replace the rivets of the radiator mounting

cross member.

a

a

Refit new rivets (1) .

III - FINAL OPERATION

a

Refit the radiator mounting cross member (see 31A,
Front axle components, Radiator support cross
member: Removal - Refitting, page 31A-83) .

135291

135294

WARNING

It is forbidden to redrill the holes in the compo-
nents of the radiator mounting cross member.

31A

-

86

FRONT AXLE COMPONENTS

Front anti-roll bar: Removal - Refitting

31A

Anti-roll bar specifications:

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front axle subframe (see 31A, Front axle com-

ponents, Front axle sub-frame: Removal - Refit-
ting, page 31A-75) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the lower nuts (1) from the anti-roll bar tie rods,

- the anti-roll bar tie rods,

- the anti-roll bar bearing bolts (2) ,

- the anti-roll bar.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean the surfaces of the subframe resting against
the anti-roll bar bearings using SURFACE CLEA-
NER (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the anti-roll bar,

- the anti-roll bar tie rods.

III - FINAL OPERATION

a

Refit:

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

No.

Ø of the bar in mm

Yellow

22,5

Blue

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .

135322

33A

-

1

REAR AXLE COMPONENTS

Rear axle assemblies: Precautions for repair

33A

I - SAFETY

1 - Advice to be followed before any operation

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).

2 - Instructions to be followed during the operation

Do not press on the brake pedal during work on the
brake system.

If, during work on the brake system, any damage on
any part is observed, it must be repaired before driving
the vehicle again.

Brake fluid is highly corrosive. Ensure any brake fluid
spilt on parts of the vehicle is cleaned off.

In case of incorrect handling, the brake fluid can cause
serious injury and damage. Follow the manufacturer's
instructions for brake fluid.

II - CLEANLINESS

1 - Advice to be followed before any operation

Protect any bodywork components that risk being da-
maged by brake fluid with a cover.

2 - Instructions to be followed during the operation

Clean around the braking system with BRAKE CLEA-
NER (see Vehicle: Parts and consumables for re-
pair) (04B, Consumables - Products).

Do not allow friction materials to come into contact with
grease, oil or other lubricants and cleaning products
which are mineral oil based.

III - GENERAL RECOMMENDATIONS

1 - Braking

When replacing brake pads, be sure to replace the
pads on the opposite side.

When replacing a disc, always replace the disc on the
opposite side.

When replacing brake discs, you must replace the bra-
ke pads.

It is essential to replace the rigid brake pipe clips.

2 - Stub axle carrier bearing

Use SURFACE CLEANER (see Vehicle: Parts and
consumables for repair) (04B, Consumables - Pro-
ducts) to clean:

- the inner surface of the new bearing, in contact with

the rear stub-axle,

- the rear stub-axle surface in contact with the new

bearing.

3 - Suspension spring

When replacing the spring, make sure it is positioned
the right way round.

When replacing a spring, always replace the spring on
the opposite side.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

WARNING

To avoid damaging the parking brake cable protec-
tors and causing premature wear of the system, do
not handle the cables with a tool.

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surrounding

components.

WARNING

To avoid any accident, bring the pistons, brake pads
and brake discs into contact by depressing the
brake pad several times.

WARNING

To avoid brake imbalance, both drums must be of
the same diameter. Regrinding one drum necessi-
tates regrinding of the opposite drum.

WARNING

To ensure that the wheel speed sensor works pro-
perly, do not mark the sensor target on the bearing.

33A

-

2

REAR AXLE COMPONENTS

Rear axle assemblies: Precautions for repair

33A

During fitting and removal operations, the surface and
protective paint should not be damaged.

There must be no impacts during operations. Any han-
dling hooks and tightening or positioning clamps
should have rubber or plastic fittings in order to avoid
damage to the springs.

It is recommended to replace springs if:

- the paint is damaged,

- there are dents on the spring.

4 - Rear axle

WARNING

To prevent the suspension spring from prematurely
breaking, do not damage the anti-corrosion protec-
tion.

WARNING

To prevent any damage, do not use the rear axle as
support for the lifting system.

WARNING

To prevent the components of the rear axle from
deteriorating (rubber bushes, brake hoses, etc.) do
not remove the two shock absorbers at the same
time. Proceed one side at a time.

33A

-

3

REAR AXLE COMPONENTS

Rear brake pads: Removal - Refitting

ELECTRONIC PARKING BRAKE

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Apply the before repair procedure using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- activate the maintenance mode.

a

Remove the rear wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the wiring from the automatic parking brake at
(1) .

a

Remove the bolts (2) from the brake calliper guide
pins.

a

Attach the brake calliper to the suspension spring.

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

diagnostic tool

Tightening torques

m

brake calliper guide pin
bolts

35 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

135442

135437

33A

-

4

REAR AXLE COMPONENTS

Rear brake pads: Removal - Refitting

ELECTRONIC PARKING BRAKE

33A

a

Remove the brake pads (3) from the brake calliper
mountings.

a

Remove the noise-reducing fins (4) from the brake
calliper mountings.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper supports,

- the callipers.

a

parts always to be replaced: Rear brake calliper
guide pin bolt (13,03,04,10).

a

Fit shim no.6 (A) (figure 6 mark towards the tool) and
shim no.5 (B) (figure 5 mark towards the piston) on
the tool (Fre. 1190-01).

a

Push the piston to the bottom of its housing using
the (Fre. 1190-01).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the noise-reducing fins onto the brake calliper

mountings,

135436

135435

137992

137993

33A

-

5

REAR AXLE COMPONENTS

Rear brake pads: Removal - Refitting

ELECTRONIC PARKING BRAKE

33A

- the brake pads onto the brake calliper mountings,

- the brake calliper.

a

Torque tighten the brake calliper guide pin bolts
(35 N.m).

III - FINAL OPERATION

a

Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Apply the after repair procedure using the diagnostic
tool:

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- deactivate the maintenance mode.

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

6

REAR AXLE COMPONENTS

Rear brake pads: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Release the parking brake.

a

Remove the rear wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip:

- the parking brake cable from the brake callipers at

(1) ,

- the parking brake cable from the rear axle.

a

Move aside the handbrake cables.

a

Remove the lower bolt (2) of the brake calliper guide
pin.

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Tightening torques

m

brake calliper guide pin
bolts

35 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

To avoid damaging the parking brake cable protec-
tors and causing premature wear of the system, do
not handle the cables with a tool.

101306

33A

-

7

REAR AXLE COMPONENTS

Rear brake pads: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

33A

a

Tilt the brake calliper over.

a

Remove the brake pads (3) from the brake calliper
mounting.

a

Remove the noise-reducing blades (4) from the bra-
ke calliper mounting.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper mounting,

- the calliper.

a

parts always to be replaced: Rear brake calliper
guide pin bolt (13,03,04,10).

a

Push the piston to the bottom of its housing using
the (Fre. 1190-01).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the noise-reducing fins on the brake calliper moun-

ting,

- the brake pads on the brake calliper mounting.

a

Fit:

- the brake calliper,

- the parking brake cable.

a

Torque tighten the brake calliper guide pin bolts
(35 N.m).

101702

125051

106309

33A

-

8

REAR AXLE COMPONENTS

Rear brake pads: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

33A

III - FINAL OPERATION

a

Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

9

REAR AXLE COMPONENTS

Rear brake hose: Removal - Refitting

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the rear wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

a

Position a pedal press on the brake pedal to limit
the outflow of brake fluid.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the brake hose union from the rigid pipe at (1) .

1 - Left-hand side

a

Loosen the brake hose unions (2) .

a

Unclip the clip (3) from the brake hose.

a

Remove the brake hose.

Essential equipment

pedal press

Tightening torques

m

brake hose unions

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

137145

137124

33A

-

10

REAR AXLE COMPONENTS

Rear brake hose: Removal - Refitting

33A

2 - Right-hand side

a

Undo the brake pipe union from the hose at (4) .

a

Remove the brake hose.

REFITTING

I - REFITTING PREPARATION OPERATION

a

II - REFITTING OPERATION FOR PART
CONCERNED

1 - Left-hand side

a

Refit:

- the brake hose,

- the brake hose clip.

2 - Right-hand side

a

Refit the brake hose.

3 - Left-hand and/or right-hand side

a

Torque tighten the brake hose unions (13 N.m).

III - FINAL OPERATION

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

134343

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surroun-

ding components.

33A

-

11

REAR AXLE COMPONENTS

Rear brake caliper: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Release the parking brake.

a

Position a pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Remove the rear wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the parking brake cable from the brake calli-
per at (1) .

a

Move aside the parking brake cable.

a

Undo the brake pipe union (2) on the calliper.

a

Remove:

- the brake calliper guide pin bolts (3) ,

- the brake calliper (4) from the calliper mounting,

- the union between the brake pipe and the calliper,

- the brake calliper.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper supports,

- the callipers.

a

parts always to be replaced: Rear brake calliper
guide pin bolt (13,03,04,10).

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

pedal press

Tightening torques

m

bolts of the brake calli-
per guide pins

35 N.m

brake pipe union on the
calliper

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

To avoid damaging the parking brake cable protec-
tors and causing premature wear of the system, do
not handle the cables with a tool.

125049

33A

-

12

REAR AXLE COMPONENTS

Rear brake caliper: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

33A

a

Push the piston to the bottom of its housing using
the (Fre. 1190-01).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the brake calliper on the mounting.

a

Tighten to torque:

- the bolts of the brake calliper guide pins (35

N.m),

- the brake pipe union on the calliper (13 N.m).

a

Fit the parking brake cable.

a

Clip the parking brake onto the brake calliper.

III - FINAL OPERATION

a

Refit the rear wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

106309

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

13

REAR AXLE COMPONENTS

Rear brake caliper: Removal - Refitting

ELECTRONIC PARKING BRAKE

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Apply the before repair procedure using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- activate the maintenance mode.

a

Fit a pedal press on the brake pedal to limit the out-
flow of brake fluid.

a

Remove the rear wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the wiring from the automatic parking brake.

a

Disconnect the connector (1) from the brake calliper
parking brake motor.

a

Loosen the calliper brake pipe union (2) .

a

Remove:

- the brake calliper guide pin bolts (3) ,

- the brake calliper from the calliper mounting,

- the calliper brake pipe union,

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

diagnostic tool

pedal press

Tightening torques

m

brake calliper guide pin
bolts

35 N.m

brake pipe union on the
calliper

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

135442

135443

33A

-

14

REAR AXLE COMPONENTS

Rear brake caliper: Removal - Refitting

ELECTRONIC PARKING BRAKE

33A

- the brake calliper.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper supports,

- the callipers.

a

parts always to be replaced: Rear brake calliper
guide pin bolt (13,03,04,10).

a

Fit shim no.6 (A) (figure 6 mark towards the tool) and
shim no.5 (B) (figure 5 mark towards the piston) on
the tool (Fre. 1190-01).

a

Push the piston to the bottom of its housing using
the (Fre. 1190-01).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the brake calliper on the calliper mounting.

a

Tighten to torque:

- the brake calliper guide pin bolts (35 N.m),

- the brake pipe union on the calliper (13 N.m).

a

Connect the automatic parking brake connector to
the brake calliper.

a

Clip on the wiring of the automatic parking brake.

III - FINAL OPERATION

a

Refit the rear wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- deactivate the maintenance mode.

137992

137993

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

15

REAR AXLE COMPONENTS

Brake calipers: Repair

WITHOUT AUTOMATIC PARKING BRAKE

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Release the parking brake.

a

Position a pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Remove:

- the rear wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the rear brake calliper (see 33A, Rear axle com-

ponents, Rear brake caliper: Removal - Refit-
ting, page 33A-11) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the piston using compressed air, making
sure to insert a wooden block between the calliper
and the piston.

a

Remove the dust seal.

a

Remove the rectangular section seal from the calli-
per groove with a round edged spring blade (feeler
gauge).

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

pedal press

IMPORTANT

Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

106308

106307

33A

-

16

REAR AXLE COMPONENTS

Brake calipers: Repair

WITHOUT AUTOMATIC PARKING BRAKE

33A

REFITTING

I - REFITTING PREPARATION OPERATION

a

Replace the complete calliper in if there is:

- a scratch in the calliper bore,

- a scratch or crack on the calliper piston.

a

Always replace the brake calliper guide pin bolts.

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper mounting,

- the brake calliper.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the new rectangular section seal in the calliper

groove,

- the piston (after having smeared it with the grease

supplied in the repair kit) using the (Fre. 1190-01),

- the dust seal.

III - FINAL OPERATION

a

Refit:

- the brake calliper (see 33A, Rear axle compo-

nents, Rear brake caliper: Removal - Refitting,
page 33A-11) ,

- the rear wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

106309

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

17

REAR AXLE COMPONENTS

Rear brake calliper mounting: Removal - Refitting

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Release the parking brake.

a

Apply the before repair procedure using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- activate the maintenance mode.

a

Remove:

- the rear wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the brake pads (see 33A, Rear axle components,

Rear brake pads: Removal - Refitting, page 33A-
3) .

a

Remove the upper bolt (1) from the brake calliper
guide pin.

Essential special tooling

Fre. 1190-01

Brake calliper piston return
tool.

Essential equipment

diagnostic tool

Tightening torques

m

brake calliper mounting
bolts

80 N.m

upper bolt of the brake
calliper guide pin

35 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WITHOUT AUTOMATIC PARKING BRAKE

ELECTRONIC PARKING BRAKE

WITHOUT AUTOMATIC PARKING BRAKE

135434

33A

-

18

REAR AXLE COMPONENTS

Rear brake calliper mounting: Removal - Refitting

33A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the brake calliper mounting bolts (2) ,

- the brake calliper mounting.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products):

- the calliper mounting,

- the calliper.

a

parts always to be replaced: Rear brake calliper
mounting bolt (13,03,04,11).

a

parts always to be replaced: Rear brake calliper
guide pin bolt (13,03,04,10).

a

Push the piston to the bottom of its housing using
the (Fre. 1190-01).

a

Fit shim no.6 (A) (figure 6 mark towards the tool) and
shim no.5 (B) (figure 5 mark towards the piston) on
the tool (Fre. 1190-01).

135441

WITHOUT AUTOMATIC PARKING BRAKE

106309

ELECTRONIC PARKING BRAKE

137992

33A

-

19

REAR AXLE COMPONENTS

Rear brake calliper mounting: Removal - Refitting

33A

a

Push the piston to the bottom of its housing using
the (Fre. 1190-01).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the brake calliper mounting.

a

Torque tighten the brake calliper mounting bolts
(80 N.m).

III - FINAL OPERATION

a

Refit the new upper bolt of the brake calliper guide
pin.

a

Torque tighten the upper bolt of the brake calliper
guide pin (35 N.m).

a

Refit:

- the brake pads (see 33A, Rear axle components,

Rear brake pads: Removal - Refitting, page 33A-
3) ,

- the rear wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Apply the after repair procedure using the diagnostic
tool:

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- deactivate the maintenance mode.

a

137993

WITHOUT AUTOMATIC PARKING BRAKE

ELECTRONIC PARKING BRAKE

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

20

REAR AXLE COMPONENTS

Rear brake disc: Removal - Refitting

33A

Brake discs cannot be reground. If there is excessive
scoring or wear, they will need to be replaced (see
30A, General information, Brake: Specifications,
page 30A-16) .

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the rear brake pads (see 33A, Rear axle compo-

nents, Rear brake pads: Removal - Refitting,
page 33A-3) .

a

Remove the brake calliper mounting (see 33A, Rear
axle components, Rear brake calliper mounting:
Removal - Refitting, page 33A-17) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the hub's nut cover (1) .

a

Remove:

- the nut (2) from the hub,

- the brake disc.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean the brake discs using a parts washer.

Essential equipment

parts washer

Tightening torques

m

hub nut

220 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

135433

135440

33A

-

21

REAR AXLE COMPONENTS

Rear brake disc: Removal - Refitting

33A

a

Dry the disc surfaces.

a

Clean the stub axle using a wire brush and BRAKE
CLEANER (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Pro-
ducts).

a

Always replace the hub nut.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the brake disc.

a

Torque tighten the hub nut (220 N.m).

a

Refit the hub nut cover.

III - FINAL OPERATION

a

Refit:

- the calliper mounting (see 33A, Rear axle compo-

nents, Rear brake calliper mounting: Removal -
Refitting, page 33A-17) ,

- the rear brake pads (see 33A, Rear axle compo-

nents, Rear brake pads: Removal - Refitting,
page 33A-3) ,

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

22

REAR AXLE COMPONENTS

Rear brake disc: Description

33A

I - PREPARATION OPERATION FOR CHECK

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

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

II - CHECKING OPERATION FOR PART
CONCERNED

Position the Palmer tool (1) to measure the disc thic-
kness.

Measure the thickness of the disc at 4 points in order
(90˚ apart).

Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-16) .

III - FINAL OPERATION

Replace the discs if necessary (see 33A, Rear axle
components, Rear brake disc: Removal - Refitting,
page 33A-20) .

Refit the rear wheel concerned (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .

Note:

Use a Palmer type tool to check the thickness of the
disc.

117058

99582

33A

-

23

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

B95 or D95

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the rear axle guard clips,

- the rear axle guard bolts,

- the rear axle guard.

a

Remove the emergency spare wheel cover (1) .

a

Remove the luggage compartment carpet.

a

Remove the emergency spare wheel compartment
(2) .

Essential equipment

component jack

diagnostic tool

Tightening torques

m

the shock absorber nut

105 N.m

shock absorber bolt

62 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle.

WARNING

To prevent the components of the rear axle from
deteriorating (rubber bushes, brake hoses, etc.) do
not remove the two shock absorbers at the same
time. Proceed one side at a time.

B95, and UTILITY

138183

B95, and STANDARD

138184

33A

-

24

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

B95 or D95

33A

a

Remove:

- the nut (3) from the ball joint of the headlight beam

adjustment rear sensor linkage,

- the ball joint (4) of the headlight beam adjustment

rear sensor linkage from its mounting.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the shock absorber bolt (5) on the body.

a

Fit a component jack under the lower suspension
spring cup.

a

Remove the shock absorber nut (6) on the rear axle.

a

Move the shock absorber away from the rear axle.

a

Remove:

- the component jack,

- the shock absorber bolt on the body,

XENON BULBS

135402

134346

135438

33A

-

25

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

B95 or D95

33A

- the shock absorber.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Always replace:

- the shock absorber lower nut,

- the shock absorber upper bolt.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the shock absorber head on the body.

a

Fit without tightening the shock absorber upper bolt.

a

Fit a component jack under the shock absorber
spring cup.

a

Use the component jack to adjust the dimension (X)
to 432.5 mm.

a

Torque tighten the shock absorber nut (105 N.m).

a

Remove the workshop jack.

a

Torque tighten the shock absorber bolt (62 N.m).

a

Repeat these operations on the shock absorber on
the opposite side.

III - FINAL OPERATION

a

Refit the ball joint of the headlight beam adjustment
rear sensor linkage on its mounting.

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select « Headlight adjustment computer » ,

- go to repair mode,

106178

Note:

The vehicle must be in the « half-empty - load »
position when tightening the rubber bushes on
the shock absorbers (shock absorber length of
432.5 mm).

XENON BULBS

33A

-

26

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

B95 or D95

33A

- apply the « before/after repair procedure » for the

computer selected,

- select « Headlight beam adjustment rear sensor »

in the « List of components controlled by this
computer » section,

- carry out the operations described in the « After re-

pair procedure » section.

a

Refit the emergency spare wheel compartment.

a

Refit the luggage compartment carpet.

a

Refit the emergency spare wheel cover.

a

Refit:

- the rear axle guard,

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

B95, and STANDARD

B95, and UTILITY

33A

-

27

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

J95, and LONG CHASSIS, and 2 SEATS 3RD ROW

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Activate the tilt system to raise the third row rear
seat.

a

Align the holes in the frame on the third row seat.

a

Lock the hinge of the third row seat using a roll pin
punch in the frame holes.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the shock absorber bolt (1) on the body.

Essential equipment

roll pin punch

component jack

diagnostic tool

Tightening torques

m

the shock absorber nut

105 N.m

shock absorber bolt

62 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle.

WARNING

To prevent the components of the rear axle from
deteriorating (rubber bushes, brake hoses, etc.) do
not remove the two shock absorbers at the same
time. Proceed one side at a time.

138741

138753

33A

-

28

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

J95, and LONG CHASSIS, and 2 SEATS 3RD ROW

33A

a

Remove:

- the nut (2) from the ball joint of the headlight beam

adjustment rear sensor linkage,

- the ball joint (3) of the headlight beam adjustment

rear sensor linkage from its mounting.

a

Remove:

- the rear axle guard clips (4) ,

- the rear axle guard bolts (5) ,

- the rear axle guard.

a

Fit a component jack under the lower suspension
spring cup.

a

Remove the nut (6) from the rear axle shock absor-
ber.

XENON BULBS

135402

137155

138740

33A

-

29

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

J95, and LONG CHASSIS, and 2 SEATS 3RD ROW

33A

a

Move the shock absorber away from the rear axle.

a

Remove:

- the component jack,

- the shock absorber bolt on the body,

- the shock absorber.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Always replace:

- the shock absorber lower nut,

- the shock absorber upper bolt.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the shock absorber head on the body.

a

Fit without tightening the shock absorber upper bolt.

a

Fit a component jack under the shock absorber
spring cup.

a

Use the component jack to adjust the dimension (X)
to 432.5 mm.

a

Torque tighten the shock absorber nut (105 N.m).

a

Remove the workshop jack.

a

Torque tighten the shock absorber bolt (62 N.m).

a

Refit the ball joint of the headlight beam adjustment
rear sensor linkage on its mounting.

a

Refit the rear axle guard.

a

Repeat these operations on the shock absorber on
the opposite side.

106178

Note:

The vehicle must be in the « half-empty - load »
position when tightening the rubber bushes on
the shock absorbers (shock absorber length of
432.5 mm).

XENON BULBS

33A

-

30

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

J95, and LONG CHASSIS, and 2 SEATS 3RD ROW

33A

III - FINAL OPERATION

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select « Headlight adjustment computer » ,

- go to repair mode,

- apply the « before/after repair procedure » for the

computer selected,

- select « Headlight beam adjustment rear sensor »

in the « List of components controlled by this
computer » section,

- carry out the operations described in the « After re-

pair procedure » section.

a

Remove the roll pin punch from the third row seat
frame.

a

Refit the third row seat.

XENON BULBS

33A

-

31

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

J95, and LONG CHASSIS, and 0 SEAT 3RD ROW

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the luggage compartment carpet.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Undo the shock absorber bolt (1) on the body.

a

Remove:

- the nut (2) from the ball joint of the headlight beam

adjustment rear sensor linkage,

Essential equipment

component jack

diagnostic tool

Tightening torques

m

the shock absorber nut

105 N.m

shock absorber bolt

62 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle.

WARNING

To prevent the components of the rear axle from
deteriorating (rubber bushes, brake hoses, etc.) do
not remove the two shock absorbers at the same
time. Proceed one side at a time.

138752

XENON BULBS

135402

33A

-

32

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

J95, and LONG CHASSIS, and 0 SEAT 3RD ROW

33A

- the ball joint (3) of the headlight beam adjustment

rear sensor linkage from its mounting.

a

Remove:

- the rear axle guard clips (4) ,

- the rear axle guard bolts (5) ,

- the rear axle guard.

a

Fit a component jack under the lower suspension
spring cup.

a

Remove the shock absorber nut (6) on the rear axle.

a

Move the shock absorber away from the rear axle.

a

Remove:

- the component jack,

- the shock absorber bolt on the body,

- the shock absorber.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Always replace:

- the shock absorber lower nut,

- the shock absorber upper bolt.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the shock absorber head on the body.

a

Fit without tightening the shock absorber upper bolt.

137155

138740

33A

-

33

REAR AXLE COMPONENTS

Shock absorber: Removal - Refitting

J95, and LONG CHASSIS, and 0 SEAT 3RD ROW

33A

a

Fit a component jack under the shock absorber
spring cup.

a

Use the component jack to adjust the dimension (X)
to 432.5 mm.

a

Torque tighten the shock absorber nut (105 N.m).

a

Remove the workshop jack.

a

Torque tighten the shock absorber bolt (62 N.m).

a

Refit the ball joint of the headlight beam adjustment
rear sensor linkage on its mounting.

a

Repeat these operations on the shock absorber on
the opposite side.

III - FINAL OPERATION

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select « Headlight adjustment computer » ,

- go to repair mode,

- apply the « before/after repair procedure » for the

computer selected,

- select « Headlight beam adjustment rear sensor »

in the « List of components controlled by this
computer » section,

- carry out the operations described in the « After re-

pair procedure » section.

a

Refit:

- the rear axle guard,

- the luggage compartment carpet.

106178

Note:

The vehicle must be in the « half-empty - load »
position when tightening the rubber bushes on
the shock absorbers (shock absorber length of
432.5 mm).

XENON BULBS

XENON BULBS

33A

-

34

REAR AXLE COMPONENTS

Rear suspension spring: Removal - Refitting

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the rear wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

a

Remove:

- the rear axle guard clips (1) ,

- the rear axle guard bolts (2) ,

- the rear axle guard.

a

Remove:

- the luggage compartment carpet,

- the emergency spare wheel compartment.

a

Undo the shock absorber bolt (3) on the body.

Essential equipment

component jack

Tightening torques

m

the shock absorber nut

105 N.m

shock absorber bolt

62 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

To prevent the components of the rear axle from
deteriorating (rubber bushes, brake hoses, etc.) do
not remove the two shock absorbers at the same
time. Proceed one side at a time.

137155

134346

33A

-

35

REAR AXLE COMPONENTS

Rear suspension spring: Removal - Refitting

33A

a

Fit a component jack under the lower suspension
spring cup.

a

Remove the shock absorber nut (4) on the rear axle.

a

Move the shock absorber away from the rear axle.

a

Remove the workshop jack.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Mark the position of the lower spring support on the
rear axle.

135438

134354

Note:

The mark must be positioned towards back of the
vehicle.

33A

-

36

REAR AXLE COMPONENTS

Rear suspension spring: Removal - Refitting

33A

a

Remove the left spring with its lower support.

REFITTING

I - REFITTING PREPARATION OPERATION

a

The lower shock absorber nut must always be repla-
ced.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the lower support on the spring,

- the spring in their housing.

III - FINAL OPERATION

a

Fit a component jack under the shock absorber
spring cup.

a

Use the component jack to adjust the dimension (X)
to 432.5 mm.

a

Torque tighten the shock absorber nut (105 N.m).

a

Remove the workshop jack.

a

Torque tighten the shock absorber bolt (62 N.m).

a

Refit:

- the emergency spare wheel compartment,

- the luggage compartment carpet,

- the rear axle guard,

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

101307

Note:

If the upper support is unclipped, replace it with a
new one.

106178

Note:

The vehicle must be in the « half-empty - load »
position when tightening the rubber bushes on
the shock absorbers (shock absorber length of
432.5 mm).

33A

-

37

REAR AXLE COMPONENTS

Rear stub-axle carrier: Removal - Refitting

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the rear wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the brake pads (see 33A, Rear axle components,

Rear brake pads: Removal - Refitting, page 33A-
3) ,

- the brake calliper mounting (see 33A, Rear axle

components, Rear brake calliper mounting: Re-
moval - Refitting, page 33A-17) ,

- the brake disc (see 33A, Rear axle components,

Rear brake disc: Removal - Refitting, page 33A-
20) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the wheel speed sensor (1) from the sensor
holder.

a

Remove:

- the bolts (2) of the rear stub axle carrier,

- the rear stub axle carrier.

Tightening torques

m

bolts of the rear stub
axle carrier

185 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

135421

135439

33A

-

38

REAR AXLE COMPONENTS

Rear stub-axle carrier: Removal - Refitting

33A

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean the stub axle using a wire brush and BRAKE
CLEANER (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Pro-
ducts).

a

parts always to be replaced: Rear brake calliper
mounting bolt (13,03,04,11).

a

Always replace the bolts of the rear stub axle carrier.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the rear stub axle carrier.

a

Torque tighten the bolts of the rear stub axle car-
rier (185 N.m).

a

Refit the wheel speed sensor.

III - FINAL OPERATION

a

Refit:

- the brake disc (see 33A, Rear axle components,

Rear brake disc: Removal - Refitting, page 33A-
20) ,

- the brake calliper mounting (see 33A, Rear axle

components, Rear brake calliper mounting: Re-
moval - Refitting, page 33A-17) ,

- the brake pads (see 33A, Rear axle components,

Rear brake pads: Removal - Refitting, page 33A-
3) ,

- the rear wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

IMPORTANT

To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

33A

-

39

REAR AXLE COMPONENTS

Rear axle rubber bearing: Removal - Refitting

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the rear axle (see 33A, Rear axle components,

Complete rear axle: Removal - Refitting, page
33A-41) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Make a mark (1) on the rear axle which is aligned
with the coloured mark of the rubber bearing.

a

Remove the rubber bushes (2) by hitting them with a
hammer and the bush castor of the tool (Tar. 1838)
(3) .

Essential special tooling

Tar. 1838

Tool for removing and refit-
ting rear axle rubber bushes

Tightening torques

m

the cover nut

16 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

134351

134348

33A

-

40

REAR AXLE COMPONENTS

Rear axle rubber bearing: Removal - Refitting

33A

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Rear axle flexible
bearing (13,02,05,12).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Position the rubber bush so as to align the paint
marks of the new rubber bush and the mark made
previously on the rear axle.

a

Fit:

- the covers of the tool (Tar. 1838) (4) ,

- the threaded rod of the tool (Tar. 1838) (5) ,

- the washer of the tool (Tar. 1838) (6) ,

- the nut of the tool (Tar. 1838) (7) .

a

Tighten the rod (8) of the tool (Tar. 1838) until the
cover comes into contact with the rear axle.

a

Check that the marks are always aligned at (9) .

a

Torque tighten the cover nut (16 N.m).

a

Remove the tool (Tar. 1838).

III - FINAL OPERATION

a

Refit:

- the rear axle (see 33A, Rear axle components,

Complete rear axle: Removal - Refitting, page
33A-41) ,

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

134349

134350

33A

-

41

REAR AXLE COMPONENTS

Complete rear axle: Removal - Refitting

33A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Fit the pedal press to the brake pedal to limit the
outflow of brake fluid.

a

Remove:

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the rear axle guard bolts,

- the rear axle guard clips,

- the rear axle guard.

a

Unclip the parking brake cables on the callipers.

a

Apply the before repair procedure using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- activate the maintenance mode.

a

Disconnect the parking brake connectors.

a

Remove the wiring from the electronic parking bra-
ke.

a

Fit the component jack under the rear axle.

a

Undo the brake hose unions at (1) .

Essential equipment

pedal press

diagnostic tool

component jack

safety strap(s)

Tightening torques

m

rubber bearing bolts

125 N.m

brake hose unions

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page
33A-1) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

WITHOUT AUTOMATIC PARKING BRAKE

WARNING

To avoid damaging the parking brake cable pro-
tectors and causing premature wear of the sys-
tem, do not handle the cables with a tool.

ELECTRONIC PARKING BRAKE

134343

33A

-

42

REAR AXLE COMPONENTS

Complete rear axle: Removal - Refitting

33A

a

Remove the nut from the linkage ball joint (2) of the
headlight beam adjustment rear sensor.

a

Disconnect the connectors from the wheel speed
sensors (3) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the rear shock absorbers (see 33A, Rear axle

components, Shock absorber: Removal - Refit-
ting, page 33A-23) ,

- the rear suspension springs (see 33A, Rear axle

components, Rear suspension spring: Remo-
val - Refitting, page 33A-34) .

a

Loosen the rubber bearing bolts (4) .

a

Attach the rear axle to the component jack using a
safety strap(s).

a

Remove:

- the rubber bearing studs,

- the rear axle.

XENON BULBS

135402

134471

134347

137125

33A

-

43

REAR AXLE COMPONENTS

Complete rear axle: Removal - Refitting

33A

III - DISMANTLING

a

Remove:

- the brake pipes,

- the wheel speed sensors (see 38C, Anti-lock bra-

king system, Rear wheel speed sensor: Remo-
val - Refitting, page 38C-17) ,

- the clips of the brake pipes and of the wheel speed

sensor wiring,

- the brake pads (see 33A, Rear axle components,

Rear brake pads: Removal - Refitting, page 33A-
3) ,

- the brake callipers (see 33A, Rear axle compo-

nents, Rear brake caliper: Removal - Refitting,
page 33A-11) ,

- the brake calliper mountings (see 33A, Rear axle

components, Rear brake calliper mounting: Re-
moval - Refitting, page 33A-17) ,

- the brake discs (see 33A, Rear axle components,

Rear brake disc: Removal - Refitting, page 33A-
20) ,

- the stub axle carriers (see 33A, Rear axle compo-

nents, Rear stub-axle carrier: Removal - Refit-
ting, page 33A-37) .

REFITTING

I - REFITTING PREPARATION OPERATION

a

Always replace the rubber bearing bolts.

II - REBUILDING

a

Refit:

- the stub axle carriers (see 33A, Rear axle compo-

nents, Rear stub-axle carrier: Removal - Refit-
ting, page 33A-37) ,

- the brake discs (see 33A, Rear axle components,

Rear brake disc: Removal - Refitting, page 33A-
20) ,

125484

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surroun-

ding components.

33A

-

44

REAR AXLE COMPONENTS

Complete rear axle: Removal - Refitting

33A

- the brake calliper mountings (see 33A, Rear axle

components, Rear brake calliper mounting: Re-
moval - Refitting, page 33A-17) ,

- the brake pads (see 33A, Rear axle components,

Rear brake pads: Removal - Refitting, page 33A-
3) ,

- the brake callipers (see 33A, Rear axle compo-

nents, Rear brake caliper: Removal - Refitting,
page 33A-11) ,

- the clips of the brake pipes and of the wheel speed

sensor wiring,

- the wheel speed sensors (see 38C, Anti-lock bra-

king system, Rear wheel speed sensor: Remo-
val - Refitting, page 38C-17) ,

- the brake pipes.

III - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the rear axle on a component jack.

a

Attach the rear axle to the component jack using a
safety strap(s).

a

Refit the rear axle onto the vehicle.

a

Torque tighten the rubber bearing bolts (125 N.m).

a

Refit:

- the rear shock absorbers (see 33A, Rear axle

components, Shock absorber: Removal - Refit-
ting, page 33A-23) ,

- the rear suspension springs (see 33A, Rear axle

components, Rear suspension spring: Remo-
val - Refitting, page 33A-34) .

IV - FINAL OPERATION

a

Refit the headlight beam adjustment rear sensor lin-
kage.

a

Clip on the parking brake cables.

a

Connect the parking brake connectors.

a

Apply the after repair procedure using the diagnostic
tool:

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- deactivate the maintenance mode.

a

Clip the parking brake cables onto the brake calli-
pers.

a

Refit the brake hose unions.

a

Torque tighten the brake hose unions (13 N.m).

a

Connect the connectors for the wheel speed sen-
sors.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit:

- the rear axle guard,

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

Note:

These operations require two people.

XENON BULBS

ELECTRONIC PARKING BRAKE

WITHOUT AUTOMATIC PARKING BRAKE

35A

-

1

WHEELS AND TYRES

Wheel: Removal - Refitting

35A

The removal - refitting procedure is the same for alloy
and steel wheels.

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Release the parking brake.

a

Remove the trim.

a

Position the wheel so that the valve is at the top.

a

Mark the position of the wheel on the hub.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Loosen the wheel bolts with the wheel on the
ground.

a

Raise the lift.

a

Remove:

- the wheel bolts,

- the wheel.

If the wheel cannot be removed after the bolt has
been undone:

a

Position all the wheel bolts.

a

Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.

a

Undo the wheel bolts by one turn.

a

Strike around the edge of the tyre walls (1) several
times using a mallet on the inner and outer surfaces
of the wheel to detach the wheel.

a

Remove:

- the wheel bolts,

- the wheel.

Tightening torques

m

wheel bolts

110 Nm

Note:

This mark is necessary for:

- marking the initial position of the wheel rim on

the hub,

- perform the balancing operation.

Note:

Use sockets with protective sheaths in order to
avoid scratching the alloy wheel rims.

100682

35A

-

2

WHEELS AND TYRES

Wheel: Removal - Refitting

35A

If this procedure does not work:

a

Strike the inner surface of the wheel (2) using a mal-
let and a wooden block to detach it.

a

Remove:

- the wheel bolts,

- the wheel.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Clean the hub carrier using a wire brush.

a

Check the condition of the tyre.

a

Do not move or remove the balance weights.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Clean the "wheel - hub carrier" contact surfaces
using a wire brush.

a

Coat the wheel-mating face (3) with COPPER ANTI-
SEIZE AGENT (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
Products).

a

Align the mark on the wheel with the mark made on
the hub when it was removed.

a

Fit the wheel to the vehicle, positioning the valve at
the top.

a

Insert the wheel bolts.

a

Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.

106089

Note:

Do not strike the surface of the wheel using
excessive force as this may damage it.

Note:

There are two types of wheel bolts for aluminium
and steel wheel rims; do not swap them.

124750

100682

35A

-

3

WHEELS AND TYRES

Wheel: Removal - Refitting

35A

a

Pre-tighten the wheel bolts to 30 Nm, with the wheel
hanging, starting with the bottom bolts.

a

Rotate the wheel through 180˚ to bring the valve into
the bottom position.

a

Position the vehicle on its wheels.

a

Torque tighten in order the wheel bolts (110 Nm).

a

Refit the trim piece.

35A

-

4

WHEELS AND TYRES

Wheel: Balancing

35A

I - PREREQUISITES FOR WHEEL BALANCING

a

Wheel balancing is a measurement operation.

Several conditions must be met to achieve a reliable
result in a single operation.

The wheel balancer must be installed in accordance
with the manufacturer's instructions.

It is essential to calibrate the balancer according to
the frequency recommended by the manufacturer.

Do not grease the threaded shaft.

Check the condition of the supports, centring com-
ponents and mountings.

Replace any faulty parts (see manufacturer's ins-
tructions).

The wheel and the wheel balancer must be clean.

Driver's perception

a

If the wheels are not correctly balanced this causes
the steering wheel and/or the vehicle floor to vibrate.

These vibrations appear between 54 mph (90 km/h)
and 90 mph (150 km/h).

II - BALANCING PREPARATION OPERATION

a

Adjust the tyre pressure (see 35A, Wheels and ty-
res, Tyre inflation pressure: Identification, page
35A-14) .

a

Always carry out a road test for a minimum distance
of 1 mile (2 km) before balancing the wheels, in or-
der to remove any flat spots on the tread caused by
the vehicle being immobilised.

a

Actions to be carried out immediately after the test
drive:

- Position the vehicle on a two-post vehicle lift (see

Vehicle: Towing and lifting) ,

- raise the vehicle,

- leave the four wheels hanging free,

- release the parking brake.

a

To reproduce the exact vehicle wheel assembly, use
a ring (1) of diameter:

a

66 mm

a

There are three types of weight:

105870

Note:

The ring is available from the supplier of the
equipment used.

35A

-

5

WHEELS AND TYRES

Wheel: Balancing

35A

a

In some countries, the use of lead weights is forbid-
den; in this case it is recommended to use ZAMAK
weights instead.

Only use weights provided by the Parts Department.

a

a

Remove the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Always clean the wheel, disc, and hub bearing surfa-
ces.

III - PROCEDURE FOR BALANCING THE WHEEL IN
QUESTION

a

Make sure that the wheel balancer bearing surface
and all the centring equipment (ring, thrust plate,
etc.) are kept clean.

a

Try not to scratch the (alloy) wheel rim with the
wheel tightening device.

a

The wheel is fitted on the wheel balancer as follows:

- (5) ring,

- (6) wheel balancer back-plate,

- (7) wheel tightening device (certain alloy wheels

require a device 200 mm in diameter to ensure that
the wheel has been correctly tightened),

- (8) outer wheel plane,

- (9) wheel.

a

Place the wheel on the wheel balancer, with the val-
ve at the top, then lock the wheel in place.

a

Remove any stones trapped in the tyre tread.

113742

(2)

Steel wheel with flange

(3)

Alloy wheel with flange

(4)

Alloy wheel without flange

Note:

Only use bonded weights with a maximum thic-
kness of 4.5 mm.

105871

100681

35A

-

6

WHEELS AND TYRES

Wheel: Balancing

35A

a

Enter the specific wheel parameters when starting
the wheel balancer.

a

Start the wheel balancer and check the wheel balan-
ce, which should be 0 g on each plane of the wheel.

a

If this is not the case, remove the old wheel balan-
cing weights and repeat the wheel balancing proce-
dure, checking that the wheel balance equals 0 on
each wheel plane.

IV - FINAL OPERATION

a

Refit the wheel (see 3 5 A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

WARNING

To avoid detachment of the balance weights, use
only weights which correspond to the vehicle
wheel rims.

35A

-

7

WHEELS AND TYRES

pneumatic: Precautions for repair

35A

I - CLEANLINESS

Clean:

- the tyre bead,

- the tyre bead/wheel rim contact surface.

Remove any grit trapped in the tyre treads.

Clean the bearing surfaces on:

- the wheels,

- the discs,

- the hubs.

II - GENERAL RECOMMENDATIONS

WARNING

If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.

WARNING

In order to remove any flat spots on the tread after
the vehicle has stopped, it is essential to carry out a
road test for a minimum distance of 1 mile (2 km)
before balancing the wheels.

WARNING

To avoid detachment of the balance weights, use
only weights which correspond to the vehicle wheel
rims

35A

-

8

WHEELS AND TYRES

Tyres: Identification

35A

Example of a tyre identification mark: 205/65 R 15 91
V.

Speed code table:

101008

123448

205

Tyre width in mm (L)

65

Height/width ratio

R

Radial structure

15

Internal diameter in inches (c)

91

Load index

V

Speed code

Code

Maximum
s p e e d i n
mph (km/h)

R

170

S

180

T

190

U

200

H

210

V

240

ZR

above 240

W

270

Y

300

35A

-

9

WHEELS AND TYRES

Tyres: Removal - Refitting

35A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

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

Wheel: Removal - Refitting, page 35A-1) ,

- the balance weights,

- the valve mechanism.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

a

Detach:

- the bead from the outside of the tyre, starting with

the side opposite the valve,

- the bead from the inside of the tyre.

a

Position the tyre lever approximately 15 cm from the
valve on the outside of the wheel rim in order to re-
move the exterior bead from the tyre.

a

Remove the exterior bead of the tyre, finishing at the
valve.

a

Position the tyre lever approximately 15 cm from the
valve on the outside of the wheel rim in order to re-
move the bead from inside the tyre.

a

Remove the interior bead of the tyre, finishing at the
valve.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Tyre valve (13,05,
02,02)

a

Lubricate the two tyre beads correctly using the
TYRE PASTE (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
Products).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Engage the lower tyre bead approximately 15 cm af-
ter the valve.

TYRE PRESSURE SENS.

WARNING

To avoid any damage to the sensor, make sure
the tyre bead never presses on the sensor.

18884

18885

WITHOUT TYRE PRESSURE SENS.

35A

-

10

WHEELS AND TYRES

Tyres: Removal - Refitting

35A

a

Finish fitting the tyre at the valve.

a

Fit the exterior bead approximately 15 cm after the
valve using the tyre lever.

a

Inflate the tyre to 3.5 bar to press the tyre beads
against the wheel rim.

III - FINAL OPERATION

a

Refit the valve mechanism.

a

Inflate the tyre to the recommended pressure (see
35A, Wheels and tyres, Tyre inflation pressure:
Identification, page 35A-14) .

a

Balance the wheel (see 35A, Wheels and tyres,
Wheel: Balancing, page 35A-4) .

a

Refit the wheel in question (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .

Note:

It is not necessary to drive the vehicle before and
after a new wheel is balanced.

35A

-

11

WHEELS AND TYRES

Tyres: Repair

35A

Perforation

There are two types of perforation:

- single perforation: perforation caused by nail etc. not

requiring a reinforced tyre boot and which can be re-
paired when the tyres are cold,

- damage: rubber detachment etc. requiring repair and

reinforcement of damaged plies.

This repair method only covers single perforations.

Tyre areas

Areas which cannot be repaired:

- tyre bead (1) ,

- shoulder (3) .

Areas which can be repaired:

- sidewall (2) ,

- crown (4) .

Perforation table *

LV: Light Vehicle

LCV: Light Commercial Vehicle

HGV: Heavy Goods Vehicle

* If the diameter of the puncture is greater than these fi-
gures, replace the tyre.

The tyre cannot be repaired if:

- a compulsory marking has been worn away (see 35A,

Wheels and tyres, Tyres: Identification, page 35A-
8) ,

- the interior of the tyre shows signs of under-inflation

or overloading,

- the rubber shows signs of chemical damage (hydro-

carbons and other corrosive substances),

- incorrect and irreversible repairs have previously

been made to the tyre,

- the carcass has been damaged,

- cuts or circumferential wear (cracks) are visible on the

interior or exterior of the tyre,

- the tyre bead has been damaged (ply visible),

- the tyre's bead wires are visible, damaged or defor-

med,

- the tyre shows an irregular wear pattern which may

impair vehicle handling,

- the repair requires two tyre boots to be overlapped,

- the manufacturer has expressly prohibited any re-

pairs, in writing,

- there is damage to the shoulder area (junction

between the sidewall and the crown),

- the angle of the perforation channel (hole) is greater

than 15˚.

123449

Area

Crown: max
Ø in mm

Sidewall:
max Ø in
mm

LV speed rating
less than or equal
to T

6

3

LV speed rating
greater than or
equal to H

6

0

LCV load index less
than or equal to
121

6

3

HGV load index
122 to 177 (inc.)

10

3

35A

-

12

WHEELS AND TYRES

Tyres: Repair

35A

Tyre inflation kit

using the tyre inflation kit, supplied with vehicles or
available from retailers, will leave a film on the inner
surface of the tyre.

Before carrying out the repair, clean the inner surface
of the tyre and the valve with water.

If the tyre cannot be cleaned in this way, contact the
tyre supplier for details of cleaning products which can
be used.

REPAIR

I - REPAIR PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Inflate the tyre.

a

Locate the perforation on the exterior of the tyre and
mark it with chalk.

a

Remove the tyre.

a

Locate the perforation on the interior of the tyre and
mark it with chalk.

a

Remove the foreign body which caused the punctu-
re.

a

Determine the direction of the perforation channel.

a

Determine the size of the hole:

- measure the size of the foreign body,

- measure the extent of the damage to the tyre.

a

Choose the size of plug (mushroom type plug) de-
pending on the size of the hole.

II - REPAIR OPERATION

a

Use a drill fitted with a suitable bit, perpendicular to
the surface of the tyre, to bore the interior then the
exterior of the perforation channel.

119741

119740

119742

35A

-

13

WHEELS AND TYRES

Tyres: Repair

35A

a

Carefully scrape the rubber seal around the perfora-
tion, to the size of the base of the plug (mushroom
type plug).

a

Remove any dust and remaining particles of rubber
using a clean, dry cloth.

a

Apply the solution to the scraped surface.

a

Fit the (mushroom type) plug via the interior of the
tyre by pulling on it using pliers.

a

Press gently on the base of the mushroom plug, in-
side the tyre.

a

Refit the tyre.

a

Inflate the tyre (see 35A, Wheels and tyres, Tyre
inflation pressure: Identification, page 35A-14) .

a

Cut the protruding end of the stalk without pulling on
it.

a

Check the tyre seal.

III - FINAL OPERATION.

a

Balance the wheel (see 35A, Wheels and tyres,
Wheel: Balancing, page 35A-4) .

a

Refit the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

119743

Note:

If the rubber seal is damaged during this opera-
tion, replace the tyre.

119744

Note:

Respect the required drying time for the solution.

119746

119747

35A

-

14

WHEELS AND TYRES

Tyre inflation pressure: Identification

35A

I - INFLATION

WARNING

If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.

B95, and STANDARD – D95, and EQT LEVEL EA1
or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4

Engine

Tyre

Tyre inflation pressure when cold (bar)

Front

Rear

Emergency
spare wheel

Normal

Motorway

Normal

Motorway

K4M

195/65 R15 91H

2.3

2.4

2.0

2.2

2.3

205/55 R16 91H

2.3

2.4

2.0

2.2

2.3

205/50 R17 89V

2.3

2.6

2.0

2.3

2.3

M4R

195/65 R15 91H

2.3

2.4

2.0

2.2

2.3

205/55 R16 91H

2.3

2.4

2.0

2.2

2.3

205/50 R 17 89V

2.3

2.6

2.0

2.3

2.3

K9K

195/65 R15 91T

2.3

2.4

2.0

2.2

2.3

205/55 R16 91H

2.3

2.4

2.0

2.2

2.3

205/50 R17 89V

2.3

2.6

2.0

2.3

2.3

F9Q

205/55 R16 91H

2.3

2.4

2.0

2.2

2.3

205/50 R17 89V

2.3

2.6

2.0

2.3

2.3

F4R

225/45 R17 94V

2.3

2.6

2.0

2.3

2.3

H4J

195/65 R15 91H

2.3

2.4

2.0

2.2

2.3

205/55 R16 91H

2.3

2.4

2.0

2.2

2.3

205/50 R17 89V

2.3

2.6

2.0

2.3

2.3

H4M

195/65 R15 91H

2.3

2.4

2.0

2.2

2.3

205/55 R16 91H

2.3

2.4

2.0

2.2

2.3

205/50 R17 89V

2.3

2.6

2.0

2.3

2.3

M9R

225/45 R17 94V

2.3

2.6

2.0

2.3

2.3

B95, and UTILITY

Engine

Tyre

Tyre inflation pressure when cold (bar)

Front

Rear

Emergency
spare wheel

Normal

Motorway

Normal

Motorway

35A

-

15

WHEELS AND TYRES

Tyre inflation pressure: Identification

35A

K9K

195/65 R15 91T

2.3

2.4

2.4

2.4

2.4

205/55 R16 91H

2.3

2.4

2.4

2.4

2.4

J95

Engine

Tyre

Tyre inflation pressure when cold (bar)

Front

Rear

Emergency
spare wheel

Normal

Motorway

Normal

Motorway

K4M

195/65 R15 91T

2.4

2.6

2.3

2.6

2.4

205/55 R16 91H

2.4

2.6

2.3

2.6

2.4

205/60 R16 96H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

K9K

195/65 R15 91T

2.4

2.6

2.3

2.6

2.4

205/55 R16 91H

2.4

2.6

2.3

2.6

2.4

205/60 R16 96H

2.4

2.6

2.3

2.6

2.4

205/60 R16 92H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

H4M

205/60 R16 92H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

205/60 R16 96H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

H4J

205/60 R16 92H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

205/60 R16 96H

2.4

2.6

2.3

2.6

2.4

M4R

205/60 R16 92H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

205/60 R16 96H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

F9Q

205/60 R16 92H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

205/60 R16 96H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

35A

-

16

WHEELS AND TYRES

Tyre inflation pressure: Identification

35A

Maximum wheel rim run-out checked on the external
diameter of the rim:

- alloy wheel rim: 0.3 mm,

- steel wheel rim: 0.8 mm.

Maximum runout checked on the surface of the wheel
rim:

- alloy wheel rim: 0.3 mm,

- steel wheel rim: 0.7 mm.

Wheel offset:

- 15-inch wheels: 43 mm,

- 16-inch wheels: 47 mm,

- 17-inch wheels: 49 mm,

- 18-inch wheels: 65 mm,

- 19-inch wheels: 65 mm.

II - SPECIAL NOTES ON VEHICLES FITTED WITH
THE TYRE PRESSURE MONITORING SYSTEM

When assembling a set of "winter" tyres, if the pro-
gramming has already been carried out, the "summer"
or "winter" mode is automatically detected.

H4Jt

205/60 R16 96H

2.4

2.6

2.3

2.6

2.4

205/55 R17 95H

2.4

2.6

2.3

2.6

2.4

F4R

225/50 R17 98V

2.4

2.6

2.3

2.6

2.4

M9R

225/50 R17 98V

2.4

2.6

2.3

2.6

2.4

D95, and EQT LEVEL SPORT

Engine

Tyre

Tyre inflation pressure when cold (bar)

Front

Rear

Emergency
spare wheel

Normal

Motorway

Normal

Motorway

F4R

225/40 R18 92Y

2.3

2.6

1.7

2.0

2.4

235/40 R18 95Y

2.1

2.3

1.5

2.0

2.4

235/35 R19 91Y

2.4

2.6

1.8

2.0

2.4

35A

-

17

WHEELS AND TYRES

Wheel rim: Identification

35A

IDENTIFICATION

1 - Marking

There are two types of identification marking on the
wheel rims:

- engraved marking for steel wheel rims,

- cast marking for alloy wheel rims.

The marking gives the main dimensional specifications
of the wheel rim.

This marking may be:

- complete, for example 6 J 15 5 CH 36,

- simplified, for example 6 J 15.

There are 3 types of wheel rim edges (2) :

- those with two flat edges,

- those with two raised edges,

- those with one flat edge and one raised edge.

2 - Installation diameter for the wheel bolts

The wheel bolts are positioned with a pitch circle dia-
meter of 114.3 mm (5 holes).

3 - Rim run-out

The maximum run-out is measured at the wheel rim
edge (7) .

Steel wheel rims: 0.8 mm

Alloy wheel rims: 0.3 mm

4 - Out-of-roundness

The maximum out-of-round value is measured on the
tyre bead bearing surface.

Steel wheel rims: 0.7 mm

Alloy wheel rims: 0.3 mm

Wheel type

6 J 15

1

Width (in inches)

6

2

Rim edge profile

J

3

Nominal diameter (in inches)

15

4

Number of holes

5

5

Anchorage profile of the tyre

CH

6

Offset (in mm)

36

100988

35A

-

18

WHEELS AND TYRES

Spare wheel winch: Removal - Refitting

J95, and LONG CHASSIS, and 2 SEATS 3RD ROW

35A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Activate the swing system to raise the third row rear
right-hand seat.

a

Remove the blanking cover (1) .

a

Undo the pulley bolt (2) .

a

Press the emergency spare wheel lock (3) .

a

Rotate the emergency spare wheel lock a quarter of
a turn (4) .

a

Remove the emergency spare wheel.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

Tightening torques

m

nuts of the emergency
spare wheel winch

37 N.m

WARNING

Take care not to insert the tool between the unloc-
king mechanism and the screw head.

This could lead to the destruction of the emergency
spare wheel winch mechanism.

IMPORTANT

To remove the emergency wheel:

- do not work over a pit,

- do not lift the vehicle.

140460

WARNING

Do not use an air tool.

140459

141705

35A

-

19

WHEELS AND TYRES

Spare wheel winch: Removal - Refitting

J95, and LONG CHASSIS, and 2 SEATS 3RD ROW

35A

a

Remove:

- the nuts (5) of the emergency spare wheel winch,

- the emergency spare wheel winch.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the emergency spare wheel winch.

a

Torque tighten the nuts of the emergency spare
wheel winch (37 N.m).

II - FINAL OPERATION

a

Refit the emergency spare wheel.

a

Rotate the emergency spare wheel lock a quarter of
a turn (6) .

a

Tighten the pulley bolt.

a

Refit:

- the blanking cover,

- the third row rear right-hand seat.

140458

141704

WARNING

Do not use an air tool.

35B

-

1

TYRE PRESSURE MONITOR

SSPP: List and location of components

35B

The system consists of:

- four pressure sensors (1) built into the valves (one per

wheel); the sensors transmit a radiofrequency signal,

- a computer (2) which collects, decodes and proces-

ses sensor signals, and then determines which mes-
sage to display,

- a display (3) integrated to the instrument panel.

135457

(1) Pressure

sensor

137957

(2) UCH

136723

(3) Display

35B

-

2

TYRE PRESSURE MONITOR

SSPP: Precautions for repair

35B

I - CLEANLINESS

Clean the bearing faces on the tyre pressure monitor
valve.

II - GENERAL RECOMMENDATIONS

Do not swap the wheels if they have been removed.

WARNING

Hold the sensor in position on the wheel to prevent
it from turning during tightening.

WARNING

To avoid any damage to the sensor, make sure the
tyre bead never presses on the sensor.

35B

-

3

TYRE PRESSURE MONITOR

Pressure sensor: Removal - Refitting

TYRE PRESSURE SENS.

35B

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the wheels (see 35A, Wheels and tyres, Wheel:

Removal - Refitting, page 35A-1) ,

- the tyres (see 35A, Wheels and tyres, Tyres: Re-

moval - Refitting, page 35A-9) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the nut (1) whilst holding the pressure sensor on

the wheel rim,

- the pressure sensor (5) .

When replacing the valve only

a

Remove:

- the seal (2) ,

- the cup (3) .

Tightening torques

m

pressure sensor nut

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 35B, Tyre pressure monitor, SSPP:
Precautions for repair, page 35B-2) .

137979

(1) Retaining

nut

(2) Valve

seal

(3) Cup

(4) Valve

(5) Pressure

sensor

135457

137978

35B

-

4

TYRE PRESSURE MONITOR

Pressure sensor: Removal - Refitting

TYRE PRESSURE SENS.

35B

a

Disconnect the valve from the pressure sensor ac-
cording to the order of the arrows.

REFITTING

I - REFITTING PREPARATION OPERATION

1 - When replacing the valve only

a

Always replace the pressure sensor valve.

a

parts always to be replaced: tyre pressure moni-
tor valve seal (13,05,03,05).

2 - When replacing the pressure sensor

a

parts always to be replaced: Pressure sensor
(13,05,03,01).

a

parts always to be replaced: tyre pressure moni-
tor valve seal (13,05,03,05).

II - REFITTING OPERATION FOR PART
CONCERNED

1 - When replacing the valve only

a

Refit the new valve in accordance with the order of
the arrows.

2 - Refitting the pressure sensor

a

Refit:

- the cup (3) on the pressure sensor, ensuring that

the bevel of the cup is facing towards the bottom of
the wheel,

- the seal (2) on the cup by placing the conical face

on the wheel rim side,

- the pressure sensor on the wheel rim.

137976

137975

138081

35B

-

5

TYRE PRESSURE MONITOR

Pressure sensor: Removal - Refitting

TYRE PRESSURE SENS.

35B

a

Make sure that the sensor is correctly positioned on
the wheel rim:

- (1) : incorrectly fitted,

- (2) : correctly fitted.

a

Check that the cup is completely pressed around the
wheel hole.

a

Pretighten the nut of the pressure sensor while kee-
ping the sensor in contact on the bottom of the wheel
rim.

a

Torque tighten the pressure sensor nut (8 N.m).

III - FINAL OPERATION

a

Refit the tyres (see 35A, Wheels and tyres, Tyres:
Removal - Refitting, page 35A-9) .

a

Balance the wheels (see 35A, Wheels and tyres,
Wheel: Balancing, page 35A-4) .

a

Refit the wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

102242

36A

-

1

STEERING ASSEMBLY

Steering: List and location of components

36A

127570

(1) Track

rod

(2)

Axial ball joint linkage

(3) Steering

column

(4)

Steering box gaiter

(5) Steering column adjustment

lever

(6) Steering

wheel

36A

-

2

STEERING ASSEMBLY

Steering: Precautions for repair

36A

I - SAFETY

1 - Advice to be followed before any operation

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).

2 - Instruction to be followed during the operation

II - CLEANLINESS

1 - Advice to be followed before any operation

Use a cover to protect any chassis elements that may
be contaminated with power-assisted steering fluid.

2 - Instruction to be followed during the operation

Clean around the power-assisted steering system
using BRAKE CLEANER (see Vehicle: Parts and in-
gredients for the repairwork) (04B, Consumables -
Products).

III - GENERAL RECOMMENDATIONS

To ensure correct operation and performance of the
system, do not attempt to repair any components other
than those supplied in After-Sales.

To ensure the quality of the repair, only use the tooling
recommended by the manufacturer.

1 - Power assisted steering circuit:

a - Power-assisted steering fluid

Only use the fluid recommended by the manufacturer,
in order to ensure correct system performance (see
Vehicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products).

b - Blanking plugs

To prevent impurities from entering the power assisted
steering circuit, use blanking plugs on the various dis-
mantled parts.

2 - Seals

To ensure a sound power-assisted steering circuit
seal, replace the power-assisted steering pipe seals
each time a pipe is removed.

3 - Steering column

Do not rest the steering column on the adjustment han-
dle.

Do not handle the steering column by the adjustment
handle or by the wiring.

Manoeuvre the «

steering column - intermediate

shaft » assembly by holding each section (one hand on
the column and the other on the intermediate shaft). If
the steering column is not handled correctly, there is a
risk that the steering column or intermediate shaft
could fall, which could destroy the system.

Always replace the steering column if it is dropped or in
the event of an impact.

4 - Steering box

The steering box should not be carried by the gaiters or
pipes, as this may damage them.

When the vehicle is positioned with the wheels suspen-
ded, the steering rack must not be subjected to violent
movements from lock to lock.

Risks: Damage to the teeth of the steering rack and pi-
nion may cause a safety risk relating to the steering
unexpectedly locking.

5 - Axial ball joint

IMPORTANT

Wear protective gloves during the operation.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

WARNING

In order not to damage the steering wheel or stee-
ring column, the steering wheel-column foolproofing
devices must be aligned.

116991

36A

-

3

STEERING ASSEMBLY

Steering: Precautions for repair

36A

The axial ball joint limiters (1) are colour coded for fool-
proofing purposes. When removing or replacing the
axial ball joint, check that the limiter with the correct co-
lour code is refitted.

6 - Power-assisted steering pump

Do not run the engine without steering fluid in the cir-
cuit.

7 - Pump assembly

Do not run the engine without steering fluid in the cir-
cuit.

8 - Wiring harnesses

Ensure that the electrical wiring is clean and correctly
routed.

36A

-

4

STEERING ASSEMBLY

Steering rack: Removal - Refitting

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front axle subframe (see 31A, Front axle com-

ponents, Front axle sub-frame: Removal - Refit-
ting, page 31A-75) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the bulkhead seal (1) of the steering box.

a

Remove the bulkhead seal from the steering box.

a

Remove:

- the heat shield bolts from the steering box,

- the heat shield from the steering box,

- the steering box bolts (2) ,

- the steering box.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Steering rack bolt
(13,04,03,05).

Tightening torques

m

steering box bolts

180 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

134345

135320

36A

-

5

STEERING ASSEMBLY

Steering rack: Removal - Refitting

36A

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the steering box.

a

Torque tighten the steering box bolts (180 N.m).

a

Refit:

- the heat shield from the steering box,

- the bulkhead seal.

a

Clip on the bulkhead seal.

III - FINAL OPERATION

a

Refit:

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the engine undertray,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

If necessary, adjust the geometry of the axle assem-
blies (see 30A, General information, Front axle:
Adjusting, page 30A-31) .

36A

-

6

STEERING ASSEMBLY

Track rod: Removal - Refitting

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the front wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Loosen the wheel alignment adjustment lock nut (1)
.

a

Remove the track rod ball joint nut (2) .

a

Extract the ball joint using (Tav. 476).

a

Unscrew the track rod anti-clockwise and note the
number of turns for refitting.

a

Remove the track rod (3) .

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Track rod end nut
(13,04,02,03).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Screw the track rod back in place by the number of
turns noted during removal.

a

Fit the track rod end in the hub carrier.

a

Refit the track rod end nut.

a

Tighten to torque:

- the track rod ball joint nut (37 N.m),

- the wheel alignment adjusting lock nut (53

N.m).

Essential special tooling

Tav. 476

Ball joint extractor.

Tightening torques

m

track rod ball joint nut

37 N.m

wheel alignment adjus-
ting lock nut

53 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

134367

36A

-

7

STEERING ASSEMBLY

Track rod: Removal - Refitting

36A

III - FINAL OPERATION

a

Refit the wheel (see 3 5 A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

a

Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-31) .

36A

-

8

STEERING ASSEMBLY

Axial ball joint linkage: Removal - Refitting

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the track rod (see 36A, Steering assembly, Track

rod: Removal - Refitting, page 36A-6) .

1 - Driver's side

a

Remove the steering rack gaiter (see 36A, Steering
assembly, Steering rack gaiter: Removal - Refit-
ting, page 36A-16) .

2 - Passenger side

a

Cut the large clip (1) from the left-hand steering gai-
ter.

a

Move the left-hand steering gaiter to one side.

a

Remove the right-hand steering box gaiter (see 36A,

Steering assembly, Steering rack gaiter: Remo-

val - Refitting, page 36A-16) .

II - OPERATION FOR REMOVAL OF PART

CONCERNED

a

Lock the wheels to disengage the rack teeth on the

pinion end.

a

Fit the tool (Dir. 1903) (1) on the steering rack at

the pinion end.

a

Unlock the axial ball joint linkage using the tool (Dir.
1305-01) (2) .

a

Remove the axial ball joint linkage.

Essential special tooling

Dir. 1903

Steering rack locking tool

Dir. 1305-01

Tool for removing/refitting 35
mm to 41 mm diameter axial
ball joints.

Tightening torques

m

axial ball joint linkage

53 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

137139

102206

36A

-

9

STEERING ASSEMBLY

Axial ball joint linkage: Removal - Refitting

36A

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Steering axial ball
joint washer (13,04,02,04).

a

parts always to be replaced: Track rod end nut
(13,04,02,03).

a

parts always to be replaced: Steering rack gaiter
(13,04,03,02) removed.

a

parts always to be replaced: Steering box gaiter
clip (13,04,03,06).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the axial ball joint linkage.

a

Torque tighten the axial ball joint linkage (53 N.m)
using the tool (Dir. 1305-01).

III - FINAL OPERATION

1 - Passenger side

a

Refit the right-hand steering gaiter (see 36A, Stee-
ring assembly, Steering rack gaiter: Removal -
Refitting, page 36A-16) .

a

Fit the left-hand steering gaiter.

a

Refit a new left-hand steering clip.

2 - Driver's side

a

Refit:

- the left-hand steering box gaiter (see 36A, Stee-

ring assembly, Steering rack gaiter: Removal -
Refitting, page 36A-16) ,

- the left-hand track rod (see 36A, Steering assem-

bly, Track rod: Removal - Refitting, page 36A-6)
,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-31) .

101355

36A

-

10

STEERING ASSEMBLY

Steering column: Removal - Refitting

LEFT-HAND DRIVE

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Apply the procedure before repair using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Power-assisted steering computer",

- go to repair mode,

- display the "Before repair procedure" for the com-

puter,

- select "Power-assisted steering assembly" under

"List of components stored in this computer",

- carry out the operations described in the "Before

repair procedure" section,

a

Set the wheels straight ahead.

a

Remove the floor carpet.

a

Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a

Remove:

- the driver's front airbag (see Driver's front airbag:

Removal - Refitting) (88C, Airbags and pretensio-
ners),

- the steering wheel (see 36A, Steering assembly,

Steering wheel: Removal - Refitting, page 36A-
22) ,

- the steering wheel cover bolts,

- the steering wheel covers,

- the steering column switch assembly (see Stee-

ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals).

- the dashboard lower trim (see Dashboard: Remo-

val - Refitting) (57A, Interior equipment),

- the front footwell distribution duct (see A-pillar air

distribution duct: Removal - Refitting) (61A,
Heating).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Lift the floor carpet to access the universal joint.

a

Remove the bolt (1) from the universal joint.

a

Remove the universal joint.

Essential equipment

diagnostic tool

Tightening torques

m

steering column nuts

21 N.m

universal joint bolt on
the steering box

62 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

137147

36A

-

11

STEERING ASSEMBLY

Steering column: Removal - Refitting

LEFT-HAND DRIVE

36A

a

Disconnect the connector (2) from the electric stee-
ring column lock.

a

Disconnect the steering column connectors (3) .

a

Unclip the steering column wiring.

a

Remove:

- the steering column nuts (4) ,

- the steering column.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Steering shaft yoke
bolt (13,04,01,07).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the steering column.

136692

134365

134366

36A

-

12

STEERING ASSEMBLY

Steering column: Removal - Refitting

LEFT-HAND DRIVE

36A

a

Torque tighten in order the steering column nuts
(21 N.m).

a

Clip the wiring on the steering column.

a

Connect:

- the steering column connectors,

- the electric steering column lock connector.

a

Fit the universal joint on the steering box, being ca-
reful not to shift it more than one tooth in relation to
its initial position.

a

Torque tighten the universal joint bolt on the stee-
ring box (62 N.m).

a

Refit the floor carpet.

III - FINAL OPERATION

a

Refit:

- the front footwell distribution duct (see A-pillar air

distribution duct: Removal - Refitting) (61A,
Heating),

- the dashboard lower trim (see Dashboard: Remo-

val - Refitting) (57A, Interior equipment),

- the steering column switch assembly (see Stee-

ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals),

- the steering wheel covers,

- the steering wheel (see 36A, Steering assembly,

Steering wheel: Removal - Refitting, page 36A-
22) ,

- the driver's front airbag (see Driver's front airbag:

Removal - Refitting) (88C, Airbags and pretensio-
ners).

a

Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

a

Apply the After repair procedure using the diagnostic
tool:

- connect the diagnostic tool,

- select "Power-assisted steering computer",

- go to repair mode,

- display the "After repair procedure" for the selected

computer,

- select "Power-assisted steering assembly" under

"List of components stored in this computer",

- carry out the operations described in the "After re-

pair procedure" section.

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

Adjust the front axle, if necessary (see 30A, General
information, Front axle: Adjusting, page 30A-31)
.

134366

Note:

Check that the secured locking system of the
connectors is correctly engaged.

36A

-

13

STEERING ASSEMBLY

Steering column: Removal - Refitting

RIGHT-HAND DRIVE

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Apply the procedure before repair using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Power-assisted steering computer",

- go to repair mode,

- display the "Before repair procedure" for the com-

puter,

- select "Power-assisted steering assembly" under

"List of components stored in this computer",

- carry out the operations described in the "After re-

pair procedure" section.

a

Straighten the wheels.

a

Remove the floor carpet.

a

Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a

Remove:

- the driver's front airbag (see Driver's front airbag:

Removal - Refitting) (88C, Airbags and pretensio-
ners),

- the steering wheel (see 36A, Steering assembly,

Steering wheel: Removal - Refitting, page 36A-
22) ,

- the steering wheel cover bolts,

- the steering wheel covers,

- the steering column switch assembly (see Stee-

ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals),

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the front footwell air distribution duct (see A-pillar

air distribution duct: Removal - Refitting) (61A,
Heating).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Lift the floor carpet to access the universal joint.

a

Remove the bolt (1) from the universal joint.

a

Remove the universal joint.

Essential equipment

diagnostic tool

Tightening torques

m

steering column nuts

21 N.m

universal joint bolt on
the steering box

62 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

137147

36A

-

14

STEERING ASSEMBLY

Steering column: Removal - Refitting

RIGHT-HAND DRIVE

36A

a

Disconnect the connector (2) from the electric stee-
ring column lock.

a

Disconnect the steering column connectors (3) .

a

Unclip the steering column wiring.

a

Remove:

- the steering column nuts,

- the steering column.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Steering shaft yoke
bolt (13,04,01,07).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the steering column.

136692

134365

137655

36A

-

15

STEERING ASSEMBLY

Steering column: Removal - Refitting

RIGHT-HAND DRIVE

36A

a

Torque tighten the steering column nuts (21 N.m).

a

Clip the wiring on the steering column.

a

Connect:

- the steering column connectors,

- the electric steering column lock connector.

a

Fit the universal joint on the steering box, being ca-
reful not to shift it more than one tooth in relation to
its initial position.

a

Torque tighten the universal joint bolt on the stee-
ring box (62 N.m).

a

Refit the floor carpet.

III - FINAL OPERATION

a

Refit:

- the front footwell air distribution duct (see A-pillar

air distribution duct: Removal - Refitting) (61A,
Heating),

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the steering column switch assembly (see Stee-

ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals),

- the steering wheel covers,

- the steering wheel (see 36A, Steering assembly,

Steering wheel: Removal - Refitting, page 36A-
22) ,

- the driver's front airbag (see Driver's front airbag:

Removal - Refitting) (88C, Airbags and pretensio-
ners).

a

Check that the steering wheel is properly aligned.

a

Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select "Power-assisted steering computer",

- go to repair mode,

- display the "After repair procedure" for the selected

computer,

- select "Power-assisted steering assembly" under

"List of components stored in this computer",

- carry out the operations described in the "After re-

pair procedure" section.

a

Check the axle geometry (see 30A, General infor-
mation, Front axle: Adjustment values, page
30A-27) .

137655

Note:

Check that the secured locking system of the
connectors is correctly engaged.

36A

-

16

STEERING ASSEMBLY

Steering rack gaiter: Removal - Refitting

36A

REMOVAL

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the lock nut on the track rod end,

- the track rod (see 36A, Steering assembly, Track

rod: Removal - Refitting, page 36A-6) .

OPERATION FOR REMOVAL OF PART
CONCERNED

a

Cut the clip (1) on the gaiter of the steering box.

a

Remove the clip (2) from the gaiter of the steering
box.

a

Remove the steering box gaiter (3) .

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Steering rack gaiter
(13,04,03,02)

a

parts always to be replaced: Steering box gaiter
clip (13,04,03,06)

a

parts always to be replaced: Track rod end nut
(13,04,02,03)

a

Coat the bearing face of the steering box gaiter with
SILICONE GREASE (see Vehicle: Parts and con-
sumables for repair) (04B, Consumables - Pro-
ducts) to facilitate fitting on the axial ball joint
linkage.

a

Clean the gaiter - steering box contact surfaces
using SURFACE CLEANER (see Vehicle: Parts
and consumables for repair) (04B, Consumables -
Products).

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

137139

134344

Note:

Be sure to centre the steering to ensure the air in
the gaiters is equalised.

Note:

Be careful not to damage the gaiters: risk of irre-
versible damage.

36A

-

17

STEERING ASSEMBLY

Steering rack gaiter: Removal - Refitting

36A

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- a new steering box gaiter,

- a new steering box gaiter clip on the steering box

end,

- a new steering box gaiter clip on the track rod end.

III - FINAL OPERATION

a

Refit:

- the lock nut on the track rod end,

- the track rod end (see 36A, Steering assembly,

Track rod: Removal - Refitting, page 36A-6) ,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-31) .

36A

-

18

STEERING ASSEMBLY

Bulkhead seal: Removal - Refitting

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the front axle subframe (see 31A, Front axle com-

ponents, Front axle sub-frame: Removal - Refit-

ting, page 31A-75) .

II - OPERATION FOR REMOVAL OF PART

CONCERNED

a

Unclip the bulkhead seal (1) at (2) using a flat-blade
screwdriver.

a

Remove the bulkhead seal from the steering box.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the bulkhead seal on the steering box.

a

Clip the bulkhead seal onto the steering box.

II - FINAL OPERATION

a

Refit:

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

Adjust the front axle, if necessary (see 30A, General
information, Front axle: Adjusting, page 30A-31)
.

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

134345

36A

-

19

STEERING ASSEMBLY

Intermediate shaft: Removal - Refitting

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Set the wheels straight ahead.

a

Lift the floor carpet to access the universal joint bolt.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the bolt (1) from the universal joint.

a

Mark the position of the intermediate shaft (2) on the
steering column.

Tightening torques

m

intermediate shaft bolt
on the steering column
end

31 N.m

universal joint bolt

62 N.m

137527

(1)

Universal joint bolt

(2) Inter mediate

shaft

(3) Inter mediate shaft bolt on stee-

ring column side

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

137147

127653

36A

-

20

STEERING ASSEMBLY

Intermediate shaft: Removal - Refitting

36A

a

Remove the bolt (3) from the intermediate shaft on
the steering column side.

a

Remove the universal joint from the steering box.

a

Remove the intermediate shaft by pulling it in the di-
rection of the arrow.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Steering shaft yoke
bolt (13,04,01,07).

a

Always replace the intermediate shaft bolt on the
steering column end.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the intermediate shaft on the steering column
while taking care not to shift it more than one tooth in
relation to its initial position.

a

Ensure the intermediate shaft is correctly positioned
on the steering column side.

a

Pretighten the intermediate shaft bolt on the steering
column side.

a

Pull on the intermediate shaft of the steering column
to check presence of the bolt in the neck.

118664

118922

36A

-

21

STEERING ASSEMBLY

Intermediate shaft: Removal - Refitting

36A

a

Refit the universal joint.

a

Check that the universal joint is in the correct posi-
tion on the steering rack attack pinion stem.

a

Pretighten the universal joint bolt.

a

Tighten to torque:

- the intermediate shaft bolt on the steering colu-

mn end (31 N.m),

- the universal joint bolt (62 N.m).

III - FINAL OPERATION

a

Refit the floor carpet.

a

Check that the steering wheel is straight.

a

Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .

a

Adjust the front axle, if necessary (see 30A, General
information, Front axle: Adjusting, page 30A-31)
.

137147

36A

-

22

STEERING ASSEMBLY

Steering wheel: Removal - Refitting

36A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Apply the procedure for deactivating the safety sys-
tems. (see Airbag and Pretensioners: Precau-
tions for repair)

a

a

Remove the driver's front airbag (see Driver's front
airbag: Removal - Refitting) .

a

Set the wheels straight ahead.

a

Disconnect the connectors.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the steering wheel bolt (1) .

a

Remove the steering wheel.

a

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Steering wheel bolt
(13,04,01,09).

Tightening torques

m

new steering wheel bolt

44 N.m

IMPORTANT

Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-2) .

WARNING

Incorrect wheel alignment may damage the
rotary switch.

122730

WARNING

To ensure that the electronic systems operate
correctly, do not damage the locking systems of
the connectors.

WARNING

To prevent damaging the rotary switch, do not
turn the mobile section of the rotar y switch.

36A

-

23

STEERING ASSEMBLY

Steering wheel: Removal - Refitting

36A

II - REFITTING OPERATION FOR PART
CONCERNED

a

Check that the index (3) is aligned with the clips (4) .

a

Check that the index appears in the little window (5) .

a

a

Refit the steering wheel.

a

Connect the connectors.

a

Refit the new steering wheel bolt.

a

Torque tighten the new steering wheel bolt (44
N.m).

III - FINAL OPERATION

a

Refit the driver's front airbag (see Driver's front air-
bag: Removal - Refitting) .

IV - CHECKING AFTER REPAIR

a

Switch on the ignition.

a

Check the operation of the rotary switch:

- turn the steering wheel to the left until it stops,

- turn the steering wheel to the right until it stops,

- check that there are no faults on the instrument pa-

nel.

125367

125368

105327

WARNING

In order not to damage the steering wheel or
steering column, the steering wheel-column fool-
proofing devices must be aligned.

37A

-

1

MECHANICAL COMPONENT CONTROLS

Braking mechanism: Precautions for repair

37A

I - SAFETY

1 - Advice to be followed before any operation

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).

2 - Instructions to be followed during the operation

Using a mixture of two incompatible brake fluids in the
brake circuit may give rise to:

- serious risk of leakage due mainly to deterioration of

the cups,

- degradation of the ESP system.

To avoid such risks, only ever use brake fluids which
comply with the RENAULT standard (see Vehicle:
Parts and ingredients for the repairwork) (04B, Con-
sumables - Products).

Reminder:

- The pipes between the master cylinder, the callipers,

and the hydraulic unit are connected using threaded
unions with a metric thread.

- Therefore, only parts specified in the Parts Catalogue

for this vehicle should be used.

If, during work on the brake system, any damage on
any part is observed, it must be repaired before driving
the vehicle again.

II - CLEANLINESS

1 - Advice to be followed before any operation

Protect any bodywork components that risk being da-
maged by brake fluid with a cover.

2 - Instructions to be followed during the operation

To avoid contaminating the brake circuit, do not allow
the brake circuit components to drop on the ground.

Clean around the braking system with BRAKE CLEA-
NER (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products).

III - GENERAL RECOMMENDATIONS

1 - Master cylinder - brake servo

Always replace the master cylinder seals.

Check that the brake servo seal is in place. Replace
the seal if it is damaged.

Always replace the master cylinder - brake servo as-
sembly when the master cylinder leaks into the brake
servo. The brake servo becomes unusable when the
rubber diaphragm is contaminated with brake fluid.

2 - Brake hose

WARNING

Switch off the vehicle ignition so as not to activate
the hydraulic unit solenoid valves when bleeding the
brake circuit.

IMPORTANT

To ensure that the ABS and ESP systems operate
correctly, check that the underbody brake pipes are
clipped in place and are not crossed.

IMPORTANT

To avoid any accident, bring the pistons, brake pads
and brake discs into contact by depressing the
brake pad several times.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

IMPORTANT

To avoid breaking the connection between the
brake servo pushrod and the brake pedal, check
that the safety clevis pin is locked onto the brake
servo pushrod by tilting it from the top downwards.

WARNING

In order not to damage the brake hose:

- do not tension the hose,

- do not twist the hose,

- check that there is no contact with the surrounding

components.

37A

-

2

MECHANICAL COMPONENT CONTROLS

Master cylinder: Removal - Refitting

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter box (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Drain the brake fluid reservoir with a syringe.

a

Position a container to catch any brake fluid remai-
ning in the master cylinder which may run out.

a

Remove the clutch master cylinder supply pipe at (1)
.

a

Disconnect the brake fluid level sensor connector at
(2) .

a

Remove:

- the brake fluid reservoir bolt (3) ,

- the brake fluid reservoir.

Tightening torques

m

brake fluid reservoir bolt

4 N.m

master cylinder nuts

27 N.m

rigid brake pipe unions

14 N.m

WARNING

Always replace the master cylinder if it is dropped
or in the event of an impact (risk of malfunction).

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

134302

137153

37A

-

3

MECHANICAL COMPONENT CONTROLS

Master cylinder: Removal - Refitting

37A

a

Remove:

- the rigid pipe unions at (4) ,

- the master cylinder nuts (5) ,

- the master cylinder.

a

Fit blanking plugs on the openings of the master cy-
linder and the brake pipes.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Master cylinder seal
on brake fluid reservoir side (13,03,01,11).

a

parts always to be replaced: Master cylinder seal
on brake servo side (13,03,01,10).

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit:

- the brake fluid reservoir onto the master cylinder,

- the « master cylinder - reservoir » assembly.

a

Torque tighten the brake fluid reservoir bolt (4
N.m).

a

Refit:

- the master cylinder nuts,

- the rigid brake pipe unions,

- the clutch master cylinder pipe.

a

Tighten to torque:

- the master cylinder nuts (27 N.m),

- the rigid brake pipe unions (14 N.m).

III - FINAL OPERATION

a

Refit:

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Bleed the braking circuit (see 30A, General infor-
mation, Brake circuit Bleeding, page 30A-4) .

a

Connect the brake fluid level sensor connector.

134359

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

Note:

The brake fluid level sensor connector is cor-
rectly connected when the "locking click" sound
is heard.

37A

-

4

MECHANICAL COMPONENT CONTROLS

Brake servo non-return valve: Removal - Refitting

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the brake servo non-return valve (1) .

a

Fit blanking plugs into openings.

a

Unclip the non-return valve pipe (2) from the vacuum
pump.

a

Fit blanking plugs into openings.

137157

K9K

137126

37A

-

5

MECHANICAL COMPONENT CONTROLS

Brake servo non-return valve: Removal - Refitting

37A

a

Unclip the non-return valve pipe (3) from the vacuum
pump.

a

Fit blanking plugs into openings.

a

Unclip the non-return valve pipe (4) from the air dis-
tributor.

a

Fit blanking plugs into openings.

F9Q

137158

F4R

137122

37A

-

6

MECHANICAL COMPONENT CONTROLS

Brake servo non-return valve: Removal - Refitting

37A

a

Unclip the non-return valve pipe (5) from the air dis-
tributor.

a

Fit blanking plugs into openings.

a

Remove the brake servo non-return valve.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Check the condition of the non-return valve (see
Braking assistance circuit: Check) .

a

Replace any faulty parts.

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Fit the non-return valve.

a

Clip the non-return valve onto the vacuum pump.

a

Clip the non-return valve onto the air distributor.

a

Refit the non-return valve on the brake servo.

a

Push and pull to check for a good connection.

III - FINAL OPERATION

a

Refit:

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

K4M

137140

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

F9Q or K9K

F4R or K4M

138090

37A

-

7

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

B95 or D95, and LEFT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Battery : Removal - Refit-

ting) (12A, Fuel mixture),

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

- the brake servo non-return valve (see 37A, Mecha-

nical component controls, Brake servo non-re-
turn valve: Removal - Refitting, page 37A-4) .

a

Unclip the manual gearbox control cables on the
gearbox (see 37A, Mechanical component con-
trols, Manual gearbox selector cable: Removal -
Refitting, page 37A-88) .

a

Move the bulkhead heat shieldto one side.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the rubber ring (1) from the dual safety con-
necting shaft.

a

Remove the dual safety connecting shaft (2) .

Tightening torques

m

height adjuster nuts on
the brake servo

21 N.m

nuts of the «

brake

servo - height adjuster »
assembly

21 N.m

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

IMPORTANT

To avoid a loss of braking efficiency, do not bend
the brake servo pipe.

K4M

F9Q or K4M or K9K

137142

137141

37A

-

8

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

B95 or D95, and LEFT-HAND DRIVE

37A

a

Remove:

- the nuts (3) of the brake servo height adjuster from

the brake pedal,

- the « brake servo - height adjuster » assembly,

- the nuts of the brake servo height adjuster,

- the brake servo.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).

a

Always replace the rubber ring of the dual safety
connecting shaft.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Torque tighten the height adjuster nuts on the
brake servo (21 N.m).

a

Refit the « brake servo - height adjuster » assembly
on the vehicle.

a

Torque tighten the nuts of the « brake servo - hei-
ght adjuster » assembly (21 N.m).

a

Refit:

- the dual safety connecting shaft between the brake

servo rod and the brake pedal,

- the dual safety connecting shaft rubber ring.

III - FINAL OPERATION

a

Fit the heat shield to the bulkhead.

a

Clip the manual gearbox control cables onto the
gearbox (see 37A, Mechanical component con-
trols, Manual gearbox selector cable: Removal -
Refitting, page 37A-88) .

a

Refit:

- the brake servo non-return valve (see 37A, Mecha-

nical component controls, Brake servo non-re-
turn valve: Removal - Refitting, page 37A-4) ,

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

134696

F9Q or K4M or K9K

K4M

37A

-

9

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

B95 or D95, and LEFT-HAND DRIVE

37A

37A

-

10

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

B95 or D95, and RIGHT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

- the non-return valve (see 37A, Mechanical com-

ponent controls, Brake servo non-return valve:
Removal - Refitting, page 37A-4) ,

- the glovebox (see Glovebox: Removal - Refit-

ting) ,

- the brake light switch (see 37A, Mechanical com-

ponent controls, Brake pedal switch: Removal -
Refitting, page 37A-45) .

a

Unclip the gear controls from the gearbox (see 37A,
Mechanical component controls, Manual gear-
box selector cable: Removal - Refitting, page
37A-88) .

a

Remove the bulkhead heat shield clips.

a

Move the bulkhead heat insulating material to one
side.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the dual safety connecting shaft rubber ring,

- the dual safety connecting shaft between the brake

servo rod and the link rod,

- the dual safety connecting shaft.

Tightening torques

m

nuts of the brake servo
height adjuster

21 N.m

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

K4M

F9Q or K4M or K9K

109879

37A

-

11

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

B95 or D95, and RIGHT-HAND DRIVE

37A

a

Remove:

- the nuts (1) of the brake servo height adjuster,

- the "brake servo - height adjuster" assembly.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the "brake servo - height adjuster" assembly,

- the nuts of the brake servo height adjuster.

a

Torque tighten the nuts of the brake servo height
adjuster (21 N.m).

a

Refit:

- the dual safety connecting shaft between the brake

servo rod,

- the rubber ring.

II - FINAL OPERATION

a

Fit the heat shield to the bulkhead.

a

Clip the gear control cables onto the gearbox (see
37A, Mechanical component controls, Manual
gearbox selector cable: Removal - Refitting,
page 37A-88) .

a

Refit:

- the brake switch (see 37A, Mechanical compo-

nent controls, Brake pedal switch: Removal -
Refitting, page 37A-45) ,

- the glovebox (see Glovebox: Removal - Refit-

ting) ,

- the non-return valve (see 37A, Mechanical com-

ponent controls, Brake servo non-return valve:
Removal - Refitting, page 37A-4) ,

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

134660

F9Q or K4M or K9K

K4M

37A

-

12

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

J95, and LEFT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Battery : Removal - Refit-

ting) (12A, Fuel mixture),

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

- the brake servo non-return valve (see 37A, Mecha-

nical component controls, Brake servo non-re-
turn valve: Removal - Refitting, page 37A-4) .

a

Move the bulkhead heat shieldto one side.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the rubber ring (1) from the dual safety con-
necting shaft.

a

Remove the dual safety connecting shaft (2) .

Tightening torques

m

height adjuster nuts on
the brake servo

21 N.m

nuts of the «

brake

servo - height adjuster »
assembly

21 N.m

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

IMPORTANT

To avoid a loss of braking efficiency, do not bend
the brake servo pipe.

F9Q or K4M or K9K

137142

137141

37A

-

13

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

J95, and LEFT-HAND DRIVE

37A

a

Remove:

- the nuts (3) of the brake servo height adjuster from

the brake pedal,

- the « brake servo - height adjuster » assembly.

a

If replacing the brake servo, remove:

- the nuts (4) of the brake servo height adjuster,

- the brake servo.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).

a

Always replace the rubber ring of the dual safety
connecting shaft.

II - REFITTING OPERATION FOR PART
CONCERNED

a

If replacing the brake servo, refit:

- the brake servo on the height adjuster,

- the height adjuster nuts on the brake servo.

a

Torque tighten the height adjuster nuts on the
brake servo (21 N.m).

a

Refit the « brake servo - height adjuster » assembly
on the vehicle.

a

Torque tighten the nuts of the « brake servo - hei-
ght adjuster » assembly (21 N.m).

a

Refit:

- a new dual safety connecting shaft between the

brake servo rod and the brake pedal,

- a new rubber ring for the dual safety connecting

shaft.

III - FINAL OPERATION

a

Fit the heat shield to the bulkhead.

a

Refit:

- the brake servo non-return valve (see 37A, Mecha-

nical component controls, Brake servo non-re-
turn valve: Removal - Refitting, page 37A-4) ,

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

134696

139233

F9Q or K4M or K9K

37A

-

14

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

J95, and LEFT-HAND DRIVE

37A

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

37A

-

15

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

J95, and RIGHT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Battery : Removal - Refit-

ting) (12A, Fuel mixture),

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

- the brake servo non-return valve (see 37A, Mecha-

nical component controls, Brake servo non-re-
turn valve: Removal - Refitting, page 37A-4) ,

- the glovebox (see Glovebox: Removal - Refit-

ting) ( 57A, Interior equipment),

- the brake light switch (see 37A, Mechanical com-

ponent controls, Brake pedal switch: Removal -
Refitting, page 37A-45) .

a

Move the bulkhead heat shieldto one side.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the rubber ring (1) from the dual safety connecting

shaft,

- the dual safety connecting shaft (2) .

Tightening torques

m

height adjuster nuts on
the brake servo

21 N.m

nuts of the «

brake

servo - height adjuster »
assembly

21 N.m

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

IMPORTANT

To avoid a loss of braking efficiency, do not bend
the brake servo pipe.

F9Q or K4M or K9K

109879

37A

-

16

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

J95, and RIGHT-HAND DRIVE

37A

a

Remove:

- the nuts (3) of the brake servo height adjuster,

- the "brake servo - height adjuster" assembly.

a

If replacing the brake servo, remove:

- the nuts (4) of the brake servo height adjuster,

- the brake servo.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).

a

Always replace the rubber ring of the dual safety
connecting shaft.

II - REFITTING OPERATION FOR PART
CONCERNED

a

If replacing the brake servo, refit:

- the brake servo on the height adjuster,

- the height adjuster nuts on the brake servo.

a

Torque tighten the height adjuster nuts on the
brake servo (21 N.m).

a

Refit the « brake servo - height adjuster » assembly
on the vehicle.

a

Torque tighten the nuts of the « brake servo - hei-
ght adjuster » assembly (21 N.m).

a

Refit:

- a new dual safety connecting shaft between the

brake servo rod and the brake pedal,

- a new rubber ring for the dual safety connecting

shaft.

III - FINAL OPERATION

a

Fit the heat shield to the bulkhead.

a

Refit:

- the brake light switch (see 37A, Mechanical com-

ponent controls, Brake pedal switch: Removal -
Refitting, page 37A-45) ,

- the glovebox (see Glovebox: Removal - Refit-

ting) ( 57A, Interior equipment),

- the brake servo non-return valve (see 37A, Mecha-

nical component controls, Brake servo non-re-
turn valve: Removal - Refitting, page 37A-4) ,

- the master cylinder (see 37A, Mechanical compo-

nent controls, Master cylinder: Removal - Refit-
ting, page 37A-2) ,

134660

139233

F9Q or K4M or K9K

37A

-

17

MECHANICAL COMPONENT CONTROLS

Brake servo: Removal - Refitting

J95, and RIGHT-HAND DRIVE

37A

- the air inlet duct (see Air inlet duct: Removal -

Refitting) (12A, Fuel mixture),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

37A

-

18

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

B95 or K95, and K9K – D95, and K9K, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the retaining bracket bolts (1) ,

- the retaining bracket.

a

Remove the bolt (2) of the turbocharger pressure re-
gulation solenoid valve support from the battery tray.

a

Move the turbocharger pressure regulation solenoid
valve to one side.

a

Unclip the vacuum pipes (3) .

Tightening torques

m

vacuum pump bolts

21 N.m

134491

137336

137126

37A

-

19

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

B95 or K95, and K9K – D95, and K9K, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4

37A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the vacuum pump bolts (4) ,

- the vacuum pump.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Brake servo va-
cuum pump seal (13,03,07,02).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the vacuum pump complete with a new seal.

a

Torque tighten the vacuum pump bolts (21 N.m).

III - FINAL OPERATION

a

Refit:

- the vacuum pipes,

- the turbocharger pressure regulation solenoid val-

ve on the battery tray,

- the retaining bracket.

134664

37A

-

20

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

B95 or K95, and F9Q – D95, and F9Q, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Disconnect the vacuum pipes (1) from the vacuum
pump.

a

Remove:

- the lifting eye bolts (2) ,

- the gearbox side lifting eye.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the vacuum pump bolts (3) ,

- the vacuum pump.

Tightening torques

m

vacuum pump bolts

25 N.m

gearbox side lifting eye
bolts

25 N.m

137158

136230

134663

37A

-

21

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

B95 or K95, and F9Q – D95, and F9Q, and EQT LEVEL EA1 or EQT LEVEL EA2 or EQT LEVEL EA3 or EQT
LEVEL EA4

37A

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Brake servo va-
cuum pump seal (13,03,07,02).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the vacuum pump complete with a new seal.

a

Torque tighten the vacuum pump bolts (25 N.m).

III - FINAL OPERATION

a

Connect the vacuum pipes to the vacuum pump.

a

Refit the gearbox side lifting eye.

a

Torque tighten the gearbox side lifting eye bolts
(25 N.m).

37A

-

22

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

J95, and K9K

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Disconnect the secondary brake fluid reservoir con-
nector (1) .

a

Unclip the secondary brake fluid reservoir wiring.

a

Remove the secondary brake fluid reservoir bolts (2)
.

a

Move aside the secondary brake fluid reservoir.

a

Unclip the breather pipe from the gearbox.

a

Remove:

- the nuts (3) from the gearbox breather pipe sup-

port,

- the gearbox breather pipe support.

a

Unclip the turbocharger pressure regulation sole-
noid valve (4) from its support.

Tightening torques

m

vacuum pump bolts

25 N.m

secondary brake fluid
reservoir bolts

8 N.m

138734

138735

138736

37A

-

23

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

J95, and K9K

37A

a

Remove the bolt (5) of the turbocharger pressure re-
gulation solenoid valve support.

a

Move aside the turbocharger pressure regulation so-
lenoid valve support.

a

Remove:

- the retaining bracket bolts (6) ,

- the retaining bracket (7) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the vacuum pipes (8) from the vacuum
pump.

a

Remove:

- the vacuum pump bolts (9) ,

- the vacuum pump.

138737

138738

138739

138751

37A

-

24

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

J95, and K9K

37A

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Brake servo va-
cuum pump seal (13,03,07,02).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the vacuum pump fitted with a new seal.

a

Torque tighten the vacuum pump bolts (25 N.m).

a

Connect the vacuum pipes to the vacuum pump.

III - FINAL OPERATION

a

Refit:

- the retaining bracket,

- the turbocharger pressure regulation solenoid val-

ve support,

- the turbocharger pressure regulation solenoid val-

ve on its support,

- the gearbox breather pipe support.

a

Clip the gearbox breather pipe on its support.

a

Refit the secondary brake fluid reservoir.

a

Torque tighten the secondary brake fluid reser-
voir bolts (8 N.m).

a

Connect the secondary brake fluid reservoir connec-
tor.

a

Clip on the secondary brake fluid reservoir wiring.

37A

-

25

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

J95, and F9Q

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Disconnect the secondary brake fluid reservoir con-
nector (1) .

a

Unclip the secondary brake fluid reservoir wiring.

a

Remove the secondary brake fluid reservoir bolts (2)
.

a

Move aside the secondary brake fluid reservoir.

a

Remove:

- the centre section of the scuttle panel grille (see

Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),

- the centre section of the scoop under the scuttle

panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment).

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the vacuum pipes (3) from the vacuum
pump.

a

Remove the vacuum pump bolts (4) .

Tightening torques

m

vacuum pump bolts

25 N.m

secondary brake fluid
reservoir bolts

8 N.m

138734

138745

138746

37A

-

26

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

J95, and F9Q

37A

a

Pivot the vacuum pump anticlockwise (5) .

a

Remove the vacuum pump in the direction of the ar-
row.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Brake servo va-
cuum pump seal (13,03,07,02).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the vacuum pump fitted with a new seal.

a

Torque tighten the vacuum pump bolts (25 N.m).

a

Connect the vacuum pipes to the vacuum pump.

III - FINAL OPERATION

a

Refit:

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the centre section of the scoop under the scuttle

panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),

- the centre section of the scuttle panel grille (see

Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),

- the secondary brake fluid reservoir.

a

Torque tighten the secondary brake fluid reser-
voir bolts (8 N.m).

a

Connect the secondary brake fluid reservoir connec-
tor.

a

Clip on the secondary brake fluid reservoir wiring.

138747

37A

-

27

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

J95, and M9R

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Disconnect the secondary brake fluid reservoir con-
nector (1) .

a

Unclip the secondary brake fluid reservoir wiring.

a

Remove the secondary brake fluid reservoir bolts (2)
.

a

Move aside the secondary brake fluid reservoir.

a

Remove:

- the centre section of the scuttle panel grille (see

Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),

- the centre section of the scoop under the scuttle

panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

a

Remove the bolts (3) from the exhaust gas cooler
control solenoid valve.

a

Move aside the exhaust gas cooler control solenoid
valve.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the vacuum pipe from the fuel pipe at (4) .

a

Disconnect the pipes (5) from the vacuum pump.

Tightening torques

m

vacuum pump bolts

15 N.m

secondary brake fluid
reservoir bolts

8 N.m

138734

138748

138750

37A

-

28

MECHANICAL COMPONENT CONTROLS

Vacuum pump: Removal - Refitting

J95, and M9R

37A

a

Remove:

- the vacuum pump bolts (6) ,

- the vacuum pump.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Brake servo va-
cuum pump seal (13,03,07,02).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the vacuum pump fitted with a new seal.

a

Torque tighten the vacuum pump bolts (15 N.m).

a

Connect the vacuum pipes to the vacuum pump.

a

Clip the vacuum pipe onto the fuel pipe.

III - FINAL OPERATION

a

Refit:

- the exhaust gas cooler control solenoid valve,

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the centre section of the scoop under the scuttle

panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),

- the centre section of the scuttle panel grille (see

Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),

- the secondary brake fluid reservoir.

a

Torque tighten the secondary brake fluid reser-
voir bolts (8 N.m).

a

Connect the secondary brake fluid reservoir connec-
tor.

a

Clip on the secondary brake fluid reservoir wiring.

138749

37A

-

29

MECHANICAL COMPONENT CONTROLS

Accelerator pedal: Removal - Refitting

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Switch off the ignition.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the accelerator pedal potentiometer con-
nector (1) .

a

Remove:

- the accelerator pedal bolts (2) ,

- the accelerator pedal.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a

Refit the accelerator pedal.

a

Connect the accelerator pedal potentiometer con-
nector.

134355

134355

37A

-

30

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

LEFT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Switch off the ignition.

a

Disconnect the brake pedal switch.

a

Remove:

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

a

Remove:

- the brake pedal impacter bolt (1) ,

- the brake pedal impacter (2) .

a

Remove:

- the nut (1) from the brake pedal impacter,

- the brake pedal impacter (2) .

Tightening torques

m

brake pedal nuts

21 N.m

brake pedal impacter
bolt

21 N.m

brake pedal impacter
nut

21 N.m

B95 or D95 or E95 or K95

134662

J95

139552

37A

-

31

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

LEFT-HAND DRIVE

37A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the rubber ring (3) from the dual safety con-
necting shaft.

a

Remove the dual safety connecting shaft (4) .

a

Remove:

- the brake pedal nuts (5) ,

- the brake pedal.

III - REPLACEMENT OF THE PART CONCERNED

a

Remove:

- the brake pedal switch (see 3 7 A, Mechanical

component controls, Brake pedal switch: Re-
moval - Refitting, page 37A-45) ,

- the accelerator pedal (see 37A, Mechanical com-

ponent controls, Accelerator pedal: Removal -
Refitting, page 37A-29) .

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).

a

Always replace the brake pedal nuts.

II - REPLACEMENT OF THE PART CONCERNED

a

Refit the accelerator pedal (see 37A, Mechanical
component controls, Accelerator pedal: Remo-
val - Refitting, page 37A-29) .

137142

137141

134696

37A

-

32

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

LEFT-HAND DRIVE

37A

III - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the brake pedal.

a

Torque tighten the brake pedal nuts (21 N.m) in or-
der (6) , (7) , (8) , (9) and (10) .

a

Refit a new dual safety connecting shaft in the brake
servo pushrod and the brake pedal (11) .

a

Rotate the dual safety connecting shaft from bottom
to top to lock it onto the brake servo pushrod (12) .

IV - FINAL OPERATION

a

Refit the brake pedal impacter.

a

Torque tighten the brake pedal impacter bolt (21
N.m).

a

Torque tighten the brake pedal impacter nut (21
N.m).

137156

Note:

Respect the tightening order (risk of incorrectly
adjusting the brake switch otherwise).

128483

IMPORTANT

To avoid breaking the connection between the
brake servo pushrod and the brake pedal, check
that the safety clevis pin is locked onto the brake
ser vo pushrod by tilting it from the bottom
upwards.

B95 or D95 or E95 or K95

J95

37A

-

33

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

LEFT-HAND DRIVE

37A

a

Refit the brake pedal switch (see 37A, Mechanical
component controls, Brake pedal switch: Remo-
val - Refitting, page 37A-45) .

a

Connect the brake pedal switch.

a

Refit:

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

37A

-

34

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

RIGHT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Switch off the ignition.

a

Remove:

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the accelerator pedal (see 37A, Mechanical com-

ponent controls, Accelerator pedal: Removal -
Refitting, page 37A-29) ,

- the brake pedal link rod (see 37A, Mechanical

component controls, Brake pedal bell crank
rod: Removal - Refitting, page 37A-38) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the rubber ring (1) from the dual safety con-
necting shaft.

a

Remove the dual safety connecting shaft (2) .

a

Remove:

- the brake pedal impacter bolt (3) ,

- the brake pedal impacter.

Tightening torques

m

brake pedal nuts

21 N.m

brake pedal impacter
bolt

21 N.m

brake pedal impacter
nut

21 N.m

137142

137141

B95 or D95 or E95 or K95

134661

37A

-

35

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

RIGHT-HAND DRIVE

37A

a

Remove:

- the nut (3) from the brake pedal impacter,

- the brake pedal impacter.

a

Mark the wiring routing on the brake pedal.

a

Unclip the wiring (4) from the brake pedal.

a

Remove:

- the brake pedal nuts (5) ,

- the brake pedal.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Connecting shaft

between the brake pedal and the brake servo
pushrod (30,03,02,07).

a

Always replace the brake pedal nuts.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the brake pedal.

J95

139551

134656

WARNING

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.

37A

-

36

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

RIGHT-HAND DRIVE

37A

a

Torque tighten the brake pedal nuts (21 N.m) in or-
der (6) , (7) , (8) , (9) and (10) .

a

Refit the brake pedal impacter.

a

Torque tighten the brake pedal impacter bolt (21
N.m).

a

Torque tighten the brake pedal impacter nut (21
N.m).

a

Refit a new dual safety connecting shaft in the brake
servo pushrod and the brake pedal (11) .

a

Rotate the dual safety connecting shaft from top to
bottom to lock it onto the brake servo pushrod (12) .

134656

Note:

Respect the tightening order (risk of incorrectly
adjusting the brake switch otherwise).

B95 or D95 or E95 or K95

J95

137141

109205

IMPORTANT

To avoid breaking the connection between the
brake servo pushrod and the brake pedal, check
that the safety clevis pin is locked onto the brake
ser vo pushrod by tilting it from the top
downwards.

37A

-

37

MECHANICAL COMPONENT CONTROLS

Brake pedal: Removal - Refitting

RIGHT-HAND DRIVE

37A

III - FINAL OPERATION

a

Refit:

- the brake pedal link rod (see 37A, Mechanical

component controls, Brake pedal bell crank
rod: Removal - Refitting, page 37A-38) ,

- the accelerator pedal (see 37A, Mechanical com-

ponent controls, Accelerator pedal: Removal -
Refitting, page 37A-29) ,

- the wiring on the brake pedal in the position mar-

ked during removal,

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

37A

-

38

MECHANICAL COMPONENT CONTROLS

Brake pedal bell crank rod: Removal - Refitting

RIGHT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the centre console side faces (1) ,

- the glovebox (see Glovebox: Removal - Refit-

ting) ( 57A, Interior equipment),

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

a

Mark the routing of the wiring to the pedal assembly.

a

Remove:

- the clutch pedal (see 37A, Mechanical compo-

nent controls, Clutch pedal: Removal - Refit-
ting, page 37A-54) ,

- the accelerator pedal (see 37A, Mechanical com-

ponent controls, Accelerator pedal: Removal -
Refitting, page 37A-29) .

a

Move the floor carpet on the driver's side to access
the universal joint.

a

Remove the steering box universal joint bolt (2) .

a

Remove the universal joint.

Tightening torques

m

brake pedal nuts

21 N.m

brake servo mounting
plate nuts

21 N.m

brake pedal impacter
bolt

21 N.m

brake pedal impacter
nut

21 N.m

137019

WARNING

To prevent damage to the wiring harness when
refitting, observe the original routing.

137147

37A

-

39

MECHANICAL COMPONENT CONTROLS

Brake pedal bell crank rod: Removal - Refitting

RIGHT-HAND DRIVE

37A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Mark the routing of the clutch circuit pipes.

a

Unclip the clutch circuit pipes from the brake pedal
link rod plate at (3) .

a

Remove:

- the brake pedal switch (see 3 7 A , Mechanical

component controls, Brake pedal switch: Re-
moval - Refitting, page 37A-45) ,

- the dual safety connecting shaft rubber ring,

- the dual safety connecting shaft (4) .

a

Remove:

- the brake pedal link rod clip (5) .

- the brake pedal link rod ball joint nuts (6) from the

plate,

- the brake pedal link rod ball joint from the plate.

a

Remove the nuts (7) from the brake pedal link rod
plate.

a

Move the brake pedal link rod plate away from the
bulkhead.

134660

109879

138021

134660

37A

-

40

MECHANICAL COMPONENT CONTROLS

Brake pedal bell crank rod: Removal - Refitting

RIGHT-HAND DRIVE

37A

a

Remove:

- the brake pedal impacter bolt (8) ,

- the brake pedal impacter.

a

Remove:

- the brake pedal impacter nut (8) ,

- the brake pedal impacter.

a

Remove:

- the rubber ring (9) of the connecting shaft,

- the connecting shaft (10) .

B95 or D95 or E95 or K95

134661

J95

139551

137653

37A

-

41

MECHANICAL COMPONENT CONTROLS

Brake pedal bell crank rod: Removal - Refitting

RIGHT-HAND DRIVE

37A

a

Remove the nuts (11) from the brake pedal.

a

Move the « brake pedal - link rod » assembly away
from the bulkhead.

a

Remove:

- the brake pedal link rod clip (12) ,

- the nuts (13) from the brake pedal link rod ball joint,

- the brake pedal link rod ball joint,

- the brake pedal,

- the brake pedal link rod plate,

- the brake pedal link rod.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).

a

parts always to be replaced: Steering shaft yoke
bolt (13,04,01,07)

a

Always replace:

- the connecting shaft clips (5) and (12) ,

- the connecting shaft (10) between the link rod and

the brake pedal,

- the clip (9) of the connecting shaft (10) between the

link rod and the brake pedal.

- the brake pedal nuts,

- the nuts of the brake servo mounting plate.

a

Always replace the bolt of the brake impacter.

a

Always replace the nut of the brake impacter.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the brake pedal link rod from the left-hand side of
the vehicle.

134656

138021

B95 or D95 or E95 or K95

J95

37A

-

42

MECHANICAL COMPONENT CONTROLS

Brake pedal bell crank rod: Removal - Refitting

RIGHT-HAND DRIVE

37A

a

Refit:

- the brake pedal,

- the brake pedal link rod ball joint on the brake pe-

dal,

a

Clip the clip (14) onto the link rod shaft.

a

Refit the shaft (15) in the holes of the link rod bracket
(17) and the brake pedal bracket (18) .

a

Clip the clip (16) onto the shaft (15) .

a

Refit:

- the brake pedal link rod ball joint on the plate.

- the brake pedal link rod plate on the brake servo,

a

Clip the clip (19) onto the link rod.

138021

137653

Note:

Observe this fitting order to ensure correct ope-
ration.

Note:

Check that the clips (14) and (16) are fitted cor-
rectly.

138021

Note:

Check that the clip (19) is correctly fitted

37A

-

43

MECHANICAL COMPONENT CONTROLS

Brake pedal bell crank rod: Removal - Refitting

RIGHT-HAND DRIVE

37A

a

Torque tighten in order the brake pedal nuts (21
N.m) (20) , (21) , (22) , (23) and (24) .

a

Torque tighten in order the brake servo mounting
plate nuts (21 N.m) (25) , (26) , (27) , (28) and (29) .

a

Clip the clutch circuit pipes onto the brake pedal link
rod plate in the position marked during removal.

a

Refit the brake pedal switch (see 37A, Mechanical
component controls, Brake pedal switch: Remo-
val - Refitting, page 37A-45) .

a

Refit the new dual safety connecting shaft in the bra-
ke servo pushrod and the brake pedal (30) .

a

Rotate the dual safety connecting shaft from top to
bottom to lock it onto the brake servo pushrod (31) .

134656

134660

137141

109205

IMPORTANT

To avoid breaking the connection between the
brake servo pushrod and the brake pedal, check
that the safety clevis pin is locked onto the brake
ser vo pushrod by tilting it from the top
downwards.

37A

-

44

MECHANICAL COMPONENT CONTROLS

Brake pedal bell crank rod: Removal - Refitting

RIGHT-HAND DRIVE

37A

a

Refit the brake pedal impacter

a

Torque tighten the brake pedal impacter bolt (21
N.m).

a

Torque tighten the brake pedal impacter nut (21
N.m).

a

Refit the pedal wiring in the position marked during
the removal operation.

III - FINAL OPERATION

a

Refit:

- the accelerator pedal (see 37A, Mechanical com-

ponent controls, Accelerator pedal: Removal -
Refitting, page 37A-29) ,

- the clutch pedal (see 37A, Mechanical compo-

nent controls, Clutch pedal: Removal - Refit-
ting, page 37A-54) ,

- the universal joint on the steering box (see 36A,

Steering assembly, Steering column: Removal -
Refitting, page 36A-10) ,

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the glovebox (see Glovebox: Removal - Refit-

ting) ( 57A, Interior equipment),

- the centre console side faces.

B95 or D95 or E95 or K95

J95

37A

-

45

MECHANICAL COMPONENT CONTROLS

Brake pedal switch: Removal - Refitting

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Switch off the ignition.

a

Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

a

Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the brake pedal switch connector (1) .

a

Turn the brake pedal switch (2) an eighth of a turn
anti-clockwise.

a

Remove the brake pedal switch.

a

Unclip the brake pedal switch ring (3) .

Essential equipment

set of feeler gauges

diagnostic tool

LEFT-HAND DRIVE

RIGHT-HAND DRIVE

137344

LEFT-HAND DRIVE

137345

37A

-

46

MECHANICAL COMPONENT CONTROLS

Brake pedal switch: Removal - Refitting

37A

a

Unclip the brake pedal switch ring (4) from the left-
hand yoke on the link rod.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Brake pedal switch
(30,03,02,02) as well as the brake pedal switch ring
on the brake pedal.

II - REFITTING OPERATION FOR PART
CONCERNED

a

clip the new brake pedal switch ring (3) onto the pe-
dal assembly.

RIGHT-HAND DRIVE

137343

LEFT-HAND DRIVE

137345

37A

-

47

MECHANICAL COMPONENT CONTROLS

Brake pedal switch: Removal - Refitting

37A

a

Put the brake pedal in the raised position.

a

Insert the new brake pedal switch (2) in its ring (3) .

a

Position the end of the switch against the body of the
pedal.

a

Lock the brake pedal switch an eighth of a turn cloc-
kwise.

Adjusting the brake pedal switch:

a

Use a set of feeler gauges to check that the dimen-
sion (X) is between 1 and 2.5 mm.

With the brake pedal maintained in the raised posi-
tion:

the 1mm shim should fit between the switch and the
brake pedal.

the 2.5mm shim should not fit between the switch
and the brake pedal.

137344

Note:

This operation must be performed with the brake
servo rod connected to the brake pedal.

Note:

Incorrect adjustment may cause premature brake
wear or an injection system malfunction.

139549

(X)

This is the dimension between
the body of the switch and the
mating surface of the piston on
the body of the brake pedal.

37A

-

48

MECHANICAL COMPONENT CONTROLS

Brake pedal switch: Removal - Refitting

37A

a

Clip the new brake pedal switch ring (4) on the left-
hand yoke of the link rod.

a

Put the brake pedal in the raised position.

a

Insert the new brake pedal switch (2) in its ring (4) .

a

Put the end of the switch against the left-hand yoke
of the link rod.

a

Lock the brake pedal switch an eighth of a turn cloc-
kwise.

RIGHT-HAND DRIVE

137343

134659

Note:

This operation must be performed with the brake
ser vo rod connected to the link rod.

Note:

Incorrect adjustment may cause premature brake
wear or an injection system malfunction.

37A

-

49

MECHANICAL COMPONENT CONTROLS

Brake pedal switch: Removal - Refitting

37A

Adjusting the brake pedal switch:

a

Use a set of feeler gauges to check that the dimen-
sion (X) is between 1 and 2.5 mm.

With the brake pedal maintained in the raised posi-
tion:

the 1mm shim should fit between the switch and the
left-hand yoke of the link rod.

the 2.5mm shim should not fit between the switch
and the left-hand yoke of the link rod.

a

Lock the brake pedal switch by turning it an eighth of
a turn clockwise.

a

Connect the brake pedal switch connector.

III - FINAL OPERATION

a

Switch on the ignition.

a

Check that the brake light switch is operating cor-
rectly:

- depress the brake pedal to switch on the lights,

- release the brake pedal to switch off the lights.

a

Connect the diagnostic tool.

a

Depress the brake pedal 3 mm.

a

Check that the first signal of the switch has not swit-
ched (the first signal does not illuminate the bulbs).

a

Switch off the ignition.

a

Refit the dashboard lower trim (see Lower section
of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).

a

Refit the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

139549

(X)

This is the dimension between
the body of the switch and the
mating surface of the piston on
the left-hand yoke of the link rod.

LEFT-HAND DRIVE

RIGHT-HAND DRIVE

37A

-

50

MECHANICAL COMPONENT CONTROLS

Parking brake lever: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove the centre console (see Centre console:
Removal - Refitting) (57A, Interior equipment).

a

Make a 20 cm cut in the carpet.

a

Move the soundproofing (1) away from the airbag
computer protector.

a

Remove the airbag computer protector (2) .

Tightening torques

m

nuts of the parking
brake lever

21N.m

137970

137971

137972

37A

-

51

MECHANICAL COMPONENT CONTROLS

Parking brake lever: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

37A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Loosen the adjusting nut (3) of the parking brake ca-
bles.

a

Remove the parking brake cables (4) from the com-
pensator.

a

Mark the routing of the wiring on the floor.

a

Disconnect the parking brake switch connector (5) .

a

Remove:

- the nuts (6) from the parking brake lever under the

soundproofing,

- the parking brake lever.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Airbag computer
protector (31,02,01,46).

137123

137123

WARNING

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.

37A

-

52

MECHANICAL COMPONENT CONTROLS

Parking brake lever: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

37A

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the parking brake lever,

- the parking brake cables on the compensator.

a

Tighten the nuts of the parking brake lever
(21N.m) in the order (7) (8) (9) .

a

Connect the connector on the parking brake switch.

a

Refit the wiring in the position marked during the re-
moval operation.

a

Adjust the parking brake (see 37A, Mechanical
component controls, Parking brake lever: Adjus-
ting, page 37A-53) .

III - FINAL OPERATION

a

Refit:

- a new airbag computer protector,

- the soundproofing on the airbag computer protec-

tor.

a

Clip the carpet where it was cut using clips (part
number: 77 01 047 751).

a

Refit the centre console (see Centre console: Re-
moval - Refitting) (57A, Interior equipment).

137123

37A

-

53

MECHANICAL COMPONENT CONTROLS

Parking brake lever: Adjusting

WITHOUT AUTOMATIC PARKING BRAKE

37A

ADJUSTMENT

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the rear wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

a

Apply and release the parking brake five times to
bring the cables into their normal conditions of use.

a

Check:

- that the cables slide freely,

- the travel of the parking brake cables and engage

them fully on the rear callipers.

a

Remove the centre console (see Centre console:
Removal - Refitting) (57A, Interior equipment).

a

Gradually tighten the cables with the adjuster nut (1)
on the parking brake lever to bring the cables into
contact with the levers, without moving them.

a

Fine adjust so that the calliper levers (2) are re-
leased between the first and second notches of the
parking brake lever travel and remain released on
the second notch.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

137123

134352

37A

-

54

MECHANICAL COMPONENT CONTROLS

Clutch pedal: Removal - Refitting

LEFT-HAND DRIVE, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Switch off the ignition.

a

Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a

Remove:

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the UCH (see UCH: Removal - Refitting) (87B,

Passenger compartment connection unit).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the clutch pedal start of travel switch (see
37A, Mechanical component controls, Clutch pe-
dal switch: Removal - Refitting, page 37A-58) .

a

Remove the clutch pedal end of travel switch (see
37A, Mechanical component controls, Clutch pe-
dal switch: Removal - Refitting, page 37A-58) .

a

Remove the clutch pedal position sensor (see 37A,
Mechanical component controls, Clutch pedal
position sensor: Removal - Refitting, page 37A-
64) .

a

Unclip the clutch pedal wiring.

a

Unclip the clutch master cylinder rod by pressing on
the clips.

a

Remove:

- the accelerator pedal nuts (1) ,

- the clutch pedal.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Always replace the clutch pedal nuts.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the clutch pedal.

Tightening torques

m

clutch pedal nuts

21 N.m

CRUISE CONTROL

DOOR OPEN SYST. 433 NML

ELECTRONIC PARKING BRAKE

137128

137652

37A

-

55

MECHANICAL COMPONENT CONTROLS

Clutch pedal: Removal - Refitting

LEFT-HAND DRIVE, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

a

Torque tighten the clutch pedal nuts (21 N.m) in or-
der (2) , (3) and (4) .

a

Clip on the clutch master cylinder pushrod.

a

Clip the wiring onto the clutch pedal.

a

Refit the clutch pedal position sensor (see 37A, Me-
chanical component controls, Clutch pedal posi-
tion sensor: Removal - Refitting, page 37A-64) .

a

Refit the clutch pedal end of travel switch (see 37A,
Mechanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-58) .

a

Refit the clutch pedal start of travel switch (see 37A,
Mechanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-58) .

III - FINAL OPERATION

a

Refit:

- the UCH (see UCH: Removal - Refitting) (87B,

Passenger compartment connection unit),

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

a

Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

137652

Note:

Respect the tightening order (risk of incorrectly
adjusting the clutch switch otherwise).

ELECTRONIC PARKING BRAKE

DOOR OPEN SYST. 433 NML

CRUISE CONTROL

37A

-

56

MECHANICAL COMPONENT CONTROLS

Clutch pedal: Removal - Refitting

RIGHT-HAND DRIVE, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Unclip the clutch circuit pipes from the brake pedal
link rod plate at (1) .

a

Switch off the ignition.

a

Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Mark the routing of the pedal wiring on the bulkhead.

a

Remove the clutch pedal start of travel switch (see
37A, Mechanical component controls, Clutch pe-
dal switch: Removal - Refitting, page 37A-58) .

a

Remove the clutch pedal end of travel switch (see
37A, Mechanical component controls, Clutch pe-
dal switch: Removal - Refitting, page 37A-58) .

a

Remove the position sensor from the clutch pedal
(see 37A, Mechanical component controls,
Clutch pedal position sensor: Removal - Refit-
ting, page 37A-64) .

a

Unclip the clutch pedal wiring.

a

Remove the clutch pedal nuts (2) .

a

Remove the pedal assembly with the clutch master
cylinder.

Tightening torques

m

clutch pedal nuts

21 N.m

134660

WARNING

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.

CRUISE CONTROL

DOOR OPEN SYST. 433 NML

ELECTRONIC PARKING BRAKE

137154

37A

-

57

MECHANICAL COMPONENT CONTROLS

Clutch pedal: Removal - Refitting

RIGHT-HAND DRIVE, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

a

Remove the clutch master cylinder from the pedal
(see 3 7 A , Mechanical component controls,
Clutch master cylinder: Removal - Refitting,
page 37A-73) .

REFITTING

I - REFITTING PREPARATION OPERATION

a

Always replace the clutch pedal nuts.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the clutch master cylinder onto the clutch pedal

(see 3 7 A , Mechanical component controls,
Clutch master cylinder: Removal - Refitting,
page 37A-73) ,

- the clutch pedal.

a

Clip the wiring onto the clutch pedal in the position
marked during removal.

a

Torque tighten the clutch pedal nuts (21 N.m) in or-
der (3) , (4) , (5) and (6) .

a

Refit the clutch pedal position sensor (see 37A, Me-
chanical component controls, Clutch pedal posi-
tion sensor: Removal - Refitting, page 37A-64) .

a

Refit the clutch pedal end of travel switch (see 37A,
Mechanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-58) .

a

Refit the clutch pedal start of travel switch (see 37A,
Mechanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-58) .

III - FINAL OPERATION

a

Refit the dashboard lower trim (see Lower section
of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).

a

Clip the clutch circuit pipes onto the brake pedal link
rod plate at (7) .

137154

Note:

Respect the tightening order (risk of incorrectly
adjusting the clutch switch otherwise).

ELECTRONIC PARKING BRAKE

DOOR OPEN SYST. 433 NML

CRUISE CONTROL

134660

37A

-

58

MECHANICAL COMPONENT CONTROLS

Clutch pedal switch: Removal - Refitting

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Switch off the ignition.

a

Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

a

Mark the routing of the pedal wiring on the clutch pe-
dal and on the bulkhead.

a

Move aside the UCH (1) .

Essential equipment

set of feeler gauges

diagnostic tool

WARNING

To avoid a malfunction of the cruise control - speed
limiter or the starting function, do not remove any
clutch pedal switches. If any switches are removed,
replace them with new switches.

RIGHT-HAND DRIVE

LEFT-HAND DRIVE

137958

37A

-

59

MECHANICAL COMPONENT CONTROLS

Clutch pedal switch: Removal - Refitting

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

II - OPERATION FOR REMOVAL OF PART
CONCERNED

1 - Clutch pedal end of travel switch

a

Disconnect the connector (2) from the pedal end of
travel switch.

a

Turn the clutch pedal switch (3) one quarter of a turn
anti-clockwise.

a

Remove the clutch pedal switch.

2 - Clutch pedal start of travel switch

a

Disconnect the connector (4) from the start of travel
switch.

a

Turn the clutch pedal switch (5) one eighth of a turn
anti-clockwise.

a

Remove the clutch pedal start of travel switch.

134695

135448

134695

135447

37A

-

60

MECHANICAL COMPONENT CONTROLS

Clutch pedal switch: Removal - Refitting

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

a

Unclip the ring (6) from the pedal start of travel
switch.

REFITTING

I - REFITTING PREPARATION OPERATION

1 - Clutch pedal end of travel switch

a

a

BITRON switch

Measure the piston dimension X (8) . If dimension X
is less than 29 mm, pull carefully on the end of the
piston (8) to adjust the dimension X between 28 mm
minimum and 29 mm maximum.

135446

134304

WARNING

To avoid damaging the multifunction switch:

- handle the switch (7) with care,

- only activate the piston (8) during the adjust-

ment phase,

- do not perform more than 3 adjustments to

dimension (X),

- do not separate the piston (8) from the switch

(7) .

Replace the switch:

- if the piston (8) is separated from the switch

- if more than 3 consecutive adjustments to

dimension (X) have been performed.

37A

-

61

MECHANICAL COMPONENT CONTROLS

Clutch pedal switch: Removal - Refitting

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

2 - Clutch pedal start of travel switch

a

parts always to be replaced: Clutch pedal switch
(30,03,01,04) as well as the clutch pedal switch ring
on the clutch pedal.

II - REFITTING OPERATION FOR PART
CONCERNED

1 - Clutch pedal end of travel switch

a

Refit the clutch pedal switch (3) on the pedal assem-
bly.

a

Lock the clutch pedal switch by turning it one quarter
of a turn clockwise.

a

Depress the clutch pedal by hand.

a

Support the return of the clutch pedal.

a

Connect the clutch pedal end of travel switch con-
nector.

2 - Clutch pedal start of travel switch

a

Clip the new clutch pedal switch ring (6) onto the pe-
dal assembly.

a

Keep the clutch pedal in the upper position.

a

Keep the clutch pedal in the upper position.

135448

Note:

This operation must be performed with the clutch
master cylinder clipped onto the clutch pedal.

Note:

The clutch pedal switch has an automatic adjust-
ment feature, adapting to the pedal position.

The automatic adjustment makes a clicking noise
when in operation.

135446

Note:

This operation must be performed with the clutch
master cylinder clipped onto the clutch pedal.

37A

-

62

MECHANICAL COMPONENT CONTROLS

Clutch pedal switch: Removal - Refitting

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

a

Insert the new start of travel switch (5) in its ring (6) .

a

Position the end of the switch against the body of the
pedal.

a

Lock the clutch pedal switch by turning it one eighth
of a turn clockwise.

Adjusting the clutch pedal switch:

a

Use a set of feeler gauges to check that the dimen-
sion (X) is between 1 and 2.5 mm.

With the clutch pedal maintained in the raised posi-
tion:

the 1mm shim should fit between the switch and the
clutch pedal.

the 2.5mm shim should not fit between the switch
and the clutch pedal.

a

Connect the clutch pedal start of travel switch con-
nector.

III - FINAL OPERATION

a

Refit the pedal wiring in the position marked during
removal on the clutch pedal and on the bulkhead.

a

Refit the UCH.

a

Refit the dashboard lower trim (see Lower section
of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).

a

Switch on the ignition.

138157

Note:

Incorrect adjustment may cause premature
clutch wear.

139549

(X)

this is the dimension between
the body of the switch and the
mating surface of the piston on
the body of the clutch pedal.

RIGHT-HAND DRIVE

LEFT-HAND DRIVE

137959

37A

-

63

MECHANICAL COMPONENT CONTROLS

Clutch pedal switch: Removal - Refitting

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

a

Check the operation of the clutch pedal switches
using the diagnostic tool.

37A

-

64

MECHANICAL COMPONENT CONTROLS

Clutch pedal position sensor: Removal - Refitting

ELECTRONIC PARKING BRAKE, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the clutch pedal position sensor connec-
tor.

a

Unlock:

- the section connected to the pedal by pulling the

lock (1) ,

- the sensor body by moving the lock (2) .

a

Tilt the sensor to the left taking care not to damage
the sensor lower mounting bracket (3) .

REFITTING

I - REFITTING PREPARATION OPERATION

a

In the case of a new sensor, unlock the arm of the
sensor.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Insert the clutch pedal position sensor at (3) , by po-
sitioning the sensor arm between its mounting shaft
on the pedal and the clutch pedal compensation
spring.

a

Lock:

- the sensor body by using the lock (2) ,

- the section connected to the pedal by moving the

lock (1) .

a

Reconnect the clutch pedal position sensor connec-
tor.

III - FINAL OPERATION

a

Switch on the ignition.

a

Connect the diagnostic tool.

a

Check the operation of the clutch pedal position sen-
sor.

Essential equipment

diagnostic tool

135450

135449

37A

-

65

MECHANICAL COMPONENT CONTROLS

Clutch pedal position sensor: Removal - Refitting

ELECTRONIC PARKING BRAKE, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

37A

a

Refit the dashboard lower trim (see Lower section
of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).

37A

-

66

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Bleeding

AJ0 or JH3 or JR5 or PK4 or TL4

37A

Bleed in the event of:

- dead travel,

- pedal at mid-travel,

- pedal to the floor,

- poor gear changing.

I - PRECAUTIONS DURING REPAIR

Risks relating to contamination.

a

The hydraulic clutch system is very sensitive to con-
tamination. The risks caused by contamination are:

- impossible to change gears,

- damage to or destruction of the clutch system,

- leaks on the hydraulic circuit.

All the operations on the hydraulic clutch circuit sys-
tem must be carried out under excellent cleanliness
conditions. This ensures that no impurities enter the
hydraulic circuit during the operation.

The cleanliness principles apply to all components
of the hydraulic clutch circuit.

Items causing contamination are:

- metal or plastic swarf,

- fibres:

• cardboard,

• brushes,

• paper,

• clothing,

• cloth,

• dust and particles in the air,

• etc.

Cleaning cloths.

a

Use lint-free cleaning cloths (see Recommended
products for repairwork) (04B, Consumables -
Products).

Each cloth must only be used once.

There are two types of equipment used to bleed the
clutch circuit:

a

ARC50 via the brake fluid reservoir.

a

Syringe via the bleed hole located on the clutch sla-
ve cylinder.

There are two procedures used to bleed the clutch
circuit:

a

If no parts of the clutch hydraulic circuit are remo-
ved:

- Carry out the bleed operation using the ARC50 via

the brake fluid reservoir or using a new syringe via
the bleed hole located on the clutch slave cylinder.

a

If no parts of the clutch hydraulic circuit are remo-
ved:

- Only carry out the bleed operation using a new sy-

ringe by injecting the brake fluid via the bleed hole
on the clutch slave cylinder.

Consumables required for the repair:

a

Bleed the clutch circuit using approved (see Vehi-
cle: Parts and ingredients for the repairwork)
brake fluid (04B, consumables - products).

II - PREPARATION STAGE

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the engine undertray.

Essential equipment

brake circuit bleeding device

hydraulic circuit bleed syringe

Note:

- Even the tiniest air bubble in the circuit can

cause faulty operation (pedal failing to return
properly, crunching sound when changing gear,
etc.).

- Incorrect bleeding can lead to incorrect detec-

tion of faults and unnecessary part replace-
ments.

37A

-

67

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Bleeding

AJ0 or JH3 or JR5 or PK4 or TL4

37A

There are several versions of bleed screw:

Screw type bleed screw.

a

To open the bleed screw, hold the plastic union (1)
using a ring spanner and undo the bleed screw (2) .

Half-turn bleed screw.

a

To open the bleed screw, fully turn the bleed screw
(3) by hand.

Bleed screw with a clip.

a

To open the bleed screw, press and hold the clip (4)
while pulling by one notch.

Bleed screw with a clip.

a

To open the bleed screw, lift the clip (5) while pulling
by one notch.

113919

114335

112868

107280

37A

-

68

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Bleeding

AJ0 or JH3 or JR5 or PK4 or TL4

37A

Bleed screw with two clips.

a

To open the bleed screw, lower the clip (6) and lift
the clip (7) while pulling by one notch.

III - BLEED PROCEDURE IF NO PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED

1 - Bleed using the ARC50.

a

Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti-
nuity of the hydraulic circuit during the bleed opera-
tion.

a

Connect the brake circuit bleeding device (after
having received Renault approval) to the master cy-
linder reservoir (see the instructions for the equip-
ment).

a

Remove the bleed plug from the clutch slave cylin-
der.

a

Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.

a

Open the bleed screw.

a

Open the circuit between the bleeding device and
the brake fluid reservoir.

a

Let the brake fluid run until all air bubbles have been
released.

a

Stop the bleeding device to dump the pressure in the
clutch circuit.

a

Close the bleed screw.

a

Remove the transparent pipe from the bleed hole.

a

Refit the bleed plug.

a

Top up the brake fluid level in the master cylinder re-
servoir after disconnecting the bleed device.

a

Disengage and engage the clutch quickly around
twenty times.

a

Check that the clutch system is operating correctly.

a

Repeat the bleed operation if necessary.

a

Check the adjustment of the switch. (see 37A, Me-
chanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-58) (37A,
mechanical control elements).

113732

Note:

Take care not to disrupt the adjustment of the
clutch start of travel switch.

37A

-

69

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Bleeding

AJ0 or JH3 or JR5 or PK4 or TL4

37A

2 - Bleed using a new syringe.

a

Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti-
nuity of the hydraulic circuit during the bleed opera-
tion.

a

Remove the bleed plug from the clutch slave cylin-
der.

a

Connect a transparent pipe of sufficient length to the
bleed hole (at least thirty centimeters) in order to pla-
ce it at the same height as the reservoir.

a

Open the bleed screw.

a

Fill the brake fluid master cylinder reservoir until bra-
ke fluid flows out of the bleed screw.

a

Connect a new hydraulic circuit bleed syringe
filled with a useful volume of 60 ml of approved bra-
ke fluid to the end of the transparent pipe.

a

Slowly inject the entire contents of the syringe into
the hydraulic clutch circuit without injecting any of
the air from the top section of the syringe.

a

Close the bleed screw.

a

Remove the transparent pipe from the bleed hole.

a

Refit the bleed plug.

a

Top up the brake fluid level in the master cylinder re-
servoir.

a

Disengage and engage the clutch quickly around
twenty times.

a

Check that the clutch system is operating correctly.

a

Repeat the bleed operation if necessary.

a

Check the adjustment of the switch. (see 37A, Me-
chanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-58) (37A,
mechanical control elements).

IV - BLEED PROCEDURE IF PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED.

a

Note:

Take care not to disrupt the adjustment of the
clutch start of travel switch.

Note:

The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.

WARNING

The master cylinder pipe must be disconnected
from its take-off point on the brake fluid reservoir,
to avoid any foreign matter penetrating inside the
brake system hydraulic circuit.

WARNING

Prepare for the flow of fluid and protect the sur-
rounding components.

Note:

Prefill the hydraulic circuit pipe equipped with a
filter.

Position the filter head facing downwards to
ensure that it fills.

37A

-

70

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Bleeding

AJ0 or JH3 or JR5 or PK4 or TL4

37A

There are several versions of pipe with and without
a filter:

Pipe without filter.

Filling position for pipe with filter.

Filling position for pipe with filter.

Filling position for pipe with filter.

a

Prefill the clutch pipe using the syringe.

a

Plug the prefilled pipe on the master cylinder end to
stop any brake fluid from escaping.

141812

141811

141810

141813

37A

-

71

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Bleeding

AJ0 or JH3 or JR5 or PK4 or TL4

37A

a

Prefill the hydraulic tappet using the new syringe (by
gravity).

a

Refit the part(s) concerned.

V - BLEED PROCEDURE AFTER A REMOVING A
COMPONENT OF THE HYDRAULIC CIRCUIT.

a

Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti-
nuity of the hydraulic circuit during the bleed opera-
tion.

a

Remove the bleed plug from the clutch slave cylin-
der.

a

Connect a transparent pipe of sufficient length to the
bleed hole (at least thirty centimeters) in order to pla-
ce it at the same height as the reservoir.

a

Open the bleed screw.

a

Fill the brake fluid master cylinder reservoir until bra-
ke fluid flows out of the bleed screw.

a

Connect a new syringe containing 60 ml of appro-
ved brake fluid to the end of the transparent pipe.

a

Slowly inject the entire contents of the syringe into
the hydraulic clutch circuit without injecting any of
the air from the top section of the syringe.

a

Close the bleed screw.

a

Remove the transparent pipe from the bleed hole.

a

Refit the bleed plug.

a

Top up the brake fluid level in the master cylinder re-
servoir.

a

Disengage and engage the clutch quickly around
twenty times.

a

Check that the clutch system is operating correctly.

a

Repeat the bleed operation if necessary.

a

Check the adjustment of the switch. (see 37A, Me-
chanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-58) (37A,
mechanical control elements).

141809

Note:

Take care not to disrupt the adjustment of the
clutch start of travel switch.

Note:

The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.

37A

-

72

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Bleeding

AJ0 or JH3 or JR5 or PK4 or TL4

37A

VI - FINAL OPERATION

a

Refit the engine undertray.

a

Remove the vehicle from the two-post lift (see Vehi-
cle: Towing and lifting) (02A, Lifting equipment).

37A

-

73

MECHANICAL COMPONENT CONTROLS

Clutch master cylinder: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and LEFT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the bleed plug.

a

Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.

a

Turn the tap (1) one turn anti-clockwise.

a

Turn the tap (2) one turn anti-clockwise.

a

Remove clip (3) .

Essential special tooling

Mot. 1495-01

22 mm socket for removing/
refitting oxygen sensors.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

ND4

137651

PK4

137349

JH3 or JR5

134658

37A

-

74

MECHANICAL COMPONENT CONTROLS

Clutch master cylinder: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and LEFT-HAND DRIVE

37A

a

Lift the clips (4) .

a

Depress the pedal with your hand to drain the reser-
voir, the master cylinder and the clutch pipe.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the clutch master cylinder rod by pressing on
the clips.

a

Remove the clutch master cylinder supply pipe (5)
from the brake fluid reservoir.

a

Pull out the clip (6) of the clutch master cylinder pipe
(7) by one notch.

a

Move the clutch master cylinder pipe aside.

TL4

135454

137128

134302

135453

37A

-

75

MECHANICAL COMPONENT CONTROLS

Clutch master cylinder: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and LEFT-HAND DRIVE

37A

a

Remove:

- the clutch master cylinder by turning it a quarter of

a turn clockwise using the tool (Mot. 1495-01),

- the clutch master cylinder supply pipe.

a

Fit blanking plugs on:

- the clutch master cylinder,

- the brake fluid reservoir,

- the clutch master cylinder pipe.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Check the condition of the seals.

a

The cut that receives the 'bayonet' connection on the
bulkhead must be clean, free of grease and without
any burrs.

a

The routing of the supply pipe must always ascend
from the master cylinder to the reservoir, as any low
points may cause air pockets.

Any pinching of the pipe is prohibited.

a

Dismantling the components of the master cylinder
is prohibited.

a

The blanking plugs must be removed when connec-
ting with the adjacent parts.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the clutch master cylinder by turning it a quarter of

a turn anti-clockwise using the tool (Mot. 1495-01),

- the clutch master cylinder supply pipe,

- the clutch master cylinder supply pipe on the brake

fluid reservoir,

- the clutch pipe on the clutch master cylinder,

- the clutch pipe clip on the clutch master cylinder.

a

Connect the clutch master cylinder rod to the clutch
pedal.

a

Bleed the clutch circuit (see 37A, Mechanical com-
ponent controls, Clutch circuit: Bleeding, page
37A-66) .

III - FINAL OPERATION

a

Refit:

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

19399

37A

-

76

MECHANICAL COMPONENT CONTROLS

Clutch master cylinder: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the bleed plug.

a

Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.

a

Turn the tap (1) one turn anti-clockwise.

a

Turn the tap (2) one turn anti-clockwise.

a

Remove clip (3) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

ND4

137651

PK4

137349

JH3 or JR5

134658

37A

-

77

MECHANICAL COMPONENT CONTROLS

Clutch master cylinder: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

a

Lift the clips (4) .

a

Depress the brake pedal by hand to empty the clutch
circuit.

a

Fit blanking plugs on the openings of the master cy-
linder and on the clutch circuit pipes.

a

Remove:

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the glovebox (see Glovebox: Removal - Refit-

ting) ( 57A, Interior equipment),

- the clutch pedal nuts.

a

Separate the clutch pedal from the bulkhead.

a

Unclip:

- the clutch master cylinder pipe (5) ,

- the clutch master cylinder supply pipe (6) ,

a

Remove the « clutch pedal - master cylinder » as-
sembly.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the clutch master cylinder rod by pressing on
the clips.

TL4

135454

134654

137128

37A

-

78

MECHANICAL COMPONENT CONTROLS

Clutch master cylinder: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

a

Remove the clutch master cylinder from the pedal by
turning it a quarter of turn clockwise.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Check the condition of the seals.

a

Any pinching is prohibited.

a

Dismantling the components of the master cylinder
is prohibited.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the master cylinder on the clutch pedal by tur-
ning it a quarter of turn anti-clockwise.

a

Clip the master cylinder rod onto the clutch pedal.

III - FINAL OPERATION

a

Refit the "clutch pedal - master cylinder" assembly.

a

Clip:

- the clutch master cylinder pipe,

- the clutch master cylinder supply pipe.

a

Refit:

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the glovebox (see Glovebox: Removal - Refit-

ting) (57A, Interior equipment).

a

Bleed the clutch circuit (see 37A, Mechanical com-
ponent controls, Clutch circuit: Bleeding, page
37A-66) .

138158

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

37A

-

79

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and LEFT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter box (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the bleed plug.

a

Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.

a

Turn the clutch slave cylinder bleed tap (1) one turn
anti-clockwise.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

ND4

137651

37A

-

80

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and LEFT-HAND DRIVE

37A

a

Turn the clutch slave cylinder bleed tap (2) one turn
anti-clockwise.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

a

Remove clip (3) .

a

Pull out the clutch control pipe by one notch.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

a

Remove clip.

PK4

137349

JH3 or JR5

134658

37A

-

81

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and LEFT-HAND DRIVE

37A

a

Remove clip (4) .

a

Pull out the clutch control pipe by one notch.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

a

Disconnect the hydraulic clutch control pipe from the
clutch slave cylinder.

a

Fit blanking plugs into all openings.

a

Remove the clip (5) from the master cylinder pipe
union.

a

Disconnect the pipe (6) from the master cylinder.

a

Fit blanking plugs into all openings.

a

Unclip the clutch pipe from the gearbox.

a

Remove the clutch pipe.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Check the condition of the seals.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit the hydraulic clutch control pipe.

a

Clip the hydraulic clutch control pipe on the gearbox.

a

Connect the hydraulic clutch control pipe on the sla-
ve cylinder side.

TL4

135454

135453

Note:

Carefully remove the clutch pipe taking care to
correctly follow the routing.

Note:

The blanking cover caps must be removed when
connecting the adjacent par ts.

37A

-

82

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and LEFT-HAND DRIVE

37A

a

Press the hydraulic clutch control pipe clip on the
slave cylinder.

a

Connect the hydraulic clutch control pipe to the mas-
ter cylinder.

a

Refit the retaining clip of the hydraulic clutch control
pipe on the master cylinder.

a

Bleed the clutch circuit (see 37A, Mechanical com-
ponent controls, Clutch circuit: Bleeding, page
37A-66) .

III - FINAL OPERATION

a

Refit:

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

37A

-

83

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the glovebox (see Glovebox: Removal - Refit-

ting) ( 57A, Interior equipment),

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the bleed plug.

a

Connect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.

a

Turn the clutch slave cylinder bleed tap (1) one turn
anti-clockwise.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

ND4

137651

37A

-

84

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

a

Turn the clutch slave cylinder bleed tap (2) one turn
anti-clockwise.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

a

Remove clip (3) .

a

Pull out the clutch control pipe by one notch.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

a

Remove clip.

PK4

137349

JH3 or JR5

134658

37A

-

85

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

a

Remove clip (4) .

a

Pull out the clutch control pipe by one notch.

a

Depress the clutch pedal by hand to empty the
clutch circuit.

1 - Engine compartment end

a

Unclip the clutch slave cylinder pipe.

a

Disconnect the hydraulic clutch control pipe from the
clutch slave cylinder.

a

Fit blanking plugs into all openings.

a

Remove the clip (5) from the clutch link module pipe
union.

a

Disconnect the pipe (6) from the clutch link module.

a

Remove the supply pipe (7) from the bulkhead link
module.

a

Fit blanking plugs into all openings.

a

Unclip the clutch pipe from the gearbox.

a

Remove the clutch pipe on the engine compartment
end.

TL4

135454

ND4 or PK4

135453

Note:

Carefully remove the clutch pipe taking care to
correctly follow the routing.

37A

-

86

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

2 - Passenger compartment side

a

Unclip the clutch control pipes at (8) from the bulk-
head link module.

a

Unclip the clutch control pipes at (9) from the master
cylinder.

a

Remove the clutch pipes on the passenger compart-
ment side.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Check the condition of the seals.

II - REFITTING OPERATION FOR PART
CONCERNED

1 - Engine compartment end

a

Clip the clutch pipe to the bulkhead link module.

a

Refit the clutch circuit supply pipe on the bulkhead
link module.

a

Fit the hydraulic clutch control pipe.

a

Clip the hydraulic clutch control pipe onto the gear-
box.

a

Connect the clutch control pipe to the slave cylinder.

2 - Passenger compartment side

a

Connect the hydraulic clutch control pipe to the
clutch link module.

a

Clip the hydraulic clutch control pipe to the link rod
plate.

a

Clip the hydraulic clutch control pipe onto the master
cylinder.

a

Bleed the clutch circuit (see 37A, Mechanical com-
ponent controls, Clutch circuit: Bleeding, page
37A-66) .

III - FINAL OPERATION

a

Refit:

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

134665

134654

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

37A

-

87

MECHANICAL COMPONENT CONTROLS

Clutch circuit: Removal - Refitting

JH3 or JR5 or ND4 or PK4 or TL4, and RIGHT-HAND DRIVE

37A

- the glovebox (see Glovebox: Removal - Refit-

ting) ( 57A, Interior equipment),

- the dashboard lower trim (see Lower section of

dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

37A

-

88

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the exhaust pipe,

- the tunnel heat shield,

- the gear lever knob,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (1) using an open-jawed

spanner,

- the cable sleeve stops (2) .

a

Unclip the gear control cables from the control unit
at:

- the anchoring ball joint (3) using an open-jawed

spanner,

- the cable sleeve stops (4) .

ND4

134676

137342

37A

-

89

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

37A

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (5) using an open-jawed

spanner,

- the cable sleeve stops (6) .

a

Unclip the gear control cables from the control unit
at:

- the anchoring ball joint (7) using an open-jawed

spanner,

- the anchoring ball joint (8) by pressing the button,

- the cable sleeve stops (9) .

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (10) using an open-jawed

spanner,

- the cable sleeve stops (11) .

PK4

137346

134592

TL4

135455

37A

-

90

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

37A

a

Unclip the gear control cables from the control unit
at:

- the anchoring ball joint (12) using an open-jawed

spanner,

- the anchoring ball joint (13) by pressing the button,

- the cable sleeve stops (14) .

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (15) using an open-jawed

spanner,

- the cable sleeve stops (16) .

a

Unclip the gear control cables from the control unit
at:

- the anchoring ball joints (17) using an open-jawed

spanner,

134592

JH3 or JR5

134717

134668

37A

-

91

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

37A

- the cable sleeve stops (18) .

a

Remove:

- the tunnel seal bolts (19) ,

- the gear control cables (20) .

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the gear control cables,

- the tunnel seal bolts.

a

Clip the gear control cables onto the gearbox at:

- the anchoring ball joints,

- the cable sleeve stops.

a

Clip the gear control cables onto the control unit at:

- the anchoring ball joints using an open-jawed

spanner,

- the cable sleeve stops.

a

Clip the gear control cables onto the control unit at:

- the anchoring ball joint using an open-jawed span-

ner,

- the anchoring ball joint by pressing the button,

- the cable sleeve stops.

a

Adjust the gear control cables (see 37A, Mechani-
cal component controls, Mechanical gear con-
trol cable: Adjustment, page 37A-97) .

II - FINAL OPERATION

a

Refit:

- the centre console (see Centre console: Removal

- Refitting) (57A, Interior equipment),

- the gear lever knob,

- the tunnel heat shield,

- the exhaust pipe,

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

134694

Note:

Make sure that the tunnel seal is correctly fitted.

ND4

ND4 or PK4 or TL4

37A

-

92

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

J95, and PK4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the gear lever knob,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear control unit (see 37A, Mechanical com-

ponent controls, Gear control unit: Removal -
Refitting, page 37A-104) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (1) using an open-jawed

spanner,

- the cable sleeve stops (2) .

a

Unclip the gear control cables from the control unit
at:

- the anchoring ball joint (3) using an open-jawed

spanner,

- the anchoring ball joint (4) by pressing the button,

- the cable sleeve stops (5) .

a

Remove:

- the tunnel seal bolts (6) ,

- the gear control cables.

Tightening torques

m

tunnel seal bolts

21 N.m

137346

134592

134694

37A

-

93

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

J95, and PK4

37A

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the gear control cables,

- the tunnel seal bolts.

a

Torque tighten the tunnel seal bolts (21 N.m).

a

Clip the gear control cables onto the gearbox at:

- the anchoring ball joints,

- the cable sleeve stops.

II - FINAL OPERATION

a

Refit the gear control unit (see 37A, Mechanical
component controls, Gear control unit: Removal
- Refitting, page 37A-104) .

a

Adjust the gear control cables (see 37A, Mechani-
cal component controls, Mechanical gear con-
trol cable: Adjustment, page 37A-97) .

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob,

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

Note:

Make sure that the tunnel seal is correctly fitted.

37A

-

94

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

J95, and ND4 or TL4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear control unit (see 37A, Mechanical com-

ponent controls, Gear control unit: Removal -
Refitting, page 37A-104) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (1) using an open-jawed

spanner,

- the cable sleeve stops (2) .

a

Unclip the gear control cables from the control unit
at:

- the anchoring ball joints (3) using an open-jawed

spanner,

- the cable sleeve stops (4) .

Tightening torques

m

tunnel seal bolts

21 N.m

ND4

134676

137342

37A

-

95

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

J95, and ND4 or TL4

37A

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (5) using an open-jawed

spanner,

- the cable sleeve stops (6) .

a

Unclip the gear control cables from the control unit
at:

- the anchoring ball joint (7) using an open-jawed

spanner,

- the anchoring ball joint (8) by pressing the button,

- the cable sleeve stops (9) .

a

Remove:

- the tunnel seal bolts (10) ,

- the gear control cables.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the gear control cables,

- the tunnel seal bolts.

a

Torque tighten the tunnel seal bolts (21 N.m).

a

Clip the gear control cables onto the gearbox at:

- the anchoring ball joints,

- the cable sleeve stops.

TL4

135455

134592

134694

Note:

Make sure that the tunnel seal is correctly fitted.

37A

-

96

MECHANICAL COMPONENT CONTROLS

Manual gearbox selector cable: Removal - Refitting

J95, and ND4 or TL4

37A

a

Clip the gear control cables onto the gear control
unit at:

- the anchoring ball joints using an open-jawed

spanner,

- the sleeve stops.

a

Clip the gear control cables onto the gear control
unit at:

- the anchoring ball joint using an open-jawed span-

ner,

- the anchoring ball joint by pressing the button,

- the cable sleeve stops.

II - FINAL OPERATION

a

Refit the gear control unit (see 37A, Mechanical
component controls, Gear control unit: Removal
- Refitting, page 37A-104) .

a

Adjust the gear control cables (see 37A, Mechani-
cal component controls, Mechanical gear con-
trol cable: Adjustment, page 37A-97) .

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

ND4

TL4

37A

-

97

MECHANICAL COMPONENT CONTROLS

Mechanical gear control cable: Adjustment

PK4 or TL4

37A

If replaced, adjust:

- the control unit cables,

- the gearbox,

- the control unit.

I - ADJUSTMENT PREPARATION OPERATION

a

Remove:

- the gear lever knob, by lifting it upwards,

- the centre console (see Centre console: Removal

- Refitting) (57A, Interior equipment).

a

Unclip the wiring from the control unit.

II - ADJUSTMENT OPERATION

a

Unlock the clip (1) using a screwdriver.

a

Check the position of the levers on the gearbox.

Vehi-
cle

Gear-
box
type

Adjust-
ment
value
(mm)

Position
of lever

Position
on gear-
box

X95

PK4

4.8

±

0.5

Neutral

Neutral

X95

TL4

4.8

±

0.5

Neutral

Neutral

134592

Note:

The external control unit lever and the levers on
the gearbox must always be in the neutral posi-
tion.

37A

-

98

MECHANICAL COMPONENT CONTROLS

Mechanical gear control cable: Adjustment

PK4 or TL4

37A

a

Put the permanent shim (2) between the trigger and
the reverse gear interlock.

a

Lock the clip with the shim in place.

a

Engage several gears in order to check that the clip
is correctly secured in its housing.

III - FINAL OPERATION

a

Clip the wiring onto the control unit.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob.

134591

Note:

Do not apply pressure to the shims and to the
lever during adjustment.

37A

-

99

MECHANICAL COMPONENT CONTROLS

Mechanical gear control cable: Adjustment

ND4

37A

If replaced, adjust:

- the control unit cables,

- the gearbox,

- the control unit.

I - ADJUSTMENT PREPARATION OPERATION

a

Remove:

- the gear lever knob, by lifting it upwards,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

II - ADJUSTMENT OPERATION

a

Unlock the clip (1) using a screwdriver.

a

Check the position of the levers on the gearbox.

a

Put the permanent shim (2) between the trigger and
the reverse gear interlock.

a

Lock the clip with the shim in place.

a

Engage several gears in order to check that the clip
is correctly secured in its housing.

III - FINAL OPERATION

a

Clip the wiring onto the control unit.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob.

Vehi-
cle

Gear-
box
type

Adjust-
ment
value
(mm)

Position
of lever

Position
on gear-
box

X95

ND4

7.6

4th

4th

134672

Note:

The external control unit lever and the levers on
the gearbox must always be in the 4th gear posi-
tion.

134671

Note:

Do not apply pressure to the shims and to the
lever during adjustment.

37A

-

100

MECHANICAL COMPONENT CONTROLS

Automatic gear control cable: Removal - Refitting

AJ0 or FK0

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

- the gear control unit (see Manual gearbox: Remo-

val - Refitting) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the gear control cable anchoring ball joint (1)
on the gearbox using pliers.

a

Release the gear control cable sheath stop (2) on
the gearbox.

a

Remove the bulkhead seal bolts (3) .

a

Move aside the bulkhead seal (4) .

a

Remove the gear control cable.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Put the external gear control unit lever and the mul-
tifunction switch on the gearbox in position D.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit:

- the gear control unit control cable,

- the bulkhead seal,

- the bulkhead seal bolts.

a

Tighten the bulkhead seal bolts.

a

Lock the gear control cable sheath stop on the gear-
box.

a

Clip the gear control cable anchoring ball joint onto
the gearbox using pliers.

III - FINAL OPERATION

a

Refit:

- the gear control unit (see Manual gearbox: Remo-

val - Refitting) ,

138846

139026

37A

-

101

MECHANICAL COMPONENT CONTROLS

Automatic gear control cable: Removal - Refitting

AJ0 or FK0

37A

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

37A

-

102

MECHANICAL COMPONENT CONTROLS

Automatic gear control cable: Removal - Refitting

J95, and FK0

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

- the gear control unit (see 37A, Mechanical com-

ponent controls, Gear control unit: Removal -
Refitting, page 37A-104) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the gear control cable anchoring ball joint (1)
on the gearbox using an open-jawed spanner.

a

Release the gear control cable sheath stop (2) on
the gearbox.

a

Remove the bulkhead seal bolts (3) .

a

Remove the bulkhead seal.

a

Remove the gear control cable.

REFITTING

I - REFITTING PREPARATION OPERATION

a

Put the external gear control unit lever and the mul-
tifunction switch on the gearbox in position D.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Fit:

- the gear control unit control cable,

- the bulkhead seal,

- the bulkhead seal bolts.

a

Torque tighten the bulkhead seal bolts (21 N.m).

a

Lock the gear control cable sheath stop on the gear-
box.

a

Clip the gear control cable anchoring ball joint onto
the gearbox using pliers.

III - FINAL OPERATION

a

Refit:

- the gear control unit (see 37A, Mechanical com-

ponent controls, Gear control unit: Removal -
Refitting, page 37A-104) ,

Tightening torques

m

bulkhead seal bolts

21 N.m

138846

139026

37A

-

103

MECHANICAL COMPONENT CONTROLS

Automatic gear control cable: Removal - Refitting

J95, and FK0

37A

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

37A

-

104

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

PK4 or TL4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the gear lever knob by pulling it upwards,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

a

Unclip the wiring from the control unit (1) .

a

Make a 20 cm cut in the carpet.

a

Move the soundproofing (2) away from the airbag
computer protector.

Tightening torques

m

gear control unit nuts

21 N.m

134590

137970

137971

37A

-

105

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

PK4 or TL4

37A

a

Remove the airbag computer protector (3) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the control cables on the control unit at:

- the anchoring ball joint (4) using an open-jawed

spanner,

- the anchoring ball joint (5) by pressing the button,

- the cable sleeve stops (6) .

a

Remove:

- the gear control unit nuts (7) ,

- the gear control unit.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Airbag computer
protector (31,02,01,46).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the gear control unit.

137972

134592

134588

37A

-

106

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

PK4 or TL4

37A

a

Torque tighten in order the gear control unit nuts
(21 N.m).

a

Clip:

- the control cable sleeve stops on the control unit,

- the anchoring ball joint on the control unit,

- the anchoring ball joint by pressing the button on

the control unit.

a

Adjust the control unit (see 37A, Mechanical com-
ponent controls, Gear control unit: Adjusting,
page 37A-120) .

a

Check that the system and gear selection are wor-
king correctly.

III - FINAL OPERATION

a

Refit the airbag computer protector.

a

Position the soundproofing.

a

Clip:

- the carpet where it was cut using clips (part num-

ber: 77 01 047 751),

- the wiring on the control unit.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob.

134588

37A

-

107

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

ND4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the gear lever knob by pulling it upwards,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

a

Unclip the wiring (1) from the gear control unit.

a

Make a 20 cm cut in the carpet.

a

Move the soundproofing (2) away from the airbag
computer protector.

Tightening torques

m

gear control unit nuts

21 N.m

134669

137970

137971

37A

-

108

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

ND4

37A

a

Remove the airbag computer protector (3) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the control cables on the control unit at:

- the anchoring ball joints using an open-jawed

spanner (4) ,

- the cable sleeve stops (5) .

a

Remove:

- the gear control unit nuts (6) ,

- the gear control unit.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Airbag computer
protector (31,02,01,46).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the gear control unit.

137972

137342

134675

37A

-

109

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

ND4

37A

a

Torque tighten in order the gear control unit nuts
(21 N.m).

a

Clip:

- the control cable sleeve stops on the control unit,

- the anchoring ball joints on the control unit.

a

Adjust the gear control unit (see 37A, Mechanical
component controls, Mechanical gear control
cable: Adjustment, page 37A-97) .

a

Check that the system and gear selection are wor-
king correctly.

III - FINAL OPERATION

a

Refit the airbag computer protector.

a

Position the soundproofing.

a

Clip:

- the carpet where it was cut using clips (part num-

ber: 77 01 047 751),

- the wiring on the gear control unit.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob.

134675

37A

-

110

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

JH3 or JR5

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the gear lever knob by pulling it upwards,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

a

Unclip the wiring (1) from the gear control unit.

a

Make a 20 cm cut in the carpet.

a

Move the soundproofing (2) away from the airbag
computer protector.

Tightening torques

m

gear control unit nuts

21 N.m

134669

137970

137971

37A

-

111

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

JH3 or JR5

37A

a

Remove the airbag computer protector (3) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the gear control cable at:

- the anchoring ball joint using an open-jawed span-

ner (4) ,

- the anchoring ball joint by pressing the button (5) ,

- the cable sleeve stops (6) .

a

Remove:

- the gear control unit nuts (7) ,

- the gear control unit.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: Airbag computer
protector (31,02,01,46).

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the gear control unit,

- the gear control unit nuts.

137972

134668

134675

37A

-

112

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

JH3 or JR5

37A

a

Torque tighten in order the gear control unit nuts
(21 N.m).

a

Clip:

- the control cable sleeve stops on the control unit,

- the anchoring ball joint on the control unit using an

open-jawed spanner,

- the anchoring ball joint by pressing the button on

the control unit.

III - FINAL OPERATION

a

Refit the airbag computer protector.

a

Position the soundproofing.

a

Clip:

- the carpet where it was cut using clips (part num-

ber: 77 01 047 751),

- the wiring on the gear control unit.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob.

134675

Note:

For the JH3 and JR5 gearboxes, there is no
adjustment of the gear control cables.

37A

-

113

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

AJ0 or FK0

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

a

Move the gear lever to position R.

a

Turn the ring on the gear lever knob a sixteenth of a
turn clockwise (1) .

a

Remove:

- the gear lever knob, by lifting it upwards,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

a

Place the gear selector in position D.

a

Cut the carpet at (2) .

a

Move aside:

- the soundproofing (3) ,

- the airbag computer protector (4) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the connector (5) from the gear control
unit.

a

Unclip the wiring on the control unit at (6) .

Tightening torques

m

gear control unit nuts

21 N.m

138881

138882

Note:

Do not damage the soundproofing.

138883

37A

-

114

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

AJ0 or FK0

37A

a

Unlock the white clip (7) .

a

Unlock the white clip (8) .

a

Remove:

- the nuts (9) ,

- the gear control unit (10) .

REFITTING

I - REFITTING PREPARATION OPERATION

a

Put the external control unit lever and the multifunc-
tion switch on the gearbox in position D to facilitate
attachment of the control cables to the gearbox.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the gear control unit.

a

Fit the gear control unit nuts without tightening.

a

Torque tighten the gear control unit nuts (21 N.m).

123282

123284

138884

138884

37A

-

115

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

AJ0 or FK0

37A

a

Press on:

- the clip (7) ,

- the clip (8) .

a

Clip the wiring onto the control unit.

a

Connect the connector to the gear control unit.

a

Adjust the control unit (see 37A, Mechanical com-
ponent controls, Gear control unit: Adjusting,
page 37A-120) .

a

Check that the system and gear selection are wor-
king correctly.

III - FINAL OPERATION

a

Fit:

- the airbag computer protector,

- the soundproofing.

a

Clip the carpet at the cutting point.

a

Place the gear selector in position R.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob.

a

Turn the ring on the gear lever knob a sixteenth of a
turn anti-clockwise.

a

Refit:

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

123285

37A

-

116

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

J95, and TL4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove the centre console (see Centre console:
Removal - Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the control cable on the gear control unit at:

- the anchoring ball joint (1) using an open-jawed

spanner,

- the anchoring ball joint (2) by pressing the button,

- from the cable sleeve stop (3) .

a

Remove the control unit nuts (4) .

a

Move aside the control unit.

a

Remove the centre console mounting.

a

Unclip the control cable on the gear control unit at
the sleeve stop (5) .

a

Remove the gear control unit.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the gear control unit.

a

Clip the control cable sheath stop onto the gear con-
trol unit.

a

Torque tighten the gear control unit nuts (21 N.m).

a

Clip:

- the control cable sleeve stop onto the gear control

unit,

- the anchoring ball joints onto the gear control unit.

a

Adjust the gear control unit (see 37A, Mechanical
component controls, Gear control unit: Adjus-
ting, page 37A-120) .

a

Check that the system and gear selection are wor-
king correctly.

II - FINAL OPERATION

a

Refit the centre console (see Centre console: Re-
moval - Refitting) (57A, Interior equipment).

Tightening torques

m

gear control unit nuts

21 N.m

140461

140463

37A

-

117

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

J95, and FK0

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Place the gear selector in position D.

a

Remove the centre console (see Centre console:
Removal - Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the connector (1) from the gear control
unit.

a

Unlock:

- the clip (2) ,

- the clip (3) .

a

Remove:

- the gear control unit nuts (4) ,

- the gear control unit.

Tightening torques

m

gear control unit nuts

21 N.m

140457

123285

140457

37A

-

118

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

J95, and FK0

37A

REFITTING

I - REFITTING PREPARATION OPERATION

a

Put the external control unit lever and the multifunc-
tion switch on the gearbox in position D to facilitate
attachment of the control cables to the gearbox.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the gear control unit.

a

Fit the gear control unit nuts without tightening.

a

Torque tighten the gear control unit nuts (21 N.m).

a

Press the clip (5) .

a

Connect the connector to the gear control unit.

a

Adjust the control unit (see 37A, Mechanical com-
ponent controls, Gear control unit: Adjusting,
page 37A-120) .

a

Check that the system and gear selection are wor-
king correctly.

III - FINAL OPERATION

a

Refit the centre console (see Centre console: Re-
moval - Refitting) (57A, Interior equipment).

123285

37A

-

119

MECHANICAL COMPONENT CONTROLS

Gear control unit: Removal - Refitting

J95, and ND4

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Remove the centre console (see Centre console:
Removal - Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the nuts (1) from the gear control unit.

a

Move aside the gear control unit.

a

Remove the centre console mounting (2) .

a

Unclip the control cables on the gear control unit at:

- the anchoring ball joints (3) using an open-jawed

spanner,

- the cable sleeve stops (4) .

a

Remove the gear control unit.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Clip:

- the control cable sleeve stops on the gear control

unit,

- the anchoring ball joints on the gear control unit.

a

Refit the gear control unit.

a

Torque tighten the gear control unit nuts (21 N.m).

a

Adjust the gear control unit (see 37A, Mechanical
component controls, Gear control unit: Adjus-
ting, page 37A-120) .

a

Check that the system and gear selection are wor-
king correctly.

II - FINAL OPERATION

a

Refit the centre console (see Centre console: Re-
moval - Refitting) (57A, Interior equipment).

Tightening torques

m

gear control unit nuts

21 N.m

141159

37A

-

120

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

AJ0 or FK0

37A

If replaced, adjust:

- the multifunction switch,

- the control unit cable,

- the gearbox,

- the control unit.

I - ADJUSTMENT PREPARATION OPERATION

a

Place the gear selector in position R.

a

Turn the ring on the gear lever knob a sixteenth of a
turn clockwise (1) .

a

Remove:

- the gear lever knob, by lifting it upwards,

- the gear selection grid (2) ,

- the cup holder (3) .

a

Turn the ring on the gear lever knob a sixteenth of a
turn clockwise.

a

Remove:

- the gear lever knob, lifting it up and off,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

a

Place the gear selector in position D.

a

Place the gear selector in position P.

Vehicle

Type of
gear-
box

Adjust-
ment
values

Posi-
tion of
lever

Posi-
tion on
gear-
box

X95

FK0

Auto-
matic

P

P

X95

AJO

Auto-
matic

D

D

B95 or D95

138886

J95

AJ0

FK0

37A

-

121

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

AJ0 or FK0

37A

II - ADJUSTMENT OPERATION

a

Unlock the clip (4) using a screwdriver.

a

Check the position of the multifunction switch at D.

a

Unlock the clip (5) using a screwdriver.

a

Check the position of the multifunction switch at P.

AJ0

123282

Note:

The external gear control unit lever and the multi-
function switch on the gearbox must be in posi-
tion D.

FK0

123282

Note:

The external gear control unit lever and the multi-
function switch on the gearbox must be in posi-
tion P.

37A

-

122

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

AJ0 or FK0

37A

a

Lock the clip (6) .

a

Engage several gears in order to check that the clip
is correctly secured in its housing.

III - FINAL OPERATION

a

Place the gear selector in position R.

a

Refit:

- the cup holder,

- the gear selection grid,

- the gear lever knob.

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob.

123283

B95 or D95

J95

37A

-

123

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

J95, and PK4

37A

If replaced, adjust:

- the control unit cables,

- the gearbox,

- the control unit.

I - ADJUSTMENT PREPARATION OPERATION

a

Remove:

- the gear lever knob, lifting it up and off,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

II - ADJUSTMENT OPERATION

a

Unlock the clip (1) using a screwdriver.

a

Check the position of the levers on the gearbox.

Vehi-
cle

Gear-
box
type

Adjust-
ment
value
(mm)

Position
of lever

Position
on gear-
box

X95

PK4

4.5

Neutral

Neutral

128180

Note:

The external control unit lever and the levers on
the gearbox must always be in the neutral posi-
tion.

37A

-

124

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

J95, and PK4

37A

a

Put the permanent shim (2) between the trigger and
the reverse gear interlock.

a

Lock the clip with the shim in place.

a

Remove the adjusting shim.

a

Engage several gears in order to check that the clip
is correctly secured in its housing.

III - FINAL OPERATION

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the gear lever knob,

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

141162

Note:

Do not apply pressure to the shims and to the
lever during adjustment.

37A

-

125

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

J95, and ND4

37A

If replaced, adjust:

- the control unit cables,

- the gearbox,

- the control unit.

I - ADJUSTMENT PREPARATION OPERATION

a

Remove:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

II - ADJUSTMENT OPERATION

a

Unlock the clip (1) using a screwdriver.

a

Check the position of the levers on the gearbox.

a

Put the permanent shim (4) between the locking ring
and the reverse gear interlock.

a

Lock the clip (5) with the shim in place.

a

Remove the adjusting shim.

a

Engage several gears in order to check that the clip
is correctly secured in its housing.

Vehi-
cle

Gear-
box
type

Adjust-
ment
value
(mm)

Position
of lever

Position
on gear-
box

X95

ND4

7.6

4th

4th

141159

Note:

The external control unit lever and the levers on
the gearbox must always be in the 4th gear posi-
tion.

141706

(2) "neutral"

position

(3)

"4th gear engaged" position

141161

Note:

Do not apply pressure to the shims and to the
lever during adjustment.

37A

-

126

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

J95, and ND4

37A

III - FINAL OPERATION

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

37A

-

127

MECHANICAL COMPONENT CONTROLS

Gear control unit: Adjusting

J95, and TL4

37A

If replaced, adjust:

- the control unit cable,

- the gearbox,

- the control unit.

I - ADJUSTMENT PREPARATION OPERATION

a

Remove:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery).

II - ADJUSTMENT OPERATION

a

Unlock the clip (1) using a screwdriver.

a

Check the position of the levers on the gearbox.

a

Put the permanent shim (2) between the trigger and
the reverse gear interlock.

a

Lock the clip with the shim in place.

a

Remove the adjusting shim.

a

Engage several gears in order to check that the clip
is correctly secured in its housing.

III - FINAL OPERATION

a

Refit:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

Vehicle

Type of
gearbox

Adjust-
ment
values

Posi-
tion of
lever

Posi-
tion on
gearbox

X95

TL4

4.9 mm

Neutral

Neutral

141161

Note:

The external control unit lever and the levers on
the gearbox must always be in the neutral posi-
tion.

Note:

Do not apply pressure to the shims and to the
lever during adjustment.

37A

-

128

MECHANICAL COMPONENT CONTROLS

Parking brake cables: Removal - Refitting

WITHOUT AUTOMATIC PARKING BRAKE

37A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment),

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Loosen the adjusting nut (1) of the parking brake ca-
bles.

a

Remove the parking brake cables (2) from the com-
pensator.

a

Remove:

- the parking brake cables at (3) from the rear brake

callipers,

- the parking brake cables, noting their routing.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit:

- the parking brake cables,

- the parking brake cables on the brake callipers,

- the parking brake cables to the compensator.

a

Adjust the parking brake cables (see 37A, Mechani-
cal component controls, Parking brake lever:
Adjusting, page 37A-53) .

II - FINAL OPERATION

a

Refit:

- the rear wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the central console (see Centre console: Remo-

val - Refitting) (57A, Interior equipment).

WARNING

To avoid damaging the parking brake cable protec-
tors and causing premature wear of the system, do
not handle the cables with a tool.

137123

134352

37A

-

129

MECHANICAL COMPONENT CONTROLS

Brake servo: Check

37A

There is no “RENAULT” tool to check the braking as-
sistance circuit.

Use a vacuum pump, adapting the end pieces, part
nos. 77 01 349 942 and 77 00 105 874 with a pipe, part
no. 82 00 027 352 or 82 00 376 245.

I - CHECKING THE SEALS

a

When checking the brake servo seal, ensure that
there is a perfect seal between this and the master
cylinder.

If there is a leak in this area, replace the seal
between the master cylinder and the brake servo.

The brake servo seal must be checked on the vehi-
cle. The hydraulic circuit must be in operation.

II - CHECKING THE BRAKE SERVO

a

Connect a vacuum pump directly to the brake servo.

a

Activate the vacuum pump a few times.

a

Check that the vacuum does not fall by more than 33
mbar in 15 seconds. If it does, the leak may be lo-
cated:

- on the non-return valve seal, in this case change

the non-return valve seal (see 37A, Mechanical
component controls, Brake servo non-return
valve: Removal - Refitting, page 37A-4) ,

- on the pushrod membrane; in this case, replace the

brake servo (see 37A, Mechanical component
controls, Brake servo: Removal - Refitting,
page 37A-7) .

III - CHECKING THE BRAKE SERVO NON-RETURN
VALVE

a

Disconnect the non-return valve on the intake distri-
butor side but leave it connected to the brake servo.

a

Disconnect the non-return valve on the vacuum
pump side but leave it connected to the brake servo.

122228

122866

F4R or K4M

F9Q or K9K

37A

-

130

MECHANICAL COMPONENT CONTROLS

Brake servo: Check

37A

a

Connect a vacuum pump to the end of the non-re-
turn valve.

a

Check to see if the pressure drops. If it does, there is
a hole in the non-return valve. Replace the non-re-
turn valve (see 37A, Mechanical component con-
trols, Brake servo non-return valve: Removal -
Refitting, page 37A-4) .

a

Connect the non-return valve to the intake distribu-
tor.

a

Connect the non-return valve to the vacuum pump.

F4R or K4M

F9Q or K9K

37B

-

1

ELECTRONIC PARKING BRAKE

Assisted parking brake: List and location of components

ELECTRONIC PARKING BRAKE

37B

I - LIST OF COMPONENTS

The "Electronic parking brake" consists of:

- a control unit

- a lever

- electric motors

- a clutch pedal position sensor

II - LOCATION OF COMPONENTS

Control unit

Lever

Lever

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 37B, Electronic parking brake, Assis-
ted parking brake: Precautions for repair, page
37B-4) .

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

134467

B95 or D95 or K95

134456

J95

138743

37B

-

2

ELECTRONIC PARKING BRAKE

Assisted parking brake: List and location of components

ELECTRONIC PARKING BRAKE

37B

Electronic parking brake motor

Electrical wiring

137130

137133

137135

139553

37B

-

3

ELECTRONIC PARKING BRAKE

Assisted parking brake: List and location of components

ELECTRONIC PARKING BRAKE

37B

Clutch pedal position sensor

To remove the clutch pedal position sensor (see 37A,
Mechanical component controls, Clutch pedal po-
sition sensor: Removal - Refitting, page 37A-64) .

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

135450

37B

-

4

ELECTRONIC PARKING BRAKE

Assisted parking brake: Precautions for repair

ELECTRONIC PARKING BRAKE

37B

GENERAL RECOMMENDATIONS

1 - Advice to be followed before any operation

To ensure that the battery does not run down and to
avoid the risk of the electronic parking brake triggering
erratically, ensure the RENAULT Card is removed.

2 - Control unit

Do not refit a control unit which has been removed to
another vehicle.

Always replace the computer if it falls on the ground.

When replacing the computer, apply the « After repair
procedure » using the diagnostic tool.

3 - Electronic parking brake electric motor

The electronic parking brake electric motor is not
available separately. If the electronic parking brake
motor fails, replace the complete calliper ( « brake cal-
liper - electronic parking brake electric motor » assem-
bly).

If the electronic parking brake does not release (red
warning light on the instrument panel), use the dia-
gnostic tool to identify the fault.

Procedure in the event of a fault relating to the
electronic parking brake electric motor

Remove the bolts (1) from the electronic parking brake
electric motor.

Turn the shaft of the piston clockwise.

Note:

If the configuration is not fully performed, the com-
puter remains in its « factory » configuration.

When the procedure is complete, the computer can
go to « customer » mode.

Note:

Do not work on the front callipers before using the
diagnostic tool.

Note:

The application of this procedure always requires
the complete calliper to be replaced( « brake calli-
per - electronic parking brake electric motor » ).

137130

137129

37B

-

5

ELECTRONIC PARKING BRAKE

Control unit: Removal - Refitting

ELECTRONIC PARKING BRAKE

37B

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a flat level surface.

a

Engage 1st gear.

a

Fit a block behind the rear wheel.

a

Loosen the electronic parking brake using the lever.

a

Apply the before repair procedure using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- display the "Before repair procedure" for the selec-

ted computer,

- carry out the operations described in the "Before

repair procedure" section.

a

Switch off the ignition.

a

Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a

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

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the connector (1) from the electronic
parking brake control unit.

a

Mark the position of the electronic parking brake
control unit in relation to the body.

a

Remove:

- the nuts (2) from the electronic parking brake con-

trol unit,

- the electronic parking brake control unit.

Essential equipment

diagnostic tool

Tightening torques

m

nuts of the electronic
parking brake control
unit

2 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 37B, Electronic parking brake, Assis-
ted parking brake: Precautions for repair, page
37B-4) .

137135

134467

37B

-

6

ELECTRONIC PARKING BRAKE

Control unit: Removal - Refitting

ELECTRONIC PARKING BRAKE

37B

REFITTING

I - REFITTING PREPARATION OPERATION

a

Always replace the nuts of the electronic parking
brake control unit.

II - REFITTING OPERATION FOR PART
CONCERNED

a

Connect the electronic parking brake control unit
connector.

a

Refit the electronic parking brake control unit in the
position marked during removal.

a

Torque tighten the nuts of the electronic parking
brake control unit (2 N.m).

III - FINAL OPERATION

a

Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

a

Switch on the ignition.

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- display the "After repair procedure" for the selected

computer,

- carry out the operations described in the "After re-

pair procedure" section.

a

Refit the rear wheel arch trim (see Rear wheel arch
lining: Removal - Refitting) (71A, Body internal
trim).

Note:

Always replace the electronic parking brake con-
trol unit if it falls on the ground.

37B

-

7

ELECTRONIC PARKING BRAKE

Handle: Removal - Refitting

B95 or D95 or K95, and ELECTRONIC PARKING BRAKE

37B

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Apply the before repair procedure using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- display the "Before repair procedure" for the selec-

ted computer,

- carry out the operations described in the "Before

repair procedure" section.

a

Switch off the ignition.

a

Remove the centre console upper panel (see Cen-
tre console upper fascia: Removal - Refitting)
(57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the bolts (1) from the lever,

- the lever.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the lever.

II - FINAL OPERATION

a

Switch on the ignition.

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- display the "After repair procedure" for the selected

computer,

- carry out the operations described in the "After re-

pair procedure" section.

a

Refit the centre console upper panel (see Centre
console: Removal - Refitting) (57A, Interior equip-
ment).

Essential equipment

diagnostic tool

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 37B, Electronic parking brake, Assis-
ted parking brake: Precautions for repair, page
37B-4) .

134465

37B

-

8

ELECTRONIC PARKING BRAKE

Handle: Removal - Refitting

J95, and ELECTRONIC PARKING BRAKE

37B

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Apply the before repair procedure using the dia-
gnostic tool :

- connect the diagnostic tool,

- select "Electronic parking brake 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.

a

Switch off the ignition.

a

Remove the gear lever knob (1) .

a

Remove the gear lever trim (2) .

a

Remove the upper trim (3) from the centre console.

a

Disconnect the cruise control switch connector.

Essential equipment

diagnostic tool

139428

139427

139430

CRUISE CONTROL

37B

-

9

ELECTRONIC PARKING BRAKE

Handle: Removal - Refitting

J95, and ELECTRONIC PARKING BRAKE

37B

a

Disconnect the cigarette lighter connector.

a

Disconnect the offset multimedia socket connector.

a

Disconnect the connector from the lever.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove:

- the bolts (4) from the lever,

- the lever.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the lever.

II - FINAL OPERATION

a

Connect the lever connector.

a

Connect the offset multimedia socket connector.

a

Connect the cigarette lighter connector.

a

Connect the cruise control switch connector.

a

Refit the centre console upper trim.

a

Refit the gear lever trim.

a

Refit the gear lever knob.

a

Switch on the ignition.

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select "Electronic parking brake computer",

- go to repair mode,

- display the "Before/after repair procedure" for the

computer selected,

- carry out the operations described in the "After re-

pair procedure" section.

WITH ACCESS. FOR SMOKING

138744

WITH ACCESS. FOR SMOKING

CRUISE CONTROL

38C

-

1

ANTI-LOCK BRAKING SYSTEM

ABS system: List and location of components

38C

110486

134715

(1) hydraulic

unit

126179

38C

-

2

ANTI-LOCK BRAKING SYSTEM

ABS system: List and location of components

38C

137957

(4) UCH

134674

(5) Lateral

acceleration and yaw

speed sensor

134460

(6)

Brake disc with instrumented
bearing

(7)

Wheel speed sensor

123048

(8)

ESP deactivation switch

38C

-

3

ANTI-LOCK BRAKING SYSTEM

ABS system: List and location of components

38C

134302

(9) Master

cylinder

38C

-

4

ANTI-LOCK BRAKING SYSTEM

ABS system: Precautions for repair

38C

I - SAFETY

- If a lift must be used for an operation, respect the sa-
fety instructions (see Vehicle: Towing and lifting)
(02A, Lifting equipment).

- Protect any bodywork components which could be
damaged by brake fluid with covers.

- to ensure there is no risk of sparks, do not place any
metallic objects on the battery.

- Brake fluid is highly corrosive. Carefully clean any
brake fluid spilt on parts of the vehicle.

II - CLEANLINESS

- Clean around the braking system with BRAKE
CLEANER (see Vehicle: Parts and ingredients for
the repairwork) (04B, Consumables - Products).

- If a component is being replaced by a new one, do not
remove the new component from its packaging until its
is ready to be fitted onto the vehicle.

III - GENERAL RECOMMENDATIONS

- During an operation which requires the braking circuit
to be opened, position a pedal press on the brake pe-
dal to limit the outflow of brake fluid.

- After any operation on the ABS, it is essential to con-
firm the repair with a road test and a check using the
diagnostic tool.

1 - Yaw speed and lateral acceleration sensor

The sensor must be fitted facing the vehicle's direction
of travel (as shown by the arrow).

Be sure to replace any sensor which has sustained an
impact.

2 - Hydraulic unit

3 - Wheel speed sensor

4 - Brake servo

Essential equipment

pedal press

diagnostic tool

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

WARNING

Switch off the vehicle ignition so as not to activate
the hydraulic unit solenoid valves when bleeding the
brake circuit.

WARNING

To ensure that the wheel speed sensor works pro-
perly, do not mark the sensor target on the bearing.

WARNING

In order to prevent irreversible damage to the front
hub bearing:

- Do not loosen or tighten the driveshaft nut when

the wheels are on the ground.

- Do not place the vehicle with its wheels on the

ground when the driveshaft has been loosened or
removed.

IMPORTANT

To avoid breaking the connection between the
brake servo pushrod and the brake pedal, check
that the safety clevis pin is locked onto the brake
servo pushrod by tilting it from the top downwards.

38C

-

5

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

B95 or D95

38C

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side.

a

Support the exhaust pipe using a safety strap(s).

a

Remove the front catalytic pre-converter (see Front
catalytic pre-converter: Removal - Refitting)
(19B, Exhaust).

Essential equipment

pedal press

refrigerant charging station

safety strap(s)

diagnostic tool

Tightening torques

m

hydraulic unit bolts on
its support

8 N.m

hydraulic unit support
bolts

8 N.m

rigid brake pipe unions
on the hydraulic unit

13 N.m

hydraulic unit earth wire
nut

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 38C, Anti-lock braking system, ABS
system: Precautions for repair, page 38C-4) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

AIR CONDITIONING or CLIMATE CONTROL

F4R or K9K, and 836

38C

-

6

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

B95 or D95

38C

a

Loosen the clip on the air filter unit air outlet pipe.

a

Remove:

- the bolt (1) of the air filter unit air outlet pipe,

- the air filter unit air outlet pipe bolts (2) from the tur-

bocharger,

- the air filter unit air outlet pipe.

a

Remove the intercooler air inlet pipe (see Intercoo-
ler air inlet pipe: Removal - Refitting) (12B, Turbo-

charging).

a

Remove:

- the intercooler air inlet pipe (see Intercooler air in-

let pipe: Removal - Refitting) (12B, Turbochar-
ging),

- the lifting eye of the cylinder head.

a

Remove the heat shield clips (3) from the tunnel.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

K9K, and 836

139155

139154

F9Q

137151

38C

-

7

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

B95 or D95

38C

a

Remove:

- the bulkhead heat shield clips (4) ,

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (5) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Remove the nut (6) from the hydraulic unit earth wi-
re.

a

Disconnect the connector (7) from the hydraulic unit.

136467

134715

AIR CONDITIONING or CLIMATE CONTROL

134716

135383

38C

-

8

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

B95 or D95

38C

a

Undo the hydraulic unit pipe unions (8) .

a

Fit blanking plugs on the openings of the hydraulic
unit and brake pipes.

a

Remove:

- the bolts (9) of the hydraulic unit support,

- the "hydraulic unit - support" assembly,

- the hydraulic brake unit bolts from its support,

- the hydraulic brake unit.

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit:

- the hydraulic brake unit,

- the hydraulic unit bolts on its support.

a

Torque tighten the hydraulic unit bolts on its sup-
port (8 N.m).

a

Refit:

- the "hydraulic unit - support" assembly,

- the bolts of the hydraulic unit support.

a

Torque tighten the hydraulic unit support bolts (8
N.m).

a

Refit the brake pipe unions on the hydraulic unit.

a

Clip on hydraulic unit pipes.

a

Torque tighten the rigid brake pipe unions on the
hydraulic unit (13 N.m).

a

Connect the hydraulic unit connector.

a

Refit the nut of the hydraulic unit earth wire.

a

Torque tighten the hydraulic unit earth wire nut (8
N.m).

II - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

134715

135382

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

WARNING

Position the terminal wire towards downwards to
optimise the sealing on the hydraulic unit compu-
ter connector.

38C

-

9

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

B95 or D95

38C

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield.

a

Refit the front catalytic pre-converter (see Front ca-
talytic pre-converter: Removal - Refitting) (19B,
Exhaust).

a

Refit:

- the intercooler air outlet pipe (see Intercooler air

outlet pipe: Removal - Refitting) (12B, Turbo-
charging),

- the lifting eye of the cylinder head.

a

Refit the air filter unit air outlet pipe.

a

Tighten the clip on the air filter unit air outlet pipe.

a

Refit the intercooler air inlet pipe (see Intercooler
air inlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a

Refit:

- the exhaust pipe,

- the exhaust connecting hose,

- the front axle subframe (see 31A, Front axle com-

ponents, Front axle sub-frame: Removal - Refit-
ting, page 31A-75) .

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery).

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning is working correctly
(see Coolant circuit check) (62A, Air conditioning).

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select « ABS- ESP computer » ,

- go to repair mode,

- display the « After repair procedure » for the selec-

ted computer,

- select « ABS- ESP computer » in the « List of com-

ponents controlled by this computer » section,

- carry out the operations described in the « After re-

pair procedure » section.

a

Refit the engine undertray.

AIR CONDITIONING or CLIMATE CONTROL

F4R or K9K, and 836

F9Q

K9K, and 836

AIR CONDITIONING or CLIMATE CONTROL

38C

-

10

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

J95

38C

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Position the pedal press on the brake pedal to limit
the outflow of brake fluid.

a

Drain the refrigerant fluid circuit using the refrige-
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).

a

Remove:

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the engine undertray bolts,

- the engine undertray,

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the exhaust connecting hose nuts.

a

Move the exhaust pipe to one side (1) .

a

Strap the exhaust pipe to the right-hand driveshaft.

Essential equipment

pedal press

refrigerant charging station

Tightening torques

m

bolts of the brake
hydraulic unit on its sup-
port

8 N.m

brake hydraulic unit
mounting bolts

8 N.m

brake pipe unions on
the hydraulic unit

13 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 38C, Anti-lock braking system, ABS
system: Precautions for repair, page 38C-4) .

WARNING

Prepare for the flow of fluid, and protect the sur-
rounding components.

139222

38C

-

11

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

J95

38C

a

Unclip the control cables from the gearbox at:

- the anchoring ball joints (2) using an open-jawed

spanner,

- the cable sleeve stops (3) .

a

Unclip the control cable on the gearbox at:

- the anchoring ball joint (4) using an open-jawed

spanner,

- from the cable sleeve stop (5) .

a

Remove the intercooler air outlet pipe (see Inter-
cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

a

Remove the heat shield clips (6) from the tunnel.

a

Move the heat shield of the tunnel towards the rear
of the vehicle.

a

Remove:

- the bulkhead heat shield clips (7) ,

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

134676

6 SPEED AUTO GBOX

138846

F9Q or K9K or M9R

137151

136467

38C

-

12

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

J95

38C

- the bulkhead heat shield.

a

Unclip the fuel pipes from the bulkhead at (8) .

a

Remove the "expansion valve - intermediate pipe"
connecting pipe (see Expansion valve - interme-
diate pipe connecting pipe at the expansion val-
ve outlet: Removal - Refitting) (62A, Air
conditioning).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the connector (9) from the hydraulic unit.

a

Unclip:

- the clip of the front right-hand brake pipe from the

hydraulic brake unit mounting at (10) ,

- the clip of the electrical wiring from the hydraulic

brake unit.

a

Undo the hydraulic unit pipe unions (11) .

a

Fit blanking plugs on the openings of the hydraulic
unit and brake pipes.

134715

AIR CONDITIONING or CLIMATE CONTROL

135383

134715

38C

-

13

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

J95

38C

a

Remove the bolts (12) from the hydraulic brake unit
mounting.

a

Turn over the "hydraulic unit - mounting" assembly.

a

Remove:

- the hydraulic brake unit bolts from its mounting,

- the hydraulic brake unit,

- the hydraulic brake unit mounting.

REFITTING

I - REFITTING PREPARATION OPERATION

a

parts always to be replaced: seal between cata-
lytic converter and exhaust downpipe hose (10,
08,02,21).

II - REFITTING OPERATION FOR PART
CONCERNED

a

a

Fit the "hydraulic brake unit - mounting" assembly.

a

Refit the hydraulic unit bolts on its mounting.

a

Torque tighten the bolts of the brake hydraulic
unit on its support (8 N.m).

a

Refit the "hydraulic unit - mounting" assembly.

a

Torque tighten the brake hydraulic unit mounting
bolts (8 N.m).

a

Refit the brake pipe unions on the hydraulic unit.

a

Clip on hydraulic unit pipes.

a

Torque tighten the brake pipe unions on the hy-
draulic unit (13 N.m).

a

Clip:

- the clip of the front right-hand brake pipe onto the

hydraulic brake unit mounting,

- the clip of the electrical wiring from the hydraulic

brake unit.

a

Connect the hydraulic unit connector.

III - FINAL OPERATION

a

Clip the fuel pipes onto the bulkhead.

a

Refit the "expansion valve - intermediate pipe" con-
necting pipe (see Expansion valve - intermediate
pipe connecting pipe at the expansion valve out-
let: Removal - Refitting) (62A, Air conditioning).

a

Refit:

- the bulkhead heat shield,

- the tunnel heat shield.

a

Refit the intercooler air outlet pipe (see Intercooler
air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

135382

WARNING

Do not remove the blanking plugs from each
component until the last moment.

Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING

To prevent any premature wear, ensure that there
is no contact between the rigid pipe and the
body.

AIR CONDITIONING or CLIMATE CONTROL

F9Q or K9K or M9R

38C

-

14

ANTI-LOCK BRAKING SYSTEM

Brake hydraulic assembly: Removal - Refitting

J95

38C

a

Clip the control cables onto the gearbox at:

- the anchoring ball joints,

- the cable sleeve stops.

a

Clip the control cable onto the gearbox at:

- the anchoring ball joint,

- the cable sleeve stop.

a

Refit:

- the exhaust pipe,

- the exhaust connecting hose,

- the front axle sub-frame (see 31A, Front axle

components, Front axle sub-frame: Removal -
Refitting, page 31A-75) ,

- the right-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the front wheel arch liners (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

a

Remove the pedal press from the brake pedal.

a

Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .

a

Refit:

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the air filter unit (see Air filter unit: Removal - Re-

fitting) (12A, Fuel mixture),

- the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)

(80A, Battery),

- the scoop under the scuttle panel grille (see Scoop

under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment).

a

Perform the following operations:

- fill the refrigerant circuit using the refrigerant char-

ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning),

- a leak test (see Coolant circuit check) (62A, Air

conditioning).

a

Check that the air conditioning is working correctly
(see Air conditioning: Check) (62A, Air conditio-
ning).

a

Refit the engine undertray.

5 SPEED MANUAL GBOX or 6 SPEED MANUAL
GBOX

6 SPEED AUTO GBOX

AIR CONDITIONING or CLIMATE CONTROL

38C

-

15

ANTI-LOCK BRAKING SYSTEM

Front wheel speed sensor: Removal - Refitting

38C

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove:

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) ,

- the front wheel arch liner (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion).

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the wheel speed sensor connector (1) .

a

Unpick the wheel speed sensor wiring at (2) .

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 38C, Anti-lock braking system, ABS
system: Precautions for repair, page 38C-4) .

134463

134462

134460

38C

-

16

ANTI-LOCK BRAKING SYSTEM

Front wheel speed sensor: Removal - Refitting

38C

a

Remove:

- the wheel speed sensor bolt (3) ,

- the wheel speed sensor (4) .

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

a

Refit the wheel speed sensor.

a

Clip on the wheel speed sensor wiring harness.

a

Connect the wheel speed sensor connector.

II - FINAL OPERATION

a

Refit:

- the front wheel arch liner (see Front wheel arch

liner: Removal - Refitting) (55A, Exterior protec-
tion),

- the front wheel (see 35A, Wheels and tyres,

Wheel: Removal - Refitting, page 35A-1) .

134461

WARNING

To avoid damaging the wheel speed sensor
cable:

- Do not tension the cable,

- Do not twist the cable,

- Check that there is no contact with the surroun-

ding components,

- Do not use tools that may damage the cable.

38C

-

17

ANTI-LOCK BRAKING SYSTEM

Rear wheel speed sensor: Removal - Refitting

38C

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

a

Remove the rear wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Unclip the wheel speed sensor (1) from the sensor
holder.

a

Unpick the wheel speed sensor wiring at (2) .

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 38C, Anti-lock braking system, ABS
system: Precautions for repair, page 38C-4) .

134468

134469

134470

38C

-

18

ANTI-LOCK BRAKING SYSTEM

Rear wheel speed sensor: Removal - Refitting

38C

a

Disconnect the wheel speed sensor connector (3) .

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

a

Connect the wheel speed sensor connector.

a

Clip:

- the speed sensor wiring,

- the wheel speed sensor to the sensor holder.

II - FINAL OPERATION

a

Refit the rear wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .

134471

WARNING

To avoid damaging the wheel speed sensor
cable:

- Do not tension the cable,

- Do not twist the cable,

- Check that there is no contact with the surroun-

ding components,

- Do not use tools that may damage the cable.

38C

-

19

ANTI-LOCK BRAKING SYSTEM

Yaw speed and transversal acceleration sensor: Removal - Refitting

38C

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a

Remove the centre console (see Centre console:
Removal - Refitting) (57A, Interior equipment).

a

Cut the soundproofing to a length of approximately 5
cm.

a

Remove the soundproofing from the lateral accele-
ration and yaw sensor.

II - OPERATION FOR REMOVAL OF PART
CONCERNED

a

Disconnect the connector from the lateral accelera-
tion and yaw sensor (2) .

a

Remove:

- the lateral acceleration and yaw sensor nuts (3) ,

- the lateral acceleration and yaw sensor (4) .

Essential equipment

diagnostic tool

Tightening torques

m

lateral acceleration and
yaw sensor nuts

8 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 38C, Anti-lock braking system, ABS
system: Precautions for repair, page 38C-4) .

134673

134674

38C

-

20

ANTI-LOCK BRAKING SYSTEM

Yaw speed and transversal acceleration sensor: Removal - Refitting

38C

REFITTING

I - REFITTING OPERATION FOR PART
CONCERNED

a

Refit the lateral acceleration and yaw sensor.

a

Torque tighten the lateral acceleration and yaw
sensor nuts (8 N.m).

a

Connect the connector for the lateral acceleration
and yaw sensor.

II - FINAL OPERATION

a

Refit the soundproofing onto the lateral acceleration
and yaw sensor.

a

Clip on the soundproofing.

a

Refit the centre console (see Centre console: Re-
moval - Refitting) (57A, Interior equipment).

a

Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

a

Apply the after repair procedure using the diagnos-
tic tool :

- connect the diagnostic tool,

- select « ABS- ESP computer » ,

- go to repair mode,

- display the « After repair procedure » for the selec-

ted computer,

- select « ABS- ESP computer » in the « List of com-

ponents stored in this computer » section,

- carry out the operations described in the « After re-

pair procedure » section.